ELPIDIO ALIPIO

**** ******* ****** ****., *********, MI 48197

Phone: 734-***-****

acd4lj@r.postjobfree.com

CONTROLS ENGINEER

CAREER SUMMARY

Green Belt Six Sigma Certified Controls Engineering Professional with in-depth expertise in controls system design, hardware and

software development, application validation, installation, integration and implementation, run-off machineries, and final commissioning of

controls system. Skilled in automation controls, embedded systems, PLC/SCADA systems, PC front end controls, distributed I/O & Open

Architecture, network communications, factory information portals and technologies. Keen ability in applying problem-solving approaches

that draws on years of technical training and experience. I have years of experience in international leadership in Europe, North America

and South America.

PROFESSIONAL EXPERIENCE

COMAU NORTH AMERICA-SOUTHFIELD - MI - CONTRACT Jan 2014 to May 2014

Controls Engineer –FORD OAKVILLE CANADA – BIW Assembly Plant

• Lead Engineer responsible for developing Hardware Design including Main Electrical Control Panel to provide control power,

power to the robots, power to the roller beds, power to the PLC’s & HMI’s, power to the weld timers electrical circuits, air pressure to

stations/air pressure valves and pneumatic circuits, power to elevators/lifts and conveyor transfers, load and unload stations, safety

circuits and relays using AutoCAD Electrical 2009 drawings to build Electrical Panel for all I/O hardware including interface

communication networks and pneumatic components.

• Developed Ladder Logic based from Mechanical Design Sequence and Process Sequence using RSLogix 5000 for complete

automation; manual/auto controls including Power Flex 700 VFD’s and Factory Talk View for the PanelView Plus 1500 for HMI’s

Screen applications. Responsible for the In-House Build and Debug Process making sure all devices such as hardware properly

installed. Complete simulation process; loading PLC ladder logic / HMI screen / Internet Network communications to all I/O; testing

HMI’s Screen PB’s functionality with all the Fanuc Weld/Sealer Robots, Skid Conveyors, Lifts, Transfers, Sealer Units, and all

interfaces required for the complete automation. Complete debug In-House and simulation required before the machine tear down

and delivered to the client facility before installation.

• Interface Fanuc Robots to the PLC and HMI for complete Weld Automation Process making sure all the End Effector and Fixture

working properly/effectively including safeties as required.

• Onsite Controls Automation Installations and Final Debug Process of the systems. Completed successfully just in time for

production making sure machine jobs/hour and production quality were achieved.

• Trained operations and maintenance personnel during production making sure maintenance personnel were able fix any

problems and reduce downtime during production.

DCS - DYNAMIC CONTROLS SOLUTION - WIXOM - MI - CONTRACT Aug 2013 to Sept 2013

Controls Engineer – Mercedes Benz Tuscaloosa Assembly 1, Alabama

• Lead Engineer responsible for Hardware Design/Build Electrical Panels for Tire Wheels Delivery/Line Side Assembly 1 for

Mercedes Benz plant. Hardware design includes Tire De-Stacker, Power & Free/ Roller Conveyors, Lifts Stations, Upper/Lower

Unload Stations. Developed Electrical AutoCAD 2009 drawings to build the Electrical Panel for all I/O hardware,

interface/communication networks, and pneumatic components.

• Developed Ladder Logic based from Mechanical Design Sequence and Process Sequence using RSLogix 5000 for complete

automation; manual/auto controls including Power Flex 700 VFD’s and Factory Talk View for the Panel View 1000 HMI’s Screen

applications. Responsible for the In-House Build Process making sure all devices such as hardware properly installed. Complete

simulation process; loading PLC ladder logic / HMI screen / Internet Network communications to all I/O; testing HMI’s Screen PB’s

functionality before electrical panel delivered to the plant.

THYSSENKRUPP SYSTEM ENGINEERING INC. AUBURN HILLS - MI - CONTRACT Aug 2012 to May 2013

Controls Engineer – Ford Camacari, Bahia, Brazil

• Lead Engineer responsible for building Engine & Head Assembly Machine, using FAST Trans line / Siemens Simatic S7 V5.5 for

PLC’s & Servos, WinCC Flex 2008 programming for HMI Screen development which include all Lifts, Clamps, Atlas CopCo

Nutrunners, and Conveyors for the complete turnkey project. Attend weekly progress report meeting to address/resolve issues during

Build process in preparation for machine start-up.

• Responsible for the In-House Build Process making sure all devices such as hardware properly installed. Complete machine

Start-up & Debug Process, Machine Pre Buy-Off Process in simulated production; making sure production Jobs/Hour is achieved.

Start-up & Debug process includes Ladder logic/HMI screen applications for homing/setting parameters to run servos, Faults/Alarms

messages, Run in Auto/Dry/Continuous/Single/Recovery Cycle, FIS/OMS Systems, Production Counts and Sequence Diagnostics.

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Trained Ford Operations and Maintenance personnel after Pre-Buy Off process to ensure proper machine applications and Final

Acceptance of the equipment. Final commissioning completed December 2012.

• Responsible for the On-site installations at Ford Camacari Brazil; Responsible for the final installations, debug, complete run-off

machines with parts including conveyors/RFID tags/ OMS/FIS data monitoring systems and final check for accurate machine alarm

messages necessary for the Auto/Manual recovery systems.

Applied Manufacturing Technologies, Inc. Orion, MI - CONTRACT Jan 2012 to Jul 2012

Automation Engineer – FleetwoodGoldcoWyard Co. / Chicago IL

• Lead Engineer responsible for complete Turnkey Automation Can Packaging Machine for China & South Korea. Automation

includes Hardware design; interface with KuKa Robots, IN feed/Discharge Lanes, Buffers/Empty/Full Trays, and Conveyors using

RSLogix 5000 for the PLC Controls Systems. Developed Hardware Controls Design using AutoCAD Electrical 2009.

• Responsible for Software Development/HMI Screen for machine Manual/Auto controls using Factory View Studio which includes

Faults/Alarms Messages generated from the PLC and monitored to the HMI screen for maximum machine operations. Responsible

for the In-House Build Process making sure all devices properly installed, complete machine Start-up & Debug Process, Machine Pre

Buy-Off Process in actual production; making sure production Jobs/Hour is achieved. Chinese & Korean

Engineers/Operators/Maintenance personnel assisted/attended the 24 Hour Run for the Final Machine Acceptance in USA.

• Machine Build / Installations / Machine Start-up / Debug and Commissioning process successfully completed Just In Time at

Fleetwood facility in Chicago.

• Trained operators and maintenance personnel after installations to ensure proper applications of equipment.

DURR AUTOMATION ECOCLEAN INC., Auburn Hills, MI - CONTRACT Jul 2011 to Jan 2012

Controls Engineer – GM Tonawanda Engine Plant

• Lead Engineer responsible for Hardware design & Software development for GM /LGE Crankshaft Line 1 & 2 using Siemens

Simatic S7 V 5.5 for PLC’s & Servos, WinCC Flex 2008 programming for HMI Screen development which include all Gudel Gantries/

buffers/SPC & Reject Shuttle/conveyors and lifts for the complete turnkey project.

• Responsible for the HMI screen applications, faults & alarms messages for the complete automation including the Teach

Pendant Touch screen for homing and setting all parameters necessary to set and run the servos. .

• Responsible for On-site installations, machine start-up, commissioning, and debug process for the complete turnkey automation

controls systems. Installations completed successfully, 1 week ahead of production start-up time last December 2011.

• Training for operation and maintenance personnel scheduled by January 2012, to ensure proper applications of equipment is

performing as expected.

CINETICS AUTOMATION, Farmington Hills, MI - CONTRACT Mar 2011 to Jun 2011

Controls Service Engineer – GEMA, Chrysler Dundee Plant

• Lead Engineer responsible for the Hardware and Software design using Mitsubishi PLC’s & HMI including ladder logic

development and HMI screen applications. Multiple Spindle Machine applications for World Gas Engine, Tiger Shark 2.0L, & Tiger

Shark 2.4L Engine.

• Developed and wrote ladder logic based from process, pneumatics drawings, and machine sequence of operations.

• Provided technical support during panel build, machine build, and In-house installations, start-up, and final testing of the machine

prior to delivery of equipment. Debug, and 20 hour pre-buyoff test run was completed successfully without any major faults or control

issues.

• Responsible for On-site installations at GEMA Chrysler Dundee plant scheduled on Memorial Day weekend. Installations

completed successfully for start-up, debug, and final commissioning was of the equipment working 3 days and 3 shift periods just in

time for production.

• Provided High Level of technical support and trained maintenance personnel during production; making sure proper applications

of equipment were achieved.

FANUC ROBOTICS N.A., Rochester Hills, MI - CONTRACT Jun 2010 to Jan 2011

Installation/Service Engineer – Ford SBC Brazil Paint Shop

• Lead Engineer responsible for (14) Fanuc Robots installation and startup for Prime, and Clear Coat Line (1 & 3) at Ford SBC

plant in Sao Paulo, Brazil Supervised Fanuc Robots P-500 mechanical, pneumatic, and electrical controls installations. Installations

completed (1) week ahead of production start-up time.

• Responsible for machine Start-up, debug and final commissioning of the Robots, making sure all safeties, process and

automation controls in Manual/Auto/Dry/Continuous/Single/Recovery Cycle were performing as expected including optimization of

Robot processes to maximize production efficiency. Integration and optimization includes application of equipment specifically bell

atomizers and fluid delivery systems (optimize color change; ensure proper settings per systems requirements as needed).

• Prepares work daily status report, documented Fanuc Robot and related peripheral equipment performance, failure modes,

reporting results for the purpose of troubleshooting, repairing, and re-starting the systems. Communicated frequently during

installations, pre-buyoff process and final customer’s acceptance of the equipment.

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• Provided (03) weeks high level of technical training/support step by step SOP to ensure proper application processes were

applied correctly and performing as expected. Received excellent Customer Satisfaction letter from Ford Brazil for a job well done.

GE FANUC AUTOMATION, Southfield, MI Jan 1998 -Feb 2009

Project Implementation Application Engineer

• Lead Engineer responsible for validating Profibus Distributed I/O devices & Ethernet network systems at GM Tech Center; Projects for

GM Shanghai/GM L6 and L850 & GM Globalization Controls programs including travel to GM Opel Europe Russelsheim for the

globalization process. Managed/Integrated/Implemented controls automation programs for GM Flint Engine South; GM Envoy Launch

2000 successfully completed with the 1st Project with all PC Front End HMI Screens & PLC’s 90/30, 90/70, RX3i for automation

controls.

• Lead Engineer – 1st GM Shanghai OEM’s support 1998 responsible for Start-up & Debug process for all OEM’s machineries in USA;

project completed successfully making sure Jobs/Hr., Auto/Manual/Recovery Cycle/20 Hour Run/ Pre-Buy Off/Final Acceptance/Final

delivery of equipment; 2nd GM Shanghai Assembly Expansion-OEM’s support for (07) months at COMAU- PICO, Turin Italy 2005; 1st

time GE Fanuc introduce RX3i PLC’s instead of GE Fanuc CNC’s; project successfully completed and delivered on schedule.

Provided High Level of Technical Support to COMAU/Turin Italy making sure Jobs/Hour, Auto/Dry/Manual/Recovery Cycle achieved,

Pre-Buy Off/Final Acceptance process assisted and approved by GM Shanghai Chinese Engineers/Operators/Maintenance

personnel.

• Designed, developed, and implemented automation controls systems consisting of hardware/software architecture, PLC/PC code

development, using Cimplicity Manager Server network applications for Nissan Smyrna plant. Realized $500K annual savings for

Nissan by eliminating need for back-up programs CD/Floppy Disk vs. Server automatic scheduled back-up programs. Received

excellent Customer Satisfaction letter from Nissan.

• Developed, integrated, implemented Process Controls Systems Design, Proficy Real-Time Information Portal; a centralized

component of achieving a real time enterprise with a single, integrated tool for accessing, analyzing and visualizing production data.

Joint venture project with GE-US Water Ethanol Plant. Provided a web-based overview for all key metrics to operate production

efficiently and reporting capabilities of the high performance data storage ability of Proficy I Historian allowing user to focus on

continuous production improvement. Provided Start-up & Commissioned Ethanol project including Woodbury MI/Ord Nebraska/

Redfield South Dakota plant; all issues address and completed successfully just in time for production.

• Provided High Level of technical support for Start-up/Debug and controls commissioning machineries for Automotive Industry; GM, Ford,

Chrysler, and Nissan. Projects completed successfully Just In Time for production; GM Shanghai/ GM Flint/GM Bay City/GM Saginaw/GM

Defiance, Chrysler Kokomo/Toledo, Ford Bedford IN; & Nissan Smyrna TN.

QUANTUM CONTROLS INC., Plymouth, MI Mar 1993 - Dec1997

Senior Project Engineer / Sales Engineer

• Managed, developed, automation controls from concept idea thru designed including build, installations, integration, and implementation

of computerized seat delivery systems for GM Hamtramck and Lake Orion plant. Pre-scheduled and bar coded seats from Lear and Delphi

Corporation were transported by trucks to GM plant, unloaded and loaded, scanned and delivered by automated electrified monorail system

and dropped directly to the assembly line. Realized $1.5M annual savings by eliminating need for warehouse to store product vs. direct

delivery to assembly line.

• Controls Systems Integrator and experience Machine Tool Builder with Process Controls and Automation Control Systems Design

which include (PLC, CNC, DCS, HMI, SCADA) software applications programming such as Allen Bradley, Siemens S5 & Step 7/

WinnCC Flexible Programming, Mitsubishi, In Touch Wonder ware, Honeywell, and GE Fanuc products

• Designed, developed, automation controls using PLC/SCADA embedded systems for electrified monorail systems to deliver empty/full

pallets from (05) core machines to (03) casting machines. System included roller conveyors, lifts, transfers, buffer towers, and carriers

with AB RFID tags, AB PLC 5/60 for controls system at Ford Aluminum Casting Plant, Windsor Canada. Increased 95% production

efficiency and realized $1.2 M annual savings by eliminating manual operations vs. automation delivery system.

HESS OIL REFINERY, St. Croix, USVI Apr 1991 -Feb 1993

Engineering Supervisor / Electrical & Instrumentation

• Responsible for reviewing bids and proposals for sizing electrical substations design (HV, MV, and LV switchgears), protective

relaying interface design, load flow analysis and short circuit calculations. Evaluated bids, selected, recommended contractors,

developed cost estimates, prepared schedules, and oversaw budget costs. Expansion project installations completed successfully 20

days ahead of schedule.

• Responsible for the conversion of gasoline blending projects, Sulfur plants 3 and 4 from pneumatic controls to smart transmitters and

using Honeywell TDC 3000 system. Completed projects on schedule such as Benzene Recovery system, CEM’s analyzer sulfur

plants 1, 2, 3, 4, and waste recovery system.

EDP & CONTRACT SERVICES, Southfield, MI Mar 1990 - Mar1991

Controls Engineer - Technical Consultant

• Lead Engineer responsible for the software tools development for FIS (Factory Information Systems) at Chrysler Motor Corporation

Sterling Heights plant, which provided real time information of machine status, robots, AS/RS weld stations, conveyors, production

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counts, process controls, faults and alarms, downtime logs, upload and download programs to the system. Provided successful on-

site system implementation, product training and support resulting in a 96% effective client solution rate.

JERVIS B. WEBB COMPANY, Farmington Hills, MI May 1986 - Feb1990

Controls Engineer / Field Service Engineer

• Responsible for Hardware design and layout of industrial equipment for the following fields such as robotics, automation, unit

handling, bulk handling machines, chain conveyor system, electrified monorails, baggage handling conveyor system, heavy duty roller

conveyor system, Power & Free Conveyor system, and Inverted Power & Free Conveyor system.

• Responsible for complete turnkey design from electrical controls system to Panel Build, Machine assembly and wiring, PLC ladder

logic development and HMI screen programming applications for AB PLC’s 2/30, 2/15, 3, 5/60, RSLogix 5, 500, & 5000; and Siemens

Simatic S5/S7, WinCCFlex 2005; and GE Fanuc PC’s 90-30/90-70,GE HMI’s

• Designed and completed projects successfully just in time for production including Chrysler Warren Truck/Chrysler Kokomo Indiana/

Chrysler Sterling Heights/Belvidere Assembly plant; GM Detroit Hamtramck/GM Lake Orion/GM Flint/GM Warren Truck Assembly

plant; Ford Avon Lake/Ford Wixom/Ford Van Dyke Assembly plant; Venezuela Aluminum Plant and Chicago O-hare United Air Lines

Terminal Airport.

• Responsible for the Start-up & Debug of Jervis Webb conveyors which includes field wiring check out, debug PLC ladder logic,

change or modify HMI screens for controls and final commissioning of the controls system. Provided technical training for

maintenance personnel for the overall functionality of the controls system. Jobs completed successfully just in time for production.

TECHNICAL SKILLS

• Proven Green Belt Six Sigma Certified Professional & PMP (Project Management Professional) leader with proven track record of

managing teams that performs well under time and resource pressures.

• Controls Systems Integrator & Experience Machine Tool Builder with Process Controls and Automation Control Systems Design

including (PLC, CNC, DCS, HMI, SCADA) software applications programming such as Allen Bradley RSLogix 5, 500, 5000, Siemens

S5 / Step 7 V 5.5 & WinCC Flexible Programming 2009, Mitsubishi, In Touch Wonder ware, Honeywell TDC 3000, & GE Proficy (ME

8.0, Change Management, Real Time Information Portal, iHistorian, HMI/SCADA –iFix 4.5, CNC Series i(16/18/20/160).

• Extensive knowledge of Electrical Power Design including substations (HV, MV, & LV), load flow analysis, short circuit calculations,

schematic and physical drawings including 3 phase and single line diagrams, bid preparations, specifications and documentations.

Extensive knowledge with Electrical Codes including NEC.

• Extensive knowledge of AutoCAD Electrical 2009 including Mechanical, hydraulic, and custom panel build with complete schematic

wiring diagrams.

• Cisco Training & Certified - Interconnecting Cisco Network Devices Part 1 & 2 including LAN network systems.

• Proficient in Microsoft Outlook, Excel, Access, Word, Visio, Project, and PowerPoint

• Build Server PC’s / Desktop PC’s customized with all the necessary interface network devices including operating systems such as

Windows NT, 2000, XP, & 7.

EDUCATION

MBA, Technology Management, May 2005, University of Phoenix, USA

BSEE, May 1967, Feati University, Manila, Phil.

BSME, May 1971, Feati University, Manila Phil.

TRAINING / CERTIFICATIONS

Green Belt Six Sigma Certified, 2001

Open Control Programming Nematron PC, 2000

Open CNC Systems, 2002

Cimplicity ME 4.0, 2002

Cimworks Visual SPC, 2004

Proficy Plant Applications 4.0 Administrator and Reporting, 2004

Siemens Step 7 / WinCC Flexible Programming, 2009

LANGUAGES

Fluent in English, Portuguese & Spanish

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ASSOCIATIONS

Member, GE Elfun, 1998-present

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