Ungureanu Alin George

Conducted daily preventive and corrective maintenance across 80+ assembly lines, including injection molding presses, conveyor systems, and robotic screwdriver cells.

Performed electrical diagnostics on omron cj1m / cj2m plc systems (id211 / od211 modules npn sink wiring) employing multimeters and signal tracers to pinpoint broken wires, poor contacts, and oxidized pins on robot cables with an average fix duration of

Modified wiring of **iai robocylinder pcon-cfa/scon-cb linear actuators** and executed replacement of malfunctioning 14-pin my4n safety relays.

Cut unplanned line downtime by 32% via creation of visual checklists and strategic scheduling of predictive wear part replacements.

• Analyzed and fixed electromechanical systems to ensure maximum performance and reliability.
• Administered consistent maintenance on tools and machinery, elevating operational efficiency and reducing downtime.
• Analyzed and fixed electromechanical systems to ensure maximum operational efficiency.
• Carried out scheduled maintenance on machinery, increasing operational efficiency
• Coordinated with external vendors for specialized repairs or routine servicing of complex electromechanical assets when necessary.

Created embedded C/C++ control firmware for high-voltage EV cable test benches aimed at tension current crimp quality measurement interfaced with Omron Sysmac NJ PLC and Delta AH500 I/O

Created production monitoring HMI and web dashboards (React, TypeScript, Node.js, Modbus TCP) for eDrive HV wire extrusion lines, supplying real-time scrap-rate KPIs and 8D-ticket integration to more than 450 plant operators in Germany and Romania.

Created eplan electric p8 schematics for 6 new end-of-line HV tester cells, featuring integration of Pilz safety relays and Ethernet/IP scanners that met VDA 6.3 audit standards on first run.

• Championed design of scalable software solutions to enhance operational effectiveness and decrease processing time.
• Trained junior engineers in best practices, promoting a culture of continuous progression and technical expertise
• Developed technical documentation for software applications, facilitating knowledge transfer and supporting future maintenance efforts.

Implemented and upheld PLC software for Bosch Rexroth servo-pneumatic production lines by means of Siemens TIA Portal S7-1500 and Omron NX using structured text and ladder logic.

Deployed OPC-UA/MQTT interfaces that connect production machines to internal MES, streamlining downtime report delays by 65%.

Directed junior team of 3 engineers conducting code reviews and overseeing VDA 6.3 process audits on production lines.

Overhauled legacy C++ embedded control software for hydraulic test benches, attaining 40% enhancement in test cycle speed and zero critical bugs within a 6-month timeframe.

• Optimized dust, temperature and humidity controls for installed systems.
• Estimated work hours and tracked progress using Scrum methodology.

Configured and simulated KUKA KR C4 industrial robots with KRL (KUKA Robot Language) and Process Simulate for automotive welding cells, establishing more than 20 spot weld trajectories per cell.

Combined robots with Omron NJ controllers and safety PLCs (Pilz PNOZmulti), achieving successful ISO 10218-1 safety certification at first audit.

Constructed electrical schematics for robot cells using EPLAN Electric P8, featuring servo drives, I/O modules, and safety circuits.

• Documented software development methodologies in technical manuals to be used by IT personnel in future projects.
• Enhanced user experience with intuitive interface design and responsive web applications.

Junior process engineer (full-time — initiated right after graduation)

Directed comprehensive production workflow of HV cable harnesses encompassing raw copper wire entry, extrusion, crimping, ultrasonic welding, braiding, final testing, and packaging per customer technical drawings.

Oversaw 12 operators on one traction line, ensuring alignment of daily OEE performance with zero PPM defect standards.

Formulated pioneering written visual-standard work instructions (arbeitsanweisungen) for 4 vital operations — utilized throughout factory.

- **Promoted to Team Lead** of the HV (High-Voltage)

Traction Line Assembly section, owning end-to-end technical responsibility for 2 cable harness production cells.

Coordinated efforts of cross-functional team comprising 3 process engineers and 18 machine operators, ensuring achievement of daily production OEE targets and resolving technical escalations for BMW iX / i4 and VW ID.3 cable programs.

Facilitated SMED (Single-Minute Exchange of Die) adjustments on extrusion and crimping stations, minimizing average line setup time from 38 minutes to 14 minutes and generating +2 hours of production each day.

- Conducted root-cause analysis using **8D / Ishikawa / 5-Why methods** on recurring crimping defects, reducing scrap rate by 22% YoY on the flagship BMW harness.

- Owned PLC diagnostics, backup restoration and small program changes on **Omron Sysmac NJ/NX, Delta AH500 and Siemens S7-1200** controlling the extrusion, winding and end-of-line testing machines.

• Assisted in recruitment to build team of top performers.
• Coordinated resources effectively to meet project deadlines and achieve desired results.

web and software specialist (entry-level projects during university)

june 2017 – january 2018 (duration of eight months)

Developed small-business websites, landing pages, and CRUD dashboards for community clients leveraging HTML5, CSS3, JavaScript, PHP, MySQL, WordPress, and Laravel.

Constructed responsive product catalogs and booking systems featuring Stripe payment integration for 3 service clients.

Refined early problem-solving acumen and client engagement techniques prior to transitioning fully into industrial automation.

• Inspected equipment, assessed functionality, and optimized controls.
• Applied responsive design principles to ensure consistent display and functionality across a wide range of devices, including mobile phones, tablets, and desktop computers.

Delivered engaging practical lab sessions in basic electrical circuits, motor control, and introductory web development at post-secondary vocational school, supporting mentorship for more than 60 students.

Produced engaging learning kits and formulated exercises consistent with Romanian Ministry of Education standards.

• Developed and implemented vocational training programs for diverse learner groups.
• Facilitated hands-on workshops to enhance practical skills and knowledge retention.