Description

LARRY TESSARI— Controls Engineer or Infotainment Engineer
5871 Pine St., Taylor, Michigan 48180
Phone (313)673-7502
Email LarryTessari@earthlink.net

 

SUMMARY OF QUALIFICATIONS

An innovative, hands-on team player and leader who leverages a valuable blend of interpersonal and technical skills to drive engineering efficiency and productivity.  Having over 30 years of experience in control system design and building/facilities design.  Experience includes management, engineering, financial, and supervisory duties, as well as hands on design.  Project management includes feasibility studies, cost estimates, cost-benefit analyses, (including payback and ROI), specification writing, project preparation, competitive bidding, OEM selection, supervision, and coordination, design approval, timeline management, scope management, quality management, resource management, and cost management, risk control, machine runoff, installation, debugging, operator and maintenance training, and billing verification. Personnel Management includes the coaching, mentoring, development, training and supervision of engineers and skilled tradesmen within a union shop plant as well as direct supervision, employee and team motivation, candidate evaluation, hiring recommendation, performance review, conflict resolution, and union grievance resolution  Control System Design includes hardware designing, material requisition, software programming, build supervision, installation, startup, and debugging. Architectural/Facilities includes power, lighting, fire protection, communications networks, energy management systems, and HVAC.  Testing And Validation includes infotainment systems and diesel locomotive engine control.

 

PROFESSIONAL HIGHLIGHTS

MANAGEMENT

·   Directed the efforts of 6 engineers, 14 electricians, and 2 millwrights in a union shop environment at Ford Motor Company.

·   Established plant electrical standards and collaborated with plant safety and corporate standards groups at Ford Motor Company to ensure the quality of controls systems used on new tools, machinery, and systems.

·   Managed the installation of a conveyor system commissioned at GM Janesville two months ahead of schedule and $80,000 under budget while achieving zero personnel injuries, safety infractions, or work slowdowns.  Successfully managed projects up to $5.5M.

·   Performed a feasibility study for GM Metal Fabricating Division and determined that a machine vision system could not replace an expensive, trouble-prone part-positioning system, saving the company from spending $20,000 on a system incapable of functioning in the production environment.

ENGINEERING

·   Developed a simple control system for an automatic tool changer for Valeo that incorporated energy-saving design and extensive diagnostics, including cycle-time totalizers, which provided user-screen prompting when periodic and preventive maintenance was required.

·   Devised a simplified control scheme for a particular filtration system that allowed it to be implemented in an SLC-5-04 PLC rather than the more expensive PLC-5-20 previously used.

·   Rewrote programs in Microsoft Basic to make several gauging stations at two Allied Signal plants Y2K compliant, eliminating the need for a company to spend $20,000 to replace the stations.

·   Provided in-plant support of 1 large material handling system, one class A and one class G paint finishing system, 63 injection-molding machines, and 16 large blow molding machines.

·   Did the last large substation/bus duct upgrade at a Ford parts plant entirely in-house without the aid of outside consultants.  Project consisted of a medium-voltage substation, two 5,200-volt substations, several 5,200-volt motor controllers and several 480-volt substations and over 2000 feet of bus duct.  Project was completed on time and within budget.

·   Added a safety pendant to several existing milling machines at Ford Batavia for automatic transmission valve bodies, allowing setup personnel to enter the machine’s work area to make adjustments without risk of injury.

 

PROFESSIONAL EXPERIENCE

-General Motors, Warren, MI…………………………………………………………………….. 11/2011-9/2013

INFOTAINMENT ENGINEER

Debugged Infotainment systems networks including MOST, LIN and CAN, Cadillac Cue, Chevy MyLink. Validated vendor software using Optolyser Suite and Intrepid Vehicle Spy Put problems in the ESIMS database and troubleshot issue causes.

 

Filtra Systems, Farmington Hills, MII……………………………………………………………. 7/2011-9/2011

CONTROLS ENGINEER

Did hardware and software design of control systems for filtration of industrial coolants using Siemens Step 7 with WinCC Flex and Telmecanique Unity Pro PLCs and AutoCAD for hardware design

 

GE Transportation Division, Erie PA…………………………………………………………… 5/2010-7/2011

TEST ENGINEER

Did regression testing of hardware and software controlling diesel locomotive engines up to 4500 horsepower.  Wrote purchase specifications.  Designed test panel that reduced test time by 22%, had fabricated, and debugged.  Did some programming with Matlab and Simulink.

 

Indicon Corporation, Sterling Heights, MI…………………………………………………….. 8/2009-3/2010

PROCESS CONTROLS ENGINEER

Hardware (AutoCAD) and software design, control system for T. I. Simon Power Plant at Michigan State University, including controls building, substation equipment, and control system using Allen Bradley GuardLogix PLC with safety I/O, Ethernet interfaces to auxiliary equipment and FactoryTalk based HMI

 

Ben-Tech Division of Curtiss-Wright, Rochester Hills, MI                                                9/2008-12/2008

CONTROLS ENGINEER

Wrote software (PLC and HMI) debugged, and started up complex conveyor/material handling system for Diesel Engines for Cummins using Telmecanique Unity Pro PLC and Vijeo HMI system and AutoCAD.

 

Ambitech Engineering, Downers Grove, IL………………………………………………….. 4/2008-9/2008

SENIOR ENGINEER

Created and checked P&ID and loop drawings and cable schedules to upgrade a Beckman MVCU system to an Emerson DeltaV system at a CITGO refinery.  Checked P&ID, loop drawings, and device specifications for a Unilever Food Processing plant and an HSC Semiconductor solar cell manufacturing plant.

 

Outbound Technologies, Novi, MI…………………………………………………………….. 11/2007-3/2008

CONTROLS ENGINEER

Debugged automated AGV/Assembly operation at Detroit Diesel using Step 7 with Transline for motor assembly.  Programmed a robotic weld station w/gauging for a small machine shop using RSLogix and a paint system air house/heater/humidity control system for GM Spring Hill Tennessee and a Mexican location using a ControlLogix PLC with a Siemens WinCC Flex HMI.

 

ThyssenKruppKruase, Janesville, WI………………………………………………………… 8/2007-11/2007

CONTROLS ENGINEER

Debugged automated automatic transmission assembly line for GM Toledo using Siemens Step 7 with Graph and WinCC Flex HMI system with ProAgent Diagnostic software at ThyssenKrupp’s Janesville, WI shop.

 

Independent Contract Work (1099,) Various………………………………………………… 9/2006-8/2007

CONTROLS ENGINEER

Converted steel mill blast furnace from S5 to S7 hardware and software for Nucor.  Debugged and started up robotic welding equipment from Comau/Pico and Kuka for Ford and Daimler Chrysler at customer’s plant.

 

 Lowry Controls, Loveland, OH…………………………………………………………………… 4/2006-9/2006

CONTROLS ENGINEER

Developed PLC programs for adding a pendant control station to existing CNC-based milling machines (Siemens S7) for transmission valve bodies, eliminating several safety problems.  Developed PLC hardware and software for system to remove chips from precision-machined transmission gears (Siemens S7), reducing failure rates 17%.  Developed PLC programs for silo/bin storage and conveyance of various granular and powdered materials. (Allen Bradley SLC-500)

 

Previously employed 14 years with Ford Motor Company as a Controls Engineer, promoted to Plant Electrical Engineer, and promoted again to Senior Controls Engineer at the Milan Plastics Plant 1984-1997. A long form of this resume with a 20-year work history is available Click Here to Request

 

SKILLS

PROGRAMMABLE CONTROLLER/HMI
• Siemens S5, S7, Graph Siematic, ProTool, Transline, WinCC Flex
• Allen Bradley SLC, PLC, ControlLogix, RSLogix, PanelView, 1336 and Powerflex Drives, Servos
• Telmecanique PL7, Magellis,UnityPro,Vijeo
• Modicon 384, 484, 584, 984, PanelMate, Concept
• Barber Coleman Maco4, Maco8000, Edic
• ABB Masterpiece
• Cognex Checker Vision System
• Emerson DeltaV(HW only)

 

NETWORKS• DeviceNet ControlNet Profibus, AS-I bus Modbus DH+ and RIO Industrial Ethernet

ROBOTS• Prab Kuka ABB IRB and Tralfa GCA CIMcon

VEHICLE NETWORKS MOST, LIN, CAN Optolyser Suite Intrepid Vehicle Spy

INSTRUMENTATION P&ID Drawings Loop Drawings 4-20 mA Current Loop Hart Protocol

SOFTWARE• AutoCAD Electrical• Microsoft Office•Project

ARCHITECTUAL/FACILITIES Fire protection, lighting

• Substation, power distribution, bus duct, load study, trip coordination, power factor correction

 

MAJOR APPLICATION AREAS
• Infotainment System Validation
• Plastics processing machines
• Casting and foundry operations
• Powerhouse equipment
• Powertrain.
• Material handling, conveyors, assembly
• Material handling, granules/powder/silos
• Liquid filtration
• Elpo/Phosphate
• Metal boring, tuning
• Petroleum Refinery
• Food Processing
• Paint finishing systems
• Glass product fabrication
• Chemical mixing
• Sheet metal stamping
• Spot welded assembly (Body in White)

 

PROFESSIONAL AFFILIATIONS
Member: ISA (International Society of Automation)
Member: SAE (Society of Automotive Engineers)
Member: ESD (Engineering Society of Detroit)
Member: IEEE (Institute of Electrical Electronic Engineers)

 

EDUCATION

University of Phoenix,………………………………………………………………………………………….. 8/2008

Master’s in Business Administration

 

 Detroit Institute of Technology (now part of Lawrence Technological University)……… 6/1972

Bachelor of Science in Electrical Engineering

 

Ford Human Resources Center,……………………………………………………………………….. Pre 1996

Management, Managing Skilled Trades

 

Education

University of Phoenix,

8/2008 Master’s in Business Administration

Detroit Institute of Technology (now part of Lawrence Technological University)

6/1972 Bachelor of Science in Electrical Engineering

Experience

General Motors, Warren, MI

11/2011-9/2013 INFOTAINMENT ENGINEER

Debugged Infotainment systems networks including MOST, LIN and CAN, Cadillac Cue, Chevy MyLink. Validated vendor software using Optolyser Suite and Intrepid Vehicle Spy Put problems in the ESIMS database and troubleshot issue causes

Filtra Systems, Farmington Hills, MI

7/2011-9/2011 CONTROLS ENGINEER

Did hardware and software design of control systems for filtration of industrial coolants using Siemens Step 7 with WinCC Flex and Telmecanique Unity Pro PLCs and AutoCAD for hardware design

GE Transportation Division, Erie PA

5/2010-7/2011 TEST ENGINEER

Did regression testing of hardware and software controlling diesel locomotive engines up to 4500 horsepower. Wrote purchase specifications. Designed test panel that reduced test time by 22%, had fabricated, and debugged. Did some programming with Matlab and Simulink

Indicon Corporation, Sterling Heights, MI

8/2009-3/2010 PROCESS CONTROLS ENGINEER

Hardware (AutoCAD) and software design, control system for T. I. Simon Power Plant at Michigan State University, including controls building, substation equipment, and control system using Allen Bradley GuardLogix PLC with safety I/O, Ethernet interfaces to auxiliary equipment and FactoryTalk based HMI

Ben-Tech Division of Curtiss-Wright, Rochester Hills, MI

9/2008-12/2008 CONTROLS ENGINEER

Wrote software (PLC and HMI) debugged, and started up complex conveyor/material handling system for Diesel Engines for Cummins using Telmecanique Unity Pro PLC and Vijeo HMI system and AutoCAD

Ambitech Engineering, Downers Grove, IL

4/2008-9/2008 SENIOR ENGINEER

Created and checked P&ID and loop drawings and cable schedules to upgrade a Beckman MVCU system to an Emerson DeltaV system at a CITGO refinery. Checked P&ID, loop drawings, and device specifications for a Unilever Food Processing plant and an HSC Semiconductor solar cell manufacturing plant

Outbound Technologies, Novi, MI

11/2007-3/2008 CONTROLS ENGINEER

Debugged automated AGV/Assembly operation at Detroit Diesel using Step 7 with Transline for motor assembly. Programmed a robotic weld station w/gauging for a small machine shop using RSLogix and a paint system air house/heater/humidity control system for GM Spring Hill Tennessee and a Mexican location using a ControlLogix PLC with a Siemens WinCC Flex HMI

ThyssenKruppKruase, Janesville, WI

8/2007-11/2007 CONTROLS ENGINEER

Debugged automated automatic transmission assembly line for GM Toledo using Siemens Step 7 with Graph and WinCC Flex HMI system with ProAgent Diagnostic software at ThyssenKrupp’s Janesville, WI shop

Ford Motor Company, Milan Plastics Plant Milan, MI

2/1984-1/1997 CONTROLS ENGINEER Salary Grade 6, promoted to PLANT ELECTRICAL ENGINEER, Salary Grade 7, promoted to SENIOR CONTROLS ENGINEER, Salary Grade 8

• Lead and supervised, engineers, draftsmen/CAD operators, contractors, and tradesmen (Union Shop).
• Did the last large substation/bus duct upgrade at a Ford parts plant that was accomplished entirely in-house without the aid of outside consultants. Project consisted of a medium-voltage substation, two 5,200-volt substations, several 5,200-volt motor controllers and several 480-volt substations and over 2000 feet of bus duct. Project was completed on time and within budget.
• Managed projects as large as $6.5 million dollars including feasibility study, funding procurement, specification writing, competitive bid procedure, scheduling around production, contractor supervision and cost control.
• SPC, Q1, and QS9000 procedures, documentation, and certification.
• Conducted training on new equipment and processes.
• Developed maintenance procedures
• Generated plant electrical standards and worked with corporate standards group.
• Evaluated new products and technologies.
• Specified acceptable manufacturers and products.
• Spearheaded implementation of new technologies such as CAD, fishbone diagrams, and FEMA analysis.
• Provided in-plant support of 1 large material handling system, one class A and one class G paint finishing system, 63 injection-molding machines, and 16 large blow molding machines.
• Insured the quality of controls systems used on new tools, machinery, and systems.
• Developed plant electrical specifications…
• Approved machine tool designs, control system architecture, and machine runoff.
• Improved relations with suppliers including cost control and negotiation of extras