Maintenance Engineer

Edward Paluch

*** ***** ***. ******, ** *****

**************@***.*** 248-***-****

The enclosed resume outlining my education and qualifications as they

pertain to the Electrical Controls and Plant Engineering fields is in

response to the position available at your facility.

In addition to a highly successful twenty five year career in plant

engineering and electrical control system project management, with a proven

history of achieving increased OEE and process efficiency while optimizing

product quality and significantly reducing operating costs, I have spent

twenty of these years in a senior process improvement capacity within a

lean manufacturing environment.

I have demonstrated the ability to successfully accomplish all tasks

associated with plant engineering and maintenance management including new

plant construction, lean value stream mapping, equipment selection and

purchasing, facility and process automation, environmental reporting, OSHA

compliance, leading the plant maintenance team, leading process improvement

initiatives, QS and TS registration, and long term capital planning and

project management. The strength of my maintenance management approach is

in the design and implementation of a computerized maintenance management

program utilizing the total productive maintenance principles combined with

a comprehensive predictive maintenance program incorporating vibration

monitoring, oil analysis, infrared imaging, electronic motor circuit

analysis, precision alignment, root cause failure analysis, new and rebuilt

equipment acceptance criteria and mechanical stress and wear analysis to

achieve a reliability based maintenance program. At the core of this

program is the building of a highly motivated maintenance team with the

emphasis on team member empowerment, training, and continuous improvement.

To complement this world class program, I add twenty years of seasoned

management experience in both unionized and non-unionized facilities.

During these twenty years, my management skills have been developed to

include management techniques such as root cause problem solving utilizing

6 sigma, employee empowerment and development programs, individual and team

motivating, continuous improvement, and vision sharing with strong emphasis

on lean manufacturing principles such as Kaizen, 5S, KPI, value stream

mapping, consensus building, A3 project management, and A3 problem solving.

I am also capable of providing the engineering design and project

management for any plant automation, process control improvement,

efficiency improvement, automated inspection/rejection, scrap reduction, or

equipment capability expansion projects. Some of the projects I have

successfully managed include refitting obsolete equipment with state of the

art PLC control systems, upgrading process control capabilities through

automated variation monitoring and reduction, installation of real time

plant wide data collection systems, integration of pneumatic and servo

controlled robots, design and installation of quick tool change and quick

material change systems, automated inspection/rejection systems, computer

integrated assembly cells utilizing machine vision systems, design and

installation of lean manufacturing and customer order driven sequencing

cells, design and installation of plant wide machine control Ethernet

systems used in PLC communications and data exchange, and the design and

installation of Web based HMI and machine diagnostic/troubleshooting system

that allow 24/7 worldwide troubleshooting of all facility equipment from

any smart phone along with real time machine operation, production status

and process monitoring of all production lines at all facilities around the

world from any smart phone.

I am an energetic, dedicated, self-motivated, career minded

professional with the goal of joining a team that shares the same standards

of quality and commitment to excellence as I do. I would welcome the

opportunity to discuss my background and qualifications as they pertain to

your companies needs in a personal interview.

Crown Cork and Seal January 2013 to March 2014

Position: Corporate Senior Electrical Engineer Alsip,

Illinois

. Senior electrical control system and process engineer for a 9 Billion

dollar a year high speed manufacturer of consumer metal packaging for

the food and beverage industries.

. Responsible for the design and installation of state of the art

machine control systems throughout the corporation.

. Lead continuous improvement efforts at all facilities by designing and

implementing machine modifications that put into action specific plant

continuous improvement ideas for OEE improvements and process

optimization.

. Provide engineering support to all plant's maintenance departments in

resolving intermittent and reoccurring machine interruption and

component failure issues as well as provide training to plant

technical teams as required.

. Responsible for redesign and retrofitting of all existing plant

production equipment to meet compliance with CAT 3/SIL4 electrical

control system safety standards as well as reducing personnel arch

flash hazards by improved designs.

. Provide 24/7 troubleshooting support to the all facilities in issues

of critical or extended production interruption.

Woodbridge Corporation March 1994 to June 2012

Position: Senior Process Control Engineer/Plant Engineer Romulus,

Michigan

. Provide leadership mentoring and support to maintenance and

engineering team of thirty for a chemical batch processing facility

with annual sales of $60 million as part of a 2 billion dollar global

automotive supplier.

. Promoted to provide engineering support to multiple facilities with a

maximum of twelve facilities at one time.

. Awarded lead role in corporation wide research and development

projects including the development of enterprise machine vision

systems, web based HMI system, tag based PLC upgrades and

standardization, smart phone based enterprise asset management system,

and distributed Ethernet based machine control redundant networks.

. Implemented a TPM system that resulted in an 86 percent reduction in

machine downtime while reducing the annual maintenance budget by

$900,000 and reducing annual maintenance related costs by $330,000 per

year.

. Designed lean manufacturing work cells that resulted in $1,200,000 in

annual labor savings while reducing scrap costs.

. Designed and implemented process control improvements resulting in a

ten percent increase in right the first time production output while

significantly reducing the rework costs.

. Developed and implemented maintenance department continuous

improvement and employee empowerment program that results in over 250

maintenance Kaizens completed annually.

. Reliability based and TPM maintenance strategies leading to equipment

up time of 99.5 percent for 16 straight years, a record that still

stands in the corporation.

. Designed and installed robotic applicator systems with vision system

inspection resulting in savings of $750,000/year.

. Designed and taught in house maintenance technician training program

in order to insure the required skill sets are in place to support new

technologies being introduced. Classes and bench trainers focused on

basic electrical trouble shooting, PLC programming and maintenance,

robot programming and maintenance, hydraulic trouble shooting and

utilizing HMI diagnostic capabilities for rapid trouble shooting.

. Designed and implemented web based HMI and machine

diagnostic/troubleshooting system that allows 24/7 machine

troubleshooting from a smart phone while providing free machine

operation and monitoring at any facility PC.

Thyssen Krupp January 1989 to January 1994

Position: Maintenance Manger Detroit, Michigan

. Development of laser welding lines and products for the production of

automotive exterior body panels as part of a multibillion dollar

international corporation with over 200,000 employees headquartered in

Germany.

. Design and implemented Siemens PLC and motion control programs that

allowed continuous laser welding with the assistance of multiple ABB

material handling robots with fully automated acoustic weld monitoring

systems.

. Designed and implemented a total productive maintenance program that

resulted in a 50 percent downtime reduction at the facility while

improving the quality and consistency of our manufacturing process.

. Responsible for new plant construction, equipment layout, equipment

installation, equipment standardization and capital budget planning

and management.

. Designed and implemented a real time computer integrated manufacturing

system that linked all production equipment on a central network

allowing for immediate part approval/rejection, automatic SPC

collection of 1024 data points per production part, machine capability

monitoring, production reporting, and scrap analysis.

. Developed and implemented a comprehensive in house employee

empowerment and training program.

. Provide leadership, mentoring and support for the Maintenance,

Engineering, Process, Scheduling, Shipping, Receiving, and Production

functions within the facility.

. Reason for leaving was the laser welding division was sold.

Cyber Control February 1985 January 1989

Position: Electrical Controls Engineer Bellville,

Michigan

. Electrical controls engineer for a systems integration and automation

contractor responsible for the design, building, and installation of

custom automated manufacturing solutions for a vast array of

manufacturing processes and industries focusing on automated

production and inspection, and automated process control and

reporting.

. Responsible for the design, programming, installation, and start-up of

industrial automation control systems utilizing ABB and Fanuc robots,

Allen-Bradley, Siemens, Modicon, Square D, and Texas Instruments PLCs,

Allen-Bradley, Siemens and Emerson Drives and Wonder Ware, US Data

Factory Link SCADA, RTES, and Lab View HMI systems.

. Supervised panel and controls build shop as well as field

installations, new system start up teams, field service.

. Reason for leaving was the owner past away and the company was

liquidated.

Education

. Lawrence Technological University (Southfield, Michigan): Classes

pursuant to a Bachelor's Degree in Electrical Engineering. 3.6

GPA.

. State licensed Journeyman Electrician and state licensed storm

water discharge operator.

. Emergency response hazmat Incident Commander and confined space

entry supervisor certified.

. Allen Bradley PLC5, SLC5/xx, Micologix, Compactlogix, Controllogix,

and Safety PLC programming class completed.

. Allen Bradley Factory Talk View Studios and Panel Builder 32

programming training classes completed.

. Allen Bradley RSlogix 5, RSlogix 500 and RSlogix 5000 programming

classes completed.

. Square D PLC programming part 1 and part 2 training classes

completed.

. Direct Logics 200 and 400 series PLC programming training classes

completed.

. Fanuc S5 robot maintenance, Fanuc RJ1 and RJ5 robot controller

programming classes completed.

. ABB robot maintenance and robot controller programming part 1 and

part 2 training classes completed.

. Rofin Sinar industrial laser maintenance, operations, and

programming training classes completed.

. Cincinnati Milacron and Omeron PLC programming part 1 and part 2

training classes completed.

. Siemens S5 and S7 PLC programming part 1 and part 2 training

classes completed.

. Siemens, Allen Bradley series, Parker, Direct Logics, and Modicon

HMI programming classes completed.

. Siemens, Control Techniques, Indramat, and Allen Bradley servo

drive programming training classes completed.

. Vickers and Oil Gear hydraulic pump and control valves training

classes completed.

. Vickers and Rex Roth hydraulic servo control and proportional valve

training classes completed.

. Modicon Unity, Concept, and Proworx 32 PLC programming part 1 and

part 2 training classes completed.

. Programming classes complete on Wonder Ware In Touch SCADA, US Data

Factory Link SCADA, Lab View SCADA.

. Control Techniques, Power Flex series, Toshiba, Yaskawa, and

Siemens VF drive programming class completed.

. Lean manufacturing, continuous improvement, and six sigma programs

completed at The University of Michigan.

. Industrial communications classes completed including Ethernet

TCP/IP, Ethernet IP, Profibus, ProfiNet, Modbus +, DH+, Interbus S,

DeviceNet, ControlNet, Modbus, Data Highway, and remote I/O.

. Machine vision system controls integration with Banner, Keyence,

and Cognex vision systems.

Contact this candidate