LARRY TESSARI Electrical Controls Engineer or Project
Manager
(313)673-7502
LarryTessari@earthlink.net
http://www.linkedin.com/in/Larry-Tessari-Controls
Experience in
Control System Design, hardware, and software (HMI/PLC, Allen Bradley, Siemens,
and several others.)
Experience in
Management and Leadership. Excellent communication and
interpersonal skills.
Detroit Area Candidate
can travel 20%, CANT RELOCATE.
Physical limitations prefer desk-based positions to plant floor. ANY RECRUITER WHO CONTACTS ME ABOUT OUT-OF-AREA JOBS
WILL BE BLOCKED!
An innovative
leader and team player who uses a valuable blend of
interpersonal and technical skills to drive engineering efficiency and
productivity, with extensive experience in hands-on control system and
building/facilities design including management, engineering, financial, and
supervisory duties.
Project management: Feasibility studies, cost estimates,
cost-benefit analysis, specification writing, project preparation, competitive
bidding, OEM selection, supervision, coordination, design approval, timeline
management, scope management, quality management, resource management, cost
management, risk control, machine runoff, installation, debugging, operator and
maintenance training, and billing verification.
Managed the installation of a control system for 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
Personnel
Management: Coaching, mentoring, development, training and supervision of
engineers and skilled tradesmen, employee and team motivation, candidate
evaluation, hiring recommendation, performance review, conflict resolution, and
grievance resolution. Managed 6
engineers, 14 electricians, and 2 millwrights in a union shop environment at
Ford Motor Company.
Control
System Design: Hardware design, material requisition, software programming,
build supervision, installation, startup, debugging, commissioning, and
troubleshooting. Have done both revisions to existing
systems and design from scratch. Like to create PLC/HMI
programs with comprehensive diagnostics to improve process capability, system
uptime, throughput, reliability, both in the machine HMI and in the Factory
Information System including notices a week before preventive maintenance is
due. This increases Mean Time Between
Failures (MTBF) as well as reducing Mean Time to Repair (MTTR.) Prefer having sensors to detect every mode of
failure (Poka-Yoke) for greater error-proofing and preventing, correcting, or
drawing attention to errors either before or as soon as they occur.
Architectural/Facilities:
Lighting, fire protection, communications networks, substation, bus duct, load
study, trip coordination, power distribution, power factor correction, energy
management, HVAC. Did the last large
substation/bus duct upgrade at a Ford parts plant entirely in-house without the
aid of outside consultants. The 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. Completed the project on time and
within budget.
Testing and
Validation includes infotainment systems and diesel locomotive engine
control.
Performed a feasibility study for GM Metal
Fabricating Division and found 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.
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 supplied
user-screen prompting when periodic and preventive maintenance was needed.
Devised a simplified control scheme for a
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, ending 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.
Added a safety pendant to several existing
milling machines at Ford Batavia for automatic transmission valve bodies,
allowing setup personnel to enter the machines work area to make
adjustments without risk of injury.
Designed
revisions to a gear deburring system at Ford Batavia that reduced failure rates
by35%
Programmable
Controller/HMI:
Siemens Step 5, Step 7, Graph, Siematic, ProTool, Transline,
WinCC Flex
Allen Bradley/Rockwell SLC, PLC5, 500,
5000, ControlLogix, GuardLogix, RSLogix, PanelView, FactoryTalkViewME, Powerflex Drives, 1336
drives
Telemecanique PL7, Magellis,
UnityPro, Vijeo
Modicon 384, 484, 584, 984, PanelMate, Concep
Barber Coleman Maco4, Maco8000,
Edic
ABB Masterpiece
Vision
Systems Cognex Checker, Keyence, Sick
Emerson DeltaV (HW only)
Networks RSNetworx,
DeviceNet, ControlNet, Profibus,
Profinet,
Fieldbus, AS-I bus, Modbus, DH+, RIO, Ethernet/IP
Robots Prab, Kuka, ABB, IRB, Tralfa, and GCA CIMcon
Vehicle
Networks MOST, LIN, CAN, GMLAN, Optolyser Suite, Intrepid Vehicle Spy
Instrumentation
P&ID, Loop Drawings,4-20 mA Current Loop, Hart Protocol, Pneumatics,
Hydraulics, Actuators
Software AutoCAD Electrical, Microsoft Project
Safety Standards CE, UL, NFPA 79
(ESIM), NFPA 70 (NEC), UL508, ANSI B11.19, ANSI R15.06, IEC 61508, IEEE 1584
FCA Chrysler, Auburn Hills,
MI June
2018-April 2019
Controls Engineer Contracted through Enterprise-Logic
Created template PLC and HMI software to
communicate with the APICS, AVI, FIS, PFCS, and QAS systems using RSLogix5,
RSLogix 5000, Studio 5000, Factorytalk View for vendors to use. Worked with machine tool builders to ensure plant floor equipment communicates
with upper-level systems so vehicles are built with correct options, colors, etc.
Responded to plant problems and aid in resolving them so production
can continue
Jervis B. Webb, Farmington Hills, MI. Mar
2016-Nov 2016
Controls Engineer
Contracted through Trialon.
Upgraded
airport baggage handling systems using multiple Siemens Step 7 PLCs with ladder logic, statement list (STL), and Profibus. The system had hot standby to automatically switch to the backup processor in the
event of failure.
Debugged
software on a simulator to make in-field startup go more smoothly.
Global
Rollforming Systems, Roseville, MI. Sep
2015-Dec 2015
Controls Engineer
Contracted through Resource Professionals.
Supported
maintenance electricians and programmed interfaces to plant supervisory network
using Allen Bradley RSLogix with Panelview and Factorytalk View HMI.
General Motors, Warren, MI. Nov
2011-Sep 2013
Infotainment Engineer
Contracted through RCO Engineering.
Debugged Infotainment systems networks including MOST, LIN GMLAN
and CAN. Systems including Cadillac Cue, Chevy MyLink. Validated
vendor software using Optolyser Suite and Intrepid Vehicle Spy.
Troubleshot issue
causes, entered problems in the ESIMS database and communicated findings
with suppliers.
Filtra Systems,
Farmington Hills, MI. Jul
2011-Aug 2011
Controls Engineer Contracted through
Hire Talent 1.
Designed
control system hardware and software for filtration of industrial coolants
using Siemens Step 7 with WinCC Flex using ladder logic and STL
and Telemecanique Unity Pro PLCs and AutoCAD for hardware design.
GE Transportation
Division, Erie PA. May
2010-Jul 2011
Test Engineer
Contracted
through Adecco.
Did regression testing of hardware and software controlling
diesel locomotive engines up to 4500 horsepower.
Wrote technical and 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. Aug
2009-Mar 2010
Process Controls Engineer
Contracted
through Otterbase.
Designed
hardware (AutoCAD) and software, for 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
Worked with mechanical engineer and
building supplier to coordinate facilities in the building and ensure that the building could support the
weight of the required cable trays and substation. Coordinated the design of substation and MCC
with the Siemens rep.
Ben-Tech Division of Curtiss-Wright, Rochester Hills, MI. Aug
2008-Dec 2008
Controls Engineer Contracted through Custom Controls
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.
Included tracking functions to ease the removal
and reinsertions of engines on the conveyor system for repair purposes.
Ambitech Engineering,
Downers Grove, IL. Apr
2008-Sep 2008
Senior Engineer Contracted through Aspen
Technical.
Created and checked P&ID and loop drawings and cable
schedules to upgrade an obsolete Beckman MVCU system to an Emerson DeltaV
system at a CITGO refinery.
System had over 6000 I/O points, many of them 4-20 ma analog.
Checked P&ID, loop
drawings, and device specifications for a Unilever Food Processing plant making
Bertolli Products and for a. Hemlock Semiconductor factory. Created and checked purchase orders for
sensors and valves.
Outbound Technologies, New Hudson, MI. Nov
2007-Mar 2008
Controls
Engineer Contracted through Wolfgreen.
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.
Debugged automated AGV/Assembly operation at Detroit Diesel using Siemens
Step 7 with Transline for diesel motor assembly.
Designed Interlock wiring and programmed new part
sequence for a robotic weld station w/gauging for a small machine shop using RSLogix and several pieces of peripheral equipment
with Micrologix controllers.
Debugged a paint finishing system air house/heater/humidity control system for GM Spring Hill Tennessee
Saturn Plant and a Mexican location using an Allen Bradley ControlLogix PLC
with a Siemens WinCC Flex HMI
ThyssenKruppKruase, Janesville,
WI. Aug
2007-Nov 2007
Controls Engineer Contracted through Oxford.
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 ThyssenKrupps Janesville,
WI shop
Independent
Contract Work (1099,) Various Sep
2006-Aug 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 customers plant.
Lowry
Controls, Loveland, OH. Apr
2006-Sep 2006
Controls
Engineer, Contracted
through Belkan.
Developed PLC programs for adding a pendant control station to
existing CNC-based milling machines for transmission valve bodies, eliminating several safety problems using Siemens Step 7
with Transline HMI.
Developed PLC hardware and software
for system to remove chips from precision-machined transmission gears, reducing
failure rates 17% using Siemens Step 7 with WinCC HMI.
Developed PLC programs for silo/bin
storage and conveyance of various granular and powdered materials using Allen
Bradley PLC-5.
Added a safety pendant to several
existing milling machines at Ford Batavia for automatic transmission valve
bodies, allowing setup personnel to safely enter the machines work area to make adjustments without risk of injury using Siemens Step 7
with Transline
Siemens Postal
Automation Division, Grand Rapids, MI. Jul
2005-Feb 2006
Controls Engineer, Contract Position, contract house unknown
Designed, debugged, and
commissioned hardware and software for assorted types of conveyor equipment for
bar-coding, sorting, and routing packages, letters, and assorted parcels for
DHL Express and FedEx shipping hubs in California, Ohio, and Pennsylvania Using
Allen Bradley PLC-5.
The system included
extensive error checking to reduce incorrect routing problems.
Ghafari Associates, Dearborn, MI. Jan 2005-Apr 2005
Controls Engineer, Contracted through
G-Tech
Prepared bid
package for revisions to E-coat/ Phosphate system at Ford Atlanta, including
building and architectural revisions, layouts, panel hardware design, and
general specifications using Allen Bradley PLC with Panelview HMI.
Developed user-friendly, ergonomic PanelView
screens that improve accessibility to information and should significantly
reduce MTTR
Independent Contract
Work (1099). Jan 2001-Nov 2004
Controls Engineer
Debugged
Siemens PLCs (S7) for Daimler Chryslers Kokomo, Indiana transmission plant at
an OEM facility.
Designed Tool Changer (Allen Bradley
SLC-5-04/PV550) for Valeos Galesburg, Indiana plant
at an OEM facility.
Directed and supervised the installation
contractors and performed program debugging at the Valeo plant. The system included energy-saving design and comprehensive
diagnostics.
Programmed Siemens PLC's (Step 7/Protools) with Profibus for a waterjet cutting machine for
automotive headliners that featured user-friendly HMI screens and self-diagnostic
capabilities, which reduced downtime 42% and required one less person to operate.
GM CRW Metal
Fabricating Division Troy, MI. Jun 2000-Dec 2001
Controls Engineer, Contracted through
Aerotek
· Conducted all phases of the project management lifecycle.
Observed runoff on new machines, troubleshot in-plant
problems; revised existing equipment designs to correct issues and satisfy
production requirements.
Performed a feasibility study and found that a
machine vision system could not be used to 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.
Filtra Systems Southfield, MI. Jan 2000-May 2000
Service Engineer, Contract Position,
contract house unknown
Designed
startup and field service liquid filtration systems for industrial coolants,
cutting fluids, oil refining, municipal water treatment, and other
applications.
Allied Signal Akuna, Mexico, Frankfort, Ky, and Marion, IN. Jun 1999-Dec 1999
Controls Engineer, Contracted through
Compuware
Performed Y2K
analysis of computers, robots, PLCs. torque
controllers, temperature controllers, and other intelligent devices at Allied
Signal Brake plants in Frankfort, Kentucky, Akuna, Mexico, and Marion, Indiana.
Rewrote programs in Microsoft Basic to make
several gauging stations at 2 Allied Signal plants Y2K compliant, eliminating the need for the company to spend $20,000 to
replace the stations.
General Motors, Lindon, NJ and Janesville, WI. Jun 1998-Jun1999
Controls Engineer, Contracted through
Aerotek
Performed Y2K
analysis of computers, robots, PLCs. torque
controllers, temperature controllers and other intelligent devices at GM plants
in Janesville, Wisconsin and Linden, New Jersey.
Rewrote the PLC and Panelview programs for the
system at Janesville that tracked individual vehicles through the assembly
process and assured that each vehicle had the correct options, paint colors,
etc.
Chrysler Corporation Belvedere, WI. Jun 1997-Apr 1998
Controls Engineer, Contracted through STI.
Added
Ethernet connectivity to several stations at the Belvedere. Illinois
Neon plant for future communications with a factory information system.
Eisenmann Conveyor, Crystal Lake, IL. Feb 1997-Jun 1997
Controls Engineer, Contract through
Resource Technologies
Managed the
electrical installation of a conveyor system to be commissioned at GM
Janesville. Brought the system online two months ahead
of schedule and $80,000 under budget while achieving zero personnel injuries,
safety infractions, or work slowdowns.
Ford Motor Company,
Milan Plastics Plant Milan, MI. Feb 1984-Jan 1997
CONTROLS ENGINEER Salary Grade 6, promoted to PLANT ELECTRICAL ENGINEER,
Salary Grade 7, promoted to SENIOR CONTROLS ENGINEER, Salary Grade 8,
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. The 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. The 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.
Lead and supervised drafters/CAD operators, contractors, and tradesmen
(Managed 6 engineers, 14 electricians, and 2 millwrights Union Shop.) Conducted
training on new equipment and processes.
Developed maintenance procedures.
SPC, Q1, and QS9000 procedure s, documentation, and certification.
Generated plant electrical standards and worked with corporate standards
group. Wrote Plant Electrical
Specification. Approved machine tool designs, control
system architecture, and machine runoff.
Evaluated new products and technologies. Specified acceptable products. Spearheaded
implementation of new technologies such as CAD fishbone
diagrams, and FEMA analysis.
Insured the
quality of controls systems used on new tools, machinery, and systems,
Improved relations with suppliers including cost control and negotiation of
extras.
Direct hire, Took
buyout in1997
Production
Scheduling in an automotive assembly plant
Complex
Conveyor Systems
Infotainment
system validation
Plastics
processing machines
Casting and
foundry operations
Powerhouse
equipment (pumps, chillers, cooling towers, air compressors, steam, and boiler)
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)
Masters in Business Administration (MBA) University of Phoenix
Bachelor of Science in Electrical Engineering (BSEE) Detroit Institute of Technology
(D.I.T. is now
part of Lawrence Technological University, accredited by NorthCentral. It was the only college in the United States
with an astronaut (Wally Schirra) on the faculty. Henry
Ford also taught there.
Project Management, Managing Skilled Trades Ford Human Resources Center
Senior Member: IEEE (Institute of Electrical
Electronic Engineers.)
Classic Member: SAE
(Society of Automotive Engineers.)
Member: ESD
(Engineering Society of Detroit.)
Member: ISA
(International Society of Automation.)
Member ASCE
(American Society of Civil Engineers.)
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