Manufacturing / Robotics Engineer (253071) Automotive / BSME, Six Sigma / Programming Robots, PLCs, HMIs, Camera Systems, Welding Systems/ Motoman, Fanuc, Yaskawa, Yshin Robots / Dayton, Cincinnati OH Area
Hands-on Controls / Manufacturing Engineer with a reputation for taking on whatever is needed to get the job done right with minimal supervision. He is a BSME and is Six Sigma Trained. His is highly skilled with multiple robotic types and platforms. He has developed the required skills (PLC programming, maintenance troubleshooting, milling, etc.) to improve all processes and sourced all required equipment, manufacturing processes, and tooling for required projects. He utilizes lean manufacturing techniques to provide manufacturing with the best work cell possible and has continued to improve the work cell with manufacturing’s input during production.
As a manufacturing engineer, he learned how to both create new machines as well as improve existing machinery for the evolving needs of production. He is currently employed but his company continues to move manufacturing to Mexico and he is interested in confidentially exploring new opportunities in the Dayton, Cincinnati areas. His notable experience includes:
• Programming of six-axis robots, Omron and Allen Bradley PLCs, and HMIs
• Development of floor work cells(including time studies, work balance, ergonomics, etc.) for several $14+ million-dollar programs.
• Utilization of sensors(color, laser, vision) to poke yoke defects.
• Interface with customers and vendors.
• Electrical and mechanical troubleshooting of equipment for both maintenance purposes and improvement purposes
• Quoting of engineering costs for new projects and project revisions
• Mechanical and electrical troubleshooting of robotic welding, pneumatic, ultrasonic welding, and vibration welding equipment.
• Developed 3D CAD models(CATIA, SOLIDWORKS, INVENTOR) and prints for new and modified parts.
• Debug and Process Improvement of fixturing and custom testing machinery
• Traveled to Telamon’s Mexico facility to modify equipment to run multiple parts with quick changeover capability.
o This saved $15,000 by eliminating the need to build a new test machine.
• Developed PFMEAs for future projects based on quoted information.
• Oversaw building of a $100K robotic soldering system to solder wires to slider switches.
• Programmed and debugged a Keyence laser marking system to mark plastic connectors prior to assembly.
• *Validated and modified an Apollo Seiko Soldering Robot.
• Programmed Motoman robots and Omron PLCs to change welding robot operation from a spray lubricant to a nozzle dip.
o This eliminated the replacement of $600 spray valves.
• Revised an outdated weld jig and integrated it into an existing line to improve line TACT time.
• Used CATIA to design and build an end of line Cognex Camera system to evaluate correct part presence.
• Revised machine weld sequence and operation to improve tact time from 110 to 82 seconds.
• Integrated sensors into an existing line for error prevention.
• Established process plan, quoted equipment, and oversaw installation of a $2M welding jig project.
• Electrical and mechanical troubleshooting of robotic welding lines for defects and maintenance issues.
• Developed spreadsheets to analyze work cell balance and improved workflow based on actual cycles.
• Used AutoCAD to develop cell layouts on the production floor.
• Programmed Fanuc six axis robots for sonic weld assembly of a plastic console.
• Programmed Cognex cameras to detect missing components.
• Troubleshot vibration welders, 20 and 40 khz sonic welders, heat stake machines, and pneumatic clip installation machines.
• Wrote custom programming for Yushin pick and place robots.
o One program eliminated two operators per shift from a job, resulting in a $60,000 savings.
• Cost justified part assembly methods such as hot melt gluing vs. ultrasonic welding.
o This resulted in a $0.50 per part savings after a 1 ½ year payback.
• Error proofed a project with brackets for $600; sensors would have cost $2000.
• Reworked a production cell to remove one operator per shift.
• Completed six sigma training.
• Factory Automation
• Automated Welding Applications
• Automotive Automation
• General Manufacturing Automation
• Programmed PLCS and HMIs
• Allen Bradley Studio 5000 Software
• Oversaw Build of a $100K Robotic Soldering System
• Programming / Debugging a Keyence Laser Marking System
• Build An End of Line Cognex Camera System
• Reprogram Welding Transfer Line
• Automatic Assembly Machines
• Automated Transfer Lines
• HMI – Human Machine Interface
• Industrial Process Automation Integration
• Configures/Tests/Debugs System Network and Data Acquisition Equipment Designs
• Developing Cabinet Drawing Layouts
• PLC Programming / Troubleshooting
• Touch Screen
• Analog circuits
• Pneumatic systems
• FlexPicker Robots
• Material Handling Robots
• Welding Robots
• Inspection Robots
• Assembly Robots
• Gantry Robots
• Writing Custom Programming for Pick and Place Robots
• Troubleshoot Robotic Welding Lines
• Programming Six Axis Robots
• Dismantling Equipment
• Documentation Packages
• Equipment Upgrades
• Troubleshooting Plant Automation
• Developing Cell Layouts
• Soldering Robot
• Wire Harness Testing
• Designed a Build Fixture
• Omron PLCs
• 20 and 40 khz Sonic Welders
• Vibration Welders
• Motoman Robots
• Fanuc Robots
• Yshin Robots
• Yaskawa Robots
• Teach Pendant
• Troubleshooting Robotics
• Allen Bradley PLCs
• Rockwell PLCs
• OMRON PLCs
• CNC Equipment
• Cognex Camera system
• Programming Cameras
• Standardized Work for Cells
• Analyze Work Cell Balance
• Improved Workflow
• Designed Brackets and Tooling
• AutoCAD
• STUDIO5000
• CATIA
• INVENTOR
• Allen Bradley PLC Ladder Logic
• Fanuc Karel Language
• Cost Justified, Sourced, Trialed, and Installed All Production Molds
• Making Technical Recommendations
• Optimizing Injection Molds
• Heat Stake Machines
• Pneumatic Clip Install Machines.
• PFMEA
• Developing BOMs and Routings
• Reworking a Production Cell
EDUCATION
• Bachelors Mechanical Engineering / BSME, Purdue University (1995)
• Six Sigma Training