Josh Spacht

Responsible for plant reliability and controls engineering across Crunchy Bars, Extruded Bars, Softbake Bars, and Cereal production lines at the Belvidere facility.

• Plant Reliability: Maintain and improve uptime across bar and cereal manufacturing lines through proactive controls support and troubleshooting.
• Line Support: Provide hands-on technical support for PLC, HMI, motion control, and process systems on the plant floor.
• Vendor Coordination: Work with OEMs, integrators, and equipment vendors to resolve control issues and implement system improvements.
• Controls Projects: Plan and deliver upgrades, retrofits, and improvement initiatives—from scoping and vendor selection through installation, checkout, commissioning, and handoff to operations.
• Cross-Functional Collaboration: Partner with maintenance, operations, and engineering teams to keep production running safely and efficiently.

Spearheading the design, programming, and commissioning of complex automation systems, ensuring high performance and reliability across Allen-Bradley platforms.

• PLC Architecture Design: Design and program ControlLogix/CompactLogix systems for high-speed manufacturing environments.
• System Reliability: Optimize machine uptime by creating precise control schematics and comprehensive technical documentation.
• Cross-Functional Collaboration: Collaborate directly with plant managers and maintenance teams to ensure systems meet site-specific needs.
• Motion Control: Configure and troubleshoot complex motion profiles using VFDs and servo systems.
• Machine Safety: Design and validate safety circuits (E-Stops, light curtains, interlocks).
• Continuous Improvement: Lead feature enhancements that improve operational efficiency.
• Legacy Migration: Diagnose and migrate aging controls to modern ethernet-based architectures.
• Data Visibility: Implement sensor integration for real-time process analytics.
• Startups & Commissioning: Lead on-site checkout procedures and electrical troubleshooting.

Focused on reliability engineering and preventative maintenance for mission-critical Data Center infrastructure.

• Predictive Maintenance: Designed scheduled maintenance plans using Thermal Scanning and Ultrasound tools.
• Power Quality Analysis: Performed analysis on power buss rails in data centers nationwide.
• Data Analysis: Organized thermal and energy data into exception reports.

Integrated Defense Solutions division. Optimized production workflow and safety compliance.

• Process Optimization: Redesigned factory floor layouts to improve continuous manufacturing flow.
• Lean Management: Managed safety metrics and led weekly 5S audits.
• Standardization: Authored and revised Standard Operating Procedures (SOPs).
• Inventory Control: Established comprehensive inventory systems and performed annual audits.

Foundational hands-on experience in machine building and fabrication.

• Fabrication: Operated brake press, shear, water jet, and band saw.
• Assembly: Performed electrical assembly, structure support, and engine enclosure line work.
• Technical Skills: Gained proficiency in blueprint reading and coordinated with teams.