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Process Controls Engineer

Birmingham, AL
April 28, 2016

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**** **** ****** **. ******, Alabama 35226



Results-driven automation and process controls Engineer with broad-based experience planning and leading operations within large-scale manufacturing environments. Solid track record devising, evaluating, and implementing continuous process improvements minimizing waste and reducing costs while maximizing quality and yield. Establish effective quality control and safety program, fostering proactive participation across manufacturing floor. Excellent communicator with deep success building and leading cohesive team, driving production goals, safety, and throughput.

Budgeting Cost Accounting Cost / Benefit Analysis Expense Control Training

Change Management Project Management Team Leadership OSHA Compliance Cost Reduction Performance Management Process Improvement Machine / Motion Control Software Development

Technical Support Business Development Procurement Process Control


1.US Steel Corp., Fairfield, Alabama 2013 to Present

Steel Mill

a.Process Control Architect

Responsible for plant level 1 control systems which include all PLC’s, HMI’s, DCS systems, and Communications I performed retrofits, upgrades and new installations while focused on improving performance, eliminating waste and reducing costs.


Set up OPC server / client interface from Archestra to plant level 2 data systems allowing Continuous monitoring of process control loop performance which led to timely identification and correction poorly functioning loops resulting a reduction of raw materiel, and energy waste.

Performed retrofit and Control System upgrade on 3 Q-BOP furnaces, which resulted in eliminating bottom burn through due to tighter and more reliable process gas control.

2.URS CORPORATION, Whitehall, Arkansas 2005 to 2012

Chemical Weapon Disposal

a.Automation Supervisor

Managed Automation department including 11 direct reports for Pine Bluff Chemical Demilitarization Facility. Oversaw condition of control systems including 25,000 I/O points, 21 Large PLC controllers, 40 Medium PLC-controllers, 17 operator Consoles, and 500+ control screens. Supervised employees developing and implementing control system modifications, upgrades, and replacements while tracking changes and maintaining strict configuration control. Handled scheduling and development of automation team supporting site operations on 24/7 basis. Reviewed operation logs identifying upset conditions and or problems. Participated in morning status review meetings with department heads discussing new developments and providing updates on work in progress. Developed condition reports documenting system issues, unexpected conditions, and safety or environmental concerns. Performed root cause analysis and recommended remediation.

Michael Napoli

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Reduced personnel performance issues through implementation of work flow process checklist and shift turnover meetings, eliminating confusion caused by rotating schedules.

Eliminated outdated technology HMI technology (Advisor PC) to (WonderWare) which included 17 consoles and over 500 screens with zero plant productivity interruptions through strategic management of project to transfer entire operation from antiquated system to new streamlined system ensuring smooth operations.

Successfully transitioned Automation team from a pre-production hybrid start-up schedule to the standard site 24/7/365 DuPont schedule.

b.Automation Specialist

Developed software, maintained, and installed upgrades and modifications on control systems employed chemical weapons disposal facility. Participated in shift turnover meeting reviewing developments and unfinished business from exiting shift, as well as, site plan of the day meetings reviewing activities and efforts for the day. Addressed operational requests for information and provided troubleshooting assistance.


Designed and implemented tool reducing time to find source of alarms and alerts within PBCDF control system.

Integrated two isolated large 450HP chillers into main control system by installing and configuring required communications hardware including status and control screens.

3.AUTOMATION CONCEPTS AND DESIGN, Little Rock, Arkansas 2003 to 2005

Industrial Controls Systems Integrator

Developed and authored code, met with clients addressing needs and deadlines. Performed installations and debugging for control panels and software. Managed contractors ensuring wiring and interconnection work was on schedule.


Delivered electrical controls and software portion of a $12M roaster replacement project for major food manufacturing facility, on-time and within budget, including specifying and procuring control hardware, authoring software, performing testing, debugging and start-up, and training operators.

4.UNILEVER – BEST FOODS, Little Rock, Arkansas 1989 to 2003

Food Manufacturer

a.Plant Engineer (Little Rock, AR)

Led $70M in capital improvements over eight year period including developing capital projects, calculating return on investments and obtaining funding approval for projects ranging from small retrofits to large system replacements and expansions. Handled facility maintenance directing plant mechanical and electrical skilled trades and supervisory personnel. Presided over plant Review Board regarding personnel disciplinary issues. Developed request for project for authorizations detailing capital cost, benefits and return on investments. Developed capital expenditure reports highlighting amounts spent and estimates to complete for approved projects in progress. Authored equipment and control system specifications.

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Brought in $8.6M project, supporting launch of new reduced fat product, against 6-month deadline, $900k under budget. Developed project scope and budget and coordinated cross-functional teams. Developed equipment specifications, electrical, mechanical contractor bid packages, as well as, generating hardware and software specifications for control system and electrical power distribution.

Reduced spare parts inventory and production downtime 40% through procurement and implementation of maintenance tracking data base system monitoring equipment maintenance, scheduling preventive maintenance, and tracking costs, and spare parts utilization, facilitating more commonly employed on-hand spare parts.

Bolstered efficiency through implementation of automated data collection system tracking production, logging downtime, and tracking raw materials usage in real time.

Garnered Chairman’s Award for slashing materials cost $1.1M annually while producing 71% return on investment for purchase and installation of sugar mill facilitating cheaper course ground sugar conversion to required powdered sugar ingredient.

b.Plant Instrument and Controls Engineer (Bayonne, NJ)

Responsible for plant processing, packaging and building utility systems as well as plant electrical maintenance department and implementing new projects in the facility. This facility was a new grass roots state-of- the-art plant completed in 1990.

c.Instrument and Controls Engineer (Union, NJ)

Specified, Procured, Programmed, Installed, and commissioned industrial control system and machinery throughout 10 food processing plants in the US and Puerto Rico. Projects included processing, packaging, and building utilities up to $30 million in costs.

5.ROCKWELL AUTOMATION– ALLEN BRADLEY, Bloomfield, New Jersey 1984 to 1989

a.Field Service Manager / Applications Engineer (Bloomfield, NJ)

Managed the field service department for the New York Region. Scheduled and dispatched service technicians. Worked with customers and end users to solve problems.

Programmed, Installed, and commissioned industrial control systems. In various manufacturing facilities including food processing, automotive, pharmaceutical, textiles, and paper milling.

b.Technical Instructor (Dallas, Tx.)

Taught classes on Allen-Bradley industrial controls systems to students throughout the Midwestern US.

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Bachelor of Science – Education

Southern Illinois University – Carbondale, Illinois


KP Problem Solving Leadership Team Building

Top Secret Security Clearance (inactive) PRP Clearance (inactive)


PLC/HMI Programming DCS Programming Systems Integration

Microsoft Office Suite AutoCad Network Administration


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