Project Engineer
ABB Korea
Robotics Division
October 2016 - June 2020
Cheonan, Korea
Role Overview
Led comprehensive automation projects for major corporations including Samsung, LG, and Hyundai across multiple countries. Responsible for full project lifecycle from design and simulation to commissioning of robotic automation systems in high-precision manufacturing environments.
Specialized in integrating industrial robots with complex manufacturing systems, achieving sub-millimeter precision requirements for critical applications like Apple LCD screen handling and automotive assembly line automation.
Major Projects
Machine Learning-based ABB Robot Lifetime Prediction System
Objective: Develop a predictive maintenance system to calculate remaining operational time for ABB robots by analyzing motor load patterns and torque data.
Research Hypothesis
Continuous robot operation increases load on each axis motor, and as load increases, motor lifespan decreases predictably through measurable torque patterns.
Technical Implementation
- Interface Development: Built C# interface using RobotStudio API for seamless integration
- Data Collection: Developed RAPID programs to extract torque data from each robot axis in real-time
- ML Algorithm: Implemented time-series machine learning algorithms in Python for predictive analysis
- Embedded Solution: Created .dll-compatible internal robot controller app for standalone operation
- Threshold Analysis: Established critical torque thresholds through experimental validation
Engineering Challenges Solved
- Motor-specific torque limitations requiring individual calibration
- Real-time data processing without external computer dependency
- Time-series pattern recognition for accurate lifetime prediction
- Integration with existing manufacturing workflows
Business Impact
Enabled predictive maintenance scheduling, reducing unexpected downtime and optimizing robot utilization across manufacturing facilities.
ABB Expense Helper - Process Automation Tool
Problem: Manual expense report processing after business trips was time-consuming and error-prone, affecting productivity across the entire organization.
Solution Evolution
Version 1.0 - OCR Approach
- Utilized OpenCV's pytesseract library for receipt text recognition
- Automated Expense Request Form completion from receipt data
- Challenge: Performance issues on laptop environments led to user abandonment
Version 2.0 - Data Integration Approach
- Integrated with credit card company Excel export systems
- Automated form filling based on chronological spending data
- Achieved 50% reduction in expense processing time
- Solution shared company-wide via internal email distribution
Technical Implementation
- Python Libraries: OpenCV, pytesseract, pandas for data processing
- Data Integration: Excel file parsing and automated form population
- User Interface: Intuitive workflow for non-technical users
- Error Handling: Robust validation and correction mechanisms
Organizational Impact
Tool adoption across the entire company resulted in significant productivity gains and employee satisfaction improvements. Demonstrated ability to identify organizational pain points and deliver scalable solutions.
Samsung Production Line (SDV) Automation - Apple LCD Screen Handling
Client Challenge: Handle Apple-destined LCD screens with extreme precision requirements where even 1mm deviation was unacceptable for supply chain quality standards.
Precision Engineering Solution
- Sub-millimeter Accuracy: Achieved <1mm precision through advanced vision-guided robotics
- Vision Integration: Implemented 2D/3D vision systems for real-time position correction
- Robot Programming: Developed sophisticated RAPID programs for micro-adjustments
- Quality Assurance: Established continuous monitoring and validation systems
Project Scale & Impact
- 40+ industrial robots integrated across production lines
- Critical supplier for Apple's global supply chain
- Zero-defect requirement successfully maintained
- Production efficiency optimization through automated workflows
LG Press Line Automation Project - Mexico
Scope: Design and implement robotic systems for LG washing machine body manufacturing using coordinated press line automation.
System Architecture
- Multi-Stage Process: Coordinated 7-8 press machines with intermediate robotic handling
- Material Flow: Automated iron plate transfer between sequential press operations
- Final Assembly: Conveyor belt integration for finished component handling
- Process Optimization: Minimized cycle time while maintaining quality standards
International Project Management
Successfully managed cross-cultural project execution in Mexico, coordinating with local teams and adapting solutions to regional manufacturing requirements and standards.
Hyundai Automotive Assembly Plant Integration
Scale: Integrated equipment in automotive assembly plant with approximately 40 industrial robots, each with specialized tools and designated positions.
Project Management Excellence
- Resource Optimization: Efficiently distributed subcontracted personnel across 40 robot installations
- Timeline Management: Delivered all robot integrations within specified project timeline
- Quality Assurance: Ensured normal operation of all robotic systems post-integration
- Coordination: Managed complex interdependencies between different automation systems
Woojin Plaimm Injection Molding - Cosmetic Lid Handling
Application: Automated handling of plastic cosmetic lids with integrated quality control and traceability systems.
Integrated Technology Stack
- Multi-Vision System: Combined 2D and 3D vision for precise material positioning
- Database Integration: Used PySQL to retrieve injection molding data from server
- Quality Traceability: Laser marker integration for QR code engraving
- Process Automation: Seamless workflow from production to quality marking
Mobile Robot Control System - Android Integration
Innovation: Developed wireless robot control system using mobile devices, enabling intuitive robot operation through smartphone interfaces.
Dual Control Modes
Mode 1: Sensor Synchronization
Robot posture changes in real-time based on smartphone accelerometer and gyroscope sensor data, providing intuitive motion control.
Mode 2: Touch Interface
Robot position adjusts based on touchscreen interactions, offering precise positional control through mobile interface.
Technical Achievement
Successfully implemented WiFi communication protocol between mobile devices and industrial robots, demonstrating early adoption of mobile-industrial integration concepts.
PC-based Robot Control System - JAVA Implementation
Objective: Control industrial robots directly from personal computers bypassing traditional robot controllers, using custom socket communication protocols.
Technical Implementation
- Direct Communication: LAN cable connection between robot and computer for reliable data transfer
- Socket Protocol: Custom socket communication for real-time position commands
- JAVA Interface: Developed intuitive control interface with position input capabilities
- Real-time Response: Immediate robot movement based on received coordinate values
Robit Korea Bar Handling Project
Challenge: Handle 6000mm long load bars for CNC machine processing with precise positioning and material stacking requirements.
System Integration
- Long Material Handling: Specialized gripping systems for 6-meter bars
- CNC Integration: Precise placement of materials into CNC machines for processing
- Servo Motor Interface: Coordinated control with servo motors and PLC systems
- Automated Stacking: Post-processing material organization and storage
Tire Mold Drilling Project
Precision Requirements: Execute drilling operations on tire manufacturing molds with 0.4mm accuracy tolerance using vision-guided robotics.
Precision Control System
- Coordinate Processing: Parse coordinates from Main Control PC and convert to robot coordinate system
- Vision Guidance: Integrated vision camera for maintaining sub-millimeter accuracy
- Mold Manufacturing: Drilling operations on jigs used for tire production molds
- Quality Control: Continuous monitoring to maintain 0.4mm precision standards
Dongseo Pressure Die Casting Project
Scale: Complete system integration for high-pressure casting operations using 3500T casting machines for automotive engine frame production.
Casting System Integration
- Massive Scale: Integration with 3500-ton casting machines for engine frame production
- PLC Communication: Coordinated robot entry and extraction from casting machine interior
- Post-processing: Automated finishing operations on cast engine components
- Conveyor Integration: Final placement on conveyor systems for downstream processing
DRAxion Gravity Casting Project
Process: Complete gravity casting system integration for aluminum engine component manufacturing with molten metal handling capabilities.
Gravity Casting Process
- Molten Metal Handling: Robot pouring of liquid aluminum from molten metal into molds
- Cooling Process: Automated monitoring and handling during component formation
- Part Extraction: Removal of formed engine components from molds
- Quality Transfer: PLC-coordinated placement on conveyor systems
Automotive Seat Durability Testing
Testing Protocol: Automated durability testing system for automotive seats using repetitive stress testing in Hyundai's subcontracted laboratory environment.
Automated Testing Protocol
- PLC Trigger: Automated testing initiation based on PLC signal reception
- Repetitive Testing: Continuous press-and-release cycles for durability analysis
- Research Environment: Laboratory-controlled testing conditions
- Quality Validation: Long-term durability assessment for automotive seating
Samsung Electronics AGV-Mounted Robot System
Mobile Robotics: Developed robot system mounted on Automated Guided Vehicles for flexible battery handling in Samsung's production environment.
Mobile Robot Integration
- AGV Mount: Robot integration on mobile Automated Guided Vehicle platform
- Battery Handling: Specialized gripping systems for electronic component handling
- Position Compensation: Vision system integration to compensate for AGV positioning variance
- Flexible Automation: Mobile automation for dynamic production line requirements
Samsung Production Line - Additional LCD Screen Project
Continuation: Additional precision handling project for Apple LCD screens maintaining the same stringent quality requirements and sub-millimeter accuracy standards.
Precision Manufacturing
- Continued Excellence: Maintained <1mm precision standards for Apple supply chain
- Vision-Guided Control: Real-time position adjustment using vision camera data
- Quality Critical: Zero-defect requirements for consumer electronics
- Process Refinement: Optimized existing processes for enhanced efficiency
GoldLine Pallet Foundry Project
Material Handling: Automated handling of injection-molded pallets with precise alignment and conveyor integration systems.
Injection Molding Integration
- Injection Machine Interface: Coordinated extraction from injection molding machines
- Pallet Handling: Specialized gripping for molded pallet components
- Conveyor Alignment: Precise placement and alignment on conveyor belt systems
- Team Coordination: Collaborative work with outsourced technical personnel
HT Mexico Automotive Project
Automotive Manufacturing: High-pressure casting and post-processing facility integration for automotive engine frame production in Mexico.
Automotive Integration
- Engine Frame Extraction: Automated removal of automotive engine frames from casting machines
- Multi-Process Inspection: Sequential quality control processes for engine validation
- Defect Detection: Automated systems to ensure engine components meet quality standards
- International Deployment: Project execution in Mexican manufacturing facility
JHENG Wiring Robot Project
Wire Management: Specialized wire winding operations using ABB positioner systems for precision cable management applications.
Wire Winding Technology
- ABB Positioner: Integration with specialized ABB positioner for precise wire placement
- Wire Winding: Automated coiling and management of electrical cables
- Precision Control: Accurate wire tension and placement control
- Industrial Application: Cable management for industrial equipment
SL Lighting Foundry Project
Automotive Lighting: Plastic injection molding integration for automotive headlight frame production with trimming and finishing operations.
Headlight Manufacturing
- Injection Molding: Automated handling of headlight frames from plastic injection machines
- Trimming Operations: Removal of excess material and finishing processes
- Quality Processing: Precision trimming for automotive lighting standards
- Team Integration: Coordination with outsourced technical personnel
Daewon Foundry Setup Project
System Setup: Robot and shuttle system configuration and setup support for foundry operations.
Configuration & Setup
- Robot Configuration: Complete setup and calibration of robotic systems
- Shuttle Integration: Automated shuttle system configuration
- System Testing: Comprehensive testing and validation procedures
- Technical Support: On-site technical assistance and troubleshooting
SL Yantai Project - China
Injection Molding Integration: Integration of injection machines with peripheral equipment for headlight frame painting operations in China.
Manufacturing Integration
- Equipment Integration: Seamless connection between injection machines and auxiliary systems
- Conveyor Systems: Automated transport of headlight frames through production line
- Painting Process: Integration with automated painting systems
- Process Flow: Continuous material flow to next production stages
Dongseo Machinery Foundry - Engine Production
Engine Manufacturing: High-pressure casting and post-processing facility integration for automotive engine frame production with comprehensive quality control.
Engine Manufacturing Process
- High-Pressure Casting: Integration with high-pressure casting equipment
- Engine Frame Handling: Automated extraction and handling of automotive engine frames
- Quality Verification: Multi-stage inspection processes for engine quality assurance
- Post-Processing: Complete finishing operations for manufactured engines
Technical Expertise Developed
Programming & Development
RAPID Programming
Advanced robot programming for precision applications and complex manufacturing workflows
C# Development
Interface development using RobotStudio API and .dll creation for embedded systems
Python Automation
Process automation, machine learning implementation, and data integration solutions
Socket Communication
Network protocols for robot-computer communication and system integration
Industrial Systems
PLC Integration
Communication protocols and interface development between robots and programmable logic controllers
Vision Systems
2D/3D vision integration for precision manufacturing and quality control applications
Process Integration
Complete manufacturing system integration including conveyors, presses, and auxiliary equipment
Quality Systems
Implementation of quality control and traceability systems in manufacturing environments
Project Management
International Projects
Cross-cultural project management and adaptation to regional manufacturing requirements
Resource Coordination
Efficient allocation of subcontracted personnel and technical resources across large-scale projects
Timeline Management
Complex project scheduling and delivery within specified constraints and quality standards
Client Relations
Direct engagement with major corporations including Samsung, LG, and Hyundai
Key Achievements
20+ Major Projects
Successfully completed automation projects across Korea, Vietnam, and Mexico for Fortune 500 companies
Sub-millimeter Precision
Achieved <1mm accuracy in critical applications like Apple LCD screen handling
40+ Robot Integration
Single project involving integration of 40+ industrial robots in automotive assembly plant
Company-wide Tool Adoption
Developed expense automation tool adopted across entire ABB Korea organization
ML Innovation
Pioneered machine learning application for predictive maintenance in industrial robotics
International Experience
Led projects across 3 countries with diverse manufacturing requirements and cultural contexts
Industry Impact
Manufacturing Excellence
Contributed to high-precision manufacturing processes for global technology leaders, enabling zero-defect production standards required by companies like Apple.
Process Innovation
Developed novel approaches to robot control including mobile integration and predictive maintenance, demonstrating forward-thinking application of technology.
Organizational Efficiency
Created and implemented tools that improved productivity company-wide, showcasing ability to identify and solve systemic operational challenges.
International Standards
Successfully adapted automation solutions across different countries and regulatory environments, proving versatility in global manufacturing contexts.