Joseph — Controls Engineer

I have hands-on experience programming, troubleshooting, modifying, and commissioning Omron PLC-controlled manufacturing equipment, primarily in automotive assembly. I have worked with NJ, CJ2, CJ1, and CP1H controllers using Sysmac Studio and CX-Programmer. My experience includes ladder logic development, machine sequencing, interlocks, part tracking, reject handling, conveyor handshakes, station-to-station communication, and EtherNet/IP device integration. I regularly troubleshoot production equipment by monitoring live PLC data, tracing machine sequences, reviewing electrical drawings, checking field I/O, and correcting logic or equipment issues. Projects have included Writting code from scratch intergating yaskawa and UR robots, rewriting and cleaning up controls for a multi-station assembly line, correcting conveyor and station handshakes, improving RFID processing, and removing obsolete barcode and recipe logic. I have also integrated and supported Keyence IV2 and IV4 vision systems, Omron V680 RFID equipment, IAI positioning controllers, Omron NA HMIs, safety devices, laser measurement equipment, printers, and other industrial automation devices. I am comfortable working with existing programs that have limited documentation and determining how the machine operates from the PLC code, electrical drawings, HMI, and physical equipment. My focus is creating reliable, understandable logic that can be maintained and troubleshot by plant personnel.

I have hands-on experience integrating, configuring, modifying, and troubleshooting Keyence vision systems used in automotive manufacturing. My experience includes IV2 and IV4 smart cameras, CV-X vision controllers, and Keyence LJ-Laser profilers. My vision troubleshooting experience includes adjusting lighting, exposure, focus, inspection thresholds, and part positioning to reduce false rejects and inconsistent inspections. I also troubleshoot camera communication faults, missed triggers, timing issues, incorrect program selection, unstable results, and problems caused by changing part presentation or production conditions. A recent retrofit project involved replacing Keyence IV2 cameras with IV4 cameras on multiple automated assembly machines. The goal was to maintain the existing PLC interface where practical, minimize changes to proven machine logic, configure the replacement cameras, verify trigger and result handshakes, and test the systems under production conditions. I have also supported Keyence CV-X and 2D/3D inspection applications involving presence, orientation, quality, and dimensional verification. My primary strength is connecting the vision system to the overall machine controls and making the inspection reliable, understandable, and maintainable for production and maintenance personnel.

Experienced programming and troubleshooting Omron CJ- and NJ-series PLCs and NA and NS-series HMIs. My work includes machine sequencing, automatic and manual modes, alarms, interlocks, conveyor handshakes, part tracking, EtherNet/IP integration, operator controls, data displays, and production troubleshooting. I have also rewritten and improved existing machine logic to make equipment more reliable and easier to maintain.

Strong production troubleshooting experience with automated manufacturing equipment. I diagnose PLC logic, sensors, safety devices, communications, vision systems, servo controls, pneumatics, and station sequencing by reviewing live data, electrical drawings, alarms, and machine behavior. I am comfortable working under downtime pressure and developing reliable corrective actions.

Experienced with Keyence IV2, IV4, CV-X, and 2D/3D vision systems. I have configured inspections, adjusted lighting and thresholds, integrated cameras with Omron PLCs over EtherNet/IP, and troubleshot triggers, program selection, communication, and false-reject issues. I have also completed vision-system retrofit work on automated automotive assembly equipment.

• Supported, modified, and improved PLC and electrical control systems for automated automotive manufacturing equipment, increasing reliability and reducing production downtime. • Troubleshot and debugged PLC programs, electrical systems, sensors, safety devices, communication networks, vision systems, and machine sequences to identify and correct equipment faults. • Developed and modified Omron PLC and HMI programs, including automatic sequences, manual controls, alarms, interlocks, station handshakes, part tracking, and fault-recovery functions. • Successfully overhauled Keyence CV-X and LJ8000 vision inspection systems on two production lines, improving inspection operation, integration, and maintainability. • Currently leading the controls and electrical portion of a new automated production line, including system design, component selection, device integration, programming, and coordination with vendors and internal teams. • Integrated and supported Keyence vision systems, Omron RFID equipment, IAI positioning controllers, EtherNet/IP devices, conveyors, and industrial safety equipment. • Created and updated hand-drawn electrical documentation for smaller machine modifications and field changes.

• Designed, developed, and implemented PLC and electrical control systems for automated manufacturing machinery, ensuring efficient and reliable operations. • Collaborated with cross-functional teams to design control solutions that met customer specifications and operational needs. • Troubleshot and debugged PLC programs and electrical systems to optimize machine performance. • Developed intuitive HMI (Human-Machine Interface) screens, enabling operators to monitor, control, and interact with machines effectively. • Created detailed electrical schematics and technical drawings using AutoCAD Electrical to guide machine assembly and ensure accurate implementation.