Automation Systems
Overview
Automation systems form the backbone of modern manufacturing, enabling precision, efficiency, and consistency at scale. My expertise spans from single-station automation to complete factory-wide integration.
Key Technologies
PLC Programming
- Platforms: Siemens S7, Allen-Bradley ControlLogix, Omron NJ/NX
- Languages: Ladder Logic, Structured Text, Function Block Diagram
- Protocols: PROFINET, EtherNet/IP, Modbus TCP/IP
HMI Development
- Software: WinCC, FactoryTalk View, Ignition SCADA
- Features: Real-time monitoring, historical trending, alarm management
- Integration: ERP/MES connectivity for data-driven decisions
Robotics Integration
- Brands: KUKA, FANUC, ABB, Universal Robots
- Applications: Pick and place, assembly, welding, packaging
- Programming: KRL, TP, RAPID, URScript
Project Examples
Automotive Assembly Line
Automated assembly system for automotive components featuring:
- 6-axis robotic arms for precision assembly
- Vision-guided quality inspection
- Real-time production monitoring
- 99.8% uptime achievement
Food Processing Automation
Complete automation solution for food processing including:
- Stainless steel sanitary design
- Recipe management system
- Traceability integration
- Washdown-rated components
Performance Metrics
| Metric | Industry Average | Our Achievement |
|---|---|---|
| OEE (Overall Equipment Effectiveness) | 65-75% | 92% |
| Changeover Time | 30-45 minutes | 8 minutes |
| First Pass Yield | 85-90% | 98.5% |
| Mean Time Between Failures | 200-300 hours | 750+ hours |
Future Developments
Exploring integration of:
- Industrial IoT for predictive maintenance
- Machine learning for process optimization
- Digital twins for simulation and testing
- Collaborative robots for human-robot collaboration