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Engineer Electrical, PLC, HMI, Rockwell, Siemens

Taylor, MI
October 17, 2019

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LARRY TESSARI— Electrical Controls Engineer or Project Manager

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



• Skilled in Control System Design, hardware, and software (HMI/PLC, Allen Bradley, Siemens, etc.)

• Skilled in Management, Leadership. Excellent organizational, communication, and people skills.

• DETROIT AREA Candidate can travel 20%, CAN’T RELOCATE. Physical limitations (bad knees) prefer desk-based positions to plant floor but capable of directing skilled tradesperson or engineers.


• Initiative-taking innovative leader or collaborator using a blend of interpersonal and technical skills to drive engineering efficiency. Experienced in control system and building/facilities design, 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, training, and billing verification.

• Personnel Management: coaching, mentoring, development, training and supervision of engineers and skilled tradespersons, 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) for greater error-proofing. 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 consisting of a medium-voltage substation, several lower-voltage 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 that incorporated energy-saving design, extensive diagnostics, and cycle-time totalizers. Devised a simplified control scheme for a filtration system using an SLC-5-04 PLC rather than the more expensive PLC-5-20 previously used Added a safety pendant to existing milling machines at Ford Batavia for transmission valve bodies, allowing setup personnel to enter the machine’s work area to make adjustments without risk of injury.


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, Powerflex Drives, 1336 drives

• Telemecanique PL7, Magellis, UnityPro, Vijeo

• Vision Systems Cognex Checker, Keyence, Sick

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

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

• 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. Aid in resolving plant problems as they occur.

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, avoid unnecessary failures. Debugged software on a simulator, 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.

Test Engineer

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

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

• Wrote and published technical and purchase specifications.

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

Previously employed 14 years (1982-2006) 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. Have supported (in-plant) 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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