Alan — Controls Engineer

Commissioned automotive assembly systems - Body In White (BIW) assembly systems, EV battery assembly systems. Experienced as individual contributor and project manager. Work with contractors and union trades. Commission PLC - IT communication and data systems.

Developed python based ML/AI vision algorithms for manufacturing error proofing application.

Allen Bradely and Siemens HMI development, configuration, and comissioning.

Lead install of multiple hydraulic presses, blanking presses, and CNC machines. Lead install of BIW manufacturing systems for customers such as VW, GM, Ford, Stellantis.

Battery assembly systems General Assembly Stamping - mechanical, hydraulic, and servo presses Spot welding Robot Vision Error Proofing

Mechanical, hydraulic, servo presses. Robotics: Fanuc, Kuka, ABB, Nachi, Kawasaki. Dispense systems. Automotive joining systems: welding, clinching, riveting, hemming, adhesives.

Design and build robot material handling tools and systems. Conveyance systems.

Keyence vision systems Matrox vision systems Python based custom vision systems

Welding engineer in BIW assemblies for VW, GM, Ford, Stellantis platforms: VW Passat, GM K2XX trucks and SUVs, Ford F150, Mustang, Explorer, and Ram. Laser welding controls engineer - Trumpf Laser welding systems for EV battery assembly.

1. Design and Development Design control systems for manufacturing processes, machinery, or automated systems. Develop control strategies using PLCs, HMIs, SCADA, DCS, or custom embedded systems. Create control logic diagrams, ladder logic, function block diagrams, and P&ID schematics. 2. Programming and Integration Program PLCs (e.g., Allen-Bradley, Siemens) and configure HMI/SCADA systems. Integrate sensors, actuators, robotics, vision systems, and other hardware with control systems. Interface with MES, ERP, and IIOT systems for data exchange and real-time monitoring. 3. Commissioning and Testing Set up, calibrate, and validate control systems during machine startup and commissioning. Troubleshoot control issues and refine logic for stable, safe, and efficient operations. Perform Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT). 4. Maintenance and Support Provide ongoing technical support for plant floor systems and automation equipment. Diagnose and resolve control-related faults, downtime, or inefficiencies. Maintain up-to-date backups and documentation for all control system configurations. 5. Compliance and Safety Ensure all designs comply with industry standards, codes, and plant safety requirements (e.g., NFPA, UL, ISO). Implement and verify machine safety functions, e.g., E-stops, safety relays, light curtains. 6. Collaboration and Project Management Work closely with mechanical, electrical, and software engineers, as well as production and maintenance teams. Manage or support control-related aspects of projects, from requirements to final delivery. Assist with vendor coordination and specification of automation equipment.

Process Development & Optimization: Design, implement, and optimize stamping and welding processes to meet safety, quality, cost, and productivity targets. Tooling & Equipment Integration: Specify, source, and validate stamping dies, welding fixtures, and automated systems, ensuring compatibility with production requirements. Project Management: Lead cross-functional teams on new product launches, model year changes, and capital equipment projects from concept to production readiness. Root Cause Analysis & Problem Solving: Investigate process failures, downtime, and defects using structured problem-solving methodologies (e.g., 5-Why, Fishbone, DMAIC). Continuous Improvement: Implement lean manufacturing principles, standard work, and error-proofing solutions to reduce waste and improve OEE. Quality Assurance: Collaborate with quality engineers to ensure compliance with specifications, weld integrity standards, and dimensional accuracy in stamped panels. Documentation & Standards: Develop and maintain PFMEAs, control plans, process flow diagrams, and work instructions in compliance with IATF 16949. Training & Support: Provide technical guidance and hands-on training to maintenance, operations, and production teams on process best practices. Data-Driven Decision Making: Utilize data acquisition systems, SPC, and manufacturing KPIs to monitor process capability and drive data-informed improvements. Safety & Compliance: Ensure all processes adhere to environmental, health, and safety regulations and promote a strong safety culture on the floor.

Facilities Maintenance & Infrastructure Management: Oversee the operation, maintenance, and upgrades of plant utilities and infrastructure systems, including HVAC, compressed air, chilled water, lighting, electrical distribution, and building structures. Capital Project Execution: Plan, budget, and manage capital improvement and expansion projects, including new construction, renovations, and utility installations, ensuring alignment with plant production needs. Energy & Utility Optimization: Monitor and improve plant energy efficiency and utility consumption through equipment upgrades, control strategies, and sustainable engineering practices. Equipment Layout & Space Planning: Support production and engineering teams in developing optimal facility layouts that enhance material flow, safety, and process efficiency. Regulatory Compliance: Ensure facility operations comply with local, state, and federal environmental, health, and safety regulations (e.g., OSHA, EPA, NFPA). Contractor & Vendor Coordination: Manage external service providers and contractors for construction, maintenance, inspections, and specialized services, ensuring adherence to scope, quality, and safety standards. Preventive & Predictive Maintenance Planning: Develop and maintain preventive maintenance schedules and systems for facility infrastructure and equipment to reduce downtime and extend asset life. Emergency Systems Management: Oversee the functionality and compliance of life safety systems, including fire alarms, suppression systems, and emergency backup power. Environmental Stewardship: Support environmental initiatives, such as waste reduction, water conservation, and air quality monitoring, aligned with corporate sustainability goals. Cross-functional Support: Collaborate with production, engineering, maintenance, and EHS teams to support smooth plant operations and continuous improvement initiatives.

Daily Operations Oversight: Manage day-to-day production activities to ensure safety, quality, delivery, and cost (SQDC) targets are met or exceeded. Team Leadership & Development: Lead, coach, and develop production supervisors and hourly team members, fostering a high-performance culture and strong engagement. Production Planning & Scheduling: Coordinate with planning, logistics, and materials teams to ensure efficient execution of production schedules and on-time delivery. Problem Solving & Root Cause Analysis: Address production issues in real-time using structured problem-solving methods and collaborate with engineering and maintenance to implement corrective actions. Performance Monitoring: Track and analyze KPIs such as OEE, scrap, downtime, labor utilization, and implement continuous improvement initiatives. Safety & Compliance: Enforce adherence to health, safety, and environmental regulations while driving a culture of safety ownership on the floor. Process Standardization: Ensure operators follow standardized work and support audits, training, and documentation updates as needed. Cost Control: Monitor and control operational costs, drive productivity, and identify waste reduction opportunities. Process Design & Optimization: Develop, document, and improve manufacturing processes to achieve efficient, repeatable, and high-quality production. New Product & Process Launches: Support APQP activities, lead process trials, capability studies, and ensure smooth integration of new products into production. Root Cause & Corrective Actions: Investigate process-related issues and implement permanent corrective actions using tools like 8D, PFMEA, and DOE. Standard Work & Documentation: Create and maintain work instructions, control plans, and process flow diagrams in accordance with IATF 16949 standards. Tooling & Equipment Support: Specify and validate tools, jigs, and fixtures. Work with vendors and internal teams to implement upgrades or replacements. Data Analysis: Monitor key metrics (cycle time, yield, downtime, scrap, etc.) and leverage SPC and data-driven methods to improve process capability. Lean Manufacturing Initiatives: Drive kaizen events, 5S, value stream mapping, and other lean tools to reduce waste and improve throughput. Cross-functional Collaboration: Work closely with production, quality, maintenance, and engineering teams to support continuous improvement and maintain process stability.