Summary
Overview
Work History
Education
Skills
Certification
Timeline
Generic

Tony Vaughn

White Hall

Summary

Resourceful RME, PE AE, Controls and Electrical Manager proudly possessing 30 years experience in Industrial Manufacturing environments with 21 years in the Maintenance and Engineering fields. Most of my roles have been highly focused on Preventative Maintenance and Process Improvement activities. I have led the daily tasks of Maintenance teams with various skill sets such as Multicraft shops, and shops with tradesmen, and specialists where I delegated specific work to the appropriate personnel. I have a Proven track record in leading maintenance teams, optimizing equipment performance, and implementing process improvements that enhance productivity and reduce downtime. I started my career as a temporary worker doing general labor. I quickly advanced in production before migrating into Maintenance and Engineering roles. It was not entirely by choice that I ended up in Controls Engineering. With the arrival of the 64bit OS and discontinued support of the 32bit OS moreover to avoid obsolete and compatibility issues, I made the choice to research and study how to upgrade our systems. I began conversions and system upgrades by utilizing the money remaining in the Maintenance, Safety and Engineering budgets. Using this variable financing method I quoted all projects and the General Manager prioritized which projects to initiate that were within budget. I soon took on the role of Lead Controls Engineer of the Process Improvement Automation Team. My focus was the OEM projects and equipment and controls upgrades. My team was hand picked by the VPO and overhead reduction was the new objective. I soon moved into the Project Manager Role on a crucial project for the company. Engineering changes in product design required an additional process to achieve China's fire test rating standards for building products. I took an idea and discussed it with the team and we agreed we could make it work and presented the idea to Management. Our proposal was accepted and we successfully designed a prototype and installed it in our continuous production line. During the testing, tweaking, and commissioning of the machines I led as many as 39 team members on three production lines until project completion. Although my strength is Process improvements, I am skilled in many areas of Industrial Manufacturing, and Facility/Equipment Maintenance Engineering. I played an important role in the overall success of the company. They invested in me by paying for my education and I reciprocated by adding value to the company using the knowledge they purchased. In 18 years, by continuously automating processes and improving processes we turned a $45M purchase into a $1 Billion dollar sale.I know team work creates success and I am a team player who excels in a team environment. I have an impeccable safety record. I lead by example. I have an amazing work ethic. I have a hands-on approach no matter what my role is. I don't ask anyone to do anything I wouldn't do myself. I am a very honest and open person. I don't make excuses, therefore, I don't like them either. I strongly support accountability, taking ownership, and safety compliance. I believe these principals are critical in building a positive, professional, and successful work culture. If hired, you will gain experience in many areas as l can compliment other departments as well. I am confident that, with my work ethic, broad skill sets, and previous Engineering and Maintenance experiences, that I would be a great addition to your team and the company as well. Thank you so much for your time and for giving me an opportunity to tell you a little bit about myself. I look forward to speaking with you and have a great day!.

Overview

30
30
years of professional experience
1
1
Certification

Work History

Controls and Electrical Manager

Big River Forest Products
Carthage
03.2025 - 06.2025
  • Safety #1
  • Evaluate and assess Maintenance personnel strengths and weaknesses and carry out quarterly performance reviews
  • Explain the importance of having an 'ownership' mentality and the positive impact it can have on operations.
  • Developed project scopes, cost estimates, schedules, and milestones on Automation projects.
  • Revised HMI programs implementing BDA and IO RCA screens to assist Maintenance troubleshooting
  • Monitored project progress against budget, schedule, and safety requirements.
  • Implemented code on systems for data gathering, validation, and trend analysis.
  • Identified early failure indicators on machine systems using Thermal Imaging and recommend preventive actions on those findings
  • Provided reports on project progress and operational performance.
  • Approved time cards and Vacation request
  • Ensured Mill coverage 24-7
  • Improved the quality of product, process and systems by Continual improvements and monitoring of equipment.
  • Distributed personnel based on individual skill sets to ensure the timely execution of maintenance activities in the Mill.
  • Prepare, monitor, and control the Maintenance budget.
  • Maintained Updates of Controls system components
  • Procured and Maintained critical spare parts and inventory

Maintenance Supervisor

Tubular LLC
Little Rock
10.2022 - 01.2025
  • SAFETY #1.
  • Issue work instructions related to electrical / mechanical maintenance.
  • LOTO
  • Preparation of maintenance preventive / predictive / shutdown maintenance for the year.
  • Ensuring preventive, predictive and planned maintenance of machines.
  • Identification and planning for equipment updates
  • Continual improvement in maintenance practices focused on equipment reliability.
  • Ensuring the timely execution of maintenance activities in the plant.
  • Improving the quality of product, process and system by imparting related knowledge to staff and workmen.
  • Preparing, monitoring and controlling the budget.
  • Preparation of utility consumption reports.
  • Ensuring execution of all maintenance activities in the plant
  • Record all activities daily in Maintenance log
  • Preparation of purchase requisition for spares & services
  • Maintaining Safe working environment and good housekeeping
  • Executing Preventive Maintenance activities with respect to WI and JSA
  • Utilized BDA reports for Process Improvement opportunities
  • Training & development of Maintenance personnel on Automation formats and principals
  • Ensured optimum availability and sustainability of equipment

Staining and Engraving Assistant

Decorative Images Concrete Designs
10.2021 - 10.2022
  • Safety#1
  • Stage supplies as needed
  • Tape up boarders
  • Install paper protection for flooring pre-stain and post stain color change
  • Buff and wax floors
  • Clean up when job is complete

Control Systems Lead

Amazon/CBRE
North Little Rock
03.2021 - 10.2021
  • Safety #1
  • Maintained software updates and programs for automated high speed conveyor and labeling systems including Sick/Cognex Vision systems, AB ControlLogix/CompactLogix/SLC/MicroLogix PLCs, C, Moret/PanelView Plus/ProFace HMI.
  • Procured critical spare parts for inventory
  • Verify completion of daily electrical PM's.
  • Training of other Control System Technicians on variations of SEV ratings and procedures to follow when they occur
  • Strive to reach and maintain Amazon's 98% efficiency on high speed conveyor, packaging and vision equipment.
  • Document shift activities accounting for all 12 hours.

Maintenance Supervisor

Welspun Tubular LLC
Little Rock
12.2019 - 03.2021
  • SAFETY #1.
  • Preparation of maintenance preventive / predictive / shutdown maintenance for the year.
  • Ensuring preventive, predictive and planned maintenance of machines.
  • Identification and planning for equipment updates
  • Focused on equipment reliability ensuring the timely execution of maintenance activities in the plant.
  • Inspection of procured items as initiated by the stores department.
  • Ensure optimum availability of equipment through PM practices.
  • Preparation of utility consumption reports.
  • Ensuring execution of all maintenance activities
  • Executing Preventive Maintenance activities with respect to WI and JSA
  • Utilized BDA reports for Process Improvement opportunities
  • Training & development of Maintenance personnel on Automation formats and principals

Electrical Superintendent

Highland Pellets
AR
07.2019 - 11.2019
  • Safety #1
  • Record all activities daily in Maintenance log
  • Prepare purchase orders for equipment spares & services
  • Share new technology controls knowledge for equipment to technicians
  • Command Safe working environment and good housekeeping for all.
  • Distribute and verify status of Preventive Maintenance activities.
  • Utilized BDA reports for Process Improvement opportunities
  • Training & development of Maintenance personnel on new technology and processes.
  • Maintained property fences, parking lot, grounds keeping, plumbing, roofing and many other building and site related maintenance activities.

Electrical/Electronic Technician

US Steel
Pine Bluff
04.2018 - 07.2019
  • SAFETY #1
  • Install and test new equipment
  • Install new electrical services
  • (C-More) HMI programming of added procedures, processes, and data collection for operations
  • (Direct Logix) PLC Programming of new processes and data collection.
  • Complete assigned work orders in a timely manner.
  • Responsible for repairing equipment, and replace electrical parts
  • Troubleshoot Electrical/Electronic circuits
  • Install 3 phase electrical systems, service feeder, conduit, wiring, cabinets, PLC, HMI, and field devices
  • Work with outside vendors if needed and oversee activities

Automation Engineer

All Weather Insulated Panels
Little Rock
04.2017 - 03.2018
  • Safety #1
  • Controls Upgrade
  • Integrations of AB PanelView HMI panels
  • Electrical Service calculations
  • Electrical Layout of new equipment
  • Cabinet Designed/Build Specifications and purchasing of Control system devices.
  • AB Ethernet Programming and Configuration.
  • Integration of Process Improvements justified by cost benefits analysis
  • Added maintenance features to HMI operating stations reducing downtime
  • Implemented Factorytalk Team One application to increase production uptime.
  • Monitored equipment runtime, duty cycles, performance with Trends.
  • Automated old relay logic equipment.
  • Work with production managers and contractors scheduling equipment installation and system upgrades/integrations.
  • Training of maintenance team on Automation projects and troubleshooting.
  • Partner with maintenance on equipment breakdowns.
  • Work with outside contractors commissioning new process installation of pellet mills.
  • Responsible for maintaining Controls and Instrumentation on all equipment.
  • Schedule and delegate PM orders.
  • Prioritize, delegate, and distribute electrical work orders to Electrical Personnel.
  • Maintained spare parts inventory
  • Create a critical spare list for plant equipment.
  • Implemented Electrical upgrades
  • Conducted daily safety and preventative maintenance team meetings.
  • Provide updates on equipment conditions, PI project status, safety concerns, Maintenance scheduling, and department budget Consumption reports.
  • Worked closely VP of Operations, Plant Manager, and Engineering addressing JSA, SOP, WI and LOTO execution and Documentation.

Automation Team Controls Engineer

Centria/ Nucor Insulated Panel Division
Sheridan
09.1995 - 04.2017
  • Safety#1
  • Meeting Organizational goals within targeted budget goal
  • Designed controls and automation systems for existing equipment for CAPEX projects.
  • Project Management over Automation projects.
  • Integrated, designed, Installed and Automated a profile finishing machine featuring a 4 axis design with vertical saws and horizontal routers cycling in line with continuous production line finishing both end profiles of the product.
  • Size and Install Service Wiring, HMI/ PLC Configuration/design, Controls local/ field wiring, PLC, HMI, Networking design/configuration
  • Stock availability electrical spares
  • Conveyor Systems Installation Programming
  • Partnering with Production Managers to Manage/Delegate production lines during project tasks.
  • Upgrade and Integrate obsolete or non-compatible Control systems with new technologies or I/O devices.
  • Convert 32bit HMI to 64 bit platforms (PB32 to FTView Studio ME.
  • Replace DC Drives with AC VFD with Ethernet IP.
  • Replace Remote I/O and Control Net with Ethernet IP.
  • Convert 32bit RSLogix 500 to 64bit Studio 5k OS Software.
  • Replace PLC5 Remote I/O with Control /Compactlogix chassis, Processors, and Ethernet modules.
  • Networking Production lines for Control Room.
  • Analyzed Processes to implement HMI message and PLC Edits for PMs and Production Optimization
  • Data logging and HMI design specifically for Quality Control on chemical systems.
  • Provide Cost Analysis to Justify Controls Automation Projects.
  • Implement Maintenance Screens to all HMI reducing downtime by providing data for continuous PLC editing focused on Equipment PM Scheduling and overall Performance.

Education

Associate of Applied Science - Engineering

Arkansas State University Three Rivers
Malvern, AR

Skills

  • OEM
  • Industrial equipment
  • Electrical engineering
  • NEC
  • AutoCAD
  • PLC
  • Electrical experience
  • Electrical systems
  • Systems engineering
  • Electrical wiring
  • Manufacturing
  • Design controls
  • Control Systems Engineer
  • Continuous integration
  • PLC Programming
  • Build automation
  • Robot programming
  • Procurement
  • Schematics
  • Project management
  • Root cause analysis
  • SAP
  • Lean manufacturing
  • Process improvement
  • Vision Systems
  • Project Management
  • Continuous Integration
  • Programmable logic controllers
  • Electrical Services
  • HMI Design and Programming

Certification

  • Rockwell Automation Certificate of Proficiency, Motion Control Level 4 Programming, RSNetworks Machine, HMI Project Configuration, Design, Development, PLC Project Design, Development, and Configuration
  • OSHA 10 Certified Safety, Construction, Industrial

Timeline

Controls and Electrical Manager

Big River Forest Products
03.2025 - 06.2025

Maintenance Supervisor

Tubular LLC
10.2022 - 01.2025

Staining and Engraving Assistant

Decorative Images Concrete Designs
10.2021 - 10.2022

Control Systems Lead

Amazon/CBRE
03.2021 - 10.2021

Maintenance Supervisor

Welspun Tubular LLC
12.2019 - 03.2021

Electrical Superintendent

Highland Pellets
07.2019 - 11.2019

Electrical/Electronic Technician

US Steel
04.2018 - 07.2019

Automation Engineer

All Weather Insulated Panels
04.2017 - 03.2018

Automation Team Controls Engineer

Centria/ Nucor Insulated Panel Division
09.1995 - 04.2017

Associate of Applied Science - Engineering

Arkansas State University Three Rivers
Tony Vaughn