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Current & Recent Projects
Chrysler –
Paint Shop Conveyors
–
Sterling Heights, MI
Responsible for the design and detail of (1) new 90 degree
turntable, (1) new crank arm power roll bed lift table,
refurbishment of (3)
crank arm power roll bed lift tables,
refurbishment of (1)
90 degree turn table, 1,800 sq. ft. of grating platform
in Pretreat and (8) inverted P&F drives in the paint shop.
Responsibilities included field checks, layout development,
cycle time studies, chainpulls, layout review meetings with
Chrysler and all fabrication details.
Toyota
– Seat EMS Rework – Princeton, IN
Responsible for the concept development, design and detail of
raising the seat delivery EMS for clearance of new models.
Responsibilities included field checks, concept development,
part clearance studies,
layout review meetings with Toyota and all fabrication details.
General Motors – O/H P&F Conveyor – Lake Orion, MI
Responsible for the detail of the structural steel for the new O/H P&F conveyor.
Responsibilities included
all fabrication details
and layouts.
Ford Motor Company – U502 Trim Shop Platforms – Chicago,
IL
Responsible for the design and detail of reworked and new Trim
shop platforms.
Responsibilities included field checks, layout development, layout review
meetings with Ford and all fabrication details.
General Motors – Trim Skuk Aisle Transfer –
Lordstown, OH
Responsible for the design and detail of new high speed skuk
aisle
transfer with new pit steel and cover plate.
Designed new transfer into existing pit for cost savings to
customer. Responsibilities included field checks, layout development,
cycle time studies, layout review meetings with GM and all fabrication details (transfers &
pit
steel).
General Motors – O/H P&F Engine Delivery Line –
Flint, MI
Responsible for the detail of the structural steel for the new and
reworked O/H P&F Engine Delivery conveyor.
Responsibilities included field checks, layout development and all fabrication details.
Toyota
– Automation of I/P Decking Fixture – San Antiono,
TX
Responsible for the concept development, design and detail of
automating I/P decking arm for different models (Tundra and
Tacoma) from a manual operation.
Responsibilities included field checks, concept development,
part/body clearance studies,
layout review meetings with Toyota, tooling
integration, all fabrication details, purchased components and
field install/debug/production support.
Ford Motor Company – Michigan Assembly Plant Body Shop – Wayne, MI
Responsible for the design and detail of
relocating
(3) cross transfers with aisle crossings including all new pit
steel and cover plate.
Responsibilities included field checks, layout development, pit
sizing, cycle time studies, layout review
meetings with Ford and all fabrication details.
General Motors – Body Shop Fork Transfers – Hamtramck, MI
Responsible for the design and detail of
(3) new carrier checking fixtures and
to rework (3) existing fork transfers.
Responsibilities included field checks, layout development, 3D
part & fork detail studies, cycle time studies, layout review
meetings with GM and all fabrication details (transfers &
fixtures).
General Motors – Body Shop Fork Transfers – Hamtramck, MI
Responsible for the design and detail of (2) new crank arm fork
transfers and rework of (2) fork transfers being reused from the
GM Oshawa plant.
Responsibilities included field checks, layout development,
3D part & fork detail studies,
cycle time studies, layout review meetings with GM, tooling
integration and all fabrication details (transfers & header
steel).
Lift
Carriage
General Motors – Inline Chain On Edge Drives – Lordstown, OH
Responsible for the design and detail of (2) new inline Chain on
Edge drives with pits integrated into an existing system.
Responsibilities included drive design, custom conveyor track
sections, modular pit steel and cover plate and all fabrication
details (conveyor & steel).
Dana Structural Frame Division – Over/Under Buffers –
Elizabethtown, Kentucky
Responsible for the design and detail to rework (1) existing
overhead over/under buffer system relocated from the Dana’s St.
Mary’s Canadian plant. The floor supported structure was
reworked using the steel from the existing system to accommodate
the E-Town system layout. Creative solutions were developed for
areas of the structure as column placement and steel frame
systems were limited by existing plant equipment and required
“open” operating floor space. All structural components were
pre-designed with no field fabrication. Responsibilities
included field checks, layout development, cycle time studies,
layout review meetings with Dana, carrier design, robot
simulations and all fabrication details (conveyor & header
steel).
Ford Motor Company –
Kentucky Truck Trim Shop Tool Rail & Support Steel – Louisville,
KY
Responsible for the design and detail of all support steel
required for tool rail and bridge cranes in the Kentucky Truck
Trim shop. All equipment was from the Michigan Truck Plant.
Responsibilities included field checks, layout development,
layout review meetings with Ford, bridge and tooling integration, all fabrication details
and on-site installation support.
Ford VOME
Letter to our Customer
Ford Motor Company – Chicago Mastic Power Roll Beds – Chicago,
IL
Responsible for the design and detail required to relocate (3)
power roll beds from the Wixom Assembly Plant. Responsibilities
included field checks, conveyor layout development/design, cycle
time studies, addition of positioning stops, rework of the
existing conveyors, tool rail support steel and all fabrication
details (conveyor & header steel).
Ford Motor Company – Michigan Truck Chassis Tooling Relocation
to Kentucky truck Plant – Wayne, MI
Responsible for the design and detail of (5) chassis tooling
shipping pallets required to relocate the tooling from the
Michigan truck Plant to the Kentucky Truck Plant.
Responsibilities included field checks, 3D pallet development,
design review meetings with customer and all fabrication
details. Job was completed in (1) week to meet Fords shipping
schedule.
Ford VOME
Letter to our Customer
Chrysler – 2011
WD/WK program Paint Shop and TCF Conveyor Controls – Detroit, MI
Responsible for the Paint Shop and TCF new and reworked Conveyor
Controls for the 2011 WD/WK program. Included all controls for
new conveyor stops and new conveyors, LASD and Sealer rework
with new style identification, routing and lifter detail
detection, new underbody sealer cells. VFD
replacements/upgrades on fork transfer, new servo control for
body to skid locking mechanisms and FIS coordination and
testing. Responsibilities included Panelview rework and new
development, CLx5000, RSLogix rework and new development, debug
and standby support.
Ford
Motor Company – Stamping Plant Scrap Conveyor System –
Cuautitlan, Mexico
Responsible for the layout & design of the new scrap conveyor
system (conveyor components where detailed in Mexico). The
system included one press branch line 117’ long with the ability
to add a second press branch line and the main line 270’ long
delivering to the scrap storage building. Responsibilities
included design, layout, cross section development, drive
sizing, B.O.M.’s, design review meetings with customer,
coordination with A/E, and checking fabrication details.
General Motors – C.O.E. Prime
Storage Extension and New Top Re-Run Delivery Conveyors – Lake Orion, MI
Responsible for the design and detail of the C.O.E. (Chain On Edge) Prime storage bank
extension and new Top Coat Re-Run delivery conveyors integrated into an existing system.
The system included pusher transfer conveyors and inline accumulating conveyors
in addition to the C.O.E. conveyors. Through our value engineering we reduced
the total number of the drives on the system for a cost savings to our customer. Responsibilities included field checks, conveyor layout development/design and all fabrication details (conveyor & header steel).
Dana Structural Frame Division – Vertical Frame Buffer – Elizabethtown, Kentucky
Responsible for the design and detail of the vertical frame buffer system which consisted of a 42’ tall floor supported vertical buffer, shuttle table and (3) sets of auxiliary lifts with a total capacity of (17) frames integrated with an existing floor conveyor and overhead transfer. System installed without interruptions to production. Design considerations included providing flexible tooling to support handling (23) current and future model frames. Responsibilities included field checks, layout development, design review meetings with Dana, supplier coordination and all fabrication details.
Dana Letter
to our Customer
General Motors – VAC Empty Carrier Storage Bank – Lansing, MI
Responsible for the design and detail of the electrified monorail conveyor VAC (vertically adjusting carrier) empty carrier storage bank integrated into an existing system. Responsibilities included field checks, truss loading, conveyor and header steel layout development, rework of electrical controls design/communications and all fabrication details (conveyor & header steel).
Auto Alliance International (Ford/Mazda) – Blind Spot Detection – Flat Rock, MI
Responsible for the design and detail of the new
Mazda J61 blind spot detection moving wall automation for on-vehicle testing in roll test. Included changes to existing roll test guarding to accommodate new moving wall automation and new tire guides and lead-ins. Responsibilities included field checks, layout development, cycle time studies, layout review meetings with Ford/Mazda, automation design and all fabrication details (automation & support steel). System was commissioned over a weekend for pre-production builds.
Ford Letter
to our Customer
Ford Motor Company – Full Frame Buffer Conveyors – Dearborn, Michigan
Responsible for the design and detail of the new full frame buffer conveyor system. System included modifications to existing floor conveyor, new floor conveyor, lift tables for robotic and tooling load/unload, and complete floor supported overhead power & free conveyor system. Responsibilities included field checks, layout development, cycle time studies, structural loadings, layout review meetings with Ford, tooling integration and all fabrication details (conveyor & header steel).
General Motors – Front & Rear Fascia Over/Under Racks – Springhill, TN
Responsible for the design and detail of the automated over/under storage racks feeding front & rear fascia’s to the assembly line. Responsibilities included layout development, design review meetings with customer and all fabrication details.
BMW – Paint to Trim A.S.R.S. Expansion – Greer, SC
Responsible for the detail of the structural steel for the new A.S.R.S. including building steel, storage racks and conveyor platforms. Responsibilities included layout and cross section development, design review meetings with customer and all fabrication details.
Auto Alliance International (Ford/Mazda) – Rear Floor Conveyor – Flat Rock, MI
Responsible for the design and detail of the new J61 rear floor pan overhead power & free conveyor system. Responsibilities included field checks, layout development, cycle time studies, truss loadings, layout review meetings with Ford/Mazda, carrier design, tooling integration and all fabrication details (conveyor, carrier & header steel).
Auto Alliance International (Ford/Mazda) – Gas Tank Conveyor – Flat Rock, MI
Responsible for the design and detail of the Mazda and Mustang gas tank delivery conveyor system. Provided cost saving alternate layout to reduce interferences and total system cost. Responsibilities included field checks, layout development, truss loadings, cycle time studies, layout review meetings with Ford/Mazda, tooling integration and fabrication details for conveyor support steel and guarding.
Auto Alliance International (Ford/Mazda) – J61 Program Paint Shop – Flat Rock, MI
Responsible for determining modifications required to (3) paint shop inverted power and free conveyor systems to accommodate the new 6” longer J61 body. Responsibilities included field checks, cycle time studies, design reviews with Ford / Mazda and detailed layouts showing electrical and mechanical conveyor modifications required for the new J61 body to meet design production rates.
Auto Alliance International (Ford/Mazda) – J61 Program Trim Shop – Flat Rock, MI
Responsible for determining modifications required to the skillet / overhead power and free conveyor transfer, (7) overhead power and free conveyor systems and overhead power and free conveyor / skillet transfer in the trim shop to accommodate the new 6” longer J61 body. Responsibilities included field checks, cycle time studies, design reviews with Ford / Mazda, all conveyor fabrication details and detailed layouts showing electrical and mechanical conveyor modifications required for the new J61 body to meet design production rates.
UPS World Port Facility – Distribution / Express Parcel Conveyors – Louisville, KY
Responsible for developing subsystem quotes using AccuBid software and providing bid clarification / support documentation as a consultant to Motor City Electric Company (http://www.mceco.com). Developed detailed electrical installation packages for each system which included drawings for Cable Tray, 480VAC, 120VAC, 24VDC routing and connectivity. Provided engineering management, customer and field installation coordination support and services.
Dana Structural Frame Division – Power and Free System – Stockton, CA
Responsible for the development, design and detail of the overhead power and free frame conveyor system. The system design included robotic loading/unloading with existing robots and the ability to rotate the frame 360 degrees in the carrier for manual welding. . Responsibilities included field checks, layout development, cycle time studies, layout review meetings with Dana, carrier design, supplier coordination, robot simulations, all fabrication details (conveyor & header steel), installation, debug and start-up. System was commissioned over a weekend into full production.
General Motors – Gmt-745 Program Conveyor Modifications – Shreveport, LA
Responsible for determining modifications required to the existing frame tilt-over station, 2-strand delivery conveyor and fork transfer based on new Gmt-745 frame. Design considerations included providing flexible tooling to support handling a total of (40) current and future model frames. Responsibilities included verification of existing tooling design and modifications required through the use of 3-dimensional software and all fabrication details required to support the new Gmt-745 frame.
Honda – POPA Paint Facility – Marysville, Ohio
Responsible for the development and design of the new Top Coat oven strip out proposal for the POPA paint shop. Responsibilities included field checks, layout and cross section development, cycle time studies, chain pull analysis, layout review meetings with Honda, clearance studies and process integration.
Dana Structural Frame Division – P&F System – Elizabethtown, Kentucky
Responsible for providing advanced planning, simulation and the development of a cost savings alternate layout for bid on the existing power & free conveyor system expansion.
Daimler Chrysler Sterling Heights Assembly “JS Program”– Sterling Heights, MI
Responsible for electrical controls design, programming and panelviews (HIMS) for Doors, Deck, Side Aperture and LH Quarter Outer conveyors as a consultant to Motor City Electric Technologies, Inc. (http://www.mceco.com). Developed system designs based on latest Rockwell platform RSLogix5000, Devicenet, Controlnet, Ethernet, Panelview(s) Machine Edition.
General Motors – Re-Rate for 66.3 JPH Program – Fairfax Paint Shop
Responsible for the design and detail of the overhead power and free delivery conveyors, skid conveyors and electric lifts for the paint shop rework. Responsibilities included field checks, layout development, cycle time studies, layout review meetings with GM, carrier design, tooling integration, all fabrication details (conveyor, carrier & header steel), installation, debug and start-up.
Ford Motor Company – Wixom Ass’y Plant Decrease Line Rates - Wayne, Michigan
Responsible for miscellaneous conveyor engineering services to prepare for line rate decreases. Responsibilities included field checks, layout development, cycle time studies, layout review meetings with Ford, and all fabrication details (conveyor, carrier & header steel).
General Motors – GMT-900 Truck I/P Rework– Fort Wayne General Assembly
Responsible for the design and detail for the rework of the I/P overhead delivery conveyors. Responsibilities included field checks, layout development, cycle time studies, layout review meetings with GM, carrier design, tooling integration and all fabrication details (conveyor, carrier & header steel).
International Transmission Company– Detroit, MI
Responsible for the upgrade to all SCADA systems within local power substations (230,000v +) in southeastern Michigan as a consultant to Motor City Electric Company (http://www.mceco.com). Project management duties included scheduling, running eight to ten field crews, coordinating with SBC, directional boring teams and property owners. Weekly time and material project updates and monthly costs projections. Prepare monthly invoices. Procure and organize required parts and miscellaneous material/equipment required by crews to complete each substation. Review engineering for labor hour accumulation counts and changes.
General Motors – GMT-900 Truck Flat Top Rework– Fort Wayne General Assembly
Responsible for the design and detail for the rework of the final line flat top conveyor to add an over riding torque over load to both the main and stand-by drives. Responsibilities included field checks, layout development, cycle time studies, layout review meetings with GM, carrier design, tooling integration and all fabrication details (custom sprockets).
General Motors – GMT-900 Truck Program – Fort Wayne Body Shop
Responsible for the design and detail of the overhead zone to zone power and free delivery conveyors for body shop. Responsibilities included field checks, layout development, cycle time studies, layout review meetings with GM, carrier design, tooling integration, all fabrication details (conveyor, carrier & header steel), installation, debug and start-up.
Dana Structural Frame Division – P&F System – Elizabethtown, Kentucky
Responsible for the development and design of the 3,300 ft. overhead power and free frame delivery conveyor system. Floor supported structure throughout the existing plant. Creative solutions were developed for areas of the structure as column placement and steel frame systems were limited by existing plant equipment and required “open” operating floor space. High bay area contains large “buffer” system supported with a unique two level 30’ high steel support structure with two empty carrier bias bank conveyor lanes above and two loaded carrier bias banks below. All structural components were pre-designed with no field fabrication. Responsibilities included field checks, layout development, cycle time studies, layout review meetings with Dana, carrier design, supplier coordination, robot simulations, all fabrication details (conveyor & header steel), installation, debug and start-up.
Dana E-town P&F Picture 5
Dana E-town P&F Picture 6
Dana E-town P&F Picture 7
Dana Structural Frame Division – Over/Under Buffers – Elizabethtown, Kentucky
Responsible for the development and design of the (5) overhead over/under buffer systems. Floor supported structure throughout the existing plant with capacities of 20 to 75 frames. Creative solutions were developed for areas of the structure as column placement and steel frame systems were limited by existing plant equipment and required “open” operating floor space. All structural components were pre-designed with no field fabrication. Responsibilities included field checks, layout development, cycle time studies, layout review meetings with Dana, carrier design, supplier coordination, robot simulations, all fabrication details (conveyor & header steel), installation, debug and start-up.
Dana E-Town Over/Under Buffer Picture 1
Dana E-Town Over/Under Buffer Picture 2
Dana E-Town Over/Under Buffer Picture 3
Dana E-Town Over/Under Buffer Picture 4
Dana Structural Frame Division – P&F System – St. Marys, Ontario Canada
Responsible for the development and design of the overhead power and free frame delivery conveyor system extension. Floor supported structure throughout the existing plant. Creative solutions were developed for areas of the structure as column placement and steel frame systems were limited by existing plant equipment and required “open” operating floor space. All structural components were pre-designed with no field fabrication. Responsibilities included field checks, layout development, cycle time studies, layout review meetings with Dana, carrier design, supplier coordination, robot simulations, all fabrication details (conveyor & header steel), installation, debug and start-up.
Dana Structural Frame Division – Over/Under Buffers – St. Marys, Ontario Canada
Responsible for the development and design of the (4) overhead over/under buffer systems. Floor supported structure throughout the existing plant with capacities of 20 to 40 frames. Creative solutions were developed for areas of the structure as column placement and steel frame systems were limited by existing plant equipment and required “open” operating floor space. All structural components were pre-designed with no field fabrication. Responsibilities included field checks, layout development, cycle time studies, layout review meetings with Dana, carrier design, supplier coordination, robot simulations, all fabrication details (conveyor & header steel), installation, debug and start-up.
Ford Motor Company – Body Shop Zone to Zone Conveyors– Wayne, Michigan
Responsible for the design/detail of the structural support steel and screenguard for (4) zone to zone Unibilt power and free conveyors. Responsibilities included field checks, layout development, truss loadings, layout review meetings with Ford, tooling coordination with robots and all fabrication details (header steel).
Ford Motor Company – Rack Delivery Conveyors– Wayne, Michigan
Responsible for the development and design of the rework and extension to the overhead power and free rack delivery and body in-white delivery conveyors. Responsibilities included field checks, layout development, chainpulls, cycle time studies, layout review meetings with Ford, carrier design, supplier coordination, all fabrication details (conveyor & header steel), installation, debug and start-up.
Ford Motor Company – Rack Delivery Conveyors– Wayne, Michigan
Responsible for the development and design of the rework and extension to the overhead power and free rack delivery and body in-white delivery conveyors. Responsibilities included field checks, layout development, chainpulls, cycle time studies, layout review meetings with Ford, carrier design, supplier coordination, all fabrication details (conveyor & header steel), installation, debug and start-up.
AM General – Hummer 2 Paint Facility – South Bend, Indiana
Responsible for the conveyor system proposal for the new paint facility. Responsibilities included developing the conveyor budget, developing and pricing alternate layouts, simulation, bid clarifications, alternate layout review meetings with AMG, conveyor contractor selection, final proposal clarifications and final pricing. Upon award managed the prime conveyor contractor overseeing layout, design, installation, debug and launch of the new paint shop conveyor systems completing the job $1 mil under $10 mil. budget.
General Motors – “560” Medium Heavy Truck Paint Facility - Flint, Michigan
Responsible for the conveyor proposal for the new paint facility. Responsibilities included developing the conveyor budget, developing and pricing alternate layouts, simulation, bid clarifications, alternate layout review meetings with GM, conveyor contractor selection, final proposal clarifications and final pricing. Upon award managed the prime conveyor contractor overseeing layout, design, installation, debug and launch of the new paint shop conveyor systems completing the job $3.7 mil under $20 mil. budget. |
