REX ALAN

BRADLEY

**** **** ***** ****

CELL: 1-919-***-****

Chapel Hill, NC 27516

abmah0@r.postjobfree.com

_________________________________________________________________________

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OBJECTIVE: Being an integral part of a conscious, growth and

innovation oriented environment where

synergy between departments, teams, and individuals, makes a

difference every day.

SUMMARY: My background encompasses over twenty years of diversified

experience in the Electronics and Industrial Automation fields.

Seven years of that experience was acquired in the U.S. Navy's

Advanced Electronics Field Program (AEF). The rest from various

industries - Lumber Manufacturing, Process Pharmaceuticals, Food,

Packaging/Labeling, a High Energy Physics research laboratory, and

Industrial Microwave Heating Systems. Descriptive titles:

Controls Technician, Maintenance Engineer, Equipment Reliability

Engineer, Continuous Improvement Engineer, Process Engineer,

Automation and Controls Designer, Field Service Engineer,

Electronics Engineering Technician

SKILLS: Control System Modification, Programming and Design - PLC,/

HMI, PC based, and Hard-

wired. Selection, Set-up, and Interfacing of SCADA systems

using various networks and PLC systems for Control, Data

Gathering, and Display. Component level through complex system

troubleshooting, Root-Cause Failure Analysis with recommendations,

Process Improvements, Preventive and Predictive maintenance

techniques, AUTOCAD used for E&I documentation.

Very comfortable with all computer and network flavors.

Comfortable with Database, scripting,

SQL, Report-writing languages, DOS, WinXX, NT/XP, Mac OS XX,

MSOffice Pro, Servers, Linux,

Internet, and wireless control systems. Excellent with

technical resources and manuals.

I have been OSHA, MSHA, and First-Responder certified .

Excellent comprehension of process

chemistry and physics principles. Have held Secret and Top

Secret Clearances.

1 INDUSTRIAL MICROWAVE SYSTEMS - Morrisville NC (2004 - 2006) -

Electronics Engineering Technician

- Technical support to all engineering staff including PLC programming

from spec, project rescue, and new technology searches.

- Assembled and tested prototypes of new proprietary electronic sensors

for product moisture, microwave power level,

and microwave leakage detection with the goal of creating both value-

added advantage to our systems and stand-

alone products. These projects included embedded controllers, surface

mount devices, and breadboarded assemblies.

- Used Labview to test new sensors and also to baseline emissions and

spectra from 100KW microwave generators.

- Troubleshooting of customer systems via telephone and site visits (USA &

Canada). Tech Support at trade shows.

- Created a clean, intuitive, standard HMI to be used with our microwave

heating systems - reducing future parts and programming costs. Extensive

macro-language programming in the HMI allowed process menu and security

functions to be removed from the PLC freeing up much PLC memory for data

and control. (AB SLC 500 & Maple-Systems HMI)

- Made numerous wiring and component placement changes to our 100 KW

Microwave Generator to create logical subsystem layout followed by

electrical drawing clean up. These changes simplified troubleshooting

and 3rd party manufacturing.

2 DUKE UNIVERSITY FREE ELECTRON LASER LAB - Durham NC (2002 - 2004) -

Operator/Technician

- Designed, documented, and performed numerous electrical control upgrades

to the Historic MARK III Free Electron

Laser System. Used AutoCAD, Excel, and Digital Camera to document

changes.

- Designed and built a rack-mounted multi-channel solid-state voltage

control system to greatly increase the lifetime of heating tapes used in

the high vacuum bake-out process. This replaced the use of bulky and

electrically dangerous

variac autotransformers. Became familiar with High Vacuum

practices, equipments, and procedures.

- Rebuilt a lost library of drawings, manuals, and other technical data

relevant to the understanding, operation, and troubleshooting of the

Historic MARK III Laser System.

- Analyzed legacy problems in networks of hundreds of temperature sensors

used throughout the OK-4 Ring-Laser System.

After signal analysis, use of alternate network topologies, and

logging of rs-232 communications, determined problem to

be in the labs own EPICS control system's serial protocol. My cost-

effective solution was a PC based software bridge to

mediate communication between the two systems using Excel, simple

DDE, and multiple serial ports.

3 AKG of AMERICA, INC - Mebane NC (Mar 2000 - Oct 2001) - Process Engineer

- PC <> iMAC Networking and LAN upgrades, implemented Maintain It Pro

Maintenance Management Software to begin automating work order flow, PM

Schedules, Tech Resource to Maintenance, Process Upgrades to Modicon

Quantum PLC and HP Process Control Systems(SCADA), R&D projects using

Cutler-Hammer and AB 500 PLC and HMI systems. Mapped entire facility

electrical system, created logical parent-child numbering scheme for

OSHA required labeling and Lock-out/Tag out procedures.

- Layoff due to economic upheaval - (911) Elimination of position.

4

5 LAMBERT SYSTEMS INC. - Greenville NC (1998 - 2000) - Project Engineer

- Styrotek, Raleigh NC. Engineering assistance to create Prototype of a

new shuttle-style bottle-labeling machine. Unique use of an ultrasonic

distance sensor to replace a rotary encoder as the machines primary

position sensor. Replacement of old "Brick" type GE PLC with GE 90-30

and touch-screen HMI. Upgrade of Safety features to a true re-settable E-

Stop for European market. Creation of I/O map for efficient PLC/HMI

communication and control. Creation of comprehensive status display and

fault diagnostics with appropriate graphics and pictures to assist

operations and maintenance personnel. Analog control of machine speed.

Extensive electrical design changes. On screen control and adjustments of

all Machine parameters. Ultrasonic sensor data not timely enough for

positioning. Devised alternate scheme using precision timing and

quadratic equations to accurately derive machine position in real time.

- Glaxo-Wellcome, Greenville, NC Set-up and programming of a unique

WonderWare based SCADA system to monitor MCC rooms and substations

facility-wide.

- Styrotek, Brazil, South America. Engineering assistance, GE 90-30 PLC

and Xycom HMI Software upgrade for Rotary bottle labeling machines at

various sites in Brazil, South America. Installed and de-bugged

additional logic to comprehensively detect encoder system malfunctions.

HMI logic was upgraded to display the various fault modes and provide

guidance to maintenance personnel for troubleshooting. When software was

finalized, visited various sites throughout Brazil to install,

demonstrate, and train the new features for Operations and Maintenance

personnel. (5wks)

THE EAST GROUP, CONTROLS DIVISION, Greenville NC (1996 - 1998),

Automation and Controls Specialist.

- Designed Screens for Eaton PanelMate HMI on AB Fiber Optic Data Highway

controlling a 3500HP Booster Pump moving process water and mine tailings

in tandem with another 3500HP pump 3 miles away. Animated graphics to

show system status including main pump, various detail and tuning

screens. Designed algorithm and programmed logic to avoid low suction

pressure emergency shutdown by smoothly reducing actual pump RPM vs.

Target RPM until desired flow was established. PCS Phosphate Aurora NC.

- Rejects Disposal System to pump phosphate ore rejects to spent mine pits

for land reclamation instead of conveying to a storage pile. The speed

of two tandem pumps were controlled to maintain level as constant water

flow and varying amounts of reject material entered the tank. Reject

material was directed by a three position chute to the tank, the original

conveyor, or to an abort bin. Designed graphics-intensive screens for

PanelMate HMI which were required to give the operator at-a-glance

critical status information during upset conditions. Created E&I

drawings, PCS Phosphate Aurora NC.

- R&D Pilot project Controls design, Installation, Startup, and

Modification. Created Logic, Loop, and Elementary dwgs. for client

confidential one-of-a-kind test bed for a new material separation

technology. Constant modifications throughout the two-week start-up

period to adapt to changing test requirements. Dwgs were constantly

redlined and sketches made on-the-fly for construction personnel to

implement. Cascaded temperature loops controlling cooling water flow and

several material flow control loops fed to AB 1336+ VF drives, capacitive

level sensing. High thermal inertia material was cooled from a varying

600 to 1000 F to between 250 and 300 F at varying flow rates. PCS

Phosphate Aurora NC.

- Member of On-Site Technical Support Team for Proctor and Gamble,

Greenville NC. Created Pre-work, Construction drawings & Electrical

Installation Packages for Attends Line #2 Glue Tank Upgrade. Provided

various types of assistance for numerous production line modifications

and upgrades. Troubleshooting assistance and De-bugging of existing PLC

and Eaton PanelMate logic. Redlined, updated and verified Logic Drawings

for record. Designed logic to detect and record various pressure

anomalies that were causing emergency nuisance shutdowns of critical

Pneumatic conveyor systems. Captured data was used to determine root-

cause of shutdowns. Assisted with Always Line 4 (MAUI) Redlines and PSI.

Created a WonderWare InTouch SCADA demo tailored for our client's

facility.

6 LAMBERT SYSTEMS INC. - Greenville NC (1995 - 1996) - Project Engineer

- Reverse engineered and greatly enhanced corrupted GE 90-70 PLC and AB

PLC software from an older 8-head rotary bottle-labeling machine.

Created a new high-performance series of programs for new 8, 12, & 18

head machines using a different I/O scheme, GE 90-30 PLC, and efficient

programming.

- Installed and de-bugged / enhanced software for 18 head machines at

various sites in Brazil South America. These machines were released

prematurely, with different I/O (Genius Blocks vs. 2 PLCs) including a

legacy Serial #001 AB PLC 5/30 system. Styrotek, Raleigh, NC. Trained

Operations and Maintenance Personnel on new features at each site.

- Designed and Implemented Control wiring changes to a Hazardous Waste

Incineration System to allow remote control capability via Foxboro DCS.

GlaxoWellcome - Greenville, NC.

- PLC code de-bug and start-up of a wastewater pH control system @

GlaxoWellcome, RTP, NC.

- Analyzed random electrical noise problems on an M-Trim DC drive

controller based specialty textile line. Made recommendations which when

implemented, resulted in 100% availability. Collins and Aikman -

Greenville, NC.

WEYERHAEUSER MAINTENANCE, Weyerhaeuser - Ayden NC (1994 - 1995)

FLUOR-DANIEL MAINTENANCE Project 2520 @ Weyerhaeuser - Ayden NC (1991

- 1994)

- Equipment Improvement Engineer, Plant wide responsibility for control

system modifications: Responsible for control wiring, PLC programming,

and documentation of major system additions and modifications including

VF drives, Soft-Start systems, DC Injection Brakes, Hydraulic and

pneumatic devices, motors, Conveyors, Start sequences, Interlocking,

Fault detection, Etc.

- Investigation and analysis of problems in all site systems (Root-cause

Failure Analysis) Made recommendations to operations and maintenance as

to modifications, PM and cleaning schedules.

- Key role in implementation of Maximo CMMS (Gupta Database) to include

the creation of an equipment numbering system that accurately depicted

the logical process relationship of each piece of equipment yet allowed

for full breakdown of assemblies and flexibility for change. This was a

work culture paradigm shift from hand-written work orders to a plant

wide, networked tracking system.

- Created complex reports using SQL and Gupta report scripting language

to monitor dollars/man-hours/parts usage per machine center. Utilized

RBASE and SQL to analyze downtime and cause data by machine center.

Reports tracked performance improvement and justification of

modifications.

FLUOR-DANIEL MAINTENANCE Project 2520, Weyerhaeuser, Commissioning and

Start-Up (1989-1991)

- Key member of Commissioning and Start-Up team and Contributing member of

weekly punch list meetings.

- Worked closely with the electrical design engineer of the facility

learning good electrical / controls practice and proper engineering

documentation techniques to implement an accurate history of original

installation and redline changes.

- Assisted various vendor PLC programmers and technical resources during

equipment installation to gain an in-depth understanding of their

products for Quality Assurance and acceptance testing.

- Was responsible for electrical commissioning and knowledge of entire

LINCK Profiling Line (A German saw milling system never tried before in

the US.) with 18 VF Drives, Setworks, 7 Hydraulic systems and largest PLC

implementation on site.

- Solved and assisted in solving numerous electrical and control

challenges mill wide during commissioning and startup.

I have ended a challenging marriage in a friendly way...

I became a Summer camp and After school counselor for Spence's Community

and Educational Farm in

Chapel Hill, NC. This has allowed me the opportunity to really know

children and improve my

communication ability all people. I led the campers on long hikes. Drove

them via bus on field-trips to points of interest. Had responsibility for

the safety and behavioral coaching of up to 20 children at a time.

I also handled technical issues with the farm and educational equipment.

Planned a comprehensive drip irrigation system for all of the different

organic crops, fruit trees, and bushes. Rebuilt / repaired an electric

kiln for the art classroom. Provided resolution of computer network issues,

WI-FI management, and security. Pond water quality, pumping and filtration

issues. Assessment of current maintenance and PM issues.

Creation of preventive maintenance manuals for heavy duty equipments (Log

Chipper, 4wd Tractor)

I enrolled in Basic and Advanced Personal Effectiveness training courses,

along with 4 months of leadership

coaching, weekend classes, and, a team-building ropes course at The Legacy

Center in Morrisville, NC.

I have taken real action to live a life of no-regrets.

I created a long-term musical project/group called New River Uprising. Our

music encourages personal

responsibility, forwarding thoughts and actions, and stewardship of all we

share in common. It is for everyone.

We perform to either raise awareness or money for a cause and also

occasionally just for fun.

I have taken a little time to fill-in unwritten areas of my life by

focusing on some very different possibilities

while turning-around some things that have caused dissatisfaction.

The economy is turning around now, I am ready to move forward on my regular

career path of Industrial Automation Design, PLC/HMI programming,

Electronics Engineering Technician, CMMS coordinator,

Maintenance/Reliability engineering, and Field Service Engineering. My

mind is fresh, I have a clear

personal vision, and new people skills to bring into my work.

I am always a computer/electronics and technology hobbyist and keep my

troubleshooting skills sharp

while I experiment with digital and analog circuits, different types of

programming, PC repair, removing viruses for friends. Lately, I'm learning

the basics of VPN.

Sincerely,

Rex A. Bradley

1 M RELIABILITY:

- Palomar - Vibration analysis course - System Setup, Route creation,

Data collection and Interpretation, theory -

Raleigh, NC

- Mechanical Failure Analysis and Prevention - Heinz P. Bloch

-

- SCADA - HMI: Rockwell SW RSView, 500, 5000

WonderWare - Control & HMI Design Course - Irvine CA Campus

USDATA/FactoryLink PC based HMI Software - Raleigh, NC.

Microsoft Network Management at Microsoft Campus - Seattle

HMI: PanelMate, Maple Systems, XyCom, PanelView, etc.

- CMMS for Maintenance, Reliability, and Justification:

- MAXIMO with SQL and Crystal Report Writer

- Maintain IT PRO, Fluor Corp - Maintenance Planner Course + CMMS.

LEADERSHIP:

Fluor Corp - Principles of Leadership 1 and 2 - Greenville, SC Campus

Legacy Center - Personal Effectiveness I and II, Group Effectiveness

and Leadership with 4 Mos of Coaching, Team-Building Ropes Course,

Morrisville, NC

-

- EDUCATION AND TRAINING...

- Washington High School, Washington NC

- Various college level, Math and English courses

- Military electronics theory and equipment-specific technical courses.

HF, VHF, UHF and Satcom systems. Military alone equivalent to

over 34 Credit Hours Electronics/Computer Theory, Troubleshooting,

and Lab.

TI and Harris computer systems (NOT PC - Repair and Sys Admin.

Nav and Air Search RADARs, and Industrial and Scientific Microwave

Generators (to 250KW CW and 40 MW pulse)

Microelectronics repair, QA, Test equipment management, etc...

CONTROLLERS:

- Allen Bradley PLC-5 and SLC- 500 & 1200 series.

GE / Fanuc Series Micro, 90/20, 90/30, and 90/70

Westinghouse PLC series 700 (ECU Greenville)

- Moore 354 Programmable Loop Controller

VF DRIVES: Various Industry Theory and Lab Courses.

- For Allen Bradley, Toshiba, Baldor, and Eaton VF Drives

- covering both V V I (6 step) and PWM types.

- 5-500 HP.

... AN ADDENDUM to my Resume... Off the beaten path

Since 2007... Rex A. Bradley

April, 23, 2010

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