Kurt J. Foster

Responsible for repairing manufacturing equipment in Powertrain Manufacturing.

Applied technical skills to install, maintain and repair high-speed high-volume mechanical and electrical systems, factory automation and robotics.

• Troubleshot and maintained 70+ large Fanuc industrial robots (welding, material handilng etc.) for the battery enclosure lines.
• First responding problem-solver managing machine breakdowns and full recovery.
• Diagnosing machine faults and laying out plan to execute repair or escalation procedure.
• Electrical systems ranging from 24VDC to 480VAC 3-phase.
• Repaired automated machinery, requiring full knowledge of the functional operation.
• Communicated with supervisors and management for fast repair execution.
• Talked with production associates on production ergonomics and improving machine output.

Work History:

Apr—Jun 2021 • 3 mos
Model 3/Y Battery Pack, Enclosure Weld

Repairing industrial automated systems.

• Editing and troubleshooting PLC ladder logic and command language programs.
• Determining root cause analysis of circuitry, control panels, and mechanical systems.
• Following through with timely repairs, updates, and documentation of issues resolved.
• First responding troubleshooter diagnosing a wide variety of electromechanical issues.
• Participating in the development of maintenance and operational documentation of equipment.
• Evaluating spare part needs and use available systems to warehouse and track inventory/availability.
• Interpreting mechanical drawings, schematics, printouts, specifications, and test procedures.
• Ensuring measuring/diagnosing instruments are calibrated and verified on a regular basis.

Gravity-fed nutrient dosing for hydroponics.

Utilized my automation experience to design, build, and test a UL-compliant consumer appliance that combines microcontrollers and industrial automation technology into a prototype product that could ideally sustain a hydroponics farming operation for years without major repairs required.

Responsibilities:

• Testing components at an individual level, keeping track of performance measured.
• Translating custom CAD to real world results, and constant iteration through the issues.
• Taking the relevant safety precautions with machine start up, shut down, and troubleshooting.
• Continuous improvement of design, as it progresses from test bed to prototype.
• Updating ladder logic to fit individual component testing, and associated wiring changes.
• Creating accurate analysis of data recorded, in order to optimize machine output in performance.

Direct-tasks:

• Adhering to UL standards of electrical design practices in prototype construction.
• Created electrical, fluid, and mechanical drawings for assembly of fixtures & prototypes.
• Used a variety of hand tools for assembly and construction of electro-mechanical systems.
• Developed CAD and 2D engineering drawings for component fabrication and assembly.
• Used continuous improvement for design to lower cost, increase quality of automated devices.
• Programmed and wired PLC and microcontroller devices for real-time process control.
• Used a variety of hand tools: WAGO Variocrimp, self-adjusting wire stripper, heat-guns, tap & die sets, metal jig saws, and other common shop tools.
• Electrical wiring involving 3.3VDC to 120VAC for powering pumps, valves, and associated electrical equipment, all organized to be functional, safe & user friendly.

Responsible for repairing manufacturing equipment in Powertrain Manufacturing.

Applied technical skills to install, maintain and repair high speed high volume mechanical and electrical systems, factory automation and robotics.

• First responding problem-solver managing machine breakdowns and full recovery.
• Diagnosing machine faults and laying out plan to execute repair or escalation procedure.
• Electrical systems ranging from 24VDC to 480VAC 3-phase.
• Repaired automated machinery, requiring full knowledge of the functional operation.
• Communicated with supervisors and management for fast repair execution.
• Talked with production associates on production ergonomics and improving machine output.

Work History:

Jan—Feb 2021 • 2 mos
Model 3 Drive Unit, Final Assembly

Oct—Dec 2020 • 3 mos
Model 3 Drive Unit, Test Line & Raven Line

Utilized automation for the advancement of easy to use and energy efficient farms.

First goal was getting product fit from prototypes of automated nutrient dosing systems.

• Adhering to UL standards of electrical design practices in prototype construction.
• Created electrical, fluid, and mechanical drawings for assembly of fixtures & prototypes.
• Used a variety of hand tools for assembly and construction of electro-mechanical systems.
• Developed CAD and 2D engineering drawings for component fabrication and assembly.
• Used continuous improvement for design to lower cost, increase quality of automated devices.
• Programmed and wired PLC and microcontroller devices for real-time process control.
• Used a variety of hand tools: WAGO Variocrimp, self-adjusting wire stripper, heat-guns, tap & die sets, metal jig saws, and other common shop tools.
• Electrical wiring involving 12VDC to 120VAC for powering pumps, valves, and associated electrical equipment, all organized to be functional, safe & user friendly.

Troubleshot & maintained machinery for a fast production ramp.

Worked within Powertrain Manufacturing, from batteries to drive units.

• Diagnosed equipment failures and suggested improvements to process engineering.
• Saved 500+ DUs from fallout in q2 2019 ($1mm+ savings according to Sr. Process Engineer).
• Repaired automated machinery, requiring full knowledge of the functional operation.
• Mentored production associates on equipment updates and safe throughput.
• Replaced required mechanical and electrical components of production equipment.
• Acted with the first intent being on creating a safe working environment for everyone.

Work History:

Jan—Jul 2019 • 7 mos
Model 3 Drive Unit, Test Line

Sep—Dec 2018 • 4 mos
Model 3 Drive Unit, Final Assembly

Jun—Aug 2018 • 3 mos
Model 3 Battery Module,
Clamshell Current Collector Attach

Built custom manufacturing equipment.

Assembled and tested equipment for the Daimler electric truck, and assembled test cells for the optical alignment of the Steam VR headset.

• Kept high-level attention to detail when fabricating/assembling complex robotic machinery.
• Drilled, tapped, fastened components for industrial electrical panels and pneumatic panels.
• Wired control panels using electrical diagrams, red-lined issues and reported to engineering.
• Stripped, crimped, assembled, MIL-Spec multi-pin connectors up to 56-pin.
• Followed work procedures associated with procurement for timely machine assembly.

I designed, built and tested a fully functional 6061 Aluminum Mountain Bicycle Frame. Some of the challenges included: learning to TIG weld aluminum, reverse engineering of bicycle frame components, project scope and aesthetics.

Links for more information:

documentation.pdf

A fully open-source, open-hardware telescope project which is currently in the early design phase. First milestone is testing a scaled down model to verify the optical system is feasible. Please follow this link to see the intended design, it's my ray-trace example of 0.4 meter binoculars.

Basic principle is: Concave primary mirror, concave secondary mirror, and a Nasmyth style tertiary flat mirror. With a fast focal ratio primary mirror, sub-f/3.0, it allows for minimal obstruction of the light path, plus combining that with a Gregorian secondary mirror in a binocular format allows for the upright image to be displayed for the user at the back end of the telescope. So no matter the size of the binoculars, the user will see a bright up-right image with both eyes open, just like a small hand-held pair of binoculars.

Links for more information:

3d-cad.stp (Currently a very work-in-progress)

documentation.pdf (Currently a work-in-progress)

Hobby project buliding a smaller 8" aperture version of the legendary Obsession Telescopes. Since I was 14-years old when I started this project, I needed some guidance, so I consulted Kreige and Berry's book, The Dobsonian Telescope.

The CAD model I drew up on the PTC OnShape platform is linked below, and it accurately matches the size of the telescope components. This CAD model however is not yet complete, as doing this can be very time consuming. It's currently lacking a primary mirror cell in the CAD model and much of the components of the secondary cage.

Tools and technologies used:

• Annealed telescope optical blanks with 1800°F kiln
• Reverse engineering of existing plans to fit specific size requirements
• Utilized a CNC wood router for side rocker construction
• 100+ hrs hand grinding the telescope mirror
• Extremely stiff frictional bearing mounts for altitude and azimuth axis control
• Tight dimensional tolerancing of wood/metal structures
• Materials used: plate and borosilicate glass, marine grade plywood, birch plywood, aluminum, and steel
• Mechanical skills: trigonometric calculating for truss design, cantilever loading

Links for more information:

3d-cad.stp (Contains 80+ parts in one assembly)

documentation.pdf (coming soon)