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Gerald K. is a seasoned control systems engineer with extensive experience in the entertainment, automotive, and industrial sectors. He has worked with top companies like Universal Studios, Walt Disney Imagineering, and Continental, developing functional safety-related activities and projects. Gerald holds a Bachelor of Science degree in Physics from Wayne State University and has completed his education at Michigan Technological University and Walsh College of Accountancy and Business Administration.

Experience

  • TÜV Rheinland North America
    • Greater Detroit Area
    • Functional Safety / Product Safety and Compliance
      • Jan 2019 - Feb 2021
      • Greater Detroit Area

    • Functional Safety
      • Mar 2016 - Dec 2018

    • Functional Safety / Product Safety Engineer
      • May 2010 - Mar 2016
      • USA

      Responsible for Functional Safety related activities / projects in the US market, this would include IEC 61508 all parts, IEC 62061, ISO 13849 ISO 26262, IEC 61511 Conducted risk assessment(s) / Hazard analysis to determine required performance of various safety functions. Aided clients in definition of the safety function and capture safety requirements. Aided in the development of all required documentation, i.e. safety plan, safety requirements specification for certification to applicable functional safety standards in the following areas- Functional Safety Management (FSM), Hardware, and Software. Conducted on site audits for FSM, Conceptual design reviews to determine at an early stage if proposed system design could meet requirements of appropriate functional safety ,application and product standard(s).

    • Senior Control Systems Engineering Manager
      • Mar 2009 - May 2010

      Continuation of Previous project

    • Senior Control Systems Engineering Manager
      • Apr 2008 - Mar 2009

      Entertainment industry. Concentration on Safety Systems. Work closely with vendors to develop new products that meet the need particular to this industry. Develop functional design requirements that meet and follow current Universal specifications, applicable national codes and engineering standards, suitable for submission to various vendors for sole source and competitive bid. Develop new and revised existing Universal Corporate specifications to reflect changes in technology, national and international engineering codes and standards. Made recommendations for safety critical systems and control system network security based on international (IEC) standards. Made recommendations with respect to hardware, software platforms and system that would reduce cost and increase system performance Safety PLC vs. dual / redundant PLC based systems for safety applications. Consulted with Operations and Maintenance upper management to identify and define any revisions to Universal specifications that would result in enhanced system reliability, maintainability, and operability resulting in reduced cost of ownership. Identify any areas in the proposal, bidding, engineering, design and build phases of the project that could potentially cause delays, increased cost, or lead to longer start-up and commissioning times than could be reasonably expected. Review ofapplication programs and PLC logic for both content and structure to ensure programs perform the intended task based on operational performance specifications. Propose solutions and/or modification of designs to ensure compliance with performance specifications

    • Motion Control Specialist
      • Oct 2007 - Apr 2008

      Machine Motion Specialist, Oct 2007 ­ Apr 2008Packaging Equipment Manufacturer. Supervised conversion of existing mechanical machine designs to servo motion control platforms. Worked on development of control system for next generation machines employ a modular build system architecture. Developed new control algorithms and created functional specification and requirements of modular software blocks to cross over various machine models. Worked closely with equipment suppliers to ensure all design requirements have been met. Prepare required technical reports, presentations and develop recommendations for performance and process improvement of existing and new equipment. Provide project coordination, estimation of the cost of equipment and services being proposed, develop spreadsheets, charting, cost controls, and provide required information to the other departments involved. Evaluated machine designs against governmental requirements and regulations in order to ensure appropriate compliance levels for a given application and industry. Develop training seminars and presentations

    • Application Engineer
      • Sep 2005 - Oct 2007

      Safe Automation Equipment Manufacturer. Perform on-site evaluations to determine best approach to customer's application. Prepare required technical reports, presentations and develop recommendations for performance and process improvement. Provide project coordination, estimation of the cost of equipment and services being proposed, develop spreadsheets, charting, cost controls, and provide required information to the other departments involved. Work closely with field sales team to support and identify new business opportunities. Identify and develop new ways to present product to the sales force and end users that is easy to understand. Evaluate products against governmental requirements and regulations in order to ensure appropriate compliance levels for a given application and industry. Develop training seminars and presentations on code and compliance requirements related to process control, burner management, combustion control, and theme-park applications for engineering department. Attend standards committee meetings

    • Independent consultant
      • Nov 2003 - Sep 2005

      Entertainment industry. Universal Studios Shanghai and Coin projects. Contracted to develop functional design requirements that meet and follow current Universal specifications, applicable national codes and engineering standards, suitable for submission to various vendors for sole source and competitive bid. Develop new and revised existing Universal Corporate specifications to reflect changes in technology, national and international engineering codes and standards. Made recommendations for safety critical systems and control system network security based on international (IEC) standards. Made recommendations with respect to hardware, software platforms and system that would reduce cost and increase system performance i.e. PLC vs. PAC vs. PC based or SCADA system, Safety PLC vs. dual / redundant PLC based systems for safety applications. Consulted with Operations and Maintenance upper management to identify and define any revisions to Universal specifications that would result in enhanced system reliability, maintainability, and operability resulting in reduced cost of ownership. Identify any areas in the proposal, bidding, engineering design and build phases of the project that could potentially cause delays, increased cost, or lead to longer start-up and commissioning times than could be reasonably expected. Review of application programs and PLC logic for both content and structure to ensure programs perform the intended task based on operational performance specifications. Propose solutions and/or modification of designs to ensure compliance with specifications

    • Senior Electronics Engineer
      • Jan 2000 - Sep 2001

      Entertainment industry. Worked in Japan on the Tokyo Disney Sea Project, Port Discovery Aquatopia and StormRider Attractions Review designs and documentation submitted by various vendors. Verify designs meet and follow Disney specifications, applicable national codes and engineering standards. Review safety critical systems for control reliability and redundancy. Developed application programs and ensured programs meet all the intended requirements based on operational performance specifications and creative requirements. Propose solutions and/or modification of designs to ensure compliance with specifications. Identify any areas in the design that could potentially cause delays or lead to longer start-up and commissioning times than could be reasonably expected.

    • Control Systems Engineer
      • Jun 1999 - Dec 1999

      Entertainment industry. Islands of Adventure and Universal Studios Japan projects. Contracted to review designs and documentation submitted by various vendors. Verify designs meet and follow Universal specifications, applicable national codes and engineering standards. Review safety critical systems for control reliability and redundancy. Review application programs and PLC logic for both content and structure to ensure programs perform the intended task based on operational performance specifications. Propose solutions and/or modification of designs to ensure compliance with specifications. Identify any areas in the design that could potentially cause delays or lead to longer start-up and commissioning times than could be reasonably expected.

    • Controls Engineer
      • Jan 1999 - May 1999

      engineering group for Islands of Adventure theme park project in Orlando.

    • Control Engineer
      • Jan 1998 - Jan 1999

      Primarily automotive. Projects included automated welding and assembly line, Boiler and combustion control.Designed and developed PLC based control systems. Developed application programs for both new and existingsystems. Performed field start-up services, installation, training and diagnostics.

    • Field Service Engineer
      • Jan 1996 - Jan 1998

      Environmental control systems. Regenerative Thermal Oxidizers (RTO) Diagnostics, field modification and parameter testing of control logic to provide enhanced machine functionality and environmental safety. Repaired mechanical and electrical as required. Performed start-up services including installation, diagnostics and personnel training in both the US and Asia.

    • Field/Project Engineer
      • Jan 1993 - Jan 1996

      Primarily automotive, power generation and petrol/chemical industries. Projects included automotive paint lines, boiler combustion and burner management control, Gas turbines and co-generation systems. Evaluated customer requirements; procured equipment and materials; supervised all project phases including training of operation and maintenance personnel. Performed field start-up services, installation, training and diagnostics in U.S. and Middle East markets.

    • Vibration Tech
      • Jan 1992 - Jan 1993

      - Data collection and analysis for noise andvibration.

    • Field Engineer
      • Jan 1989 - Jan 1992

      - Contracted to BASF to perform fieldinstallation, calibration and commissioning of instrumentation and control systems.

    • Sales Engineer
      • Jan 1988 - Jan 1989

      - Provided technical assistance to bothinside and outside sales force in the application of product lines represented.

Education

  • Wayne State University
    Bachelor of Science, Physics
  • Michigan Technological University
  • Walsh College of Accountancy and Business Administration

Suggested Services

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Industry Focus. “Entertainment”

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