Reliability Engineer, Process Engineer
Resume:
STEVE DEREN, M.Sc.
Toronto, Ontario M9R 2C3 *****.*****@*****.***
Engineering + Automation + Management + Project Management + Sales +
Manufacturing
Reliability / Process Engineer with more than 15 years of expertise in the
field of process engineering, maintenance and industrial automation,
including motion control, servos, AC/DC drives, robotics, PLCs, VLC and
PCs. Proven leader with strong problem-solving skills, equipment/process
troubleshooting and an established record of minimizing operational costs.
Provider of technical solutions and manufacturing improvement procedures.
AREAS OF EXPERTISE
Reliability Industrial Mechanical Manufacturing Risk Assessment
Engineering Automation Design Improvement Project Economics
Processing Electrical ACAD Fishbone, RCM
Engineering Engineering PSR Ivara, 5W, 5S, 8D Hazard Analysis
Application AC/DC Drives PCs Feasibility Study
Engineering Robotics Testing WCM, Kaizen
Manufacturing PLCs Procedures Cause Mapping Hazardous
Engineering Servos KPI, OEE Location Design
FMEA, PFMEA, FA Cost Reduction
Selling
SELECTED ACHIEVEMENTS
. Achieved cost reduction of more than CAN $283k (in one year) for a
brewing company through critical analysis and optimum inventory level
studies of spare parts, as well as failure analysis of machinery and
their elements.
. Conducted technical training sessions in Alberta for management and
maintenance staff of a sawmill that resulted in an order for 112 VFDs
(ranging from 5 - 300 HP), valued at CAN $800k.
. Achieved reduction of secondary production for a roof shingle plant
of 1.2% to 0.7% and fibreglass mat waste from 2.2% to 1.2% through
various manufacturing management procedures. Resulted in a time run
efficiency increase from 73% to 87% with a line speed increase from 530
to 560 fpm.
. Trained engineers and maintenance personnel in VFDs, servos, HMIs,
PLCs and VLCs for customers including GM, Toyota, Honda, Inco,
Weyerhaeuser Sawmills, and Apotex. Sessions incorporated "quiet" sales
techniques. Consistently praised for clearness of message delivery.
. Troubleshot automation equipment installed at customer sites in
Houston, Vancouver, Northern Canada, Montreal and Toronto. Consistently
provided solutions to both electrical and mechanical motion problems;
required occasional quick redesign of machinery in question as well as
new operational concepts.
. Successfully redesigned and troubleshot an electric system of 27
production cells for Level 4 safety in an automotive plant.
PROFESSIONAL EXPERIENCE
PACK-SMART INC., Concord, Canada (2013)
Manager of Electrical Department
Managed electricians at various types of electrical, pneumatic, panel
building, and control systems works for custom, high speed packing
machinery manufacturing (OEM). Developed mappings for such machinery
(ACAD), wiring schematics, troubleshot control system, set-up and tuned
air/vacuum pumps and Venturi valves operation sequences, and co-operated
with mechanics on the evaluation of machine reliability in the development
stage. Managed and participated (hands-on) in machine reversed engineering.
Developed BOM's, inventory level and works budget for the electrical
department.
AINSWORTH INC., Toronto, Canada (2011-2012)
Application Engineer/Designer
Designed various dedicated controllers and their automation procedures for
the medical and food industry, injection moulding, and automotive. Most
controllers were applicable to various classified environments for Class I
& II and Division 1 & 2 (A, B, C, D and E, F, G). The solutions provided
explosion-proof (XP) enclosures and standard 4X, with imbedded purging
system operated with air or nitrogen, where NEC (NFPA), CSC and ATEX
standards were applied (according to destination country). Designed
control for extruders and motor (PM), DC to AC conversion, and implemented
VFD drives to industrial blowers. Both designs included savings analysis
and ROI. Presented technical solutions to potential clients, including a
plan for a complete petroleum steel pipe manufacturing plant automation
control system overhaul.
STRATEGIC DISTRIBUTION INC., Bristol, Pennsylvania, US (2010-2011)
Reliability Engineer (at Molson Coors Canada) - Contract
Conducted studies and implemented programs to determine optimum inventory
levels and parts criticality. Originated and developed studies on elements
and system reliability and reviewed OEM spare parts list for newly
installed machinery, resulting in a savings of CAN $283k. Prepared
diagrams, charts, drawings and operational time studies. Ran functionality
tests on OEM substitutive parts and provided recommendations for their use.
Resulted in the replacement of less economical parts with more cost-
effective alternatives; some parts achieved a 300-percent cost savings.
Originated part test standards and set universal test methodology
(functional elements, test criteria, and heuristics). Used RCM techniques
(PM, PdM, MTTR) to avoid critical production failures and provided data for
asset managers. Conferred with engineers and advised on reliability
findings and recommendations. Initiated motor-gear combination
classification for inventory reduction. Recommended system changes (on
palletizers, de-palletizers, soaker, and pasteurizer) for better
performance, more reliable operation and cost reduction. Ran 5S (6S)
program for stores (Toronto and Vancouver) and audited changes after
primary implementation. Redesigned tool room and steel room storage set up
for better functionality and safety.
IKO INDUSTRIES LTD., Brampton, Canada (2007-2010)
Process Engineer
Provided technical guidance to plant management for this roof shingle
manufacturing plant. Plant manufactured about one million shingles/day and
process required full automation and data collection (PRODAC RS3000
system). Analyzed database for DT (Pareto analysis), production, run
performance, KPIs, waste management and "2nds" output. Led mechanical and
electrical system improvements, hazard analysis, PFMEA and safety projects.
Managed "Top 3" meetings that evaluated operational/technical DT and
provided semi-permanent solutions to commonly occurring problems. Collected
and analysed data sheet profiles from Ohmart system (a radioactive density
scanner), fixed computer/system problems, programmed shift schedules,
automatic palletizer assortment data and parameters. Assessed the adequacy
of engineering equipment, calibrated various dynamic weight scales and
volume sensors, redesigned multiple production systems. Run root cause
analysis of customer complaints. Developed and managed lab tests and data
analysis of raw materials physical properties. Sourced and procured all
necessary parts and materials, planned short- and long-term budgets. Wrote
SOPs for test and system manipulations.
KTH SHELBURNE MANUFACTURING INC., Shelburne, Canada (2001-2006)
Project Electrical Engineer
Supported production, maintenance, new developments and changes to existing
production cells as an Electrical/Automation Specialist for this highly-
automated (200-robots) automotive plant that manufactured car-chassis
frames. Programmed PLCs (GE Fanuc on the base of Logicmaster, VersaPro,
Cimplicity, and Mitsubishi - GPP, GX Developer) to accommodate new jigs and
models. Recommended new solutions to mechanics regarding actuators and
pneumatic equipment. Evaluated production cell capacity (each cell had
from 1 to 12 robots), made changes to proposals by Japanese subcontractor
designers (Hongo, Fanuc and Hirata). Developed safety standards (PSR) for
new and reorganized cells (Risk Assessment and Hazard Analysis). Developed
and programmed dynamic (time-related) overhead monitoring system for
production cells. Involved in project planning, development of purchasing
and project economics.
MITSUBISHI ELECTRIC AUTOMATION, Toronto, Canada (1997-2000)
Application Engineer
Directed custom training sessions on Mitsubishi products, including small
and large HP VFDs, vector drives, servo motors and their sizing, motion
controllers, HMIs (Mitsubishi and Beijers), PLC programming, and MC2
(Steeplechase software for PC-based control). Sold all the equipment.
Troubleshot various systems with a combination of the above-mentioned
products, provided complete process automation concepts and advised
customers of their options. Provided support for new product applications.
Commissioned new equipment installations in sawmills, automotive plants,
smelter and pulp industries. Advised OEMs on enclosure cabinet designs and
management of conductive and propagated RFI in power equipment. Proposed
new mechanical solutions better suited for servo applications for equipment
refurbishing and new applications. Wrote and edited technical application
notes, documents and commission reports. Programmed self-contained servo-
motion equipment for customer applications and trade shows. Designed,
constructed and managed approximately 30 demos and reprogrammed them based
on customer needs. Prepared PowerPoint presentations for training sessions
and new product introductions. Evaluated equipment for warranty claims and
damages.
EDUCATION
UNIVERSITY OF TORONTO, Comparative Education Services* - B.S. in Electrical
Engineering
*Technical University of Rzeszow, Rzeszow, Poland, M.S. in Industrial
Automation
CONTINUING DEVELOPMENT
. MITSUBISHI - Courses on PLC, VFDs, servos, motion control, and
VLC (Chicago)
. FANUC - J3 Fanuc Robot Controller - hardware course (Detroit)
. FANUC - Robot Teaching Course for Welding Applications (Toronto)
. GE-FANUC - PLC Programming with Cimplicity, Machine Edition
(Toronto)
. YASKAWA - Motion Control - servo motors and drives (Chicago)
. RYERSON - Assembler Programming (Toronto)
. HUMBER COLLEGE - Advanced PLCs Programming Techniques (Toronto)
. WRIGHT COLLEGE - BASIC programming for DEC and IBM computers
(Chicago)
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