Phil — Controls Engineer

Great attention to schedule management and detail to insure maximum results from each contractor. Goals are set for each day and checked at the end of the day to adjust and insure that the project schedule can be completed on schedule.

Programmed ninety Padre part counters in robot cells throughout the Bodyshop. These counters report to Eco Emos and keep count of parts used for each robot cell. When the counters show that parts are almost empty, the Padre system will alert logistics to supply more parts. Corrected PLC and reprogrammed Eco Emos software throughout the Body Shop which included analyzing EcoEmos SCADA data being sent to the server for errors and incorrect descriptions. Differentiate between real and false alarms being sent to the Server. Added new data points to the EcoEmos function block for KPI targets. The improvement for alarm and data reporting went from 40 percent accuracy to 99 percent saving downtime and increasing production job per hour throughput. Also worked with the Body Shop Engineering team to correct robot cell and conveyor downtime issues throughout the shop.

Commissioned Bodyshop Framing lines to include the new 416 (Atlas SUV) modifications while Passat production was in process without downtime.

Worked with contractors and OEMs on implementing conveyor modifications and PMCS SCADA control locations of new model vehicles in the Body, Paint and Assembly facilities. These vehicle launches include the new model Maxima, Altima, Leaf, Pathfinder, Infinity JX-35, and Rogue.

Managed the reprogramming and modifications to implement the addition of new model vehicles JX-35 and Pathfinder in an existing Paint Shop while minimizing downtime during production. I was brought into this project to manage the electrical installation and control software. At the time this project was over three weeks behind schedule and incurring significant downtime. We were able to implement a project schedule for electrical and controls while working with production and maintenance to eliminate downtime and bring this part of the project into production on time.

Worked with contractors and OEMs on the commissioning of the Nissan Leaf Battery manufacturing facility. Nissan Smyrna, TN: Worked with contractors and OEMs on the commissioning of robot cells and conveyor systems along with the implementation of new PMCS SCADA control locations in the new Paint shop facility. Nissan Smyrna, TN: Managed the contractors and OEMs to convert, rewire, reprogram, and reroute conveyors from a 30 year old paint shop to a new fascia paint facility. Through the reorganization and prioritization of project milestones we were able to accelerate project timeline to start of production two weeks early without the funding for extra resources

Worked with the Ford Motor Company on the initial Taurus Paint Shop conveyor system commissioning. Worked with General Motors on numerous body shop conveyor re-tooling projects. Worked on the Pratt & Whitney jet engine facility commissioning team.

Mesa Inc. Worked with the Tennessee Valley Authority in their Hydro Automation Group. This group is in charge of generation and spill automation for all the facilities along the Tennessee River. This group used the Siemens PCS7 software along with Win CC for database and system control. PLC systems involved were S7-400, S7-300, and S7-200. Nissan Canton, MS & Smyrna, TN: Involved in the system design, software and the supervision of each cell level contractor involved with the commissioning of the vehicle conveyor and data tracking system at the Nissan Canton, Mississippi and Smyrna, Tennessee facilities. The Canton, Mississippi system can produce a mixture or four different vehicles along with variations of each and consists of 52 individual conveyor systems, 155 decision making Routing Control Objects, within eighteen miles of conveyors. Four separate vehicle types share the same common conveyor systems throughout the body, paint, and most of the trim shop. Vehicle data is downloaded and tracked from many sub-systems to insure that the correct part reaches the correct vehicle as it progresses through the assembly lines, using vision systems to verify correct part assembly at strategic locations throughout the plant. The system tracks each vehicle from data downloads in the body shop all the way through the plant to the end of the Final Line for each vehicle. At the Smyrna, Tennessee facility, we were able to convert the paint and body shops from RFID tag readers to Smarteye applications throughout each shop while production was up and running without incurring one minute of downtime due to system installation. Programmed, installed, and commissioned the control system for a 35 million dollar tile extrusion line that took the product

from raw materials to packaging for the Mannington Corporation. Programmed and installed a data acquisition system for Tetley USA that kept track of each box of tea made, where it was warehoused and the name of the customer's name the products were shipped to. Developed and programmed a system for Dupont, based on four 32 position spinning machines. The PLC system graded each package when doffed, A, B, C, or scrap. It then created a file that kept track of how many pounds of each grade product made in the last 24 hours, pounds of scrap materials, which spinning positions were down, for how long, and why. This information was then loaded into the company database and a 24-hour report automatically printed out for the area supervisor at 8:00AM each morning. Pickett, Tarpley, and Associates: Manager, Process Control Engineering Group

Involved in the system design, software and the supervision of each cell level contractor involved with the commissioning of the vehicle conveyor and data tracking system at the Nissan Canton, Mississippi and Smyrna, Tennessee facilities. The Canton, Mississippi system can produce a mixture or four different vehicles along with variations of each and consists of 52 individual conveyor systems, 155 decision making Routing Control Objects, within eighteen miles of conveyors. Four separate vehicle types share the same common conveyor systems throughout the body, paint, and most of the trim shop. Vehicle data is downloaded and tracked from many sub-systems to insure that the correct part reaches the correct vehicle as it progresses through the assembly lines, using vision systems to verify correct part assembly at strategic locations throughout the plant. The system tracks each vehicle from data downloads in the body shop all the way through the plant to the end of the Final Line for each vehicle. At the Smyrna, Tennessee facility, we were able to convert the paint and body shops from RFID tag readers to Smarteye applications throughout each shop while production was up and running without incurring one minute of downtime due to system installation

Developed and programmed a system for Dupont, based on four 32 position spinning machines. The PLC system graded each package when doffed, A, B, C, or scrap. It then created a file that kept track of how many pounds of each grade product made in the last 24 hours, pounds of scrap materials, which spinning positions were down, for how long, and why. This information was then loaded into the company database and a 24-hour report automatically printed out for the area supervisor at 8:00AM each morning.

Programmed and installed a data acquisition system for Tetley USA that kept track of each box of tea made, where it was warehoused and the name of the customer's name the products were shipped to.