Jonathan Jerome | Automation & Controls

Automation & Controls Engineer

I design reliable automation systems, improve production efficiency, and solve complex manufacturing problems through controls engineering, system integration, and practical process improvement.

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Brands I Work With

Rockwell Automation
Siemens
Keyence
Schneider Electric
FANUC
Domino Printing Sciences
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Featured Projects

3D Modeled Wear Ring Reliability Improvement

Designed a custom wear ring to eliminate a recurring equipment failure causing production downtime. The component was 3D modeled, prototyped, and produced using additive manufacturing before being implemented in production. The solution improved reliability, reduced maintenance intervention, is currently being pursued for patent protection, and is estimated to save approximately $155,000 annually.

Bad Pallet Detection and Automatic Reject System

Currently developing a fully custom bad pallet detection and automatic reject system for an existing production line. The system is being engineered around the line's layout and operating constraints to identify defective pallets, remove them from the main pallet flow, and allow production to continue with less manual intervention.

The project includes mechanical design, metal fabrication, machining, sensor integration, PLC programming, alarm logic, installation, testing, and production tuning. It is being developed as a low-cost alternative to camera-based inspection systems used at other plants, which can cost around $75,000 per line for hardware alone.

With an estimated build cost of approximately $2,000 per line, this design has a projected savings of over $250,000 across three lines before accounting for reduced downtime and avoided production losses.

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. This included mechanical design, sourcing materials, PLC hardware, IO selection, HMI development, fabrication, installation, programming, and working directly with operations to tune performance and improve usability.

Case Coder Protection Logic

Developed line stop and alarm logic to prevent cases from moving through production without proper date code verification, reducing scrap and improving production quality.

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Technical Capabilities

Controls & Automation
PLC Programming PLC Troubleshooting New PLC Program Development PLC Logic Modifications PLC Hardware Configuration PLC I/O Integration HMI Development HMI Modifications SCADA System Development Operator Interface Design Alarm Logic Development Line Control Logic Machine Startup Support Commissioning Support Controls Debugging System Integration
Electrical & Controls Hardware
Electrical Troubleshooting Electrical Wiring Control Panel Wiring Field Device Installation Sensor Wiring Photoeye Integration I/O Card Integration Relay Logic Circuits Discrete Controls Low Voltage Controls Motor Control Basics Ethernet Device Communication Schematic Reading Panel Troubleshooting
Mechanical, Fabrication & Design
Mechanical Troubleshooting Equipment Repair Preventive Maintenance Support Root Cause Analysis Pneumatic Systems Hydraulic Systems Welding Fabrication Machining 3D Modeling 3D Printing Prototype Development Custom Part Design Reliability Modifications
Manufacturing Systems & Equipment
Production Line Support Packaging Equipment Support Conveyor Systems Labeling Systems Case Coding Systems Industrial Equipment Installation Equipment Reliability Improvement Downtime Reduction Operational Support Continuous Improvement Process Improvement Manufacturing Environment Experience Krones Equipment Experience High-Speed Production Systems
Software & Technical Tools
Studio 5000 RSLogix / Logix Designer FactoryTalk View TIA Portal Connected Components Workbench (CCW) Keyence VS Creator Vision System Configuration Vision System Tuning HMI Development SCADA Interface Development Ladder Logic Structured Text Fusion 360 3D Modeling Python Fundamentals Java Fundamentals Microsoft Excel Microsoft Word Microsoft Outlook CMMS Systems
Professional Strengths
Technical Problem Solving Cross-Functional Collaboration Operations Support Production Support Training Support Process Documentation Project Coordination Priority Management Hands-On Leadership Continuous Learning Adaptability Ownership Mentality

Certifications

Rockwell Automation Certified

Instrumentation, Automation and Controls Technician
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
Currently In Progress

Dean's List Recognition

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

Academic Performance

Dean's List recognition achieved through strong academic performance while balancing technical work and continued education.

Continuing Technical Development

Expanding technical capability through formal computer science education while continuing hands-on work in controls, automation, troubleshooting, and system integration.

Awards & Recognition

Niagara LIFE InnovACT Everyday Award

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

Outstanding Performance Award

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

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What I Do

Automation Engineering

I engineer practical automation solutions that improve uptime, reduce recurring failures, and make production systems more reliable. From concept to implementation, I develop systems that solve real plant problems instead of adding more complexity.

Controls Programming

I develop PLC logic, build operator interfaces, create custom HMI and SCADA-style systems, and troubleshoot machine behavior at the code level. My work goes beyond small edits. I design controls that give operations better visibility, better control, and better results.

System Integration

I integrate sensors, vision systems, drives, HMIs, PLC hardware, and machine controls into complete working systems. I handle the full picture, including electrical and controls design, field installation, startup, and the mechanical side needed to make the system actually work in production.

Process Improvement

I identify weak points in production and turn them into engineered improvements that reduce downtime, waste, and operator frustration. Whether it takes programming, fabrication, redesign, or hands-on troubleshooting, I serve as a one-stop automation resource for plant performance and reliability.

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About

Jonathan Jerome

I work in automation and controls with a strong focus on solving real manufacturing problems. My background includes controls programming, troubleshooting, system integration, equipment improvement, and operational reliability support.

I am especially interested in projects that have direct operational impact, whether that means improving uptime, reducing recurring downtime, integrating new technology, or designing practical solutions that make systems easier to operate and maintain.

This site is a place to document my work, certifications, education, and professional growth across automation, controls, and engineering.

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