Carlos Bernal Urbina

• Built and now lead the plant’s first in-house Automation and IT department, transitioning support from external contractors to internal ownership
• Collaborated with Production, Maintenance, and Quality Managers to align automation upgrades with plant goals, helping reduce product shrink from ~5% to 1.9%
• Led the migration from Wonderware to Ignition and deployed virtualized SCADA infrastructure, improving system reliability and mobile access
• Reduced average downtime from 8 hours to under 1 by resolving legacy control issues and standardizing logic
• Cut emergency shutdowns from 4–6 per day to less than 5 per month through alarm cleanup, instrumentation upgrades, and system stability improvements
• Implemented in-house ticketing systems for IT and Automation, improving issue response time and giving employees a structured way to report problems
• Developed SOPs and launched a training program covering electrical, instrumentation, PLCs, and troubleshooting, supporting technician growth through Pay-for-Skills

• Emerged as the primary troubleshooting contact, adept in rapid issue diagnosis and resolution, while also handling maintenance and enhancements of control equipment to boost plant efficiency and reliability.
• Expert in programming, maintaining PLCs and HMIs, diagnosing hardware issues, and field device troubleshooting.
• Led control projects encompassing design, implementation, and startup phases, and provided comprehensive training to end-users, maintenance staff, and technicians, fostering skill advancement in the Pay-for-Skills program.
• Assessed and planned for material and labor requirements for various technician work orders.

• Conducted mechanical duties, including repairing and maintaining pumps, valves, conveyors, sprockets, gearboxes, and performing welding and fabrication tasks.
• Calibrated and performed preventative maintenance on a variety of plant instrumentation across multiple types and brands to ensure 100% uptime.
• Troubleshot and repaired electrical components and machinery, utilizing a strong understanding of industrial electricity, particularly three-phase power.
• Completed preventive maintenance work orders with a focus on detail and quality.
• Utilized RSLogix 5, RSLogix 500, and RSLogix 5000 for troubleshooting and enhancing existing plant control system programs.
• Consistently adhered to Good Manufacturing Practices, ensuring high standards of housekeeping.