Electrical Engineer Maintenance Supervisor

MARK J. BROCIOUS

**** ****** ****** **., **** Orion, MI 48359

C: 248-***-****

E-mail: *****@*********.***

OBJECTIVE:

Degreed Electrical Engineer seeking a career opportunity to utilize education, advanced training, electrical engineering, maintenance, and controls

knowledge working in a team environment with a stable and progressive company.

EDUCATION

Bachelor of Technology in Electrical Design Engineering Technology, 1982 from Pennsylvania State University. Technical electives in microcomputers, high voltage, and power distribution. Passed the Engineer-In-Training Exam.

Associate in Electrical Engineering Technology, 1979 from Pennsylvania State University.

SPECIAL ACCOMPLISHMENTS

Have saved industry more than three hundred million dollars ($300M) in innovative and improved maintenance and production practices.

Discovered an electrical overbilling of $6M per year ($500,000/month); only the third largest annual savings that I have created. Designed and installed, working with UAW electricians, a device to more accurately cut slabs and eliminating waste, saving $10M per year. Have achieved countless dollars of savings through increased production, improved quality, reduced downtime, etc.

CAREER EXPERIENCE:

07/16 – Present. Maintenance Supervisor, Fiat Chrysler. Direct. Supervise skilled trades in operation of Phosphate/E-Coat, Anti-Chip Powder Lines, Dynamic Sequencing System, Sealer Line, and Paint Shop Conveyors. Utilized the eleven pillars of World Class Manufacturing to reduce down time, increase productivity and throughput, improve quality, etc.

12/15 – 05/16. Controls Engineer – Aerotek – Short term contract position working at a Big Three axle facility. Used Modicon Quantum PLC's in three lines and assisted in the installation of a two robot axle unload cell. Worked out problems and increased first Time through and JPH numbers. Assisted maintenance in troubleshooting and making repairs.

08/15 – 10/15. Electrical Engineer – AECOM – Short term contract position involving fan installations for a stamping press.

01/12 – 08/15. Electrical Engineer/Project Manager – AK Steel (formerly Severstal NA) – Managed projects (from object to scope, budget, cost, schedule to completion-to $10M), crisis management, support operation and maintenance, troubleshoot from PLC to 230 kV distribution. Troubleshoot issues with synchronous motors and switchgear dating to 1924.

03/10 – 12/11. Maintenance Supervisor, Fiat Chrysler. Direct. Supervised skilled trades in operation of Phosphate/E-Coat, Anti-Chip Powder Lines, Dynamic Sequencing System, Sealer Line, and Paint Shop Conveyors. Utilized the eleven pillars of World Class Manufacturing to reduce down time, increase productivity and throughput, improve quality, etc.

10/04 - 12/08. Project Manager - CHRYSLER, LLC AND DAIMLER-CHRYSLER (Contract) Assigned to Factory Information Systems in Information Technology Management Group. Managed FIS/MDT on Common Axle Strategy (Marysville Axle Plant). Managed FIS for 2009DS Truck Project and for the 2006PM/MK project at Belvidere, IL. Assisted with FIS Deployment on JS Project. Coordinated with vendors, ensured company directives and standards were followed, supervised integrator team performing the testing, interface with plant and corporate personnel. Reviewed OEM memory maps and logic; using ControLogix, Siemens, and Modicon PLCs, Fanuc and ABB robots, AGV’s, conveyors, etc. Assisted plant personnel during and after start-ups to decrease downtime and improve throughput.. Used generated reports for continuous improvement.

07/04 – 09/04. Controls Engineer - ASG (assy. Mach. Builder, Farmington Hills, MI). (Contract), Responsible for programming of assembly and test machines for an engine assembly plant using Mitsubishi PLCs. Finished project assignment.

11/03 - 06/04 Controls Engineer - VALENITE GAGING (gauging mach. Builder) Oak Park, MI (through CES). (Contract) Designed controls, did AutoCAD Drawings, electrical design, startup, and debug of gaging systems. Worked with and programmed multiple manufacturers PLC’s (Allen-Bradley, Modicon, Mitsubishi, etc.). Designed and performed debug of pneumatic controls.

07/03 - 10/03. Electrical Engineer - CEC CONTROLS (controls house), Warren, MI (Contract). Assisted in the start up the new Ford Heritage Assembly Plant at the Rouge Complex in Dearborn. Project was completed. Started up conveyors, hoist lifts, gantries, etc. Worked with A-B PLC 5’s, etc. in the start-up of Trim and Chassis, including Final Assembly. Worked on the new Siemens skillet (pallet) system, power and free and inverted power and free conveyors, lifts, hoists, etc. Finished project assignment.

12/99 – 06/03 Project Engineer - LOMBARDO & ASSOCIATES (consulting engineers), Rochester Hills, MI (Contract) to General Motors. Started up and maintained GE Fanuc CIMPLICITY based Energy Management Systems. Worked with Square D and PML power monitors, flow instrumentation, Programmable Logic Controllers, Time Schedule Controller and Down Time Reporter software programs, etc. Made electric demand calculations to reduce demand charges through equipment cycling. Scheduled outages in GM Plants and supervised installation of flow meters in utility lines and power monitors on substation main breakers. Estimated costs, wrote appropriation requests, managed projects, interfaced with plant personnel at 10 manufacturing facilities (U.S. and abroad in order to maximize energy savings). Helped develop utility consumption reports that show utility use by department. Worked with HVAC contractors to achieve peak performance and electrical savings. Was involved with FMEA and Six Sigma applications.

DEC. 12/98 - 11/99. Electrical Engineer - PATTI ENGINEERING (controls house) Rochester Hills, MI (Contract) Responsible for electrical design, PLC and operator interface programming and startup and debug (multiple PLC brands). Did multiple projects: conveyor projects for a Tier 1 seat supplier, a power seat test fixture, a torque hold-down fixture, a broach machine, an intrinsically safe paint kitchen for Toyota (78 PID loops), and fork transfers (auto body). Did Panelview 900 & 1400E (touch screen) HMI programming. Project ended in a slowdown of work available.

6/98 - 12/98. Electrical Engineer - FILTRA SYSTEMS (filter manuf.) Southfield, MI (Contract.) Responsible for elec. design, AutoCad 13 drawings, operator interface programming, and start-up and debug of multiple types of filters and filtration systems. Used Allen-Bradley, Modicon, & GE PLC’s and programmed A-B 1400e (keypad) Panelview.

1/98 - 6/98. Proj. Electrical Engineer - CURTRON INC. (controls house) Troy, MI. Responsible for supervising engineers (using G-E CIMPLICITY software) in the design, layout, and programming of energy management projects. Interfaced multiple PLC and microprocessor based controllers.

3/97 - 1/98. Powerhouse Engineer - CHRYSLER LLC Dearborn, MI (Contract thru G-tech) for a joint venture Chrysler engine plant in Brazil. Responsible for electrical design of power distribution, electrical specifications, drawing, facilities issues, etc. for the power distribution (15 kV - 120 VAC) of the engine plant. Received training on Telemechanique TSX 37/57 PLC’s. Used AutoCAD - Rel. 14 and various software programs. Learned the Chrysler Operating System (Toyota Production System) concepts of kaizen, 5S, jidoka, JIT, lean manufacturing, etc. Finished project assignment.

11/90 TO 3//97 ROUGE INDUSTRIES (Formally Rouge Steel – sheet steel producer) Dearborn, MI. Electrical Maintenance Supv. & Project Eng.

Reason for leaving: Was stuck on 3rd shift with no relief in site was recruited by G-Tech for contract assignment to Chrysler LLC.

Electrical Maintenance Supervisor (7/96 - 3/97 and 11/90 - 9/94) Supervised activities of 8 to 30 UAW electricians and instrument technicians in the maintenance of 2 Ladle Refining Facilities and 2 Continuous Casting Machines (3 strands total) and ancillary equipment. Used Reliance Automate, Allen-Bradley PLC 5, and Modicon PLC’s, maintained nine overhead bridge cranes and ladle cars (to 400 ton capacity), VFD’s, two off-line robots, and four separate water treatment plants, including installation and maintenance of all instrumentation. Maintained various slab handling equipment (pushers/stackers). Managed several special projects involving the improved measurement of slab width and slab length by PLC and laser detectors to minimize waste and increase yield. Worked diligently to continually improve processes within the casting facility. Pioneered several maintenance procedures where repairs are made while casting and no longer involve turning the casting machine around; eliminating costly shutdowns. Converted several off-line systems to PLC control and supervised the programming.

Electrical Project Engineer (9/94 to 7/96) Responsible for installation of a new, single strand slab casting machine and new Ladle Refining Facility into an existing, operating facility. Supervised engineers during the startup and commissioning. Interfaced with equipment suppliers. Helped formulate control philosophy for overall caster control and for hydraulic servo valve control (molten steel flow) and hydraulic proportional valve control. Approved equipment and methods. Used Allen-Bradley and Modicon PLC’s and AB drives (1336T, 1336S, 1395, and 1391) to control the casting of molten steel into a continuous slab. Designed and supervised temporary controls to allow for the relocation of several pieces of critical equipment while continuing the existing casting operation. Dealt with power issues from layout to construction of 15 kV and 35 kV switchgear. Supervised the installation of three new double-ended substations (15kV to 480V, circuit breaker and rectifier upgrades (to 1.5 megawatt). Laid out the interconnection (power and controls) for a 35MVA load-tap changing autotransformer for a new ladle refining facility. Worked with Ford Powerhouse engineers and electricians in the addition of a new 35kV feed and switchgear for a new ladle refining furnace. Supervised contractors’ crews during important outages and power switch-overs. Discovered and assisted with the successful resolution of a corona effect issue on a 35 kV feeder cable. Performed extensive training of electricians and instrument repairmen of the new facilities including PLC’s and drives.

3/89 - 11/90. Electrical Maintenance Supervisor - CITISTEEL USA (plate steel producer), Claymont, DE. Supervised a crew of mostly young apprentice level electricians and vendors in the start-up of the former Phoenix Steel Plant; a twenty year old facility that had been shut down for two years. Start-up was successful. Designed and supervised the re-wiring of the electric arc furnace. Installed a PLC5 to control spray water on the continuous casting machine. Trained electricians in instrumentation, troubleshooting, electronics, crane controls, medium and high voltage breakers (15 and 69 kv), etc. Maintained a G-E Series 6 PLC controlled static varistor (13.8 kV) for power factor correction and harmonic protection (1st, 3rd, 5th, & 7th harmonics). Coordinated outages and maintenance of 69kV feeds and breakers with the utility. Supervised the removal, repair, and re-install of all motors (to 1200 hp). Supervised electrical and mechanical maintenance of eight overhead cranes.

3/88 - 3/89. Engineer of Operations Technology - GREAT LAKES STEEL (sheet steel producer), Ecorse, MI. Interfaced with Maintenance and Operations to improve productivity and quality and decrease down time. Monitored processes, made recommendations for improvements, designed changes, and supervised and implemented changes. Regulated two electric arc furnaces using a Dranetz power analyzer and established an improved slag practice; reducing nitrogen pickup and the downgrading of more than 30,000 tons per month at more than 50 dollars per ton. Reduced electrode consumption from 10.0 to 6.5 lbs. per ton and reduced energy consumption from 500 to 440 KWH per ton while increasing furnace tons per hour output.

03/87 - 03/88. Technical Services Engineer - CARBON/GRAPHITE evaluation and in the Steelmaking GROUP (Formally Airco Carbon – graphite electrode producer), Saint Mary’s, PA. (Two cooperative education employment periods January to June of 1980 and 1981). Traveled extensively to evaluate performance of new materials and in response to customer complaints of graphite electrodes used in Electric arc furnace steelmaking.

3/83 - 3/87. Electrical Engineer - LEE-SIMPSON ASSOCIATES (consulting engineers), DuBois, PA. Performed elect. & mechanical engineering duties (lighting, power dist., HVAC, energy audits, stray voltage testing, construction and pre-blast inspections, soil and concrete testing, etc.). Wrote contract specifications for all phases of projects, conducted bid reviews and contract award procedures, and monitored contract terms and conditions.

ADVANCED TRAINING:

Siemens Step7 PLC Training – 1 Week class at Electro-Matic of Farmington Hills, MI

GE Fanuc Cimplicity Programming Class – March 2002

Telemechanique PLC TSX 37/57 - August 1997

Chrysler Operating System - 6 classes 1997 (Toyota Production System)

Allen-Bradley AC Drives (1335S and 1335T) - October 1995

Supervisor Training (Building Up People) - May 1994

Leeds & Northup MAX 1 DCS - April 1993

Allen-Bradley PLC5 - Sept. 1995

Allen-Bradley DC Drives – October 1995

Reliance Automate PLC – April 1993

Allen-Bradley PLC3 and 5 – December 1989

REFERENCES AVAILABLE UPON REQUEST

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