Engineer Project
Resume:
Michael Bronk
**** * ******** *** • Milwaukee, WI 53224 • acztxg@r.postjobfree.com • 920-***-****
Sr. Controls Engineer & Project Manager
Skilled Engineer, seamlessly executing deadline driven projects
Key Qualifications
Proven track record of leading cross-functional teams to complete projects within time and budget requirements. Collaborative leader, experienced in training and motivating others for success.
Provide technical direction, analyzing and improving machine production process capabilities.
Adept at developing and enhancing detailed procedural processes, reducing redundancy, improving accuracy, and achieving organizational objectives.
Highly focused and able to identify goals and priorities, quickly resolving issues in initial stages.
Professional Experience
Gehl Foods LLC – Germantown, Wisconsin
Senior Controls Engineer, 5/2016 to present
Provide electrical leadership to the Aseptic bottling business unit meet and exceed objectives set by management
Selected Contributions:
Development of high level maintenance team building internal skillsets to better support process line reducing need of outside resource.
Execute programs to increase productivity and machine reliability.
Develop and execute cost saving programs to reduce material waste.
Provide technical leadership in developing specification for line expansion.
Implement safety programs.
Prepare project charter, budgets, timeline and resource planning.
Global Process Management – Grey Mouth Westland, New Zealand
Senior Electrical Engineer/Project Manager, 12/2014 to 5/2016
Preserve relationships with key clients, addressing inquiries and preparing accurate specifications for equipment purchases. Collaborate with engineers; provide design direction for hardware utilization, and uphold quality control efforts.
Selected Contributions:
Develop project scopes with engineers and project managers.
Execute onsite and remote installation and converting equipment start-up support.
Control Logix Software edits for servo drives, machine controls, machine vision and operator interface. Generate status reports weekly and closeout summary at project end.
Collaborate with internal and external vendors, serve as a liaison between all parties that impact the project that impact budget, risk, resources of the project currently managing.
Track project forecasts, milestones, and actual costs, to maintain set budget and timelines.
Extended consultation of manufacturing process optimization thru process and controls improvements, training of operations and manufacturing technical support personnel, analyzing machine data (historical/current). Implementing solutions for immediate impact as well as providing operations with tools to allow for quicker response to process variability and providing management with long term solution plan to include specification requirements and budgetary estimates.
Kimberly-Clark – Neenah, WI
Senior Project Engineer, 4/1984 to 12/2014
Directed all project support efforts including budgeting, team collaborations, and resource allocation. Formulate specifications, equipment purchases, and full project scope.
Selected Contributions:
Drive product and process enhancements, increasing efficiency and productivity.
Govern project demolition, checkout, and commissioning focused on safety, completing project within budget and project time-line.
Collaborate with internal and external vendors, serve as a liaison between all parties that impact the project that impact budget, risk, resources of the project currently managing.
Track project forecasts, milestones, and actual costs, to maintain set budget and timelines.
Conduct facility-wide training in operation and maintenance of machine vision system, registration systems and new process additions.
Support clients project on-site and off-site for machine controls, servo drives, stepper drives machine vision, registration, operator interface, production reporting, packaging.
Served as a liaison with engineering leads/management team to analyze machine production and improve process capabilities.
Lead machine design safety reviews.
Extensive experience in machine and controls design, implementation and troubleshooting of manufacturing process and machine controls, Rockwell servo drives, machine vision and registration systems, HMI operator interface, medium and low power distribution, machine safety systems and packaging equipment.
Lead in Kaizen, 5 WHY sessions. Implement SMED activities in manufacturing environment.
Lead in plant safety activities writing facility lockout tag out procedure, Production line SOP’s
Lead in operations long term solutions and day-to-day support in troubleshooting and analyzing machines data positively impacting production efficiency and waste.
Implement LEAN manufacturing principles for continuous improvement, root cause failure analysis and good run setting procedures.
Develop plan for spare parts inventory, hardware obsolescence and preventive maintenance, part wear monitoring effectively reducing loss in production downtime.
Educational Background
Bachelor of Science, Electrical Engineering, MSOE, Milwaukee, WI
Associate of Science, Electro Mechanical Design, Lakeshore Technical Institute, Cleveland, WI
Associate of Science, Electrical Engineering, ICS, Scranton, WI
Associate of Arts, Mechanical Design, ACME School of Tool & Die Design, Cleveland, WI
Expanded Resume
Michael Bronk
9415 W. Goodrich Ave
Milwaukee, WI 53224
acztxg@r.postjobfree.com
1984-1986 Electrical Design Engineer – KCC New Business Technologies
Responsible for electrical equipment design and layouts for First of a Kind assets. Prepared electrical schematics for controls, drives, power distribution, motor control center, machine bay lighting calculations. Perform checkout of manufactured machine modules and electrical control panels and OEM vendor equipment checkout prior to delivery. Lead electrical contractor thru machine installation, support machine installation, checkout and start-up, providing support for power (medium/low voltage), AC fans, machine controls and drives.
1986-1994 Electrical Controls Engineer – KCC Training Pants Sector/Fem Care Sector
Responsible for electrical equipment design and layouts for First of a Kind assets and product/process upgrades. Prepared electrical schematics for controls, drives, power distribution, motor control center, A-B/Reliance drives and control software. Perform checkout of manufactured machine modules and electrical control panels and OEM vendor equipment checkout prior to delivery. Lead electrical contractor thru machine installation, support machine installation, checkout and start-up, providing support for power (medium/low voltage), AC fans, machine controls and drives. Conduct training on new machine modules and processes to plant engineers, quality and maintenance.
1994-1997 Plant Electrical Engineer – KCC Adult Care Products
Maintenance Engineering - Responsible for scheduling and supporting maintenance team for machine scheduled downs/grade changes and technical support for machine issues not resolved by technicians. Monitor and track stores spare parts and equipment obsolescence replacement strategy.
Operations Engineering – Responsible for day to day machine operations of 6 line assets in manufacturing facility. Work closely with operators and maintenance to address electrical and process problems identified during shifts. Focus on identifying key machine waste and delay in effort to increase productivity target of 90%efficiency and 2% waste in 6 months. Goal was exceeded in less than 4 months providing efficiencies of 94-96% and 1.2% waste consistently. Assist in preparing for successful machine start-up after maintenance down and grade changes by running machine prior to oncoming shift crew.
Projects Engineering – Responsible for preparing yearly budget forecast for machine upgrades. Work with design teams in preparing documentation to support projects. Responsible for controls and software changes as well as documentation to support. Oversee installations, checkout and start-up. Major projects lead in this role PLC controller upgrades PLC3 to PLC5 on machine and packaging end. Drives replacement from Contraves drives to Reliance. HMI and production reporting tools. Adhesives controls and software replacement, installing Variable frequency drives in replacement of AC fan motors, design and implement new phasing and control system.
1997-2006 Senior Electrical Engineer – KCC International Division
Responsible for electrical equipment designs, machine controls, HMI, Registration, Vision and drives for new line extensions and product/process improvements in Latin America, Asia Pacific and Middle Eastern regions. Perform checkout of manufactured machine modules and electrical control panels and OEM vendor equipment checkout prior to delivery. Lead electrical contractor thru machine installation, support machine thru checkout and start-up phase providing support for power (medium/low voltage), AC fans, machine controls, HMI, drives and packaging equipment.
2006-2014 Project Engineer/Project Manager – KCC International Division
Responsible for collaborating with product leaders in identify improvement/change justification and estimates to senior leaders. Prepare detailed budgetary and capital estimates to present to regional and mill leaders. Develop project timeline and resource plan and roles and responsibilities plan to support project scope. Prepare detailed scope of work to present to technical service providers to provide quote and write requisitions for services. Oversee design/software progress and lead design reviews as necessary. Lead Engineering design safety review as appropriate. Track and monitor spending vs. forecast. Coordinate on-site activities (equipment staging, demolition, installation, engineering checkout, process checkout). Assist plant in equipment write-off and project close-out activities.
Train technical resources in Mumbai to provide ongoing support to KCI global sites for HMI and Corporate production reporting systems.
2014-2016 Project Engineer/Project Manager/Sr. Electrical Engineer – Global Process Management
Responsible for continued leadership of projects started in 2014 with KCC. Provide on-site electrical support and training for process checkout thru end of curve production (machine controls, drives, adhesives, HMI, Machine vision, Machine registration and packaging).
Oversee project design/software for product/process upgrades. Provide process/electrical/mechanical support and training for assets to improve process stability/reliability to increase machine efficiency and production.
2016-Present Sr. Controls Engineer – Gehl Foods LLC
Responsible for daily operation of aseptic bottling lines process and packaging. Provide technical leadership to maintenance team, building internal knowledge to support the lines. Implement cost effective programs that will improve operations mfg. results. Technical lead for electrical controls specification of expansion lines.
Work Examples
Michael Bronk
9414 W. Goodrich Ave.
Milwaukee, WI 53224
acztxg@r.postjobfree.com
LAO Product improvement (2.9MM)
LAO (Latin American Operations) product developers put together a product business/feasibility plan for product improvement affecting 27 assets in 5 LAO regions. Initial order for modules had been placed and budgeted $250k per asset. I had worked closely with the 2 major equipment vendors and provided more detailed specifications of process requirements. Re-working design (electrical/mechanical) we were able to reduce cost for each asset by 60%. Wrote specification for controls/safety requirements and integration to existing machines. Reviewed and approved design/software, developed the demolition and construction documents required for installation and commissioning of equipment. Provided remote support during install and commissioning to eliminate site support costs.
Mexico asset re-build HMI/product/corporate production reporting system (.3MM)
Developed HMI operator interface. Wrote machine ladder logic routines for machine production/waste and delay information. Integrated information to plant production monitoring system as well as to corporate database.
4 asset process upgrade LAO (9.5MM)
Developed budgetary and capital estimate for major capital project in Argentina affecting 4 assets. This project required the replacement of obsolete equipment, new machine module, addition of 105 servo drives and controls, safety systems, HMI and production reporting upgrades.
Responsible for the technical scope of work, equipment specifications, requisitioning of equipment and service provider support, leadership to technical service providers conducting design and software. Assuring proper requisitioning of equipment as well as preparing customs documentation for equipment and services, monitoring budget, reviewing and approving documentation to support demolition and installation, re-design of machines safety circuit, project resource planning and scheduling of project from Kick-off meeting thru start-up. Coordinate on-site activities from equipment staging thru start-up.
31 asset product improvement/ cost savings LAO (38.75MM)
Process/electrical lead for FOAK (First of a Kind). Developed process plan and activities for FOAK machine design, start-up, quality qualification and trials to prepare for consumer product tests. Project in North America to end of curve was approx. 45 days. Challenged to develop a plan and execute, reducing project from 45 to 30 days, including 10 days consumer product test trials. Remaining assets served as project/electrical lead for development and design thru machine commissioning. Thru overall process, reduced project install thru start-up from schedule 17 days down to 9. Provided site support (process/electrical, drives, controls, machine vision) throughout project.
Asset intervention – Nigeria (.75MM)
Provide technical support for immediate process, quality and production improvements and long term plan for assets in Nigeria.
Analyze current machines production, operations, process and support to identify and prioritize solutions.
-Provided servo drive changes to have better process control of web throughout machine.
-Provide direction to machinist to modify brackets for machine sensors, and better web transfer between gaps.
-Installed a machine vision system to greatly reduce number of rejected products on machine start-up allowing the operator a visual of the product while running vs. taking sample and reviewing and making adjustment.
-improve quality by improving machines sensor and logic to effectively remove defective product.
-Provided training to technical team on RSLogix drives RSView HMI allowing for them to better support the lines.
-provide long term plans for equipment replacement to provide for more stable process. Rough draft of equipment specifications (mech/elec). Budgetary estimate for equipment and design and timeline for installation.
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