Projects
9 case studies drawn from my roles at General Motors, S and T Controls, Onyx Engineering, Vista Solutions, and SIDAC: the problem, my approach, and what was delivered. Filter by category or technology.
Showing 9 of 9 projects
General MotorsAI & Software
A platform I built as sole developer, available to all GM Automation engineers and suppliers, that reads electrical drawings and flags issues such as power supply overloads and missing safety devices.
Technologies: Python · FastAPI · React · PostgreSQL · pgvector · +9
General MotorsRobotics & Automation
Automating a manual final line at GM with new-to-industry robotics, Atlas Copco tightening, feeders, net form and pierce, and gap-and-flush cameras.
Technologies: New-to-industry robotics · Atlas Copco bolt runners · Bolt and U-nut feeders · Net form and pierce · Variation-reduction cameras · +1
General MotorsControls & PLC
Validation of EV battery mini-stack automation at two GM plants, supporting Cadillac, HUMMER, and Equinox battery builds.
Technologies: EV battery production · Automation validation · PLC · Throughput & quality audits
General MotorsReliability & Data
Analysis of production data and downtime reports at GM that cut recurring alarms by 50%, with issues tracked to closure with leadership.
Technologies: Production data analysis · Downtime reports · PLC · Issue tracking
General MotorsProject Delivery
At GM I test, validate, and audit automation systems, make sure suppliers meet their deliverables in every project phase, and complete the engineering execution checklists that equipment buyoff requires.
Technologies: Automation validation · Buyoff checklists · Supplier management · PLC · Open issues tracking · +1
S and T ControlsControls & PLC
PLC and HMI programs in Studio 5000 for five automated body shop cells, with their wiring diagrams and schematics reviewed and their logic faults debugged.
Technologies: Allen-Bradley Studio 5000 · PLC · HMI · Wiring diagrams · Schematics
Onyx EngineeringControls & PLC
Controls design for three plants in three industries across Allen-Bradley, Emerson, Modicon, and PlantPAx, plus electrical drawings and field support.
Technologies: Allen-Bradley · Emerson · Modicon · PlantPAx · Legacy controllers · +4
Vista SolutionsMachine Vision
Sealer, adhesive, weld, and options-verification inspection with Matrox Design Assistant across a GM body shop, with audits, alarm monitoring in Cimplicity, and training for the plant's skilled trades.
Technologies: Matrox Design Assistant · Blob analysis · Model Finder · Edge detection · Cimplicity SCADA · +2
SIDAC Automated SystemsElectrical Design
Five control panels designed in AutoCAD Electrical, from component selection and thermal and power calculations to helping the panel builders wire and assemble them.
Technologies: AutoCAD Electrical · Panel drawings · Component selection · Thermal calculations · Electrical calculations · +1
Get in touch
I'm open to Controls Engineer, Automation Engineer, Software Engineer, and Full-Stack Developer roles, remote or on-site. If you're building something where automation and software meet, I'd like to hear about it.
elshark.atef@gmail.com