Operational Track Record

Proven Factory-Floor Experience & Technical Delivery History

Hands-on exposure to high-volume manufacturing environments, combined with parallel independent freelance coordination and technical delivery.

Foxconn

Hon Hai Technology Group: High-volume manufacturing automation & line support

Focusight

AOI & SPM system deployment, optical calibration & client SAT validation

Flowtis

Parallel freelance project coordination, milestone tracking & delivery support

Multi-Line

Equipment commissioning, I/O checks, trials & validation sign-offs

Career History & Operational Context

From high-speed production floors to independent technical coordination, here is how practical engineering underpins my delivery method.

Perspective: Having spent years resolving machinery alarms, calibrating vision sensors, and diagnosing why automated stations halt, I understand what engineers need to succeed and what project managers must track to prevent delays.

Foxconn (Hon Hai Technology Group)

Manufacturing Automation

Environment: Tier-1 global high-volume consumer electronics manufacturing under continuous 24/7 production pressure.

Key Responsibilities & Deliverables:

Hands-on installation, setup, commissioning, and debugging of automated assembly stations and precision tooling jigs.
PLC and HMI troubleshooting alongside production operators and line maintenance technicians.
Servo teaching, mechanical home-position calibration, sensor checking, and I/O signal verification.
Coordinating rapid root-cause investigations during pilot runs to resolve component jams, micro-stoppages, and optical inspection rejects.
Daily synchronization with manufacturing engineering (ME), quality (IQC/OQC), and shift supervisors to stabilize line throughput.

Focusight Technology

AOI & SPM Systems

Environment: Automated Optical Inspection (AOI) machinery and Special Purpose Machinery (SPM) deployed in varied client manufacturing plants.

Key Responsibilities & Deliverables:

End-to-end deployment of automated vision inspection machinery at customer production sites.
Optical system calibration: camera positioning, working distance calculation, telecentric lens focus, and multi-angle lighting geometry.
Execution of Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT) qualification protocols.
Fine-tuning vision defect classification algorithms to minimize false-reject rates while catching 100% of critical flaws.
Comprehensive training for client operators, maintenance teams, and quality engineers on recipe creation and troubleshooting.

Flowtis (Parallel Freelance)

Independent Technical Coordination

Environment: Independent freelance technical project coordination and delivery support for manufacturing plants and automation builders.

Key Responsibilities & Deliverables:

Managing cross-functional Action Registers, milestone schedules, and live critical-path trackers.
Coordinating multi-vendor integration between mechanical machine builders, electrical panel builders, and software engineers.
Tracking equipment commissioning punch lists from cold-check stage through to customer acceptance sign-off.
Structuring validation evidence packages (IQ/OQ/PQ) and transparent daily/weekly status reporting.

Field Case Scenarios: How Coordination Solves Floor Bottlenecks

Anonymized examples illustrating how practical engineering coordination resolves common automation delivery roadblocks:

Case Scenario 01

Multi-Vendor SAT Alignment

The Blocker: Machine builder and robotics contractor were in a 3-week dispute over why an assembly cell failed continuous dry runs. Each claimed the other's handshake timing was causing intermittent timeouts.

Flowtis Coordination: Audited the PLC signal timing and created a unified 28-point interface signal verification sheet. Demonstrated that a pneumatic clamp sensor signal was chattering by 120ms.

Outcome

Pneumatic reed switch repositioned, debounce timer added in PLC; 100-cycle continuous dry run passed in 48 hours; SAT signed off.

Case Scenario 02

AOI False Reject Minimization

The Blocker: High-speed optical inspection system flagging 7.8% false defects on shiny metal brackets due to changing ambient factory daylight and surface glare.

Flowtis Coordination: Coordinated installation of an optical light shroud, repositioned coaxial lighting, and recalibrated the exposure trigger delay relative to the conveyor encoder pulse.

Outcome

False reject rate dropped from 7.8% down to 0.4%; avoided manual re-inspection labor and restored full line yield.

Case Scenario 03

Cycle-Time Bottleneck Shaving

The Blocker: Automated rotary indexing table missing target takt time by 3.1 seconds per cycle, causing an upstream buffer jam and costing 250 units/shift.

Flowtis Coordination: Conducted high-speed video time-study of each sub-motion. Discovered that the vacuum release delay was waiting 800ms unnecessarily, and the pneumatic cylinder return stroke was throttled.

Outcome

Adjusted pneumatic one-way flow controls and optimized vacuum blow-off timing in PLC; saved 2.9 seconds per cycle and met target UPH.

Case Scenario 04

MES Serialized Traceability Verification

The Blocker: 1 in 50 parts failing traceability handshake between PLC and plant MES server, resulting in automated line stoppages and untracked lot numbers.

Flowtis Coordination: Facilitated a joint working session between factory IT network engineers and controls programmers. Mapped the bit-level handshake sequence and implemented a buffered retry mechanism.

Outcome

Zero handshake drops over a 10,000-part validation trial; customer quality sign-off completed ahead of schedule.

The 5-Phase Execution Framework

A disciplined methodology developed from real factory floor commissioning cycles:

Pre-Site Audit

Review mechanical GA drawings & electrical schematics
Establish unified Action Item Register & owner matrix
Verify utility readiness (power, air, networking)

Cold Checks

Insulation & grounding checks
24VDC power supply cold short checks
Physical I/O signal sensor triggering

Hot Sequencing

Step-by-step dry run in manual mode
E-stop and safety circuit loop tests
Single-station automatic sequence tuning

Validation Trials

Multi-station continuous dry run
Live product trial runs with measurement logs
Execution of formal FAT / SAT qualification protocols

Handover Closure

Resolution of all Class A & B punch-list defects
Compilation of as-commissioned manuals & spare parts
Formal sign-off and operational team transition

Bring Practical Field Experience to Your Project

Avoid common commissioning traps and keep your suppliers and internal teams aligned. Let’s talk about your upcoming project milestones.

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