Work & Professional Experience: 

Toyota                         October 2023 - Present

Senior Controls Engineer - Liberty, NC

• Led cross-functional teams in the successful planning and execution of network systems for battery manufacturing, ensuring alignment with production goals and addressing key project KPIs.

• Actively contributed to project management for capital equipment installations, overseeing timelines, manpower allocation, and resource coordination to meet critical milestones from planning to start of production (SOP).

• Managed relationships with external vendors and general contractors, ensuring clear communication of project scope and requirements, contributing to smooth project execution.

• Collaborated with senior management to define project priorities and report progress, ensuring all capital projects were delivered on time, within scope, and met budget constraints.

• Provided technical expertise and mentorship to junior engineers, facilitating their skill development in line with Toyota’s continuous improvement goals and fostering a collaborative work environment.

• Led problem-solving initiatives by identifying and removing barriers to the successful implementation of new technologies, in line with Toyota’s leadership values of Respect for People and Continuous Improvement.

• Initiated efforts to standardize operational procedures and documentation, ensuring consistency in processes like network system implementation, troubleshooting, and maintenance.

• Directed in-the-field expertise to troubleshoot and resolve critical production issues, minimizing downtime and improving overall efficiency in line with Toyota’s focus on operational excellence.

 

Herbalife         January 2022 - July 2023

Senior Controls Engineer - Winston-Salem, NC

• Assembled within a 5 member multifunctional core team for the innovation and implementation of global facility artificial intelligence to drive decisions based on data.

• Transform Herbalife to IoT (Internet of things) and industry 4.0.  Proposed and sold our vision to key stakeholders for multi-million dollar project funding with the absence of a return on investment.  Project manage 5 pillar approach

• Powering cultural change for the adoption of A.I. and civilizing the impacts to all department changes. 

• Working with A.I. vendor software to design a “Digital Twin” of our facility to control loop autonomous operations

1. Monitor data - Learning, Diagnose, Stabilize

2. Model data - Predict, Recommend, Prevent

3. Visualize data - Compare, Rank, Benchmark 

• “Train the Trainer” on new facility machinery, tailored for specific departments. (EHS, cyber security, On the Job trainers, Maintenance, Lab/Quality, Sanitation)

• Global standardization of our machines and facility requirements including electrical hardware, software, and programming guidelines

• Upgrades to current SCADA and integration of new SCADA software.  Transition from GE-Proficy to Aveva.  Adoption of data tracking/historian, ERP database management planning, visual live feed of production and universal esthetics for controls

• Evaluate cyber threat vulnerabilities between OT and IT networks and implement solutions.

• Integrated cellular network gateways for various vendor support by bypassing the facility network.  Trained cyber security on hardware/software

• Controls support of current equipment. (Called on as last resort)

• Eliminating localized machinery HMIs and converting to standardize virtual computers for cross platform control.  “All-In-One”  Allows for ease of data transformation and future changes.

 

Freelance – InControl Industrial Automation                         February 2020 - Present 

Owner Managing Member - System Integrator/Automation Controls Engineer - Kernersville, NC

• Design and programming of new custom industrial automation equipment

• Industrial control panel building to UL508A and NEC standards

• Remote programming support of facility machinery

• www.incontrolautomation.net

• www.shopincontrol.com

 

Blackstone-NEY Ultrasonics (Cleaning Technologies Group)            September 2017 – January 2020 

Design Engineer - Jamestown, NY (Business relocation)

• Lead design and project manager of new custom automation equipment 

• Develop, propose, and communicate ideas and designs with customers 

• Design PLC, HMI, actuation, and instrumentation packages- using products from various manufacturers and vendors. (Siemens, Rockwell, Unitronics, Schneider) 

• Support all departments regarding electrical and mechanical components of machines 

• Review engineering job files and design products to meet applicable specifications 

• Drawing package generation including customer approval, wiring schematics, panel layout, fabrication packets, machining, sheet metal drawings, thermal transfer, and industrial exhaust. 

• Generate bill of materials, estimate costs of purchased items, and requisition all necessary material and components 

• Assist manufacturing personnel as needed for machinery builds 

• Perform “In House” engineering run off, debug and strategically resolve any customer concerns 

 

Quality Engineering & Continuous Improvement (Intern/Summer)  May 2012 - July 2013 

• Assistant to Global Quality Systems Manager, Aided the Global Quality Systems Manager in the development and implementation of procedures and policies to rectify exposed inefficiencies 

• Analyzed production and engineering processes associated with the manufacture of ultrasonic industrial cleaning devices

• Modified procedures and policies in the Blackstone NEY Ultrasonics - ISO 9001 Quality Manual 

• Used numerous Quality Engineering Lean Tools, including 5s (Sort, Set in Order, Shine, Standardize, Sustain), Bottleneck Analysis, Kanban, Root Cause Analysis, 5”Y” Problem Solving, Standardized Work and Accountability, Value Stream Mapping, Process Work Flow, General Dimensioning and Tolerancing (GD&T)

• Participated in a seven-member safety committee, involving a monthly meeting to discuss and review all aspects of the facilities safety record and compliance with OSHA requirements 

• Directed daily communication meetings

 

Truck-Lite           May 2016 - September 2017

Process Engineer – Jamestown, NY           February 2017 – September 2017

• Designs, defines, and plans manufacturing processes. Specifies and directs installation of NPI processes  

• Plans and quotes equipment build schedules and monitors vendor progress 

• Defines and recommends equipment/method/process layout/materials/manpower changes in accord with recommendation for analyses conducted 

• Continually improves current process by analyzing on a continual basis. Direct/indirect labor, equipment, and processing cost to insure the most economical manufacturing procedures and processes are utilized 

• Process product conformity to ITAR and EAR

• Integrate and troubleshooting of PLC/HMI automation software (Rockwell Studio, Unitronics) 

• Integrate vision system and barcode scanning (Cognex, Keyence)

• Applies ergonomic principles to manufacturing methods 

Validation Engineer     May 2016 – February 2017 

• Developed design verification and planning reports (DVP&R) 

• Lead PV&D representative support in new development and introduction of new products 

• Produced continuous improvement in life cycle management 

• Development of detailed technical laboratory reports and providing documentations for external customers and internal requestors 

• Maintained and calibrated laboratory equipment and perform repairs as necessary 

• Reviewed and researched customer technical questions or product complaints as directed and coordinate responses with appropriate company personnel

 

W.R. Case & Sons Cutlery Company/Zippo Manufacturing Company   February 2015 – May 2016 

Associate Engineer-Bradford, PA (resigned due to location of company)

• Programming, integrating, and process designing for the installation of ABB robotics ​

• Product fixture and end-of- arm tooling design, Use of SolidWorks, Inventor, and CAD mechanical 

• Established relationship with sub-contractor for the assembly of machined fixtures and end-of-arm tooling 

• Developed standardized operating procedures for various robotic work stations.

• Training for robotic end-users – instructed manufacturing operators on the proper use and safety protocols for newly installed robotics 

• On-site support for manufacturing, maintenance, and electrical departments.  Developed preventative maintenance schedules for various robots and machines 

• Perform diagnostics of malfunctioning machinery and equipment 

• Purchasing and installation of electric and robotic replacement components including: automation sensors, pneumatics, and common electrical equipment 

• Programming of vision systems (Cognex: In-Sight, Festo: CheckKon) 

• Integrate and troubleshooting of PLC/HMI automation software (RS Logix 5000, Direct Logic, Unitronics) 

• Added AutoCAD Electrical, and in-turn developed standardized templates for all in-house electrical schematics

• Perform in-house safety inspections, based on National Electric Code, of electrical enclosures and electrical raceways/buses 

• Software implementation 

• Capital expenditure projects and budgeting 

 

Skills:

• Capital Project Management

• Cross-functional Leadership

• Toyota Way: Continuous Improvement & Respect for People

• Production Preparation & Standardization (Shikumi, Denwacho, Job Safety Analysis)

• Kaizen, Hoshin Kanri, and Lean Manufacturing

• Problem-solving & Root Cause Analysis

• Battery Manufacturing Process

• PLCs, SCADA Systems, Automation, Andon Systems

 

Certificates: 

•OSHA 10hr - Construction  •ESWP - Electrical Safe Work Practices •ABB IRC5 Industrial Robotic Programming. •Fanuc Handling Tools and Operations. •OSHA-NFPA 70E, electrical safety. •Autodesk Inventor 2016 Solid Modeling. •International Fluid Power Society (IFPS), Hydraulic Specialist. •Cognex Machine Vision In-Sight Advance spreadsheets