Controls Engineer

ZBIGNIEW BELKA, MSEE

***** *******, ******, ** *****

Phone: cell 586-***-****

********@*****.*** or *******************@*****.***

SUMMARY

Project Manager and Senior Project Engineer with extensive experience in controls engineering. Strong program management skills covering engineering, controls design, procurement, system build, debug, installation and commissioning in the automotive and aerospace industries. Extensive knowledge of manufacturing processes, lean manufacturing, quality control procedures, assembly operations and management systems related to production operations while providing technical support for solving plant problems. Utilize management control systems and budget information to monitor performance and coordinate change leadership to ensure all deliveries are met as contracted and on time. Development and presentation of information to groups at all levels. Preparation of maintenance manuals. Experience in new plant start up.

EQUIPMENT EXPERIENCE

Assembly and Test machines: transmissions, engines, PTU’s, RDM’s, gears and axles.

Body and Assembly –Welding and Material Handling Robotic cells. Vision systems. Laser welding. Final vehicle assembly.

CNC machines, machining lines, in-line gages. Cylinder heads and blocks, transmission cases, gears, aerospace aluminum and composites. Washers.

Metal Forming and Heat Treatment.

Different types of conveyors including motorized monorails and servo. Floor, overhead, palletized.

CONTROLLERS EXPERIENCE

Siemens, Fanuc, Allen-Bradley, Rexroth: PLC’s, Servos and CNC’s.

RSLogix5000, Panel Builder, Step7. Networks: Ethernet IP, DeviceNet, Profibus.

FIS and QIS to factory server.

Modicon/Telemecanique PLC’s.

Testing equipment, gages and probes, fastening equipment (nut runners, presses) – some PC based, different manufactures.

End of line machines like balancing, NVH.

ABB and Fanuc robots, Bosch and SQ D weld controllers, weld lasers.

RF tags and Bar Codes.

RECOGNITION

Two (2) US and international Patents Granted.

Five (5) Monetary Awards.

EDUCATION

Master of Science in Electrical Engineering.

Quality Management course at Philip Crosby Quality College in Winter Park, Florida.

Extensive courses in technical topics and Program Management.

PROFESSIONAL EXPERIENCE

Belka Engineering LLC (1/2014 – present)

Contract work. Recently supervision of installation and start-up of transmission assembly system in GM Toledo. Supervision of design, build, installation and start- up of packaging machines in Berry Plant, Kentucky. Temporary, as required, test of equipment and assembly of complex electronics at MIS Controls.

ZBIGNIEW BELKA

Morrell 2023-2025. Designer, Hardware Controls: Training young engineer, Ford Buffalo Stamping Press and Cleveland Servo Gantries.

HELLER MACHINE TOOLS (9/2011 – 12/2013) – GLOBAL CO.

Controls Project Manager in Program Management Team. Responsible for build and retool of CNC machines. Also responsible for design and build of automation, gages and interfaces with customer plant systems.

Participate in Program Management weekly meetings and meetings with Customer.

Change Management: estimate cost and schedule impact for Sales/Program Manager.

Conduct: Safety reviews, DFMEA, PFMEA.

Participate in meetings with Software/Debug personnel and Manufacturing.

Work with electricians, pipe fitters, machine builders and programmers to make good parts and get Customer approval.

Travel to suppliers and customers.

Assist in machine installation and production start up at Customer Plant.

Work with user Plant Facilities Engineers on floor plan layout and utilities requirement.

Customers: global automotive.

COMAU SYSTEMS/PICO (01/24/11 – 07/29/11) – GLOBAL CO.

Contract Controls Project Engineer in Program Management Team

Provide technical support for major re-tool/upgrades of GM Volt Electric Car Production Systems and build new Systems for implementation of new model of Chevy Malibu.

KUKA SYSTEMS NORTH AMERICA (11/2010 – 01/19/11) – GLOBAL CO.

Contract Senior Controls Project Engineer in Program Management Team

Participate in Program Management weekly meetings and meetings with Customer.

Participate in meetings with Software/Debug personnel and Manufacturing.

Work with electricians, pipe fitters, machine builders and programmers to make good parts and get Customer approval.

Travel to suppliers and customers.

Assist in machine installation and production start up at Customer Plant.

Projects: welding, final assembly (glass), robotic cells, robotic material handling cells, robotic laser cells and conveyors/automation.

ABB ROBOTIC NORTH AMERICA (11/2007 – 08/2009) – FORTUNE 500 GLOBAL CO.

Senior Controls Project Engineer: Project Manager in Program Management Team

Provide Controls Architecture, supervise, check and approve Hardware and Software Designs. Supervise Panel Build and Procurement of Parts. Use JD and SAP systems.

Participate in Program Management weekly meetings and meetings with Customer.

Change Management: estimate cost and schedule impact for Sales/Program Manager.

Conduct: Safety reviews, DFMEA, PFMEA.

Participate in daily meetings with Manufacturing and Program Management.

Work with electricians, pipe fitters, machine builders and programmers to make good parts and get Customer approval.

Travel to suppliers and customers.

Assist in machine installation and production start up at Customer Plant.

Work with user Plant Facilities Engineers on floor plan layout and utilities requirement.

Customers: Ford, Chrysler/Getrag, Nemac and Magna Mexico. Project size 0.5 to 8 million.

Projects: axle, gear, transmission assembly and test machines, robotic cell welding systems, robotic washers, robotic material handling cells and conveyors. Instrumentation as required by assembly processes.

ZBIGNIEW BELKA PAGE 3

AMERICAN AXLE AND MANUFACTURING (01/2006 – 11/2007) – GLOBAL COMPANY

Corporate Controls Engineer

Placed on Special Assignment to retool axle assembly machines to add new part model and convert to 380V/50Hz voltage/frequency in new AAM Plant in China.

Placed on Special Assignment to procure, approve, test and accept machines for new plant in Poland. Supervise installation and start up in the new Plant AAM Poland.

This assignment required significant travel and stay in Germany, Poland, UK and Italy.

Responsible that newly hired engineers from Poland got required training at machine builders in Europe and training in Detroit for Siemens, Indramat and Fanuc CNC/PLC/Servo controllers.

Translate English to Polish, Polish to English of technical, safety and financial documents.

Placed on Special Assignment in Germany to train AAM Mexican Engineers in checking and approving machine drawings. Also conducted testing and approval of machines.

Involved in Factory and Quality Information Systems.

Assigned to check drawings and train Chinese Engineers in designing machine control systems via daily teleconferences and emails.

Updated Standard Component List for all AAM plants in USA.

Projects: gear, axle and prop shaft assembly and test machines, lathes, grinders, hobbers, washers, balancing, NVH machines, CNC Laser Welding Cell, Magnetic Arc Welding machine

Program sizes: multi - million.

CINCINNATI LAMB, DIV. OF MAG (03/1983 – 12/2005) – GLOBAL COMPANY

CONTROLS PROJECT Manager in Program Management Team

Controls Project Engineer in Welding Systems Group: (03/1983 – 12/1996)

“Cradle to grave” responsibilities: proposals and estimates, budgets, specifications, schedules, designs, panel build and procurement of all required parts for manufacturing.

Issue engineering PO’s.

Assist manufacturing in build, pipe and wire, debug and run off for customers.

Work with user Plant Facilities Engineers on floor plan layout and utilities requirement.

Develop Operating and maintenance manuals, training material for customers.

Responsible for Change Management: quote price, assessing schedule impact and negotiate with Customer.

Travel to the Customer Plant for installation and start up.

Welding Systems Programs: complete underbodies including motor compartment and rear compartment for GM, E&K and “W” cars – spot welding. Dash and cowl assembly for GM Truck and Bus – spot welding. Seat back for GM – arc welding. Rear axles press and weld – hydraulic, CNC and projection/forge welding. Machines and robotic weld cells

Metal Forming Programs: Hood and Deck pneumatic forming for Ford. CNC 14-axis piercing, metal forming and weld presses for Pullman (GM pickup 6- and 8-foot beds).

Controls Project Engineer/Project Manager in Machining Systems Group: (12/1996 – 12/2005)

Responsibilities: helping with proposals and estimates when required, writing specifications, designs, panel build and procurement of all required parts for manufacturing.

Issue engineering PO’s.

Assist manufacturing in build, pipe and wire, debug, test and run - off for customers.

Develop Operating and Maintenance manuals, training material for customers.

ZBIGNIEW BELKA PAGE 4

Responsible for Change Management: quote price, assess schedule impact and negotiate with Customer.

Travel to the Customer Plant for installation and start up when required.

Travel to US suppliers.

Travel to Washington State to Boeing facilities.

Travel to Lamb divisions in UK and Germany.

Travel to Mexico for retools: machine review and installation support. Chrysler, GM and Ford plants.

Automotive Programs: Transfer and CNC machining for cylinder heads – DCX Trenton. Transfer machines and CNC’s for head and blocks retools in Mexico for DCX, GM and Ford. Transfer machines and CNC’s for retools at DCX Mack Plants. Transfer machine for Ford block – PPS. Retool of transmission case for KTP DCX – pallet machines, conveyors, O/H transfers and

CNC’s. CNC’s for truck engine block – Dong Feng, China. CNC’s and transfer machine for China

Diesel, China.

CNC’s and CNC overhead transfers for ITP DCX transmission valve bodies and transfer plates.

All machines were designed with probes, test stations and gages.

Aerospace Aluminum Programs: develop, design, build and qualify Vertical and Horizontal milling machines with agile servo and hydraulic clamping fixtures for aerospace aluminum extrusions 4 to 100 feet long and different shapes. Develop, design, build and qualify high-speed high-power spindles: 50kW/23,000RPM and 80kW/10,000 RPM. Also integrated another spindle drive – sinusoidal drive for 80kW spindle. All these for Boeing plants in Washington State.

Aerospace Composite Program: adopt standard Lamb CNC machine for machining composite stringers. Develop, design, build and run - off load and unload automation.

Aerospace Spindle Monitoring and Adaptive System: develop, design, build and start up PC based system to interface with spindle mounted sensors and spindle drive monitoring sensors. Software was supplied by Boeing as a proprietary item.

ADDITIONAL INFORMATIONU

United States citizen. Also has a European Union passport.

Foreign languages: fluent in Polish and Russian.

Travel and stay is no problem.

International experience: Canada, Mexico, Germany, Poland, China, UK and Italy.

Used SAP and other systems for program management.

Contact this candidate