Roy M. Metzger, BSEE, ASEME, RSO
Preferred Name: Mike Metzger
(BS Electrical Engineering & AS Electro Mechanical Engineering)
Current and Previous Certifications Department of Energy Instrumentation, Electronics, Electrical, Metrology and Radiation Safety Officer
Master Electrician License Indiana
Member ISA (International Society of Automation)
Cell Phone: Contact Via ***.*.*******@*****.***
Technical Skills:
Employee Management Experience
Programming Allen Bradley PLC’s including ControlLogix, CompactLogix, PLC 5, SLC 500 and MicroLogix.
Programming RSView SE, ME, 32
WonderWare 2010
Experience designing screens using various vendor operator interfaces.
Programming and design of control systems
Instrumentation and control loop system design and troubleshooting
Management of EPA Systems
EPA Instrumentation system design, calibration procedures and training of Technicians
Electrical design and planning
Instrumentation and Controls Specialization
Lockheed proprietary DCS (Nuclear Facility)
Foxboro IA-51 DCS Nabisco
Factory Talk
Languages Visual Basic and VB Script. Assembly Language for various - processors and microcontrollers
Technical training of employees
Setup 70E Training
Responsible at various plants for lockout procedures and confined space entry.
Setup Maintenance (infrared, vibration, oil analysis and Calibration) programs on motors, switchgear, gearboxes, transformers and Instrumentation
Machine Troubleshooting including electrical, instrumentation, electronics, hydraulics, pneumatics and vacuum systems.
Power system design & troubleshooting up to 13.6 KV (including switchgear)
Expertise with VFDs (Variable Frequency Drives) up to 1200 HP and 4160 Volts
Project Management
MS Project
Technical Writing
AutoCad
Solid Edge 3D experience
Union Environment Experience
Licensed Master Electrician
ABB 800XA with Harmony
2/3/14-Present
Johnson Controls
Engineer 3
PLC Programs (Allen Bradley ControlLogix and CompactLogix)
Electrical Systems up to 13.6 KV
Instrumentation
When required troubleshoot problems in the plant to fix process, robotic, VFD, Instrument or Electrical problems
Primary Support on CEMS systems
Train Technicians.
Started a program with all plant instrument and electrical drawings on an iPad decreasing Tech search time.
Designed and wrote a PLC/HMI program to control NOX and CO better than previously possible
8/13/2012-2/4/14
SunCoke Energy
Electrical/Controls/Automation Engineer
Managing People and Projects
ABB 800XA with Harmony Programming and support
Micrologix
Slc-505
Planning Upgrades for ControlLogix
Hydraulic & Pneumatic system monitoring & Controls
Process controls
Teaching the automation controls instrumentation field to employees
Managing Electrical & Controls Projects
4/2012 to 8/3/2012 Scheduled Contract End Date
US Silica
Sr. Electrical & Control Systems Engineer Contractor
Management of the Electrical & Instrumentation Department
Write PLC Code ControlLogix and PLC5
WonderWare HMI Programming
Design of Power Systems
Analyze Process Problems and Train Plant Process Engineer
Assist Plant E&I Technicians with technical process control problems
Rewriting Plant Camera network software
Project Management
11/29/2011 to 3/2012
Control Systems Engineer - Contractor
Contracted to Wabash MPI for press systems design and plc programming
PLCs Used: CompactLogix and MicroLogix
Software Used RSLogix 5000 and RSLogix 500 RSView ME
Programmed from start to finish PLCs that control hydraulic and pneumatic presses used for forming plastics, rubbers and sheet metal.
1/3/2011-10/15/2011
Shuttleworth Conveyor
Sr. Control Systems Engineer
Managed Union Personnel while building my projects
Working for an Engineering firm designing small conveyor control systems, including vision system, sorters, high speed bar code reading and sorting.
PLCs Used: ControlLogix, CompactLogix, MicroLogix
Software Used RSLogix 5000, RSLogix 500 RSView ME
11/07 to 10/05/2010
Calgon Carbon (Processed Coal into Carbon)
Sr. Electrical Engineer and Electrical & Instrumentation Manager
Manage projects, contractors and union employees to complete projects.
Hired and trained 10 new additions to the Plant Electrical and Instrumentation Department
Train Technicians on instrumentation, PLC Programming and Electrical Troubleshooting
Direct day to day activities with planning and procuring parts required for projects.
Design Controls, Instrumentation and Motor Systems.
Allen Bradley PLCs including the ControlLogix, SLC and PLC 5 families
Supported a Microsoft 2003 server system running Factory Talk for over 24 months with 9 servers
Supported plant process computers for running Factory Talk for 24 months (not office PCs)
Design and troubleshoot fiber optics Ethernet communications
Corrected a failed plant wide control system installed before my arrival including Factory Talk, server corrections, network corrections and wiring problems.
Software: RSViewSE/Factory Talk, Logix 5000, Logix 500 and Logix 5
1/07 to 11/07 Contractor
Sr. Electrical Engineer
Rockwell/Allen Bradley Government Contracts Division
Navy projects included the ballast system for the USS Iwo-Jima and jet elevators for various ships. The department of the Army projects included decontamination projects for various heavy equipment returning from the Middle East. Air Force projects included rocket defense systems. Other government projects included water treatment, nuclear waste containment monitoring. While not working on PLC projects, I worked in a laboratory environment to develop a VFD for the Department of the Navy. We were successful at meeting the Navy’s EMI requirements which no other VFD manufacturer was able to do. Software use: RSLogix 5000, 500 and 5. All Equipment and Software was Rockwell and Allen Bradley.
6/1/06 to 1/07 Contractor
Sr. Electrical and Control Systems Engineer
Placed with Jacobs Engineering Battle Creek Location through CSI to Perform Controls and Electrical Engineering and Project Management for Kellogg Corporation. Performed projects for Kellogg various cereal, Poptarts, breakfast bars, and snack food plants. PLCs used included PLC-5, SLC 500 and ControlLogix. Designed and managed installation on, Machine safeties on mixers, palletizers and packaging equipment. I was also responsible for design, programming and electrical and controls startup of a complete line at the (Sunshine) Kellogg’s Plant in Kansas City, Kansas. The line started up at 130% of Kellogg’s calculated maximum output.
3/24/06-6/1/6 Freelance Performed small PLC programming and CAD work
6/05 to 3/24/06 Diamond Systems
Electrical/Electronic Engineer
Position Responsibilities: Corrected Problems with electronic instrumentation sensors that were causing about $300,000 of warranty item returns per quarter.
Redesigned electronic circuits and electrical circuits on high speed egg processing and packaging equipment.
Redesigned a Packing system that previously utilized DC motors and redesigned the system to operate with AC motors and VFD Controls. Reduced build cost of this device by about $1,000 which directly increased profit per unit sold. Supported the Allen Bradley PLCs and PLC Direct PLCs.
1/04 to 6/05 Red Gold
Control Systems Engineer (Also the Electrical Engineer for Power Distribution)
Managed personnel during projects, upgrades, downtime and scheduled outages
Final Product: Tomato Paste, Salsa, Diced Tomato, Vegetable Juice and
Spaghetti Sauce. Co-pack for Kraft, Wal-Mart’s, Kroger’s, Save-A-Lot and numerous other store brands.
During my time with this company, I was directly responsible for moving from Glass received in boxes to receiving glass in bulk. This allowed for increasing the speed of filling equipment and labeling equipment on all products. I accelerated the manufacturing capabilities for Wal-Mart and other store brands without harming quality. Safety was increased in numerous areas by using Engineering methods, such as light curtains, safety mats and guarding. Started a lockout and confined space entry program.
All Allen Bradley software packages were used. RSLogix 5000, 500 and 5.
RS View 32 and Linx Professional
ABB and Allen Bradley VFD (variable frequency drives)
I performed all Electrical Engineering and Controls Design including the code and manage electrical contractors during installation of projects. Started a program to transfer my successes to the other Red Gold Plants which previously did not communicate.
11/02-11/03
Sr. Food Process Engineer (Corporate Engineer over 3 Plants)
Managed Projects Mechanical, Ammonia Refrigeration, Electrical and Controls.
Fixed many process problems including, retorts, process air, product delivery, product mixing. Redesigned the control system and authored the code to allow for more efficient use of a reverse osmosis system. Redesigned dryer controls. Designed control loops and authored the PLC code to control them. HMI and OI screen design.
Complete design of a new mix center and authored all of the PLC code including the CIP matrix which passed the USDA (United States Department of Agriculture) inspection on the first attempt.
PLCs and related software used during this employment ControlLogix, PLC 5 and SLC 500.
Including the RSLOGIX softwares 5000, 500 and 5
Panelmate, Panelview and Eztouch
RSVIEW 32, Various models of VFDs and Trained Electricians and Mechanics
9/01-11/02 Owned a small business, Metzger Electrical and Control Systems.
During the time, I operated my business; I designed control loops, authored PLC Code using Allen Bradley RSLogix 5, 500 and 5000.
Designed Human Machine Interfaces and Operator interfaces.
Operated a small group that installed electrical wiring in new homes and industry.
5/99-9/01 Lafarge
Instrumentation and Electrical Supervisor/Electrical Engineer Electrical and Instrumentation Planner, Radiation Safety Officer and Power Champion. Cement Manufacturer (Please don't confuse this with your local concrete provider) My duties include supervising Electrical/Instrument Technicians, planning designing and ordering of new instrumentation and electrical equipment. As the Power Champion at this facility reduced power cost by 16%. Provided leadership in Radiation Safety (Nuclear Gauges, and Analysis Equipment including X-Ray Machines) and responded to all requirements of the Department of Energy and Nuclear Regulatory Commission. Assure that automated systems function
as designed. Redesigned power and control systems to increase efficiency. Manage
electrical and mechanical projects.
2/99-5/99 Self Employed (Richmond Virginia)
Performed Contract Engineering until I joined Lafarge.
7/97-2/99 Nabisco Richmond Bakery
Control Systems Engineer. Devise calibration methods document and train Maintenance Dept. Personnel in calibration and repair methods. Assist maintenance in trouble shooting and repairing control problems. Wrote code for the Allen-Bradley PLCs. Support the Foxboro AI 51 series system. Equipment consists of ControlLogix, PLC-5, SLC 500, servos, frequency drives, conveyor systems, packaging systems, process mixing and controls systems. Work with engineering projects including startups and commissioning of new equipment. Supervised Electricians and Mechanics while they performed capital projects.
7/89-7/97 Lockheed Martin Utility Services Nuclear materials facility
Martin Marietta Utility Services
Martin Marietta Energy Systems
Piketon, Ohio
Type of Facility: Chemical and Nuclear
Security Clearance: Top Secret Nuclear
Manager Instrumentation and Control with Electrical Certification
Manage bargaining unit personnel and resources to maintain instrumentation and
control production equipment, buildings, and facilities. Ensure preventive,
predicative and corrective instrumentation and control maintenance is
accomplished in an effective and efficient manner. Provide troubleshooting expertise in conjunction with Operations and Engineering. Work with Operations,
Engineering and Work Control to initiate, screen, evaluate, prioritize and plan
Instrumentation and Control maintenance activities. Responsible for overseeing
department safety and Quality Assurance/Quality control activities within the
group. Member of several Redesign Boards and held many SME (Subject Matter
Expert) areas. Responsible for approximately 60 acres of the process area. Areas of responsibility-
process control instrumentation (included hydraulic, pneumatic and electronic
controls process analytical instrumentation (potable and wastewater) and
electrical/mechanical maintenance. Developed step by step work instructions
and procedures that conform to control authorities (DOE and the NRC) requirements. This position is the same as Project Manager or Engineer at many companies with the exception that I had a crew of degreed technicians.
Education:
BS Electrical Engineering
AS Electro Mechanical Engineering
Allen Bradley/Rockwell Programming and Maintenance courses
Foxboro IA 51 Series courses
ICS Major Computer Science
Lockheed Martin Courses: Nuclear Materials Processing Certified For Instrumentation and Control by Department of Energy and NRC (Nuclear Regulatory Commission)
7 Habits of Highly Effective People
Strategic Communication Skills
Electronic and Computer Systems Qualification School and certification Nuclear Facility
Various other technical courses including Nuclear Physics and Chemistry Nuclear Facility
Radiation Safety Officer
High Voltage Switch Gear located in Dallas Texas
Electronic Warfare Intelligence