PI Integration - CAC lead plant wide installation and commissioning of OSI PI integration to various equipment: such as Kilns, Hot Rolling machines and Cold Rolling Steel machines. This project consisted of engineering and integrating software/ hardware that was used to connect to various standalone machines, these systems were then connected to the OSI PI server for trending. This new ability allowed for optimized performance during plant processes and improved overall energy efficiency.

Integrity Test Machine - CAC was electrical lead for project team of 15 members composed of mechanical, electrical, technicians and process engineer.  CAC generated gantt chart, project schedule and allocated resources for the successful implementation of automated integrity tester.  This machine inspected products through the use of vision and laser technology.  Responsibilities included generating PLC/PAC code on RSLogix 5000 software, configuring and starting up control net devices, VFDs, Servos etc.  Generating functional specifications based on concurrent engineering methodologies, programming panelview screens, troubleshooting VB.Net code and interfacing with IT via OPC connectivity for SPC (statistical process control). CAC coordinated electricians and maintenance for major installs and repairs on tester.  Cross referenced electrical schematics with field install for accuracy and generated “As Built” electrical drawing package. CAC also helped develop SOPs for operators and troubleshooting guides for engineers.  Attended software meetings and best practice seminars hosted by Corning Inc.   

Ware Material Handling System – CAC consulted in upgrading existing 30 million dollar ware handling system. Responsibilities included modifying existing Controllogix PLC, to correctly load and unload palletized ware from conveyors into ASRS (Automated Stacking and Retrieving System) this system was composed of two cranes, 10 loading cars, Vision System, RSview OPC, HMI, SQL database, VB.net and a host of panelview OITs that all had to be orchestrated to accomplish a successful loading into Kilns and synchronizing data to MES/Proficy systems.

Batch Remediation Project: CAC Programmed RsLogix PLC5 and upgraded IFix HMI . Managed/coordinated project team of individuals for multi-million dollar batching process upgrade. Developed scope, budget, schedules and other associated documentation. CAC helped establish primary focus for advancements in technology. CAC managed technical individuals while keeping project on time and within budget. Remained focal point of entire project while directing team members for efficient task excecution. Project team was awarded Quality award, and yielded cost savings over 300,000 per/yr.