Joshua Spacht
● Automation Controls Engineer | Systems Integration
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Professional Profile
I am a hands-on Automation Project Engineer and Systems Integrator specializing in Allen-Bradley architectures within the demanding Food & Beverage industry. I take projects from conceptual design to commissioning, focusing on high-value areas like Legacy Migration and seamless OEM line integration.
My success is built on collaboration. I work shoulder-to-shoulder with operators, maintenance teams, and plant management to truly understand how machines need to function. I use this field knowledge to design, program, and implement robust solutions—from panel specifications and sensor additions to complex system handovers—that deliver real reliability and clear results across the Rockford, Chicago, and Wisconsin regions.
Technical Competencies
Automation
Automation
- PLC Architectures: Allen-Bradley ControlLogix & CompactLogix, including safety implementation via GuardLogix.
- HMI/SCADA Development: FactoryTalk View SE/ME and Wonderware (AVEVA) System Platform (ArchestrA) / InTouch HMI.
- Legacy Systems: Expertise in migration and support for older platforms, specifically PLC-5 & SLC 500.
- Programming Software: Studio 5000 / RSLogix 500 Programming Environments.
Integration
Integration
- Network Architectures: Deployment and configuration of EtherNet/IP, including DLR (Device Level Ring) for resiliency, and Stratix NAT for clean network segmentation.
- High-Level Integration: Seamless integration of OEM lines, Motion Control Systems (Kinetix & PowerFlex), and vision components (Cognex).
- System Synchronization: Expertise in tuning and coordinating complex Motion Control systems and deploying Cognex Vision & Barcode Readers for quality control.
- Legacy Communications: Support and migration strategies for older protocols, including DeviceNet, ControlNet, and DH+.
Reliability
Reliability
- Formal Project Closure: Commissioning procedures and Final As-Built Verification (Ensuring documentation matches field implementation).
- Process Optimization: Advanced Loop Tuning and Root Cause Analysis (RCA) for maximizing line performance and eliminating recurring issues.
- Predictive Diagnostics: Deployment of preventative tools like Thermography and Power Quality Analysis to support predictive maintenance strategies.
- Asset Strategy: Utilizing field data to inform long-term reliability improvements and capital planning.
Strategy
Strategy
- Design & Construction: Full control over panel lifecycle, including Panel Design (UL/CSA standards), Panel Building quality control, and component compatibility checks.
- Capital Management: Detailed BOM Creation, Component Procurement strategy, and Quote Analysis for fiscally responsible project execution.
- Compliance & Safety: Formal Risk Assessment and Safety Validation procedures (e.g., OSHA, ISO standards) to ensure compliance and longevity.
- Communication & Handover: Clear Technical-to-Operational Translation for smooth project documentation, training, and management reporting.
Detailed Work Experience
Controls Engineer II - Systems Integration
Spearheaded the design, programming, and commissioning of complex automation systems, ensuring high performance and reliability across Allen-Bradley platforms.
- 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.
Preferred Device Partners
Rockwell Automation
Keyence
Cognex
Banner Engineering
SICK
FANUC
ABB
Inductive Automation
AVEVA
Endress+Hauser
Festo
nVent HOFFMAN
Belden
Grace Technologies
Itoh Denki
Kübler Group
Revere Electric Supply
Werner Electric Supply
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