James — Controls Engineer

I use AutoCAD professionally to design industrial electrical schematics, control panels, and wiring diagrams for automation customers. While I am capable of producing mechanical layouts when needed, my primary and most extensive use of AutoCAD has been in controls system design, including panel layouts, wiring documentation, and as-built drawings that support safe installation, commissioning, and long-term maintenance.

I use SolidWorks for mechanical design and engineering analysis, developing components and assemblies with consideration for real-world factors such as heat dissipation, structural stress, clearances, and mechanical movement. My work emphasizes designs that are manufacturable, serviceable, and well-integrated with automation and controls systems.

I have worked extensively with Yaskawa industrial robots, primarily in welding applications, supporting robot teaching, process setup, and system integration. My experience includes configuring robot safety systems, coordinating robots with external devices and PLC-controlled processes, and ensuring reliable operation within larger automated cells.

I have spent the majority of my automation career working on Siemens-based control systems, making Siemens platforms the area where I hold the deepest hands-on experience. My work has focused on integrating PLCs, distributed I/O, drives, HMIs, and safety systems into complex automated environments, with an emphasis on system interoperability, reliability, and long-term maintainability.

I have experience working with Omron control systems, primarily in simpler automation applications involving discrete I/O and standalone stations. Most Omron-based projects I've supported have focused on straightforward control tasks rather than highly integrated or complex system architectures, and I approach these platforms with an emphasis on clarity, reliability, and maintainability.

I bring over five years of hands-on experience programming Toyopuc PLCs, motion control systems, HMIs, and safety PLCs in production environments. I also spent a year with JTEKT Toyoda, where I trained Toyota Engineering and Maintenance Support personnel on Toyopuc-based control systems, troubleshooting methodologies, and best practices for reliable, safe operations.

I have worked extensively with Allen-Bradley automation platforms since 2019, supporting the design, commissioning, and startup of large-scale automated systems for OEM electric vehicle manufacturing, including GM rotor and stator production lines. My experience spans PLC programming, motion integration, HMI development, safety systems, and on-site commissioning in high-throughput, mission-critical environments.

I work extensively with Cognex vision systems, integrating them into automated production environments as well as deploying them as standalone quality inspection and safety systems. I value Cognex platforms for their ease of configuration, reliability in industrial settings, and strong customer support, which allows vision solutions to be implemented efficiently and maintained with confidence.

I work with Oracle-based data systems to integrate operational and enterprise data from industrial environments into structured, usable datasets. I offer data integration as a service, helping customers connect automation and production data to Oracle platforms and complementary SaaS analytics tools that provide meaningful visibility, reporting, and decision support.

I have extensive hands-on experience performing industrial electrical work in support of automation and controls systems. My background includes reading and creating electrical schematics, installing and verifying power and control wiring, terminating field devices and panels, and troubleshooting electrical faults during installation, startup, and live production. I regularly work with motor control circuits, drives, safety devices, sensors, and networked control hardware, ensuring systems are wired correctly, safely, and in accordance with design intent. My electrical skillset is closely integrated with controls and commissioning activities, allowing me to diagnose and resolve issues efficiently in real-world industrial environments.

I have extensive experience providing production support for automated manufacturing systems in live operating environments. This includes responding to downtime events, diagnosing electrical, controls, robotic, and process-related issues, and implementing effective fixes under time and safety constraints. I work closely with operators, maintenance, and engineering teams to stabilize systems, prevent repeat failures, and ensure production can resume safely and efficiently.

I have hands-on experience working with industrial instrumentation used in automated systems, including sensors, transducers, encoders, safety devices, and process feedback components. My work includes device selection, installation, wiring, signal validation, and troubleshooting during commissioning and production support. I regularly verify signal integrity, scaling, and device behavior at the PLC and HMI level to ensure accurate data and reliable system operation.

I regularly support validation activities during installation, startup, and system modifications to ensure automation systems perform as intended. My experience includes verifying wiring and I/O, confirming PLC and safety logic behavior, testing interlocks and fault responses, and validating system operation against design requirements. I focus on ensuring systems are safe, predictable, and ready for production handoff, particularly in regulated or safety-critical environments.

I have hands-on experience supporting industrial robot maintenance, primarily with Yaskawa systems in production environments. My work includes teaching robots, verifying and adjusting safety systems, troubleshooting faults, and integrating robots with PLC-controlled equipment and external devices. I support both routine operational issues and startup-related challenges, helping ensure robotic cells operate reliably and safely within the broader automation system.

I have supported industrial maintenance activities related to automation and controls systems, including troubleshooting electrical and control issues, assisting with repairs, and supporting preventive maintenance efforts. My experience allows me to work effectively alongside maintenance teams to diagnose problems quickly, restore functionality, and improve system reliability over time.

I have experience working with industrial electrical power systems in the context of automation, including motor control, drives, power distribution within panels, and equipment power verification. My work focuses on ensuring electrical systems safely and reliably support control and automation equipment, particularly during installation, commissioning, and troubleshooting activities.

I consistently apply a continuous improvement mindset to automation, controls, and operational systems by identifying inefficiencies, risks, and failure points and implementing practical, sustainable improvements. My approach includes refining PLC logic, improving alarm management, enhancing documentation, standardizing interfaces, and simplifying maintenance workflows to reduce downtime and operational friction. I regularly collaborate with operators, maintenance, and engineering teams to incorporate real-world feedback, validate improvements in production, and ensure changes deliver measurable value. I focus on improvements that enhance safety, reliability, and long-term system maintainability rather than short-term fixes.

I apply electrical engineering principles in the design, integration, and commissioning of industrial automation systems. My experience includes control panel design, power and control circuit development, safety system implementation, device selection, and interpretation of electrical standards and schematics per UL 508A / NFPA 79 / IEC. I regularly troubleshoot electrical and controls issues in live production environments, validate system behavior during startup, and ensure designs are safe, practical, and aligned with real-world installation and maintenance practices. My work bridges electrical design and controls execution to deliver reliable, maintainable industrial systems.

I approach work with a systems-engineering mindset, integrating electrical, mechanical, controls, robotics, and data components into cohesive, reliable solutions. My engineering experience includes requirements definition, system architecture, design validation, integration, testing, and commissioning across industrial automation projects. I focus on understanding how individual subsystems interact, identifying risk early, and making design decisions that support safety, reliability, and long-term maintainability. My work consistently bridges design intent and real-world operation, ensuring engineered solutions perform as expected in production environments.

I have extensive hands-on experience supporting installation, startup, and commissioning of industrial automation systems across manufacturing and process environments. My work includes coordinating electrical and controls installation, verifying wiring and I/O, configuring PLCs, HMIs, drives, safety systems, and robotics, and bringing systems online safely and efficiently. I am highly effective at troubleshooting issues during startup, validating system behavior against design intent, and working directly with operators, maintenance, and engineering teams to ensure stable production handoff. I am comfortable commissioning both standalone stations and large, integrated systems under tight timelines and live-production constraints.

I have extensive experience programming PLC-based control systems across a wide range of industrial applications, from simple I/O-driven stations to large, highly integrated automated production lines. My background includes developing, modifying, and troubleshooting PLC logic for motion control, safety systems, robotics coordination, vision integration, and data exchange with higher-level systems. I emphasize structured, readable code; clear state management; and safe, predictable machine behavior. I am highly effective at diagnosing live-production issues, improving existing logic for reliability and maintainability, and aligning PLC behavior with real-world operational and safety requirements.

I am highly effective at problem solving in complex industrial environments, particularly during system startup, commissioning, and live production. I approach problems methodically by isolating variables, validating assumptions, and tracing issues across electrical, controls, mechanical, and process boundaries. My experience includes diagnosing PLC logic faults, wiring issues, device misconfigurations, integration failures, and intermittent production problems under time and safety constraints. I prioritize root-cause resolution over temporary fixes and communicate findings clearly to operators, maintenance, and engineering teams to prevent repeat issues.

I have hands-on experience in product development from concept through deployment, with a focus on industrial automation and control systems. My work includes defining technical requirements, designing electrical and mechanical elements, integrating PLCs, HMIs, safety systems, robotics, and data interfaces, and validating designs through testing and commissioning. I emphasize practical, build-ready solutions that consider manufacturability, serviceability, safety, and long-term support. I regularly iterate designs based on field feedback, operational performance, and customer needs to deliver products and systems that are reliable, scalable, and aligned with real-world use.

I have hands-on experience working with SCADA systems to visualize, monitor, and support industrial automation processes. My experience includes integrating PLC data into operator interfaces, configuring alarms and basic trending, supporting commissioning activities, and troubleshooting data flow and display issues in production environments. I am comfortable working within existing SCADA architectures, collaborating with operations and engineering teams to improve usability and reliability, and ensuring SCADA systems accurately reflect real-world process behavior. While my primary strength is in controls and system integration, I continue to expand my SCADA skillset to support more advanced data, analytics, and operational use cases.

I have extensive experience creating industrial wiring diagrams used for panel builds, machine installation, commissioning, and long-term maintenance. My work includes developing clear, accurate schematics for power distribution, control circuits, safety systems, field devices, and networked components. I design wiring diagrams with a strong emphasis on readability, proper device identification, consistent labeling, and alignment with real-world installation practices. I regularly support as-built documentation, troubleshoot wiring-related issues during startup, and ensure diagrams remain accurate and usable throughout the system lifecycle.

I have extensive experience with system commissioning, including startup, validation, and production handoff. My work includes verifying wiring and I/O, testing PLC and safety logic, coordinating devices and processes, and stabilizing systems under live production conditions to ensure safe and reliable operation.

I work with HMI systems to provide operators with clear, accurate visibility into machine and process behavior. My experience includes integrating PLC data, supporting alarms and basic trending, and improving usability to support safe and effective operation on the plant floor.

I support installation activities for automated systems, including electrical installation, device placement, wiring verification, and readiness checks prior to startup. My experience ensures systems are installed correctly and aligned with design intent to support smooth commissioning.

I specialize in integrating industrial automation systems, bringing together PLCs, robots, safety systems, vision, drives, HMIs, and data interfaces into cohesive, reliable solutions. My work focuses on ensuring all subsystems communicate correctly, operate safely, and function as a unified system in real production environments.

I support quality control applications through automation, vision systems, and system validation. My work helps ensure processes consistently meet quality requirements by detecting defects, verifying process conditions, and providing reliable feedback to operators and engineering teams.

I have experience working with servo drive and motion systems as part of automated equipment and production lines. My work includes integrating drives with PLCs and robots, supporting motion coordination, and troubleshooting drive- and motion-related issues during startup and production.

I regularly troubleshoot complex automation issues in live production environments. My approach involves isolating root causes across electrical, controls, robotics, and process domains, resolving issues efficiently, and implementing fixes that prevent repeat failures rather than temporary workarounds.

I have hands-on experience deploying machine vision systems, particularly Cognex, for quality inspection and safety-related applications. My work includes setup, integration with PLCs, and validation to ensure reliable detection and consistent performance in production environments.

I regularly work with industrial wiring in support of automation systems, including control panels, field devices, and safety circuits. My experience emphasizes clean, accurate wiring practices that support safe operation, effective troubleshooting, and long-term maintainability.

Cincinnati, OH Develop high-reliability automation and control systems for aerospace, defense, and manufacturing clients. Advise on DoD and FAA regulatory compliance for industrial and airborne control systems. Lead systems integration projects ensuring safety, compliance, and operational efficiency. Author technical documentation for regulatory approvals and system verification. Oversee all aspects of project management, including scoping, budgeting, scheduling, and stakeholder communication. Conduct thorough risk assessments and mitigation planning for automation and control system deployments. Coordinate cross-functional teams of engineers, contractors, and external vendors to deliver solutions on time and within budget. Research and implement emerging technologies to enhance automation, cybersecurity, and data integrity for clients in highly regulated sectors. Provide technical mentorship and training to junior engineers and project collaborators. Foster relationships with aerospace and defense clients to identify new business opportunities and expand service offerings. Drive continuous improvement initiatives to optimize system performance, reduce operational costs, and ensure client satisfaction.

KCVG Sortation Facility – Hebron, KY Controls Systems (Contract) Led the design, implementation, and optimization of high-speed automation systems, ensuring seamless integration with Amazon's material handling equipment (MHE) and adherence to industry regulations. Managed and mentored a team of Control Systems Technicians and Leads, coordinating work activities to meet operational goals and enhance system performance. Developed and executed preventive maintenance programs, reducing system downtime and improving equipment reliability across the facility. Collaborated with cross-functional teams, including Operations Engineering, Safety, and IT, to support MHE systems optimization and project implementation. Utilized advanced troubleshooting techniques to resolve complex issues in PLC/PC controllers and industrial networks, including Ethernet, ControlNet, and DeviceNet. Monitored key performance indicators (KPIs) and partnered with maintenance and operations teams to address system performance issues, providing analysis and recommendations for improvement. Acted as the first level of escalation support for systems issues, providing technical assistance during and after business hours to ensure continuous operation. Facilitated Failure Analysis and Incident Review processes, implementing process improvements and retraining to prevent future incidents. Engaged in the commissioning of new automation projects, ensuring compliance with safety standards and successful integration into existing systems. Maintained comprehensive documentation for control systems, including schematics, control diagrams, and standard operating procedures, to support ongoing maintenance and training efforts.

Erlanger, KY Designed, tested, and commissioned high-speed automation systems for aerospace and defense manufacturing. Developed risk assessments and system verification protocols for military-grade production lines. Led cross-functional teams in debugging and optimizing aerospace automation systems. Designed, tested, and commissioned high-speed automation systems for aerospace, defense, and automotive manufacturing sectors, including the development of a $23 million automated system that produces an EV motor every 34 seconds for an Electrification customer in Normal, Illinois. Led root cause analysis and debugging of complex automated systems, ensuring seamless integration of mechanical, electrical, and software components to maximize production reliability. Developed and implemented risk assessments and system verification protocols, ensuring compliance with military-grade standards and O.E.M. guidelines. Collaborated with cross-functional teams to develop new control logic and automation processes that improved cycle times, minimized downtime, and increased throughput. Supported lifecycle maintenance of automation systems, incorporating updates to control logic and hardware to meet evolving O.E.M. standards and customer requirements. Provided technical leadership on the commissioning of new production lines, including training operators and maintenance personnel to ensure safe and efficient operation. Conducted on-site troubleshooting and optimization of automated production lines, leveraging extensive knowledge of control systems, robotics, and PLC programming.

Georgetown, KY Installed, wired, and commissioned low-voltage (≤480V) control panels, motor circuits, and field devices in compliance with NEC standards for industrial automation systems. Designed and implemented PLC-based control systems (Siemens, Allen-Bradley, and Mitsubishi), including ladder logic programming, I/O mapping, safety interlocks, and HMI integration. Diagnosed and repaired 24VDC and 480VAC power distribution issues, including motor starters, contactors, overloads, and variable frequency drives (VFDs), ensuring safe and continuous equipment operation. Coordinated with controls engineers and OEMs to retrofit legacy machinery with modern safety-rated electrical systems, including light curtains, e-stops, and Category 3/PLd components Interpreted and updated electrical schematics, wiring diagrams, and panel layouts to support facility upgrades and electrical permitting processes. Managed installation and startup of field equipment for robotics, servo systems, pneumatic actuators, and conveyor systems, with full traceability and documentation of circuits and controls. Maintained compliance with OSHA, NFPA 70E, and NEC standards during troubleshooting, lockout/tagout, and energized work, ensuring a hazard-free environment for multi-trade coordination. Provided cross-training and technical mentorship on troubleshooting techniques for low-voltage control circuits and PLC diagnostics in support of Toyota's continuous improvement (Kaizen) initiatives.