John — Systems Integrator
John
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Documents on File
Programming Skills 4
I have specified, configured, and written the control logic using SLC 500s, Micrologix, Compactlogix, and Controllogix PLCs. This includes process controls in a steel mill, packaging equipment, automotive, and in the food industry. VFD's: specified, configured, and installation of PowerFlex 4, 40, 525, and 750 drives HMI's, programmed and managed PanelView, Panelview Plus, and FactoryTalk SE/ME interfaces
Specified, designed, and programmed HMIs
Developed and maintained scada system
Specified and programmed for sequential logic systems in automotive applications.
Achievements
1
Profile
About Me
Professional Summary
Process Engineer and Controls Engineer with 20+ years of experience in industrial automation, manufacturing, and process optimization. Extensive background designing PLC, HMI, and electrical control systems while leading complex engineering projects from concept through implementation. Currently combines industrial automation consulting, AI product development, and subject matter expert work for technical learning platforms, applying large language models, technical writing, engineering analysis, and domain expertise to solve complex industrial problems. Recognized for analytical thinking, system integration, process improvement, and translating complex technical knowledge into practical solutions.
Core Skills
- Project Management: 7 years leading process and engineering projects.
- PLC Programming: 15+ years delivering innovative automation solutions.
- Process Optimization: 10+ years of continuous improvement initiatives.
- Team Leadership: 7 years leading cross-functional teams on project-based tasks.
- Creative Problem-Solving: 20+ years in process engineering and troubleshooting.
- System Integration: 6 years of executing successful project integrations.
- Root Cause Analysis: 7 years focused on improving system reliability.
Skilled Trades 3
Over 15 years of experience working as a technician, engineer, and manager of maintenance departments. I have experience in electrical controls, mechanical systems, pneumatics, and hydraulics in multiple sectors. Skills include schematic and print reading, manual interpretation, and installation and alignment of electrical and mechanical components.
Over 5 years of experience with installation, configuration, and calibration of various analog devices, including transmitters, transducers, RTDs, and other sensors. 4-20ma, -10-+10V, 0-10V, ethernet, HART. Temperature, flow, level, pressure, ampere, voltage, etc.
I have 2 years of experience in fabrication and MIG welding, both stainless and carbon steel.
Professional Competencies 7
Passionate about creating a positive and effective relationship with both internal and external customers.
Diverse background in field device installation and configuration, io checks, debugging, troubleshooting, project management, and program optimization.
Extensive experience in various industries including process control, automotive, and food. Using various communication protocols including ethernet ip, devicenet, rs-232, rs-485, modbus, profinet.
Over 20 years of documented troubleshooting and reliability-focused problem-solving. High first-time fix rate and effective at identifying and mitigating frequent root-cause failures.
Extensive work in process control within the steel industry. This includes cooling, evacuation, level control, EAF, and caster-based systems. Configuration, Calibration, tuning, troubleshooting.
Have managed complex integration projects up to 500K and assisted in projects from FEL to deployment up to 8M. Extensive experience in establishing deployment and reliability requirements well in advance of commissioning. Effective liaison and management of various contractors.
Passionate about finding the best products for the environment in which they are to be installed, considering the environment, ease of deployment, cost, and especially the end users' ability to maintain them.
Applications 10
My Business
Work Experience5
Started as a controls technician, then an electrical engineer, an electrical maintenance manager, and then a Process engineer. Optimized a billet weighing application, resulting in several million dollars in savings across 5 mills. Helped manage and assist in the migration of a SLC500 system to Contrologix, involving almost 10,000 IO. Dozens of reliability and process improvement projects.
Led and executed project design efforts to develop customized PLC and HMI solutions.
Managed system integration projects, designing PLC and HMI systems to improve operational efficiency and customer satisfaction. Led troubleshooting and system enhancements, optimizing existing equipment to support new production processes. Left due to a death in the family
Started as a mechanical planner and was also an electrical specialist for on-call and project work. Promoted to Mechanical Coordinator. Managed maintenance projects and led efforts to improve system reliability through root cause analysis, directly contributing to increased productivity. Drove the successful implementation of reliability improvement projects, ensuring alignment with operational goals.
Maintenance and project work in a highly automated facility with over 50 plc controlled work cells, including CNC Spring and wire form machines.
Education / Training / Certificates2
Did not complete the course; focused on electrical theory and controls, schematic reading, HVAC, and interpersonal communications.