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Engineer PLC Controls

Taylor, Michigan, United States
June 07, 2019

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LARRY TESSARI— Electrical Controls Engineer or Project Manager

**** **** **., ******, ** 48180



• Experience in Control System Design, hardware, and software (HMI/PLC, Allen Bradley, Siemens, and several others.)

• Experience in Management and Leadership. Excellent organizational, communication and interpersonal skills.

• Detroit Area Candidate can travel 20%, can’t relocate. Physical limitations prefer desk-based positions to plant floor.


• Initiative-taking innovative leader or a team player who uses a valuable blend of interpersonal and technical skills to drive engineering efficiency and productivity, with experience in the hands-on control system and building/facilities design including project and personnel management, engineering, financial, and supervisory duties.

• Project Management: feasibility studies, cost estimates, cost-benefit analysis, specification writing, project preparation, competitive bidding RFQs, OEM selection, supervision, coordination, design approval, timeline management, scope management, quality management, resource management, cost management, risk control, machine runoff, installation, debugging, operator and maintenance training, and billing verification. Managed the installation of a conveyor system commissioned at GM Janesville two months ahead of schedule and $80,000 under budget while achieving zero personnel injuries, safety infractions, or work slowdowns. Successfully managed projects up to $5.5M

• Personnel Management: coaching, mentoring, development, training and supervision of engineers and skilled tradesmen, employee and team motivation, candidate evaluation, hiring recommendation, performance review, conflict resolution, and grievance resolution. Managed 6 engineers, 14 electricians, and 2 millwrights in a union shop environment at Ford Motor Company.

• Control System Design: Hardware design, material requisition, software programming, build supervision, installation, startup, debugging, commissioning, and troubleshooting. Created PLC/HMI programs with comprehensive diagnostics (Poka-Yoke) to improve process capability, system uptime, throughput, reliability, both in the machine HMI and in the FIS to increase Mean Time Between Failures (MTBF) and reduce Mean Time to Repair (MTTR) for greater error-proofing and preventing, correcting, or drawing attention to errors either before or as soon as they occur. Have done both revisions to existing systems and design from scratch.

• Architectural/Facilities: lighting, fire protection, communications networks, substation, switchgear, bus duct, load study, trip coordination, power distribution, power factor correction, energy management, HVAC. Did the last large substation/bus duct upgrade at a Ford parts plant entirely in-house without the aid of outside consultants, The project consisted of a medium-voltage substation, two 5,200-volt substations, several 5,200-volt motor controllers and several 480-volt substations and over 2000 feet of bus duct. Completed project on time and within budget.

• Accomplishments: Developed a simple control system for an automatic tool changer for Valeo that incorporated energy-saving design and extensive diagnostics, including cycle-time totalizers, which gave user-screen prompting when the tool changer needed periodic and preventive maintenance. Devised a simplified control scheme for a filtration system that used an SLC-5-04 PLC rather than the more expensive PLC-5-20 previously used. Rewrote programs in Microsoft Basic to make several gauging stations at two Allied Signal plants Y2K compliant, ending the need for a company to spend $20,000 to replace the stations. Added a safety pendant to several existing milling machines at Ford Batavia for automatic transmission valve bodies, allowing setup personnel to enter the machine’s work area to make adjustments without risk of injury. Designed revisions to a gear deburring system at Ford Batavia that reduced failure rates by35%


Programmable Controller/HMI:

• Siemens Step 5, Step 7, Graph, Siematic, ProTool, Transline, WinCC Flex

• Allen Bradley/Rockwell SLC,PLC5,500,5000,ControlLogix,GuardLogix,RSLogix,PanelView,FactoryTalkViewME

• Telemecanique PL7, Magellis, UnityPro, Vijeo

• Modicon 384, 484, 584, 984, PanelMate, Concept

• Barber Coleman Maco4, Maco8000, Edic

• ABB Masterpiece

• Vision Systems Cognex Checker, Keyence, Sick,

• Emerson DeltaV (HW only)

• Networks RSNetworx, DeviceNet, ControlNet, Profibus, Profinet, Fieldbus, AS-I bus, Modbus, DH+, RIO, Ethernet/IP

• Robots Prab, Kuka, ABB, IRB, Tralfa, and GCA CIMcon

• Vehicle Networks MOST, LIN, CAN, GMLAN, Optolyser Suite, Intrepid Vehicle Spy

• Instrumentation P&ID, Loop Drawings,4-20 mA Current Loop, Hart Protocol, Pneumatics, Hydraulics, Actuators

• Software AutoCAD Electrical, Microsoft Project

• Safety Standards CE, UL, NFPA 79 (ESIM), NFPA 70 (NEC), UL508, ANSI B11.19, ANSI R15.06, IEC 61508, IEEE 1584


Controls Engineer

FCA Chrysler, Auburn Hills, MI June 2018-April 2019

• Created template PLC and HMI software to communicate with the APICS, AVI, FIS, PFCS, and QAS systems using RSLogix5, RSLogix 5000, Studio 5000, Factorytalk View for vendors to use. Worked with machine tool builders to ensure plant floor equipment communicates with upper-level systems so vehicles are built with correct options, colors, etc.

• Responded to plant problems and aid in resolving them so production can continue.

Controls Engineer

Jervis B. Webb, Farmington Hills, MI. March 2016-November 2016

• Upgraded airport baggage handling systems using multiple Siemens Step 7 PLCs with ladder logic, statement list (STL), and Profibus. The system had hot standby to automatically switch to the backup processor to avoid unnecessary failures.

• Debugged software on a simulator significantly reducing in-field startup time.

Controls Engineer

Global Rollforming Systems, Roseville, MI. September 2015-December 2015

• Supported maintenance electricians and programmed interfaces to plant supervisory network (SCADA) using Allen Bradley RSLogix with Panelview and Factorytalk View HMI.

Infotainment Engineer

General Motors, Warren, MI. November 2011-September 2013

• Tested and validated software for Infotainment systems on MOST, LIN GMLAN and CAN networks from various suppliers using Optolyser Suite and Intrepid Vehicle Spy. Systems included Cadillac Cue, Chevy MyLink, Buick Intellilink.

• Troubleshot issue causes and entered problems in the ESIMS database and communicated findings with suppliers.

Controls Engineer

Filtra-Systems, Farmington Hills, MI. July 2011-September 2011

• Designed control system hardware and software for filtration of industrial coolants using Siemens Step 7 with WinCC Flex using ladder logic and STL and Telemecanique Unity Pro PLCs and AutoCAD for hardware design.

Test Engineer

GE Transportation Division, Erie PA. May 2010-July 2011

• Regression tested hardware and software controlling diesel locomotive engines up to 4500 horsepower.

• Wrote and published technical and purchase specifications.

• Designed test panel that reduced test time by 22%, had fabricated and debugged.

Process Controls Engineer

Indicon Corporation, Sterling Heights, MI. August 2009-March 2010

• Designed hardware (AutoCAD) and software, fora control system for T. I. Simon Power Plant at Michigan State University, including controls building, substation equipment, and control system using Allen Bradley GuardLogix PLC with safety I/O, Ethernet interfaces to auxiliary equipment and FactoryTalk based HMI

• Worked with the mechanical engineer and building supplier to coordinate facilities in the building and ensure that the building could support the weight of the required cable trays and substation. Coordinated the design of substation and MCC with the Siemens rep.

Controls Engineer

Ben-Tech Division of Curtiss-Wright, Rochester Hills, MI. August 2008-December 2008

• Wrote software (PLC and HMI) debugged and started up complex conveyor/material handling system for Diesel Engines for Cummins using Telemecanique Unity Pro PLC and Vijeo HMI system and AutoCAD.

• Included tracking functions to ease the removal and reinsertions of engines on the conveyor system for repair purposes.

Previously employed 14 years with Ford Motor Company as a Controls Engineer, promoted to Plant Electrical Engineer, and promoted again to Senior Controls Engineer at the Milan Plastics Plant. Provided in-plant support of 1 large material handling system, one class A and one class G paint finishing system, 63 injection-molding machines, and 16 large blow molding machines. Managed 6 engineers, 14 electricians, and 2 millwrights in a union shop environment. A long form of this resume with a 20-year work history is available. Ask for an “Extended” resume.


• Master’s in Business Administration (MBA) University of Phoenix.

• Bachelor of Science in Electrical Engineering (BSEE) Detroit Institute of Technology.

(D.I.T. is now part of Lawrence Technological University, was accredited by NorthCentral.)

• Project Management, Managing Skilled Trades Ford Human Resources Center.


• Senior Member: IEEE (Institute of Electrical Electronic Engineers.)

• Classic Member: SAE (Society of Automotive Engineers.)

• Member: ESD (Engineering Society of Detroit.)

• Member: ISA (International Society of Automation.)

•Member ASCE (American Society of Civil Engineers.)

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