Phillip Beal Email & Phone Number

New Brunswick, Nj, Us

Support 3GT Legacy production lines running on Siemens TI-505 PLC line. Support reliability team while working with vendors to find new parts for obsolete servo actuators for the 3GT Legacy lines.Developed and implemented new servo control solution to replace obsolete TMC188 Servo controller with Ethernet/IP based Delta RMC200 controller.Developed and maintain an API built in C#.NET for use with communication directly with a TI-505 system over TCP sockets.Manage on-site contractors for projects and additional 3GT line support.

Irving, Texas, Us

Accountable for all automation within the Rolling Mill which includes PLC, HMI, and SCADA programming, system troubleshooting, maintenance support, and equipment improvements utilizing ABB AC450 process control systems, GE Fanuc 90/30 control systems, Rockwell Automation PLC5/Micrologix/ControlLogix control systems, Siemens S7-300/S7-400/S7-1200/S7-1500 control systems.Developed a specification for the Rolling Mill automation upgrade project for the material handling and reheat furnace. Provided support to equipment suppliers, machine integrators and project managers during course of project providing electrical and automation oversight. Verification of equipment, and enforcement of equipment supplier and machine integrators with adherence to specification and standard developed for project.Developed a specification for the entire Rolling Mill automation upgrade project for the main rolling mill through the cooling bed and rod block through the cooling conveyor. Provided support to project manager and other plant management through project requirements, design guidelines, equipment layout, and vendor selection providing electrical and automation oversight, Provided support to equipment suppliers, machine integrators through course of project. Verification of equipment, and enforcement of equipment supplier and machine integrators with adherence to specification and standard developed for projectDeveloped a Rolling Mill FactoryTalk View SE SCADA system including all equipment control under one platform for support and data acquisition utilizing redundant servers hosted on VMWare ESX platform. Created necessary scripting within system for high uptime and availability through server reboots for seamless control.Designed and implemented additional machine vision applications upgrading the commissioned billet data-matrix barcode reading system to check for mixed heats and other quality issues.

Tampa, Florida, Us

Accountable for all automation within the Rolling Mill which includes PLC, HMI, and SCADA programming, systems troubleshooting, maintenance support, and equipment improvements utilizing ABB AC450 process control systems, GE 90/30 control systems, Rockwell Automation PLC5/Micrologix/ControlLogix control systems, Siemens S7-300/S7-400/S7-1200/S7-1500 control systems.• Upgraded and supported proprietary ABB Advant HMI system running on HP UX systems. Restored multi-monitor control through recycled hardware and created additional spares for failing systems.• Supported foreign integrator and corporate project managers during CAPEX project upgrading majority of drive systems within the Rolling Mill process and auxiliary systems.• Designed, built and commissioning a redundant pump high pressure water billet de-scaler control system utilizing Siemens S7-1200 PLC with integration into the existing Intouch Wonderware SCADA system.• Designed and virtualized critical process servers with new VMWare ESXi servers and setup a VMWare vSphere management server.• Designed, Implemented and commissioned billet data-matrix barcode reading system for tracking billet heats prior to reheating and rolling.• Developed a controls specification for future automation control system upgrade to standardize equipment acquisitions, consolidate spare part requirements and reduce spare part additions.• Provide support and hands-on training to maintenance personnel.

Houston, Texas, Us

Accountable for PLC and HMI programming, systems troubleshooting, maintenance support, and machine improvements in a continuous process manufacturing environment. Contributed to plant safety programs through DuPont STOP for Supervision.• Created, updated and reviewed PFMEA, CTQ, COPQ, JSEA, and risk assessments with regards to equipment control design as part of a team of engineers, operators, supervisors and managers. Developed and implemented solutions to reduce the risk to products and people during manufacturing. • Designed and implemented machine upgrades as necessary to reduce COPQ of manufacturing. Designed and implemented an integrated length measurement and product printing system with redundant printers for final product marking of long umbilical products during final jacket extrusion. Designed and implemented several wireless PROFINET communication systems for high speed rotating equipment to reduced machine downtime and improve reliability. Designed, implemented, and commissioned several projects replacing obsolete AC/DC drives with modular SINAMICS drives.• Implemented various diagnostic improvements to automation equipment to aid in fault finding and maintenance troubleshooting for reduced equipment downtime. Applied DMAIC process to machines to improve running efficiency and reduce risk to product during manufacturing.• Developed a controls specification to aid in equipment acquisitions, consolidate spare part requirements and reduce spare part additions.• Designed and implemented several wireless PROFINET communication systems for high speed rotating equipment to reduced machine downtime and improve reliability• Provide support and hands-on training to maintenance personnel.

Southfield, Michigan, Us

Accountable for PLC and HMI programming, systems troubleshooting, maintenance support, machine improvements in a Lean Manufacturing environment. Contributed to plant safety programs through STOP for Supervision.• Programmed the Turntable system during the upgrade project while meeting required deadlines for start of production for BMW. Developed a PLC barcode reading system to interface with the label printing system to produce finished goods labels• Developed various scripts in VB and C++ for the WinCC system to report and predict possible production based on current equipment efficiency.• Created an ASP.NET web interface to record machine downtime and generate downtime reports against a Microsoft SQL database.

Greer, Sc, Us

Accountable for PLC and HMI programming, system commissioning, start-up and support coverage.• Programmed and started multiple conveyor PLCs and HMIs while meeting required deadlines for start of production at BMW.• Developed support programs with VB.NET and C#.NET for remote HMI display, remote system monitoring, and for commissioning and start-up activities.• Developed applications for interfacing with programming software to generate and compile PLC programs and functions reducing engineering time.

Munich, De

Accountable for providing technical support for Siemens product lines across North Carolina and South Carolina including the BMW plant located in Greer, SC.• Provided direct technical support for the BMW plant located in Greer, SC during the single line conversion project in assembly area and body-in-white areas during the change over from Allen-Bradley equipment to Siemens S7 equipment. Also taught several Siemens training courses within the BMW plant covering STEP7 and the BMW Core Software programming standards. • Provided technical support for new and existing automation products to Siemens sales force and local customer base.• Provided start-up and commissioning support with on-site training courses for Siemens products at various customer locations and jobsites.• Developed concept systems for customer applications for integration from the machine level to the office level for data acquisition and monitoring systems.• Developed various scripts and add-on applications for various customer requirements and needs using both simple HMI data acquisition and complex Server-Client SCADA systems.

Southfield, Michigan, Us

Maintained the programming for the Robotic systems and Automation equipment within the plant and responsible for new robotic applications and start-ups in Lean Manufacturing environment.• Provide support to maintenance personnel with troubleshooting Allen-Bradley SLC500, Control Logix 5000 and Siemens S7 automation equipment.• Developed an OPC reader to read and log chemical usage on foam application equipment into an SQL server. Developed a GUI SQL interface for production staff to utilize historical machine data from the SQL server. • Created a prototype barcode identification system with HMI GUI for production staff to control robotic programs through HMI touch screen minimizing errors in part selection.

Accountable for electrical control system design, field installation and system startup with minimal supervision.• Experience programming a variety of automation equipment from abatement equipment, automotive robots, closed loop fluid control systems, high-speed carton filling machines using Allen-Bradley PLC controls and various HMI GUI systems.