Giuseppe Randazzo

As an external consultant, I was integrated into Tesla’s Automation Team, contributing to the accelerated production of stators for the Tesla CyberTruck.

My responsibilities included ensuring that the 12 hairpin bender machines operated efficiently and met Tesla’s strict quality standards.

I focused on overseeing machine performance, troubleshooting issues, and implementing process improvements to enhance production efficiency (using Beckhoff PLCs).

By maintaining high precision and minimizing downtime, I ensured the continuous and high-quality output of stators for the CyberTruck project.

Collaborated with the RedEagle Zeppelin team to expedite the commissioning phase at Tesla’s Berlin battery plant, focusing on the anode and cathode areas.

Led the configuration and programming of Beckhoff PLCs, ensuring seamless startup operations. Imported safety PLC configurations from the US team and adapted them as needed for local requirements.

Additionally, I was responsible for programming and configuring Beckhoff HMIs, optimizing the user interface for enhanced operational efficiency.

Provided ongoing support by troubleshooting and making program adjustments to ensure smooth plant operations.

𝙍𝙤𝙗𝙤𝘼𝙘𝙘𝙚𝙡𝙚𝙧𝙖𝙩𝙤𝙧® offers comprehensive, flexible training programs designed to propel you into the rapidly expanding field of Automation and Robotics. Benefit from practical experience, expert-led guidance, and lifelong updates. Our comprehensive trainings are designed to :

• Help you quickly and effectively become proficient in automation and robotics technology, giving you a competitive edge in the job market.

• Take you from Beginner to Expert level, with a focus on using vision systems and other advanced techniques to create highly optimized programs for your robot.

• Be broken down into modules, allowing you to progress at your own pace and fully absorb the material. Whether you're a complete novice or have some prior experience, we have the resources and guidance you need to succeed in the exciting field of Automation and Robotics.

• Conducted comprehensive training programs for teams within SMEs and Fortune 500 companies, focusing on robotics and automation.
• Assisted engineers in the design, configuration, and application of robotic systems through hands-on training sessions and workshops.
• Enhanced operational efficiency by creating and implementing detailed training materials for system users, service technicians, and maintenance personnel.

• Spearheaded the project for measuring and profiling jagged rubber pieces using a Confocal Displacement Sensor (CL3000 by Keyence), ensuring precise and accurate measurements.
• Coordinated synchronization between Motion Control and the Confocal Displacement Sensor to dynamically capture cloud points, working closely with the quality team to ensure data accuracy and relevance.
• Supervised the development of a user-friendly GUI for displaying the acquired piece profiles, enhancing usability and data interpretation for end-users.
• Handled post-processing calculations to analyze measurement data, ensuring thorough and reliable results.
• Implemented recipes management to streamline operations and ensure consistent quality control, collaborating with the quality team to integrate their feedback and requirements into the system.

• Entrusted with spearheading the development of the machine, overseeing all project stages from architecture for automation programs to robot programs.

• Under my direction, 100% of the project stages were completed on schedule and within the budget of $250,000 over 2 months.

• The machine allows the robot to work on engine valves for motorcycles and cars, synchronizing its movements with a laser source to mark and then place them on empty blisters, maintaining an accuracy rate of 95%.
• Chiefly responsible for all software design, coordinating integration with Omron vision systems through EtherCAT Fieldbus to increase operational efficiency, working closely with the quality team to ensure the highest standards were met.
• Collaborated extensively with the quality team to ensure all processes and outputs met stringent quality requirements.

• Led the development and design of a deburring application for the Aerospace Industry, streamlining operational procedures to achieve 100% quality for parts traditionally processed manually.
• Managed the design and development of robot programs for deburring aerospace components, ensuring precision and efficiency.
• Oversaw the optimization of trajectories for smoothing corners using a Fanuc Robot, coordinating with the quality team to ensure compliance with Aerospace industry standards.
• Developed robot scripts to allow users to rapidly change parameters such as diameter, proximity to the pieces, and profiles to avoid, working closely with the quality team to integrate their feedback and requirements.

• Led the development of the robot program (Epson Scara LS20) and Vision Systems programs to create the "Dimensional Inspection Machine," overseeing the project from concept to implementation, where vision systems identified pieces on a conveyor belt so that the robot could orient itself accordingly.

• Demonstrated high attention to detail to maintain a 0.2% error rate.

• Managed advanced integration of Robot and Vision Systems for dynamic pick-and-place operations, coordinating cross-functional teams to achieve seamless operation.

• Created a comprehensive database to record all pieces' data, enabling real-time verification of component quality by users.

• Directed the design and development of a new platform to enhance industrial machine flexibility and collect essential data for post-processing analysis, paving the way for industry 4.0 certification.
• Managed the development of the Middle Layer, enabling machine interchangeability within its component family. For example, oversaw the creation of a plug-and-play system allowing a complete laser source to be easily substituted from one manufacturer to another by simply changing its dedicated bridge software component.
• Led the design and development of the Low-Level Layer to interface Software PLCs, Motion Controls, Vision Systems, and Robots with the Middle Layer, ensuring seamless integration and communication.
• Implemented predictive maintenance for machines by utilizing sensor data as inputs, enhancing machine reliability and reducing downtime.

• Led the integration of Avionic Systems and the design and development of Embedded Systems to control aircraft flaps, V Rudder, and elevator, ensuring seamless system functionality.
• Managed the coordination and implementation of multiple technologies, including Dynon Avionics, Arinc-429, and CAN Bus Interface, to achieve optimal performance and compliance with industry standards.
• Oversaw the development process using the Microchip Microcontroller PIC16F877A, ensuring robust and reliable system design.
• Programming Language used: C

• PLC Programming.
• Designing, sizing and building an electrical switchboard BT.
• Machines Safety Design
• Developing Systems with remote Devices.
• Cadence OrCAD PCB Design