CV (CURRICULUM VITAE)

David Allen Fischhaber

2102 Wood Acres Rd SW, Oakwood, GA 30566-0303

770-530-8231

EDUCATIONAL BACKGROUND

Bachelor of Electronics Engineering

Aerotek Engineering administers the Ramsae Test to Controls Engineers for Amazon-ELS. Of those degreed engineers taking the test, 87% fail. David Fischhaber not only passed the test, he missed only one question.

PROFESSIONAL EXPERIENCE

Caldwell Electrical Contractors, Gainesville, GA 30507

Senior Electrical Engineer, July 8, 2020 to March 1, 2023

Developed a Robotic Laser Marking Table to mark electrical enclosures with tags, labels, screw and hole outlines / locations in a fully automatic fashion. Once the mechanical engineering was complete, developed all the controls hardware without the use of enclosures. Finally, developed the software, based on Codesys, to run this machine. The machine can process enclosures as large as a 3-door closet or a variety of smaller enclosures all in one pass.
Worked on a variety of projects (some with Codesys): food processing, Cottrell Carrier Trailers, Kubota Manufacturing, etc.
Developed electrical standards and drawings, a variety of software tools to support the system analysis process, etc.
Streamlined engineering processes, greatly improved throughput, and greatly improved product quality.
Market conditions forced a change in business direction. All CAD is now Revit. I have no Revit background.

IP6xControls LLC, Dacula, GA 30019

CTO and Consultant, September 25, 2018 To July 3, 2020

Worked on a variety of projects. Was the Planner, Architect, and/or Engineer to companies needing help with their engineering processes for the express purpose of improving those processes while also greatly improving their throughput.
Worked with Bridgestone Tire on upgrades to their Tire Assembly Machines.
Developed controls standards and drawings for several companies with a focus toward building enclosure-less systems.
Streamlined engineering processes for several companies to greatly improve throughput and product quality.
Developed many new products to support enclosure-less systems. Many more are in the works.
Pandemic forced the company into lay-offs, job/function changes, etc. Am still working but without pay.

Advanced Systems & Controls, Inc., Macomb, MI 48042

Controls Engineer, February 25, 2018 To September 24, 2018

Worked on upgrades to GKN production line for Ford products at Plant #2 in Newton, NC which included Siemens S7 V5.5 software upgrades as well as installing a Bosch BS350 Series Nutrunner.
Was asked to look at engineering and shop processes for opportunities to make improvements. Had submitted a proposal detailing the recommended changes/additions. Started making those changes and getting the planned for improvements.
Developed their first Enclosure-less system using Siemens PLC, Indramat Mi series servos, and Festo pneumatics.
The company was sold and the efforts, while successful (and dramatic), were shut down.Many were laid off including the Operations Manager and me.

ATS Assembly & Test, Inc., Wixom, MI 48393

Lead Controls Hardware Engineer, November 2015 To February 2018

Developed AutoCAD-E drawing set for a Harley Davidson transmission case test machine w/ A-B PLC and FANUC Robot.
Developed AutoCAD-E drawing and software standards to apply FANUC or ABB robots to any application.
Developed a new standard for applying Cincinnati Test Systems (CTS) test controllers.
Developed program to apply one GViVentures vision system with 5 Basler cameras at Ford Sterling for Differentials.
Developed the standard for selecting a camera, lens, filter, and light for a machine vision system application.
Developed assembly system controls standards using Siemens ET200PRO, ABB robots, Promess Press, Telesis laser.
Developed ATS standards for executing any Ford Powertrain project. It includes controls plates/enclosures, RFID, I/O assignments, servos, ABB robots, etc. With this standard, ATS can handle any combination of sensor, solenoid valve, motor, pushbutton box, etc. AND can assemble the entire controls package for one station in less than a day (versus 2-6 weeks).More specifically, a station or OP drawing package can be assembled in about 2 hours and the application specific “parts” can be inserted in another 2-4 hours. Drawings for these “parts” (i.e., servo) are already complete.
Lead Controls Hardware Engineer on Ford Rawsonville transmission pump assembly and test system. The system has 4 manual stations, 4 semi-auto stations, and 12 automatic stations (3 have robots). Components ($5M) for the entire control system were ordered in the first 2 weeks of this 40-week project. Mechanical Engineering individual station detail for application specific sensors, valves, motors, etc.Because of the previously developed standardization effort, we cut >50% of actual Controls Engineering project time.
With the completion of Ford project, my work with ATS was also completed.

GUDEL, Inc., Ann Arbor, MI 48108

Senior Controls Engineer, February 2014 To October 2015

Developed “Electrical Maintenance Training” manual for Ford Buffalo, NY and trained their electricians. Beckhoff Based.
Developed “Operator Training” manual for Ford Buffalo, NY and trained their Operators. Beckhoff based.
Developed “Beckhoff System Maintenance Training” manual and trained many Ford Electricians and Engineers.
Received training on Pilz Safety PLC. Have certificate of completion and am now certified to program such PLCs.
Developed new modular program, based on Beckhoff, that controls all Gudel Press Automation products.
Developed new interface between Beckhoff PCs and Pilz Safety PLCs.
Received training on the proper selection and use of the Igus Energy Train product line as used by Gudel.
Commissioned three Press Automation systems with Beckhoff PCs, Indramat drives, Pilz PLC, Roland Blank Detectors.
A major downturn in the market forced layoffs which included me, my boss, and his boss.

Helix Systems, Inc. – Bessemer, AL 35020

Senior Electrical Engineer, May 2013 To February 2014

Provided engineering support to PACCAR Engine Company in Columbus, Mississippi.They machine, assemble, test, and paint diesel truck engines.They use Siemens S7 PLCs, WinCCFlex, Profibus, ProfiNet, Siemens motors and drives, Siemens Safety I/O, and Krause FOM programming methodologies.Also worked on Fanuc robots, some of which required the use of Fapt Ladder.Received training on FOM methodologies, Siemens Safety, and Siemens Drives.
Provided engineering support to Metalsa Tuscaloosa, Inc. in Tuscaloosa, Alabama.They stamp and assemble (via spot welding) sheet metal for the automotive market.They use Siemens S7 PLCs with WinCC, Profibus, and ProfiNet.Effort included providing OEE management systems utilizing iGear.
Have a written agreement that David would do nothing but be a development engineer. Did nothing but field service.

INP North America, Inc., Alpharetta, GA 30009

Senior Automation Engineer, August 2011 To March 2013

Provided engineering support to Kamtek in Birmingham, Alabama.They are a sheetmetal stamping plant that uses Beckhoff Industrial PCs, Strothmann 8 axes Feeder robots, Pilz Safety System, Rexroth motors and drives, VisiWinNet HMI, MS Access database, SQL, VBscript, Ethernet, Real-Time Ethernet, EtherCAT, Profibus, and DeviceNet.
Spent 4 weeks in Krefeld, Germany setting up a Strothmann eight axes Feeder as a simulator and then provided training to several Siempelkamp engineers and others on its technologies and uses.
Provided engineering support to NSM at Kamtek in Birmingham, Alabama for their Sheetmetal Destacker systems that use Beckhoff Industrial PCs, Pilz Safety System, interfaces with Allen-Bradley ControlLogix on the Press, etc.
Provided engineering support to Eagle Bend Manufacturing for a Hot Press system conversion that used Beckhoff Industrial PCs, Pilz Safety System, three Comau robots, high temp. oven with Allen-Bradley ControlLogix, etc.
Provided engineering support to Ford, Louisville Assembly Plant for their Windshield, Back, and Side light window gluing and installation system.System used six Fanuc robots, vision systems, Allen-Bradley Safety and PLCs, and Ethernet/IP.
Provided engineering support to NSM at Eagle Bend to start-up and program 3 Fanuc robots for Hot Press application.
Provided engineering support to NSM at Vehtek to start-up and program 2 systems of 3 Fanuc robots for Hot Press apps.
Provided engineering support to Regional Supply to develop HMI and PLC programs for automatic belt punch machine.
Corporate mandated business changes eliminated engineering functions. Engineering manager was laid off and so was I.

Automation, Clermont, GA 30527

Consultant, January 2010 To August 2011

Developed the controls to test fire pump systems automatically.Included EtherCAT networks, 900MHz radios, Wi-Fi, Stepper control of the flow test valves, NetBook HMI using InduSoft, Excel as a database, SQL, VBscript, and more.
Developed the controls to pin-point locate a tumor using x-ray imaging and then use a 0.5mm beam of x-ray to target and destroy the tumor.Included a Siemens S7-315 PLC, Galil 5 axis DC motor control, Siemens HMI, Gulmay High Voltage generator, laser alignment, and more.
Assisted seven inventors in the development of their respective products.
Developed a Universal Converter Controller and Bag Machine controls
Developed automated head-ball machine for Cabbage Patch Dolls.
INP North America was desperate for a Beckhoff person. President literally begged David to come on board.

Mountain Automation, Inc. Clermont, GA 30527

Chief Engineer, February 2007 To December 2009

Provided engineering/design support services to industrial, commercial, and Inventor customers.
Developed a series of engineered automation modules - six possible modules to start with - that can be used individually or combined in a multitude of configurations.One of those various combinations provides a four-axis robot manipulator and another provides a Gantry class robot.

Beckhoff Automation LLC, Duluth, GA 30096

SE Region Support/App. Engineer, July 2005 – February 2007

Provided application support for all Beckhoff hardware, software, and network products.
Developed the controls hardware and software for the DALI automatic lighting control system at a PETCO store in CA.
Supported numerous customer projects including the controls for a machine that makes flexible circuit boards.

Creative Integration, Inc. Clermont, GA 30527

Design Manager, January 2005 – July 2005

Contracted with VJ Technologies out of New York to develop controls for several industrial X-Ray systems including one for NASA to perform non-destructive testing on their Shuttle’s Solid Rocket Boosters using a PaR Robot.
Developed the controls and operator interface (HMI) for an automated bulk material warehouse with blending operations that replaced the manual switching/routing effort involving well over 300 routing combinations.
Provided engineering services for several process market customers involving, mostly, electrical controls but also provided mechanical engineering services, too.

G & L Technologies, Inc., Alpharetta, GA 30004

Electrical Engineer, July 2004 – January 2005

Developed electrical engineering department and documentation standards.
Developed several new products including:
- Controls and software for 9 axis, Plantation Shutter painting robot.
- Controls and software for 3 axis, Plantation Shutter louver/tiltrod processing machine.
Developed a Universal Power Enclosure, Universal Servo Drive Enclosure, and Universal HMI enclosure that are fully adaptable to any of the company’s machines to reduce costs, installation, training, assembly, etc.

CAMotion, Inc., Atlanta, GA 30309

Chief Electrical Engineer, Sept. 2003 – July 2004

Developed electrical engineering department and documentation standards.
Developed several new products including:
- AC Brushless Servo Drive that includes TI DSP for motion control and Intel DSP for Ethernet/CAN
- "Miniature" Robot controls for very high-speed gantry robot for packaging and other pick-and-place applications.
- Controls for a 4 axis very high-speed gantry robot used in food packaging.

Advanced X-Ray, Inc., – Buford, GA 30518

Electrical Engineer, January 2001 - August 2003

Developed electrical engineering department and documentation standards.Electrical circuit drawings utilized both traditional ladder diagrams and wired parts graphic that reduced service calls to zero over two years.
Reduced electrical engineering project/product development time from 6 weeks to less than 4 days - 87% reduction.
Reduced electrical install time from as much as 12 days to < 1 day - 92% reduction.One large project was < 4 hrs.
Reduced electrical materials project/product cost by as much as 30%
Product quality - reliability, serviceability, durability, etc. - doubled.
Reduced electrical service calls from about 60 per year to zero!
Overall electrical systems profits increased by better than 40%.
Developed Area Alarm for X-Ray personnel safety (used on virtually all X-Ray projects).
Developed Several printed circuit boards to simplify system assembly & troubleshooting while also reducing system costs.
Developed Motion and I/O controls for a system to X-Ray Hand-Grenade fuses using Baldor AC servo drive and motor.
Developed Controls for 3 systems with ABB robots to X-Ray jet engine parts plus another to X-Ray military aircraft wings.
Developed Controls for a system to X-Ray Delta II and Delta IV rocket engine parts and fuel cells.
Developed Manipulator and controls to X-Ray jet engine fuel lines using Baldor AC servo drives and motors.
Developed Manipulator and controls for several systems to X-Ray auto and truck parts.
Developed Numerous other systems and products – all of them using the new modular approach.

Southeast Automation Systems, Inc., Clermont, GA 30527

Engineering Manager, 1997 To 2001

Developed Vinyl Base Mold Forming machine and controls that will process parts at 600/hour.
Developed Plastic Blow-Mold Controls on a machine that produced 50% more product than others in its class.
Developed Plant engineering department and documentation standards.Converted German documentation to English.
Developed Start-up assistance for new automation system as well as training for maintenance.
Developed Control system for a high-speed garment sortation system - 25,000 garments per day using barcode.
Developed Welding robot with embedded controls for boiler tube and vessel repair.

Norton Construction Products, Flowery Branch, GA 30542

All Disciplines Engineer, 1996 To 1997

Designed a variety of in-plant machinery and equipment – mechanical and electrical.
Provided automation engineering services: mechanical, electrical, software, machine design, manufacturing, etc.
Provided operations analysis services.One analysis resulted in development and implementation of a plan to reduce inventories by up to 70%, increase productivity by up to 250%, reduce rework/scrap by 20%, plus many other benefits.

Welding Services, Inc., Norcross, GA 30071

Electrical Engineer, 1994 To 1996

Developed 6 axis robot control system with Yaskawa drives/motors, Prolog PC, and Motion Engineering motion controller.
Developed straight tube MIG overlay weld control system.
Developed 5 axis wall welding robot control system.Co-developed mechanical.

Creative Robotic Automation, Inc., Norcross, Ga 30096

Project Manager, 1993 To 1994

Developed large scale assembly machines and controls for a home appliance manufacturer.

SABBATICAL 1991 TO 1993 (Owner/Manager of construction business)

The M.W. Kellogg Company, Houston, TX 77002

Manufacturing Controls Manager, 1986 To 1991

Managed South American Chlorine Container Handling System.
Co-developed structured methodologies, based on IDEF, for performing an Operations Research Analysis of an enterprise.
Successfully completed several CIM projects for international companies (i.e., oil packaging, plastic manufacturing, etc.).
Developed discrete software simulation on several plastic manufacturing and oil packaging facilities.
Developed the Modicon 984 PLC software for a material handling system for iron ore.
Developed the software for a plastics compounding system using redundant PLC’s.

GMFANUC Robotics Corp – Troy, MI 48084

SRS Division Manager, 1985 To 1986

Managed four paint robot installations. Each has 40 robots and related hardware/software systems. Each system valued at $25MM. Engineered/designed world’s first electric paint application robot and controls, the P-150; all application related equipment for the installation of 162 P-150 robots; all application software based on GMF developed Karel language; three pneumatic control systems for color applications and one airless atomizer pneumatic control system; an AC servo powered robot slide and robot peripheral turntable; a maintenance robot slide; and over 50 other new application products for the P-150.

K-R Automation Corporation - Madison Heights, MI 48071

Assistant Engineering Manager, 1982 To 1985

Engineered/designed control systems for: automatic paint mix and distribution system for Ford Assembly, Atlanta $4MM; automatic selection and sonic welding of resistors to the keys of Corvettes $350k; automatic weld/assembly system for a Ford car body; control systems for 21 types of conveyors; automatic robotic paint application systems for GM Baltimore $8MM; automatic rotary paint application systems for: Ford Lorraine, Ford Wixom, Ford Wayne, and Nissan Smyna, TN $6MM ea.; “fixed” paint application systems for GM Lake Orion, and GM Wentzville plants $6.5MM ea.. Developed the General Motors Assembly Division GMAD standards and master specification for stationary air atomized paint application systems. Developed the General Motors Corporation standards and master specification for pneumatic control panels used in paint application systems.

Chevrolet Flint Truck Assembly – Flint, MI 48551

Process Engineer, 1976 To 1982

Responsible for maintenance and operation of all plant automation. Automation includes: electrostatic paint application systems, high density stackers (AS/RS), cab/box fixed weld system, misc. robot systems, tooling, and others. Also served as Project Manager for the main paint mix room and distribution system, final repair paint mix room and distribution system, two robotic truck wheel paint application systems, a Suburban/Blazer floor-pan weld/assembly system, a Suburban/Blazer side-panel weld/assembly system, the Behr “fixed” electrostatic paint application systems. Previously served as a Maintenance Supervisor responsible for up to 50 tradespersons with journeyman qualifications. Primary responsibility of this group was general maintenance/repair of the facility as well as emergency breakdown repair and preventive maintenance.

TECHNICAL SKILLS (A-B = Allen-Bradley)

Software TwinCAT, CoDeSys, IEC61131-3, ModSoft, Concept, RSview, RS5000, FactoryTalk, Indusoft, Step7, WinCC,

DirectSoft32, C/C++, VB, VBscript, SQL, and many others

Applications AutoCAD2024, AutoCAD-E 2020, Inventor 2020, SolidWorks 2007, most Microsoft app, etc.

Networks EtherCAT, Ethernet, ProfiNet, Ethernet-IP, Profibus, DeviceNet, SERCOS, +18 others

PLCs/PACs Beckhoff, Siemens, A-B, Modicon, Mitsubishi, GE, OMRON, AutomationDirect, etc.

AC Servo Drives Beckhoff, Indramat, Yaskawa, Fanuc, A-B, Emerson, Baldor, SEW, Danaher, etc.

DC Servo Drives Beckhoff, Control Dynamics, ELMO, A-B, etc.

Steppers Beckhoff, AMCI, GMD/EuroCard, Oriental Motor, US Digital, ACS, etc.

VFDs WEG, Siemens, SquareD, A-B, Mitsubishi, Baldor, Control Dynamics, etc.

Motion Control Beckhoff, Siemens, A-B, Motion Engineering, Galil, Baldor, etc.

Industrial PC Beckhoff, Dynics, EXOR, A-B, Siemens, Ziatech, Nematron, Rabbit, Tern, etc.

Robots ABB, Fanuc, KUKA, Devilbiss, Bosello, Comau, etc.

Paint App.’s Behr, Binks, Graco, Devilbiss, Sames, Kremlin

Industrial X-Ray Gulmay, Viscom, Hamamatsu, Bosello, Varian, Perkin-Elmer, Envision, Tellus, etc.

Weld Lincoln, SquareD, OTC, etc.

CAREER HIGHLIGHTS & ACCOMPLISHMENTS

ALL SYSTEMS IN THIS CV (I.E., ROBOTS, MACHINES, ETC.) WERE PROGRAMMED USING A COMBINATION OF THE SOFTWARE LISTED UNDER TECHNICAL SKILLS (SEE ABOVE).

Successfully created:

Gantry class robot that does not use chains/sprockets, cables/pulleys, rack/pinion, or linear motors.
Controls for non-destructive testing via X-Ray of Solid Rocket Boosters for NASA’s Space Shuttle.
Electrical Controls and software for 9 axis, AC servo, automatic, Plantation Shutter painting robot.
"Miniature" Robot controls on a very high-speed gantry robot for pick-and-place apps & meat packaging.
Motion and I/O controls for a system to X-Ray Hand-Grenade fuses using Baldor AC servos.
Controls for systems with ABB robots to X-Ray jet engine parts and another for military aircraft wings.
Electrical Controls for a system to X-Ray Delta II and Delta IV rocket engine parts and fuel cells.
Manipulator and controls to X-Ray jet engine fuel lines using Baldor AC servo drives and motors.
Manipulator and controls for several systems to X-Ray auto, truck, military, aerospace (i.e., Shuttle) parts.
Plastic Blow-Mold Controls on a machine that produced 50% more product than others in its class.
Electrical Control system for a high-speed garment sortation system - 25,000 garments per day using barcode.
Welding robot with embedded controls for boiler tube and vessel repair.
6 axis welding robot control system with Yaskawa drives/motors, Prolog PC, Motion Engineering controller.
5 axis wall welding robot control system.Co-developed mechanical.
Project Manager on four turnkey installations of 40 robots each with installation valued at $25MM each.
Developed HUNDREDS of products. Eleven (11) are industrial robots.