Senior Automation Controls Engineer, Automotive Industry

Mario Antonio Moreno Corona

Bloomington, IL., USA ************@*******.*** +1-309-***-**** https://www.linkedin.com/in/mario-antonio-moreno SUMMARY

Experienced Controls & Automation Specialist with 14+ years of automotive experience driving innovation and system integration from initial concept to high-speed production. Proven track record in leading high-impact new product launches (Powertrain, Speed Sensors, EV Inverters/Drive Units) and spearheading global Industry 4.0 digital transformations. Expert at bridging shop-floor hardware with enterprise IT/OT systems and managing international commissioning across the US, Mexico, Germany, and China utilizing a diverse tech stack including TwinCAT 2/3, Studio 5000, Siemens, and Ignition SCADA. Dedicated to streamlining global operations through standardization, technical mentorship, and data-driven process optimization. EXPERIENCE

Rivian (Normal, IL)

Sr. Automation Controls Engineer May. 2024 to present New Product Launch & Ramp-Up Management

• Inverter Line Startup (R2): Support with the installation, startup and high-speed ramp-up of a new Inverter production line. Verifying all technical deliverables and ensuring that every station met our corporate standards for functionality and safety.

Drive Unit Controls & Advanced Systems Integration

• High-Tech Software Management: Responsible for Drive Unit control systems fast recovery and troubleshoot, utilizing modern technical suite including TwinCAT 3, Studio 5000, Keyence Vision Systems, Fanuc Robotics and Octoplant for automated version control to ensure system recoverability. Managed and enhanced Ignition SCADA HMI interfaces to improve real-time visibility and operator control.

• Cross-Functional IT/OT Liaison: Served as a technical contact between the shop floor, IT, and MES teams, resolving complex connectivity and data-flow issues to maintain optimal line performance. Ox Machines (Leon, Gto.)

Freelance Sr. Controls Engineer Jan. 2024 to May 2024 Advanced Production Support

• Multi-Platform Systems Integration: Leveraged a diverse technical stack including Siemens, Allen- Bradley, and Fanuc to troubleshoot complex logic and maintain seamless production flow.

• Downtime Mitigation: Engineered real-time process improvements that minimized equipment failures and optimized cycle times, ensuring the facility met their output targets during the ramp-up period. Continental AG (Silao, Gto.)

EOLT Process & Software Specialist Coordinator Nov. 2020 to Sept. 2023 EOLT Process & Software Specialist May 2017 to Nov. 2020 Industry 4.0 & Digital Transformation

• Corporate I4.0 Pilot Leadership: Served as the primary plant expert for Industry 4.0 integration, implementing AR/VR solutions for remote support and virtual training. Led cloud-based (MDL) projects for real-time product traceability and station interlocking.

• Global Remote Commissioning: Managed the pre-acceptance and debugging of EOLT (End-of-Line Testing) systems at supplier facilities in Germany and China. Successfully maintained project timelines using AR glasses for remote commissioning and remote logic updates during travel restrictions.

• OT & Cybersecurity Specialist: Acted as the bridge between IT and the shop floor, implementing changes to ensure industrial equipment complied with corporate cybersecurity and connectivity specifications. Operational Excellence & Standardization

• Quality & Rejection Mitigation: Reduced EOLT rejection rates and customer complaints by engineering restricted PLC programs, implementing strict product recipe controls, and establishing centralized machine access protocols.

• Systems Standardization: Authored global equipment specifications (HW/SW) and generic RFQs based on "lessons learned" to streamline supplier deliverables and EOLT process standards.

• Infrastructure Centralization: Engineered and deployed a local server network to centralize machine backups and technical documentation, providing maintenance teams with instant access to critical recovery tools and remote troubleshooting capabilities. Team Leadership & Plant Support

• Controls Department Consolidation: Led the controls specialist team with a focus on new product integration and end-of-life equipment maintenance.

• Technical Mentorship: Served as the primary liaison for maintenance departments, developing and delivering specialized training programs that significantly reduced plant downtime and MTTR. Fives DyAG (Farmington Hills, MI & Silao, Gto.)

Sr. Controls Engineer Oct. 2012 to May 2017

Controls Engineer Nov. 2011 to Oct. 2012

Major Powertrain & Assembly Systems (GM & Chrysler)

• End-to-End System Delivery: Led the electrical design, PLC programming (from scratch), and commissioning for multiple high-speed transmission and motor head lines across the US and Mexico.

• Multi-Platform Integration: Orchestrated complex installations for GM (Toledo/Silao) and Chrysler

(Kokomo) using a diverse tech stack including Siemens, Fanuc Robotics, Cognex Vision, and Promess systems.

• Logic Development & Debugging: Developed and validated core logic for 9 Chrysler KTP lines and 5 GM Kitting stations, ensuring seamless handoffs from installation to full-scale production. Specialized Automated Solutions

• Precision Leak Testing: Commissioned and deployed PLC logic for 7 Prismatic line leak testers (Livonia, MI

& San Luis Potosí, MX), integrating ATEQ testers with Siemens and Fanuc controllers.

• Smart Infrastructure Upgrades: Spearheaded an RFID tracking system for GM Carrier lines (Toledo, OH) and a MES Down solutions for Paccar Block line to ensure data integrity and process traceability.

• Process Optimization: Provided critical production support for 8th-speed transmission plants, successfully reducing system faults and optimizing cycle times during the high-pressure initial operations phase. Project Leadership & Design

• Technical Management: Supervised cross-functional teams and managed project lifecycles from initial quoting and electrical design to final customer acceptance.

• International Commissioning: Managed on-site support and validation across USA & Mexico, ensuring compliance with automotive standards.

Nestlé CPW (Lagos de Moreno, Jal.)

System and Packaging Engineer Helper Aug. 2011 to Oct. 2011 Packaging Engineer Intern Jan. 2010 to Jan. 2011

Process Engineering & Operational Launch

• Production Line Implementation: Led the full-scale launch of a new production line, defining facility layout, labor requirements, and standardized work methods.

• SAP & Process Management: Managed complex Bill of Materials (BOM) and recipes in SAP while overseeing material cost-saving initiatives and supplier development.

• Operational Excellence: Conducted process trials and developed technical training programs for machinery and SAP systems to ensure production readiness and workforce competency. EDUCATION

Bachelor’s Degree Mechatronics Engineer 2006-2010 ITESM Campus León Diplomas & Courses

• TwinCAT 3 Beckhoff Machine Builder - Core Functionality Sep 2024 Beckhoff Online

• LDP1 (Continental - Leadership Development Program 1) Jul-Aug 2022 CONTUR

• TR1000 - TwinCAT 2 PLC programming Dec 2021 Beckhoff México

• Core Tools (APQP+PFMEA+SPC+MSA+CP+PPAP) Jul 2021 SPC Online

• Project Management: PMI certification Training (113h) Feb-Jul 2017 ITESM Online TECHNICAL SKILLS & AREAS OF EXPERTISE

Control Systems

PLC Programming (LAD, ST, FBD, SFC, IL): TwinCAT 2/3, Studio 5000/RS Logix, Siemens

(TIA Portal/Step7), and LabVIEW.

Digital & SCADA

Modern Infrastructure: Ignition SCADA, WinCC, FactoryTalk, Octoplant (Version Control), Node-RED, and MES Integration.

IT/OT Strategy

Industry 4.0: OT Cybersecurity, Cloud-based Traceability (MDL), and AR/VR Remote Commissioning.

Robotics & Vision Integration: Fanuc Robotics, Keyence, Cognex, Balluff and IFM Vision Systems. Motion & Tooling

Precision Hardware: Servos (Promess, Emerson, ServoPress, Starter, SMC, Oriental Motors, Festo, Lenze), Nutrunners (Atlas Copco), Leak Testers (ATEQ, Uson, Cincinnati), Laser Markers (Telesis and Keyence), and LVDTs.

Design &

Management

Operational Tools: AutoCAD, SAP (BOM/Recipe Management), MS Project, Power BI, and Root Cause Analysis (RCA).

Professional Skills

• Project Leadership: Managing full-lifecycle automation projects from initial RFQ quoting to final customer acceptance.

• Launch Management: Leading high-pressure New Product Launch and ramp-up.

• Standardization: Developing global hardware/software specifications and generic process standards.

• Cross-Functional Liaison: Bridging the gap between Maintenance, IT, and Engineering teams to reduce MTTR and plant downtime.

Languages Spanish (Native), English (Fluent)

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