Overview
At Calsonic Kansei, I initially focused on stabilizing an aging assembly-line control environment and resolving recurring production failures. After the immediate problems were under control, I designed and built a replacement system from the ground up.
The work covered the complete operating stack, from individual physical inputs to application logic, reporting, virtualization, servers, and networks.
Manufacturing context
The line operated nearly continuously during the workweek. Unplanned downtime carried significant financial penalties, so architecture decisions had direct production consequences.
The problem
The legacy environment suffered recurring failures, and the replacement had to coordinate real-time manufacturing decisions across physical equipment, technician workflows, management reporting, application services, and infrastructure.
The system also needed an operating environment that I could install, diagnose, and support as one coherent platform.
My role
I owned the architecture and implementation across application code, database design, industrial integration, virtualization, servers, networking, installation, and production support.
The system
I designed or implemented:
- The Microsoft SQL Server database and schema
- Java middle-tier services and central control logic
- Angular management reporting
- Ignition technician interfaces
- Automated guided cart and torque-tool integration
- Physical equipment inputs
- Server and VMware infrastructure
- Network switches, racks, and high-availability failover
The platform consumed information from automated guided carts, torque tools, and other equipment, then used that information to make real-time production decisions and coordinate assembly-line behavior.
Infrastructure ownership
I specified and ordered the servers; installed the servers, switches, and racks; configured VMware; built the production network; implemented high-availability failover; and administered the operating environment.
Application and infrastructure behavior were treated as one production responsibility rather than separate projects.
Initial release and correction
The first production version exposed database deadlocking problems and was rolled back. I diagnosed the problem, revised the design, and delivered a stable second implementation.
The correction demonstrates production troubleshooting and accountability.
Operational effect
The stable second release replaced the failing legacy environment on the initial line and provided one supportable platform spanning control logic, interfaces, data, equipment, and infrastructure.
What this demonstrates
- Full-stack and infrastructure ownership
- Industrial-system integration
- Production troubleshooting
- Database and application architecture
- High availability
- Hardware and network deployment
- End-to-end work from physical signals to enterprise systems