I am experienced in process and workflow improvement, troubleshooting, and project management. This involves both managing a project's implementation to personally developing solutions by leveraging available technologies of front-end website design and scripting, to back-end application integration and database design. The rest of this site is more of an extension to the standard resume, kind of a short-storied portfolio of information by combining the bulletpoints from the resume summary to better explain the overall projects, skills, and experience. If you prefer the hard copy listing only, you can download it below.
Currently developing a web interface to replace the QTMS section of our ERP system. Due to proprietary hardware and future support concerns for this product, we
decided to build something in-house. The current QTMS system is used to collect shop floor running data and place it into the ERP system for running metrics.
The replacement application will act as an extension to the current ERP system and pull data from four separate systems, jobs from the ERP system, press run data from the Honeywell system,
preink pages from our FPAR system, and Inserter run data from the Muller Martini system. The website will consolidate all the data pulled into a single visual display and allow the operator to modify or enter other details as necessary.
This data will then
be written and stored to an intermediate database for reporting, then processed and sent into the ERP system to complete the workflow of the
requirements of the QTMS system.
Technology: Apache, HTML5, CSS3, PHP, jQuery, SQL, MySQL, JSON
Due to constant changing technology, OS upgrades, and security patches, we were operating on an older webserver with processes and security vulnerabilities. Although it is a long process, rebuilding was the decision. Not only is it nice to start with a clean system, you can also take advantage of this time to reevaluate current processes, and look for upgrades or improvements.
The latest of all software was used in the core install including Windows, Apache, PHP, MySQL. Apache was configured using vhosts to take advantage of our internal DNS and multiple sites. Set up schemas and users, then restored database tables and data from backups of the current system. Transferred all websites to the new server and modified logons and new driver used for updated version of PHP. Removed old VB scripts that were used to capture streamed data from Serial-to-IP devices and modified webpages to pull data from the new capture devices on a separate SQL server. Due to security risks of Java and future licensing, decided to move away from Pentaho jobs and rewrite these using Python. Designed new scripts to pull data from files and write it into the local MySQL database, and then set these scripts as tasks to run daily. Auto-backup scripts were then created and set to run daily. Sendmail was setup and configured to use our internal SMTP server, used in scripting from the local task sceduler since the windows mail is being deprecated.
Technology: Apache, HTML5, CSS3, PHP, jQuery, SQL, MySQL, MySQL Workbench, JSON
Im sure, like most facilities, ours had an abundant of hanging announcements of relevent information that ends up becoming background noise after a while. To try and clean up the walls and make this process more active, dynamic, and vibrant,
I started researching display possibilities. Due to foundational technological improvements and availability of cheaper hardware, as long as there was the technological ability, this bacame a very relevant solution. After deciding the cost and
requirements, a project plan was written up, proposed, and presented. The hardware was installed, software and webpages were built, schedules and displays were configured, and training was provided for HR staff.
This became a very successful implementation that has since grown to additional monitors across the facility for the specific departments, being able to build and display metrics and data related only to those areas, this has opened up a lot more
opportunities and communication options.
Technology: Risevision, HTML5, CSS3, PHP, jQuery, SQL, MySQL, JSON, Raspberry PI
Within our industrial environment there was a lot of coordination required to manage workflows and processes invloved in estimating, planning, scheduling, distribution, invoicing, and shop floor data entry. This ultimately creted a very chaotic and inefficient situation by using various 3rd party systems to process and evalutate the information, so we decided to invest in an ERP system. After finally deciding on a system, three employees were responsible for its implementation, myself, our financial manager, and our scheduling manager. There were a lot of shared duties but specific responsibliites as related to my part include application display customization, data entry requirements, shop floor data collection interfaces, scripting, 3rd party application interfaces, and report writing. Application customization involved making specific changes to the visual style sheets for operator entry, tailoring each style sheet for each department and position. Data entry requirement design included understanding what reports are required first, then developing the fields for entry and storage in the database to satisfy the future reports filtering, grouping, and calculations. The shop floor interfaces consist of connecting into or using details from existing equipment to eliminate duplication entry from operators. The Honeywell Printa system requqired modification to the logic to provide the necessary ouptuts where the Muller inserters only required mapping current outputs. The new system and devices were installed and both interfaces were then physically wired into the new system. The system had an internal scripting system allowing for a sort of macro response to actions performed. A lot of these were set up to automate many processes such as launching reports, clearing fields, closing jobs, exporting data, and printing job packets with single operator actions. The internal reporting was an expansive system that offered a lot more than standard reporting, it also allowed for programming integrations and scripting. It was first developed for invlicing by pulling external excel-based price scales that were too complex for the internal grid pricing required for our needs. This was then expanded to reading from an excel file to calculate paper usage, import distribution quantities, insert imports and exports of invoiced items in structured xml format that another system would then import. In-depth reports were built more interactively with button-based scripts to perform actions or run more detailed, filtered results. This is a continuous process of customization and report writing to fit any need or new requiremtent.
Technology: Prism, SQL, IIS, Alcont Printa, Pentaho, Python
One project involved an engineered modification from an original design because of the cost savings and extended visibility it offered. There are large static annunciator displays attached to packaging equipment
to display important zoning information to the operators. The problem was that the display faced only one direction, toward the machine, which limited the visibility for the other processes downstream. The original
idea was to purchase two more of these annunciators to face the back of the machine. There would still be limitations due to the immobile nature of these units and less ability for future expansion. What we decided
to do was re-engineer it with more global visibility. Instead of purchasing two more annunciators, we purchased a Nintendo Wii, a Serial-to-IP converter, and 42" flat screen TVs. Since
this was prior to the explosion of IOT devices, a lot of discussions, and justifications, for our purchases were required. With these items, we intercepted the signal going to the annunciators, redirected it through a
Serial-to-IP converter, captured the stream with a VB script to a file, and then read this file into a webpage. Not only did this offer greater flexibility and visibility but the costs were significantly less than
purchasing two more annunciators.
This had since been modified using newer, cheaper IOT hardware to offer even more options for newer TVs and monitors while expanding visibility to more locations. The VB scripts were also replaced with software to capture the stream and place it in a SQL database, which were mined and placed on the new displays and into the other webpages as status updates.
Technology: Serial-To-IP, Advanced Datalogger, HTML5, CSS3, PHP, jQuery, SQL
An extremely meaningful and impacting project involved installing tension meters on the press. The issue was that the operators had no clear, reliable feedback on the status of the web tensions. This lack of visibility
made overall tension control difficult to maintain, leading to a higher amount of web breaks, waste, and overall downtime. The solution was to add visibility, and the work required to accomplish the task was extensive.
This had been a project thought about many times throughout the years but the cost and unknown ROI was not enough to justify and move forward. With in-house efforts to offset a large portion of the costs, and updated
data analysis, we were able to push forward with the project. We took on all the hardware installation and software programming, leaving only the costs of required hardware and our time and effort. Rollers with the
tension transducers were installed in critical locations, replacing the existing idle rollers. The transducer signaling was sent into converters which then transferred the signal into Honeywell analog input cards (MAI)
that were installed and configured into the Printa press control system. The logic of the Printa program was modified to integrate the MAI inputs, warnings were programmed for minimum and maximum ranges, and new
screens were built to display the information. New monitors were purchased and setup as extensions to the production PCs and integrated to display tension reading on one display and the standard operating controls on
the other. With this new visibility the operators could now see and manage tensions, drastically decreasing web breaks and increasing overall production efficiency.
Technology: Alcont Printa
One of the first projects I was involved in was very shortly after being hired into a new company. Being a new building and installation, there were a lot of minor quarks and trial and error operations.
One of the first larger issues involved an instance of breaking glass during the initial loading process. With the larger sheets of glass, automated sections of suction cups were used to pull the pieces off an A-frame
to the load conveyor. If there was a problem with the separating agent during the initial packaging, a vacuum was generated between the currently loaded piece and the adjacent one, causing the second piece to fall and break.
The repair, since we could not affect the initial packaging, was to try and mitigate the vacuum on the adjacent piece. This was done by adjusting the PLC logic to introduce a stagger and delay to each section of suction cups.
The cups would grab the piece of glass, pull back one section at a time to create a pealing effect, delay to allow any movement from the adjacent piece to settle, then finally lower it to the conveyor.
Technology: Ge Fanuc PLC Programming
One of the first more meaningful projects was an improvement to increase the overall process output. The problem was with the medium sized glass and lack of conveyor coverage. Because of the specialized manual load process,
requiring two people and driven roller assist from the conveyor, this limited the current method and amount to one piece per load process. From a time and material standpoint, there was a lot of waste in preparation and
process material while grossing less overall product. The idea was to design a way to fill the conveyor while allowing the overall load process to remain the same.
The solution involved splitting the chain mid-conveyor, adding a sensor and a clutch, and modifying the PLC logic. The resulting process was that the first piece was loaded and run up to the transfer position. The clutch
would then disengage, allowing the front half of the conveyor to continue to run, and the second piece to be loaded. This second piece would then move up to the sensor, filling the load conveyor and re-engaging the clutch,
moving both pieces to the next section. This doubled the efficiency for the medium sized pieces and decreased the amount of material wasted, and cleanup time, caused by sputtering to empty rollers.
Technology: Allen Bradley PLC Programming
Mason City, IA
Cedar Rapids, IA
Des Moines, IA
Apart from spending the majority of my time on computers at work, I continue to enjoy my time within the computer world while at home. I have always been into computers, even before they were offered in schools I would work with the Comodore 64/128 systems at home. I like to explore the latest technology and, if not using it for myself at work or for at-home work projects, I continue to be amazed at the creativity of others in the open-source community. I am fortunate it is an interest, it would be difficult to keep up on technological changes with how fast erverything evolves if there was a lack of interest. Even though I do spend a lot of time in this area, this is not something that completely dominates my time, I also enjoy online gaming and watching Esports competitions.
When away from the virtual world, I enjoy fairly standard activities. I like to go to the gym, watch movies, search and listen to a lot of music, and go to concerts or play Golf or Volleyball when possible.