ROB BODNAR

Independent Controls & Manufacturing Project Engineer

CAPABILITY OVERVIEW

Senior controls and manufacturing project engineer with 25+ years of industrial experience delivering automation, process, and production systems for automotive and manufacturing clients. Proven ability to lead Greenfield projects (new factory) and Brownfield (plant upgrade) projects, including controls modernization, IT infrastructure, and cyber security improvements. Strong background in design for manufacturing, cost reduction, and successful production launches.

CORE STRENGTHS

• PLC / HMI architecture & programming

• Robotics integration (Fanuc, ABB, Kuka)

• Vision systems & industrial networks

• Equipment commissioning & debug

• Control system upgrades & modernization

SELECTED EXPERIENCE HIGHLIGHTS

• Greenfield & Brownfield project leadership

• Design for Manufacturing (DFM)

• Process design, FMEA & control plans

• IT infrastructure & cyber security upgrades

• Lean Six Sigma Black Belt / cost reduction

General Motors – Global Paint Manufacturing — Lead controls projects for automated paint systems supporting ICE and EV programs. Greenfield new-factory work and Brownfield upgrades of existing plants, including control systems, IT infrastructure, and cyber security improvements.

GE Appliances (Louisville, KY) — Design for manufacturing on PTAC products during the move of production from China to the United States. Evaluated total cost of manufacturing, reduced costs, re-designed products/processes, and supported successful domestic launch.

ABB Powertrain Assembly — Controls design and project execution for engine, axle, and transmission assembly and functional test systems for major OEMs.

Electradyne — Controls and automation for body shop, trim, chassis, and final assembly systems.

ENGAGEMENT MODEL & RATES

Available for short- and medium-term on-site or hybrid engagements supporting project execution, commissioning, process improvement, and system upgrades.

Typical Rate Range: $115 – $140 per hour (depending on scope, duration, travel, and complexity)

Preferred Structure: Independent contractor / Corp-to-Corp

Minimum Engagement: Discussed based on project needs

Geographic Focus: Southeast Michigan and surrounding Midwest; open to project-based travel

References and detailed résumé available upon request.

email: robbodnar@gmail.com

linkedin: https://www.linkedin.com/in/robbodnar/