Daniel — Controls Engineer

Integrate custom automation and machines.

Responsible for controls integration, new project startups, troubleshooting and upgrading production equipment. Lead Controls Engineer for multiple, multi-million dollar automation lines. Including new line purchases and retro-fits for existing lines. Integrated and upgraded various cost reduction systems including AB and Siemens PLCs and HMIs, database SCADA system (MSSQL and Ignition), servos and robotics (IAI and Denso), and vision systems (Cognex) Work with and train maintenance department to improve troubleshooting skills and reduce downtime on production line calls. Develop and implement controls related standardization documentation for new projects.

Responsible for recycling manufacturing equipment and projects (disassembly and process). This includes integration, modification and troubleshooting of Allen Bradley/Siemens PLCs, HMIs, Denso robots, and Cognex/IPD vision systems. Upgraded a manual metal separation machine to a fully automatic system with automatic start-up and shut-down sequences along with generating fault/error codes for improved troubleshooting. Worked in the role of a project engineer as part of the Engineering team on the integration and installation of a multi-million dollar recycling project. Improved cartridge disassembly line from a low 90% uptime to 98% uptime and reduced the overall line reject rate. This included vision system optimization, improving robotic performance, and enhancing PLC logic for recovery.

Responsible to the Operations Manager and the Manufacturing Engineering Manager for automated assembly production. This includes integration and troubleshooting of Allen Bradley PLCs, HMIs, Cognex/Keyence/Adept vision systems, and Fanuc/Adept Robotic systems. Re-designed and implemented new robotic vision inspection system eliminating assembled "false rejects" and saving the company an estimated $29,000 a year in rework cost. Implemented an automated rework system to replace manual process increasing production up-time by 1.4 hours a day saving the company $61,000 a year in non-production machine time. Tested, implemented and verified vision system improvements on automated assembly line including part presence verification (glues, spring, o-rings) and part location for robot capture. Created production reports by connecting to a SQL database via Visual Basic for applications in Excel and Visual Studio 2010.

May 2007 - July 2011 (4 years 3 months)