100+ control system upgrades
Full system design and replacements
Extensive work with legacy PLC systems
Deep experience with Wonderware InTouch and industrial communications
I started my career in industrial controls fresh out of college, stepping into a manufacturing facility with aging control systems, limited connectivity, and years of deferred maintenance. Much of the equipment relied on older Allen-Bradley SLC 500 PLCs, often with little or inaccurate documentation.
Over time, I developed deep hands-on experience maintaining, upgrading, and retrofitting both legacy and modern control systems. I became highly skilled at troubleshooting production equipment under pressure, restoring failed PLC/HMI systems, resolving hardware and software issues, and reverse engineering processes when documentation was missing or unreliable.
My strongest experience is with Rockwell / Allen-Bradley SLC 500, ControlLogix, and CompactLogix PLC systems. I have maintained existing systems, modified legacy code, and written original PLC programs from scratch for new and upgraded equipment.
I also have extensive experience with industrial communications, including serial networks, EtherNet/IP, OPC, PLC-to-PLC messaging, remote I/O, and HMI connectivity. I deployed and supported an Ethernet-based manufacturing control network for PLCs, HMIs, remote I/O, and plant-floor data systems, with fault-tolerant logic designed to handle communication interruptions gracefully.
I also have substantial experience maintaining large AC and DC drive systems up to 1,000 HP, including Siemens, Mitsubishi, Allen-Bradley PowerFlex and Kinetix, Parker, SSD, and GE drives. This includes troubleshooting failed drives, replacing failed units in the field with available spare equipment, and modifying PLC and control-system interfaces to support legacy drive replacements or upgrades to modern hardware. My drive experience includes both practical downtime recovery and planned modernization work where older drive systems need to keep running while being integrated into newer control platforms.
My HMI and data-system experience includes Allen-Bradley PanelView, FactoryTalk View, Wonderware InTouch, Wonderware Historian, and SQL-based production data systems. I have developed new HMI applications, upgraded existing operator interfaces, supported historian servers, and written data-retrieval tools for integration with MES, OEE, and reporting systems.
I have also managed supporting infrastructure such as Windows servers, SQL databases, Wonderware Historian servers, and Synology NAS systems for engineering storage and backups.
I have received formal training in Rockwell ControlLogix, Rockwell Motion Control, Wonderware InTouch, and Wonderware Historian. My practical focus is helping manufacturers keep equipment running, recover from downtime, improve reliability, and modernize control systems without losing sight of how the real process works on the plant floor.