01

About

Factories run on systems that were never designed to talk to each other. My job is making them — enforcing the process in software and putting AI to work where it pays. The past thirteen years: production test, traceability, and data infrastructure for safety-critical controllers (SIL 3) at a major international manufacturer.

On the floor that means data entered once, steps that can't be skipped, and reports that build themselves. Management gets answers in seconds, and sensitive data never leaves the building. The foundation is two decades of software architecture on SQL Server and .NET. AI widened that reach: I now work in whatever stack fits the problem, using the frameworks and evals I built to make Claude, Gemini, and Codex deliver production-grade results.

25+
Years in software & automation
Millions
Units traced in production
SIL 3
Safety-critical scope

Drive

I take over the stalled rollouts and finish them.

Integrate

I connect the systems you already run, so data is entered once and visible everywhere.

Automate + AI

I build the automation and AI that fill the gaps, on your hardware.

02

Approach

Scan in · track the floor · bridge the data

Scan at entry Tracked through WIP AI AI bridges the disconnects

Hours saved is the visible part of an AI project. Underneath sit the layers that decide whether it survives production. I map those layers first, then build.

Strategy

Audit the workflows, score each for AI readiness, model the return. We start where the measured value is highest.

Data

An LLM call takes seconds; the pipeline behind it takes months. Most of the work is cleaning sources and filling gaps, and I start with the data you already have.

Infrastructure

Production needs more than a working demo. Pipelines, API layers, and the right model for each task keep the system reliable at scale.

The AI work

Context, guardrails, and the evals that turn a model into production-grade output. If the eval score drops, it doesn't ship.

The human side

The system has to make the operator's day shorter. I design for adoption: fewer steps, clearer screens, visible wins.

Sovereignty & longevity

Everything can run on your own hardware, so sensitive data stays inside the building and your regulatory posture stays intact. And I write it down — the system keeps running, and improving, when I'm not in the room.

03

Experience

Program · test · lock · trace

PROGRAMMER Programmed & tested LOCK SERIAL PASS TRACE Locked · serialized · traced
2013 – Present

Automation & Data Systems Architect · Major international manufacturer

I design and commission testers and test-automation systems for production lines across North America, working with international engineering teams. Sole technical owner of the production test software, the firmware programming infrastructure, and the C#/.NET and SQL Server data backbone behind the lines, across ten-plus product families and three manufacturing sites.

C#/.NETSQL ServerNI TestStandMES IntegrationIEC 62443
2011 – 2013

Senior Software Developer · O'Neil Software

Designed a secure cloud health-monitoring system (WCF, REST, ASP.NET) and an MVC 3 / Entity Framework SaaS application. Built a language parser generating ASTs and .NET Expression Trees. Everything shipped with unit and integration coverage.

ASP.NETRESTEntity Framework
2004 – 2010

Systems & Software Engineer · International Rectifier

Lead engineer for business-critical Product Reliability systems. Built the WIP-Tracker production tracker (barcode + touch terminals), designed a custom Agilent/VB.NET test-monitoring rig, and administered the SQL Server estate while mentoring a dev team.

VB.NETSQL ServerAgilent / DAQ
1999 – 2003

Systems Engineer · Advanced Mobility Systems / CE-CERT

Led software for the Smart Vehicle Management System, deployed in the field at universities, utilities, and a U.S. Air Force base. Firmware on Motorola HC08/HC11 (C) plus fault-tolerant client-server over unreliable WAN links.

Embedded CHC08/HC11Client-Server
04

Selected Projects

Founder · Shipped Product

PLCDocGen — Offline PLC Documentation Generator

A commercial Windows tool I conceived, built, and launched solo — plcdocgen.com

Point it at a Rockwell Studio 5000 export and get complete engineering documentation in seconds: tag database, cross-references, AOI definitions, alarm summary, and change reports. Offline by design — plant code never leaves the machine — because I've spent years on the OT-security side that says it shouldn't.

  • Parses Studio 5000 exports v19–v38+; ladder, structured text, and FBD cross-referenced
  • Three report styles for three readers: full reference, commissioning handover, audit summary
  • Validated against 32 real-world project files; sold and supported as a one-person product
AI · Data Integration

Private AI Knowledge System

An in-house assistant that answers from the company's own data

A secure AI layer that connects internal data across departments. Management asks a question and gets a cited answer in seconds, grounded in the company's own systems and running on infrastructure the business controls.

  • Answers that took hours of digging return in seconds
  • Joins data from multiple departments into one queryable layer
  • Runs entirely in-house; sensitive data never leaves the network
Industrial Test Automation

Universal System Test (UST) Platform

One platform for automated system test of safety-controller configurations

Central orchestration software drives the hardware, validates the signals, and runs the full test workflow against any supported controller configuration through External Termination Panels (ETP).

  • One platform replaced a dozen config-specific test rigs
  • Cut test setup time by roughly 70%
Production Automation · Security

Universal Firmware Programming & Locking Station

Secure ISP firmware deployment across every active product line

A TestStand-based, multi-fixture station for firmware programming (ISP) and secure locking. It drives PEmicro, Cyclone, and Lattice programmers from one platform, with full traceability and production routing.

  • Loads and locks firmware directly in the production environment
  • Enforces secure locking and configuration control per unit
  • Supports 40+ product variants from one station
Data Infrastructure

End-to-End Traceability Database System

Full product-lifecycle tracking from build through RMA

A production SQL Server platform that traces every unit from manufacturing through shipping and RMA, with a structured data architecture and bidirectional MES/PMS routing.

  • Tracks millions of units across manufacturing, quality, and service
  • Powers root-cause analysis, compliance, and system-wide insight
  • Sub-second queries at full production scale
05

Skills

Software & Architecture

System DesignData ArchitectureAPIs & Integration Internal Apps & ToolsCloud / CI-CDC# / .NET SQL ServerPython

Test & Automation

NI TestStandLabVIEWSTEM ATE / PXI / DAQHILDFT / DFM SPEATeradyne

Cyber & Safety

IEC 62443SIL 3 / IEC 61508Secure Boot PKIFirmware SigningCode Signing SDLThreat Modeling

AI Engineering

Context EngineeringMulti-model OrchestrationAI Guardrails RAG / Knowledge SystemsOn-prem LLMsAgentic Workflows LLM Tooling (Claude · Gemini · Codex)
06 / What's next

Let's connect your operation.

A stalled rollout, systems that don't talk, or an AI initiative that needs to survive production — that's the work I take on. Open to architect-level roles and embedded engagements. California-based, remote-friendly. Email is the fastest way to reach me.

Get in touch