PATRICK T. SCHAFER

515-***-**** acqjip@r.postjobfree.com

**** * *** *** * #2, Newton, IA, 50208

AUTOMATION / CONTROLS ENGINEER / ELECTRONIC ENGINEERING TECHNICIAN / SUPERVISOR

Self-sufficient, motivated worker with strong hands-on experience and technical and mechanical ability. Sustained work ethics include performing in high-demand, lean manufacturing environments, where quality, timeliness, and efficiency are of the essence. Solid diagnostic and problem-solving skills, including system design, programming, repair, and preventative maintenance. Abilities also include design, integration, and fabrication of new and/or existing machinery to fit or exceed company demands. Proficient areas include Rockwell Automation controls / Allen Bradley Micrologix/Contrologix PLC design, programming and troubleshooting, GE and Omron PLC troubleshooting, machine system design including AutoCAD and AutoCAD Electrical print development, DVT, Cognex, and Banner vision system integration, vacuum potting/injection of thermoplastics, vacuum and booster pump platforms and sensing equipment, injection molding, precision and custom Micro-Molding, hydraulic metering systems, setup and programming of SCARA and Cartesian robots. Also familiar with hot runner controls, precision motion control, VFD motor control, HVAC maintenance, laser/fiber-optic/sonar/proximity sensing, custom PID design and integration, and building electrical systems installation and troubleshooting. Experience with SW and W+D web converting machines. Seasoned in production line and production environment support roles of various capacities, including working in HAZMAT environments. Proficient with PC and peripheral usage. Physically fit and willing to meet demands, with organization and safety in mind. Willing to relocate or travel off-site as needed.

ACCOMPLISHMENTS

Programmed 500-point Contrologix PLC platform, and integrated and programmed associated motion hardware, robotics and vision systems into an automated injection molding work cell, resulting in a complete system that integrated molded parts on multiple leadframes, fully inspected, sorted, oriented, and packaged them at a constant average of 3 parts per second.

Integrated custom ladder-built PID-loops into complex automated systems to accommodate flow controls.

Worked with sales and quoting team members to negotiate off-site training terms with customers, including follow-up training for a multi-million dollar turn-key automation system (output cycle of 1.8 million injection molded, HIPOT tested and packaged parts per week).

Negotiated with internal sales and customers to align technical personnel training and improvement within the Automation and Engineering groups.

Helped design control schematics and build proprietary precision Micro-Molder machines, as well as seamlessly integrate custom secondary automation into Micro-Molder machine for inspection of fiber-optic transmission components using robotics, servo-controlled actuators, and vision systems.

Developed motion-control programming and communication between a Banner vision camera and an Epson SCARA robot for micron-based tracking and packaging for finished products.

Integrated and supported numerous Rockwell Automation PLC systems simultaneously to support production demands.

Diagnosed and worked with engineering staff to modify PLC architecture within Hedrich vacuum potting system, improving O.E.E. and production by 30%. This resulted in supplier making on-time shipments to Chrysler for the first time in over 13 months.

Fabricated new components and tailored them to existing automated systems, which resulted in a completely successful first-time production-run of prototype ignition system for '06+ Dodge Viper.

Trained with specialists from Germany: instruction on rebuild/repair of thermoplastic injection components and related vacuum potting system components.

Helped create, build, and modify new palletizing system, tailored to existing equipment, which helped improve O.E.E. and production quality to secure and sustain contract with new customer (SIA of North America).

Performed APQP and FMEA processes on existing and new equipment to secure contracts with General Motors.

Implemented new control systems and hardware to accommodate quality and customer requirements.

Directed engineering department and staff to implement new control systems to improve aspects of lean manufacturing and quality control.

Helped reduce manpower in assembly production areas by over 40%.

Designed new electrical layouts and schematics for a large soybean plant, including control systems as well as electrical distribution.

Designed electrical and mechanical schematics for new building expansion, as well as production machine placement, support equipment, and related infrastructure.

Designed new ink level sensing control for web tinting process using time-of-flight distance measuring retro-reflective lasers.

EXPERIENCE

Maintenance Tech II / Electronics, Fabrication and Electrical Design – JELD-WEN Windows, Grinnell, IA (2/2015-Present)

Fabricated and integrated new expansion enclosure into a large flow-through paint booth to utilize VFD control of 480VAC ventilation motors.

Installed multiple new electrical runs and service drops for machinery relocation and service stations.

Responsible for maintaining and repairing hundreds of different machines, work cells, and other facility infrastructure items and areas.

Upgraded/integrated existing equipment with newer designed mechanical fixtures, and electronic devices including but not limited to sensors, servos, motors, gearboxes, linear slides, and programming.

Responsible for documenting all activities daily into Titan software maintenance inventory system.

Maintenance / Electronics, Programming, Fabrication and Schematic Design / Production Supervisor – Priority Envelope Inc, Nevada, IA (9/2012-1/2015)

Integrated new PLC’s into existing equipment to utilize data logging for QTMS system.

Overhauled AC and DC electrical infrastructure on a prototype web converting machine to sustain higher levels of production with reduced downtime and support costs.

Designed new mechanical and electrical schematics for 50,000 sq ft production expansion, including all supported infrastructure for production needs.

Maintained and repaired HMI’s, PLC’s and peripheral controls, servos, servo drives, software enhancements, wiring, cooling systems, bearings and gearboxes, lubrication systems, hydraulics, and pneumatic controls.

Designed layout and installed new state-of-the-art plant-wide integrated high-CFM vacuum system.

Pursued and implemented numerous cost-saving solutions for production and overall plant infrastructure. Participation in new compressed air and vacuum layout and design resulted in $100,000+ per year in energy savings.

Supervised 17 employees to support production needs and logistics.

Integrated a web tinting process into an existing web delivery system, including the mechanical frame design, electrical design including controls, and a new ink level-sensing system using time-of-flight retro-reflective distance-measuring lasers.

Contract Controls Engineer – IAAAP (Iowa Army Ammunition Plant), American Ordnance, Middletown, IA (6/2011-6/2012)

Integrated into existing processes to understand and troubleshoot existing and new equipment with daily and real-time support.

Developed new troubleshooting guides and techniques for existing maintenance workers to diagnose problems and solve them quickly and safely in a hazardous Class 1 environment.

Troubleshooting, modification and integration of new control techniques with Allen Bradley PLC’s and other proprietary hardware.

Worked directly with contracted employees through the manufacturer and U.S. government inspectors and other government entities to ensure automation, quality, and safety controls were followed properly to ensure efficiency and safety of the equipment and personnel while manufacturing high-explosive ordnance for the U.S. Army, UN affiliates and other agencies.

Electrical Designer – The ESCO Group, Cedar Rapids, IA (3/2011-5/2011)

Designed new electrical layouts and schematics for a large soybean plant, including control systems as well as electrical distribution.

Utilized AutoCAD Electrical to exclusively design, document, and cross-link electrical data between hundred of drawings to fully link specific electrical pathway data between associated drawings, and to also assist programming and installation engineers with future integration.

Worked in a team environment to accomplish quick and constantly changing details.

Automation/Electronics Technician - Accumold, Ankeny, IA (11/2006-1/2011)

Construction, and technical automation support for Micro-Molder machines.

Responsible for design, hands-on installation, and support of new building electrical demands.

Responsible for engineering, design, documentation, hands-on building, programming, and support of new multi-million dollar automated systems for injected molded parts, inspection, packaging, and safety systems.

Responsible for being lead programmer, designer, and having extensive engineering knowledge and troubleshooter for the following specific automation components including (but not limited to):

- Allen Bradley: Micrologix 1000, 1100, 1200, 1400, and 1500 PLC’s

- Allen Bradley: CompactLogix and Contrologix PLC’s and associated hardware, Flex IO, etc

- Allen Bradley: SLC processors, also SCADA communications networking and support

- Denso Robotics: High-speed SCARA robots, programming, installation, and troubleshooting

- Yamaha Robotics: SCARA robots, programming, installation, and troubleshooting

- IAI Intelligent Actuator: SCARA robotics, and linear and rotary actuators, design, setup, programming, and maintenance.

- Star Automation: Cartesian robots, NC programming, installation, maintenance, modification

- GE / Proficy Machine Edition: PLC Programming and troubleshooting.

- Parker-Motion / Gemini drives: Linear and rotary actuators, installation, programming

- Yaskawa: MP2300 PLC’s, servo motors and linear actuators, troubleshooting and setup

- DVT/Cognex: Vision systems, high-speed, high-resolution, system integration and support

- Banner: Vision systems and safety, standard and high resolution, installation and support. Developed a software-driven motion-control platform over Ethernet to instruct an Epson SCARA robot to pinpoint packaging needs within a 0.015mm accuracy.

- SixNet, Moxa, Hirschmann, Cisco, Netgear: Industrial Ethernet setup and support for integrated automation platforms.

- Epson Robotics: Setup, integration, programming, and support.

- Sumitomo: Installation and integration of electric molding presses, into automated work cells

- Boy IMMs: Comprehensive troubleshooting and modification or molding presses to support production, and integrate automated inspection systems for micro-molded parts.

Responsible for coordinating outside suppliers for price competitiveness and support for automation projects.

Responsible for monitoring and maintaining HVAC and building support systems, and making modifications to the systems as necessary.

Responsible for working directly with Project, Engineering, and Production Managers to task automation projects within timelines to meet customer demands.

PLC programming above also included implementing new ladder-based programming for custom PID control into complex automated systems to accommodate flow control needs.

Technical Engineer and Manufacturing Supervisor - Penstone Inc., Rockwood, MI (12/2005-7/2006)

Responsible for directing maintenance and support staff to equipment and production processes as needed.

Responsible for designing new equipment and processes, including APQP and FMEA of processes.

Fully responsible for all PLC control systems engineering, integration, programming, and troubleshooting, as well as design and implementation of new systems (Allen Bradley and Omron).

Implemented new control systems and hardware to existing equipment to satisfy and exceed quality and customer requirements, and drastically improve overall PPM with customers.

Directed engineering department forward to establish new quality and efficiency goals, including the implementation of lean manufacturing and automation systems.

Supervised and trained 25 UAW employees for 6 weeks, in a Tier-II assembly process for GM.

Responsible for coordinating with third-party suppliers and contractors for component supply and support.

Lead responsibilities for design, programming, and full implementation of PLC and automation and related components to improve production requirements and improve overall efficiency of production process.

Potting/Maintenance Technician - Diamond Electric MFG CORP, Dundee, MI (3/1999-11/2005)

Trained production processes, quality, and safety standards to new employees.

Responsible for operation and making modifications to programming to meet O.E.E. and quality needs.

Exclusive knowledge of Hedrich, Sansow-Kikow, Lanly; schematics and repair.

Maintenance, including repair, modification, and fabrication to equipment in entire department, including:

- Vacuum pumps and boosters: Hedrich, Busch, Tuthill, and Leybold,

- Hydraulics: vane-pumps, hoses, cylinders, and precision metering scales,

- Pneumatics: multi-stage linear slides, rotary actuators, and valves,

- PLC equipment: Allen-Bradley, including Micrologix and Contrologix, and other integrated controllers,

- Sensors: proximity (EM), fiber-optic, photo-eye, laser, vacuum,

- Conveyor systems: Lanly, Hedrich, pulley and gear-driven,

- Heating: thermolators, forced-air ovens (Lanly), bands, fire rods,

- Electrical: 0-24VDC systems, 110-480VAC systems, supply, wiring, diagnostics and distribution.

- Robotics: Epson SCARA robotics, maintenance and support, and also FANUC 6-axis robotics, maintenance, programming, and troubleshooting.

Fabrication and upkeep of new equipment to support existing platforms for production requirements.

Use of MIG and TIG welding for repair and fabrication.

Maintained and calibrated thermoplastics dosing system to ensure proper precise processing requirements.

Carried out scheduled preventative maintenance tasks through regimented schedule.

Use of MP2 and PC resources to locate, delegate, and order spare parts as needed to supply demand.

Operated under QS-9000, TS-16149, Kaizen, and 5-S practices and standards.

Custom programming and diagnosis of PID functions, as well as new PID concepts and integration into PLC architecture to accommodate flow-control needs for given platforms.

EDUCATION

Ida High School, Ida, MI (1998)

Graduated with over $300,000 in awarded scholarships

United States Military Academy, West Point, NY (1998-1999)

Completed basic training and entered Corps of Cadets and Active Service in U.S. Army.

Completed academic year #991 and partial #992.

Honorably discharged from Active Service in U.S. Army, March 1999.

TRAINING

Rockwell Automation – Allen Bradley Micrologix maintenance and troubleshooting (5/2003).

Hedrich Vacuum Systems – Complete training of controls and components (2001)

Complete mechanical/electrical maintenance and troubleshooting online testing (7/2003).

Rockwell Automation – Allen Bradley Contrologix maintenance and troubleshooting (11/2006).

AutoCAD Basics and Beyond – (3/2007)

Denso Robotics – Integration and Programming (7/2007)

Star Automation – NC Programming (4/2008)

Rockwell Automation – Industrial Ethernet, RSLogix 5000, Contrologix, RSView (9/2008)

Yaskawa – MP2300 PLC Controls and Motion / Motionworks (5/2009)

Bosch-Rexroth – Drivetop and Indraworks Motion (6/2014)

Lisec automated glass cutting systems (4/2015)

REFERENCES AVAILIBLE UPON REQUEST

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