Jonathan Jerome | Plant Engineering, Automation & Continuous Improvement

Plant Engineering | Automation | Continuous Improvement

I lead plant improvement projects from concept through implementation, combining automation, equipment design, fabrication, commissioning, and controls engineering to improve safety, reliability, production performance, and operating cost.

Selected Engineering Impact

Examples of engineering ownership, innovation, project leadership, and measurable manufacturing value.

$155,500

Patent-Pending Reliability Improvement

Named inventor on a production improvement designed to eliminate a recurring failure, reduce downtime, and create lasting operational value.

$250,000+

Projected Equipment Cost Avoidance

Developing a custom pallet inspection and reject system as a low-cost alternative to commercial vision equipment across three production lines.

Greenfield

Manufacturing Facility Commissioning

Supported startup, controls optimization, equipment stabilization, and production readiness at a new high-speed manufacturing facility.

Cross-Functional

Technical Project Leadership

Coordinated technicians, contractors, vendors, shutdown work, project schedules, training, and implementation activities across plant functions.

Engineering project and fabrication illustration

Featured Projects

Selected work demonstrating problem identification, engineering design, controls integration, fabrication, implementation, and operational impact.

Patent Pending

Wear Ring Reliability Improvement

Named inventor on a custom production component designed to eliminate a recurring equipment failure and reduce unplanned downtime. The wear ring was 3D modeled, prototyped, validated, and implemented in production.

The design improved equipment reliability, reduced maintenance intervention, and is estimated to save approximately $155,500 annually. Niagara Bottling is pursuing patent protection for the invention.

In Development

Automated Pallet Inspection and Reject System

Developing a fully custom pallet inspection and automatic reject system for an existing production line. The system is engineered around the line's physical layout and operating constraints to identify defective pallets, remove them from the primary pallet flow, and allow production to continue with less manual intervention.

The project includes mechanical design, fabrication, machining, sensor integration, PLC programming, alarm logic, installation planning, testing, and production tuning.

Commercial camera-based alternatives can cost approximately $75,000 per line for hardware alone. With a projected build cost near $2,000 per line, the custom design could avoid more than $250,000 in equipment cost across three lines before accounting for reduced downtime and avoided production losses.

Greenfield Manufacturing Facility Commissioning

Supported commissioning and stabilization of a new high-speed manufacturing facility using Siemens and Rockwell automation systems. Resolved startup issues, optimized controls performance, supported equipment validation, and improved production readiness.

Coordinated with maintenance, operations, vendors, technicians, and engineering resources to address system issues and improve long-term equipment reliability after startup.

Keyence Vision Inspection System Integration

Integrated Keyence high-speed inspection cameras to verify date code presence on production lines. The system improved quality control, reduced manual inspection, and provided reliable detection at high production speeds.

Label Runaway Detection System

Designed and implemented a label runaway detection system from the ground up. The project included mechanical design, material sourcing, PLC hardware and I/O selection, HMI development, fabrication, installation, programming, and direct collaboration with operations to tune performance and usability.

Case Coder Protection Logic

Developed line-stop and alarm logic to prevent cases from progressing through production without proper date-code verification, reducing scrap risk and strengthening production quality controls.

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What I Do

Plant Engineering & Reliability

I identify recurring production and equipment problems, determine root causes, and develop lasting engineering improvements that strengthen safety, uptime, maintainability, and plant performance.

Engineering Project Leadership

I lead technical work from concept through implementation by coordinating technicians, contractors, vendors, operations, shutdown activities, schedules, training, and project execution.

Automation & Controls

I develop PLC logic, operator interfaces, alarm systems, vision applications, and integrated controls that give production teams better visibility, control, reliability, and troubleshooting capability.

Equipment Design & Continuous Improvement

I combine mechanical design, fabrication, prototyping, sensors, and controls to create practical equipment improvements that reduce downtime, waste, operating cost, and operator frustration.

Technical and engineering capabilities illustration

Technical Capabilities

Plant engineering, project execution, automation, reliability, design, and hands-on manufacturing capabilities.

Plant Engineering & Reliability
Equipment Reliability Improvement Root Cause Elimination Manufacturing Optimization Downtime Reduction Commissioning & Startup Equipment Stabilization Preventive Maintenance Support Predictive Maintenance Support Safety Improvements Maintainability Improvements Operational Problem Solving Continuous Improvement
Engineering Project Leadership
Project Planning Project Coordination Technician Work Coordination Contractor Coordination Vendor Coordination Shutdown Planning Schedule Ownership Cross-Functional Execution Technical Training Technician Mentoring Implementation Support Engineering Documentation
Automation & Controls
PLC Programming PLC Troubleshooting New PLC Program Development PLC Logic Modifications PLC Hardware Configuration PLC I/O Integration HMI Development SCADA Development Alarm Logic Vision System Integration VFD Systems Servo & Motion Systems Controls Debugging System Integration
Electrical, Instrumentation & Industrial Networks
Electrical Troubleshooting Control Panel Wiring Field Device Installation Sensor Integration Photoeye Integration Instrumentation I/O Integration Relay Logic Low-Voltage Controls Schematic Reading EtherNet/IP PROFINET Industrial Ethernet Network Troubleshooting
Mechanical Design, Fabrication & Prototyping
Mechanical Troubleshooting Equipment Modification Machine Design Custom Component Design 3D Modeling Rapid Prototyping 3D Printing Welding Fabrication Machining Pneumatic Systems Hydraulic Systems
Manufacturing Systems & Software
High-Speed Production Systems Conveyor Systems Packaging Equipment Labeling Systems Case Coding Systems Krones Equipment Studio 5000 RSLogix / Logix Designer FactoryTalk View TIA Portal WinCC Connected Components Workbench Keyence VS Creator AutoCAD Fusion 360 CMMS Systems
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Technologies & Platforms

Industrial automation, controls, inspection, robotics, and manufacturing technologies used in project development and plant support.

Rockwell Automation
Siemens
Keyence
Schneider Electric
FANUC
Domino Printing Sciences

Certifications & Technical Training

Instrumentation, Automation, and Controls Technician (IACT)

Rockwell Automation
Academy of Advanced Manufacturing
Milwaukee, Wisconsin
May 2023 – July 2023

Krones Academy North America

TIA 2 Training
Franklin, Wisconsin

TIA Level 2

Niagara Bottling
March 13, 2025

TIA Level 1

Niagara Bottling
February 20, 2025

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Education

Bachelor of Science – Computer Science

University of Phoenix
Expected March 2027

President's List Recognition

University of Phoenix
First Half of 2026
Earned for completing the qualifying credit requirement with a 4.0 GPA during the six-month recognition period.

Dean's List Recognition

University of Phoenix
College of Business & Information Technology
2024 and 2025

Continuing Technical Development

Expanding software, networking, and systems knowledge through formal computer science education while continuing hands-on work in controls, automation, commissioning, troubleshooting, and equipment design.

Awards & Recognition

Niagara LIFE InnovACT Everyday Award

Awarded in 2025 for contributions to Niagara's winning culture, innovation, and operational improvement.

Outstanding Performance Award

Recognized in 2025 for technical contribution, performance, problem solving, and impact within manufacturing operations.

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About

Jonathan Jerome

I am an engineering and automation professional focused on solving complex manufacturing problems and leading improvements from concept through implementation. My background combines PLC and controls engineering, equipment design, fabrication, commissioning, reliability improvement, and hands-on manufacturing support.

I have led technical work involving technicians, contractors, vendors, production teams, maintenance personnel, and engineering resources. My experience includes a patent-pending production improvement, custom automated inspection equipment, greenfield plant startup support, technical training, equipment redesign, and projects that have delivered measurable cost savings and improved production performance.

This portfolio documents the engineering process behind those solutions, including problem identification, design, prototyping, controls integration, fabrication, implementation, and operational impact.

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