Robert A. Bauman

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

Ann Arbor, MI *8103

Home: 734-***-****

Cell: 313-***-****

Email: abnin4@r.postjobfree.com

Objective: To obtain a long-term, challenging position as a Senior Robotics/Automation Engineer with opportunity

for growth.

Current Position:

American Axle & Manufacturing, Detroit, MI

Corporate Controls Engineering Manager/Senior Electrical Engineer Supervisor (Front/Rear Axle Divisions)

May 1998 - present

-Design Electrical Circuitry for current plant machinery.

-Program HMI's using PanelView32 for Allen Bradley 550, 600, 900, 1000, 1200 and 1400 monitors.

-Program HMI's using Iconics and Intellution for SteepleChase Software stations.

-Program Ladder Logic using A.B. PLC-5, SLC 500, Control Logix 5000 & Modicon 484, 584 & 984 also

GE Fanuc 90-30 PLC’s.

-Program Visual Logic Controllers using Steeplechase for retrofits and assembly lines.

-Experience troubleshooting Assembly/Machining Lines: I/R, ICA, Wilson, Excello, Cross, Lamb, Trio, Krause

Lines along with their material handling systems.

-Troubleshooting and Integration of Fanuc Robots that interface with automation and CNC machines. Also teach

points, develop/edit program (All robot programming which includes Main, Macros and Recovery programs written

in house) and proved AutoCAD drawings for skilled trade. Communications network that we are using to perform

our integrations are: Remote I/O, Ethernet and Interbus-S. (2004: integration of 4 Robots, 2005: 5 Robots integrated

to our plants, 2006: 8 Robot integrations for Front and Rear Axle Division, 2007: 10 Robot integrations completed

for Front and Rear Axle Division and 5 more in our Plant in Mexico during summer shut down. 2008: 8 Robot

integration in our Front and Rear axle division for material handling. All work is being performed in-house, also all

integrations interfacing with VLC, AB SCL-500, PLC 5 and Control Logix 5000.) Integration of Fanuc Robots

using FAPT LADDER III for the robot PLC and created HMI’s for the Fanuc Teach Pendent this type of system

was for total cell control or for a stand alone system…

-Programmed, Integrated and performed application with Cognex Checker cameras: applications were checking if

the right components were put on the axles during assembly also checked to make sure the right seals were applied

to the axles, and to make sure the carriers had holes drilled in them. Also programmed and integrated application

using DVT camera and Frameworks software package for detecting different types of Flanges for the Axles.

-Troubleshoot CNC Machinery, Fanuc Power mate, 18i, 160i & 180i also AB 9/230, AB 9/260 and AB 9/290

Controllers.

-Troubleshoot and program Indramat Trans-01D Systems.

-Troubleshoot AC & DC Drive Packages, for in plant machinery.

-Work with Integrators to interface Open Controls Systems to the plants in Detroit, Three Rivers and Mexico.

-Supervise installation of new machinery, automation and conveyor systems in Detroit, Three Rivers and Mexico.

-Supervise skilled trades and engineering staff for plant projects in Detroit, Three Rivers and Mexico.

-Used Projects and time lines using Microsoft Project.

-Used Power Point for Presentations to upper Management and Specification seminars.

-Used Excel for putting together reports, schedules and time sheets.

-Used Word for memos, reports and specification sheets.

Projects/Duties:

In our Three Rivers Plant: I did the Atlas Copco PF3000 Power Tool Controller upgrades on the 11.5 Axle Line.

This consists of removing all of the old rundown guns and providing prints for the Atlas Copco, Power and Ethernet

configuration of the guns for interlocks and communications to the VLC. Also I wrote all of the VLC logic; and

integrated macros for communication, pass/fail and data handling of the guns. This logic was utilized for all our

integrations in the Three Rivers and Mexico plants for the new Atlas Copco guns. This project protected the

customer and supplied the plants with the QIS information that they needed.

I put in 8 Fanuc LR mates for Uson Leak Test/Oil Fill on the axles, and wrote the robot TP programs along with the

PLC/VLC programs for the robot interface. With this we utilized the Soft Float Option on the robot because we had

issues with the axle and pallet being in the proper position; therefore we opened up the Soft Float parameters for the

X & Y axis. This let us be more consistent with the Uson Tester/Oil Fill position/location, no issues with any of the

applications after we installed the Option. All robots had a one button recovery, therefore the operator did not have

to pick up the teach pendent. On each of these applications the lines were running 2 to 3 shifts so we eliminated 4 to

6 heads per line with a pay back of $400,000/$600,000 on each project. The projects pay back was within 3 months.

These projects were completed in Three Rivers, Detroit and Mexico plants.

I also put in Fanuc Robot M-900 with RJ3IB controls for material handling and NVH testing of axles at the end of

the assembly line and wrote the robot TP programs along with the Control Logix programs for the robot interface.

This application unloaded the axles off of the line and put them on the accept/reject conveyor and on the 6th axle, It

would drop the axle off to the NVH and send a cycle start/robot clear over to the NVH. Interface was Remote I/O to

the Control Logix, Robot and SCL500 on the NVH control. On this application the line was running 2 shifts

therefore we eliminated 3 heads per shift; this system was put in to double the output of the line.

I was called into our plant in Mexico to work on a Fanuc M-710i robot with an R-30iA controller with the iRVision

2DL and 7th axis to load a Hung Mass to the axle on the NVH machine. This was a very difficult application for the

integration house and for Fanuc engineers. The issue was positioning the 7th axis when handling the Hung Mass;

during the removal of the Hung Mass from the axle you could only move the 7th axis 300 degrees or you will lockup

the Hung Mass up and rip the belt off of the 7th axis motor. I was able to control the 7th axis by capturing the position

of the 7th at the last moving after unloading the Hung Mass from the NVH and loading that position into a position

register and keep loading that position into any move that the robot was going into. I also disabled the 7th axis from

moving during a move home program in which I disabled Group 2 move in this program. With this application we

controlled the 7th axis movement with TORQUE LIMIT option this controlled the position and the amount of

Torque that was aloud to put on the Hung Mass during loading and unloading.

On another project I was called in to our Front Axle plant to make modification on one of our new assembly lines,

the line came in making 325 parts per shift it was supposed to be making 950 to 1000 per shift. I was giving a team

of 3 engineers to make the appropriate changes to the line to bring it up to speed, we were able to do this by first

making changes to the so the job setters could recover from any fault that occurred. We add a One Button Recovery

for the entire line, 39 stations total. Secondly we started to point out the mechanical limitations that the stations were

having with the FIS and the cycle time issues. We installed the American Axle FIS flowcharts to all of the stations.

We also changed out hardware on all of the robots EOAT because the switches that they were using were 5 position

programmable devices that the plant electricians could not maintain and the stations were having continuous faults.

We also installed a unload robot with two conveyors to unload at the end of the line, one reason was to have a buffer

of the parts so we could get ahead of the assembly line and the other reason for doing this was because the operators

unloading were cracking the axles while removing the axle from the pallets. Some of the other stations were also

having limitations presenting seals, bearings and vent plugs to the axle therefore we installed Cognex Checker

Cameras to the station to safe guard the axle from miss build problems. After 4 month of the above issues and re

programming the stations we were able to make 950 plus axles per shift for the plant.

-Utilized: AB 6200 and Rslogix's software for PLC-5, Control Logix 5000 & SLC-500; Taylor and Proworx’s

software for Modicon's; Fanuc Proficy Machine Edition; SteepleChase; RoboGuide, WinTPE, Handling Pro,

Kfloppy and Front page software for Fanuc Robots; Update and Deliver prints to Skill trade using AutoCad 2006:

Microsoft Office (Outlook, Word, Excel, PowerPoint, Access, Java), Microsoft Project. ODS software for AB

CNC’s, FLadder for Fanuc CNC’s and Robots, also Front Page Software for Robot Teach Pendent HMI…

Curtron Incorporated, Troy, MI

Systems Engineer

September, 1997 - May, 1998

-Program VLC using Steeplechase software for retrofits on Feeders and Straighteners.

-Use Steeplechase MMI for Front End of Control System Design

-Design Machine Layout and I/O points using AutoCAD R13

-Perform Programming, start-up and debug of retrofits on customer site.

-Supervise skilled trades for plant installations.

-Utilized: Windows NT

(Retrofits were being done at GM Warren Power Train Division)

Project/Duties:

On this system I did all the AutoCAD prints and design for the machines, along with the VLC programming. I did

all of the debug, startup and I/O check out with GM electricians. After systems were up I would train the job setters

and maintenance department on how to run the machines and debug any issues that they would run into.

Manufacturing Data Systems, Inc. (MDSI), Ann Arbor, MI

Applications Engineer

January 1997 - September 1997

-Provided field support and customer training for software based CNC Controls

-Designed Relay Control Logic and Control Logic for CNC machine tools

-Programmed PLC using ISaGRAF software; Languages include Structured Text, Ladder, List Instructions and

Sequential Function Charts

-Designed MMI in a Structured Text Environment

-Performed Programming, Start-up and Debug for CNC Machine Tool on customer site.

-Supervise skilled trades for plant installations.

Projects/Duties:

At MDSI: I would do phone support along with CNC integrations at the customer site. This would include marking

up/red lining prints, writing all the PLC programs and setting up parameters for the CNC and the drives on the

machines. After machine startup I would setup the drives and work with the maintenance department and operators

on operations of the CNC’s. We used the ISaGRAF software package to write the logic for the CNC, this software

package would aloud us the use Basic, Structure Text, Function Blocks and Ladder to write logic. With this system

we would compile the PLC logic in Windows and then run the CNC programs in a Unix platform.

-Utilized: Windows 95 and QNX

Autocon Technologies (formerly DynaPath Systems)

Manager, Application Engineering

December 1994 - January 1997

-Forecasted Application Engineering budget for FY 1994 thru 1997

-Managed projects to ensure completion

-Documented hardware tests for the Delta ISA Check Out Procedure

-Presented weekly status reports on all projects and open Issues to management and customers.

-Performed Start-Up Operations and Training for Overseas Offices in the Asian and European Markets.

Autocon Technologies

(formerly DynaPath Systems)

Application / Sales Engineer

January 1988 - December 1994

-Developed Product Demonstrations and Presentations for Autocon Controls

-Pre-Sales Support for Autocon Controls

-Programming ladder interface for CNC Machine Tool

-Performed Programming, Start-Up and Debug for Machine Control Applications on customer site.

-Designed Electrical Control Panels

-Experienced in the use of AC/DC Servos and AC Spindle Drive Packages

-Supervise skilled trades for plant installations.

Projects/Duties:

At AutoCon: I would do phone support along with CNC integrations at the customer site. This would include

marking up/red lining prints, writing all the PLC Structure Text logic and setting up parameters for the CNC and the

drives on the machines. After machine startup I would setup the drives and work with the maintenance department

and operators on operations of the CNC’s. I would also travel the world and setup distributors and train their

service/sales department so they could sell and maintain the equipment. Travels included Main Land China, Taiwan,

Philippians, Korea, Sweden, Italy, Brussels and Spain.

Other

Experience:

Lear Siegler Seating Division

Electrician, September 1987 - January 1988

Projects/Duties:

At Lear Siegler: I was an Electrician; duties included wiring and marking up prints on machines coming into the

plants, also supported the plants which would be debug of issues on the machines and conveyor systems. I utilized

and worked with Allen Brandy PLC 2 to run the conveyors and machines.

Future Technology Inc.

Electrician\Technician, January 1987 - September 1987

Projects/Duties:

At Future Tech.: I was an Electrician; we built machines and conveyors systems for the Big Three. The duties

included wiring and marking up prints, piping pneumatics and machining parts for the machines/robotics systems. I

utilized Mills, Lathes and Grinders, we made all of the parts for the machines in-house and then put the systems

together and performed run offs/setup for the customers.

Education:

-Master of Science in Information Systems, Lawrence Technological University (June, 2003)

-Bachelor of Business Administration in Applied Business, Detroit College of Business (August, 1999)

-Associate Degree in Electronic Technology, Henry Ford Community College (August, 1987)

- planned to return in the fall of ‘09 for Bachelor in Computer Science

Certification:

-Fanuc Robot: V-iRVision Operation and Programming – 2DL & 3DL

-Fanuc Robot: Handling Tool Programming for RJ3iB Robot Controllers

-Fanuc CNC: Maintenance class for 160I CNC

-AB: ControlLogic 5000 Training Seminar for Engineering

-Siemens: Simatic S7-300 PLC Training

-Phoenix Contact Inc.: Interbus_S Level 1 Technical Training Course

-Steeplechase Software: Visual Logic Controller Developers Course

-Steeplechase Software: Advance Visual Logic Controller Developers Course

-Eastern Michigan University: Process Failure Mode and Effect Analysis (PFMEA)

-Toyoda Machinery USA: CNC Maintenance/Programming Fanuc 160I/180I

-Rexroth Indramant Training: TRANS 01-D Tranfer Line Control

-Daewoo Machinery USA: Daewoo DMV-400 and Puma-300 Electrical Training

References:

Available upon request

Contact this candidate