Joshua Spacht
● Automation Controls Engineer | Systems Integration
Open to Opportunities: Rockford / Chicago
Professional Profile
I am a hands-on Controls Engineer who connects the shop floor to the engineering office, serving the Rockford, Chicago, and Wisconsin regions. My focus is on practical problem-solving: I specialize in diagnosing root causes, implementing new system features, and ensuring automation systems are robust and operator-friendly. Over the last several years, I have focused specifically on Allen-Bradley platforms within the Food & Beverage industry.
I excel at translating complex "controls speak" into data for management and operations. I don't just troubleshoot code; I analyze component compatibility, handle BOM creation, and ensure the plant remains reliable by bridging the technical gap.
I excel at translating complex "controls speak" into data for management and operations. I don't just troubleshoot code; I analyze component compatibility, handle BOM creation, and ensure the plant remains reliable by bridging the technical gap.
Technical Competencies
Automation
- Allen-Bradley ControlLogix & CompactLogix
- Studio 5000 / RSLogix 500
- Legacy PLCs: PLC-5 & SLC 500
- GuardLogix Safety Programming
Integration
- EtherNet/IP, DLR, & Stratix NAT
- Legacy Comms: DeviceNet, ControlNet, DH+
- Motion Control (Kinetix & PowerFlex)
- Cognex Vision & Barcode Systems
Reliability
- Root Cause Analysis (RCA)
- Loop Tuning & Process Optimization
- Thermography & Predictive Maintenance
- Commissioning & As-Built Verification
Strategy
- BOM Creation & Quote Analysis
- Component Compatibility & Procurement
- Technical-to-Operational Translation
- Risk Assessment & Safety Validation
Detailed Work Experience
Controls Engineer II - Systems Integration
Lead engineer for full-lifecycle automation projects, specializing in Allen-Bradley architectures. Bridge the gap between system design and practical shop-floor reliability.
- PLC Architecture Design: Design and program ControlLogix/CompactLogix systems for high-speed manufacturing environments.
- System Reliability: Optimize machine uptime by creating precise control schematics and comprehensive technical documentation for maintenance teams.
- Cross-Functional Collaboration: Collaborate directly with plant managers and maintenance teams to ensure systems meet site-specific needs, delivering hands-on operator training for seamless project handovers.
- Motion Control: Configure and troubleshoot complex motion profiles using VFDs and servo systems, ensuring precise synchronization for high-speed applications.
- Machine Safety: Design and validate safety circuits (E-Stops, light curtains, interlocks) to ensure full compliance with ISO 13849 and OSHA standards.
- Continuous Improvement: Lead feature enhancements that improve operational efficiency, reducing cycle times and minimizing waste.
- Legacy Migration: Diagnose and migrate aging controls (legacy networks) to modern ethernet-based architectures, reducing obsolescence risk.
- Data Visibility: Implement sensor integration to provide clients with real-time process analytics and visibility.
- Startups & Commissioning: Lead on-site checkout procedures, utilizing deep electrical troubleshooting skills to resolve critical path issues during installation.
Process Engineer - Critical Infrastructure
Focused on reliability engineering and preventative maintenance for mission-critical Data Center infrastructure.
- Predictive Maintenance: Designed scheduled maintenance plans using Thermal Scanning and Ultrasound tools to detect failures before they occurred.
- Power Quality Analysis: Performed analysis on power buss rails in data centers nationwide to ensure stability.
- Data Analysis: Organized thermal and energy data into exception reports, allowing clients to plan strategically for device replacement.
Manufacturing Engineer
Integrated Defense Solutions division. Optimized production workflow and safety compliance.
- Process Optimization: Redesigned factory floor layouts (cabinets, safety striping, wire racks) to improve continuous manufacturing flow.
- Lean Management: Managed safety metrics and led weekly 5S audits, presenting performance data to leadership.
- Standardization: Authored and revised Standard Operating Procedures (SOPs) and work instructions for complex military assemblies.
- Inventory Control: Established comprehensive inventory systems and performed annual audits to reduce facility waste.
Manufacturing Assembler / Fabricator
Foundational hands-on experience in machine building and fabrication.
- Fabrication: Operated brake press, shear, water jet, and band saw to fabricate custom parts.
- Assembly: Performed electrical assembly, structure support, and engine enclosure line work.
- Technical Skills: Gained proficiency in blueprint reading and coordinated with teams to adapt quickly to production issues.