Bob O’Brien: Legacy Automation Expert in Wood Products
At Concept Systems, Principal Engineers represent the highest level of technical leadership in our organization. More than senior project contributors, they are trusted advisors, system integrators, and mentors whose work impacts not just one project but the direction of our company. From developing robust safety systems to integrating large-scale motion control platforms, they bring a rare combination of experience, innovation, and cross-disciplinary expertise.
In this spotlight, we’re proud to introduce Bob O’Brien, whose contributions have shaped some of our most complex projects and inspired the next generation of engineers at Concept Systems.
Engineering Excellence Rooted in Wood Products
Bob O’Brien graduated from Portland State University in 1983 with a degree in Electrical Engineering, where he first learned to wire circuit boards. He joined Concept Systems in the summer of 2003, following a successful engineering career in wood products and food manufacturing, both industries that later became valuable to Concept thanks in part to Bob’s early connections. Over the past two decades, Bob has contributed to more than 500 projects — from quick service visits to full-scale engineering efforts requiring months of planning, execution, and integration.
According to company founder Michael Gurney, “Bob is extremely intelligent and has a depth of experience that is difficult to match.” His early background in wood products automation laid the foundation for much of his technical philosophy. Automating lumber mills — where raw material is massive, irregular, and unpredictable — demands a deep understanding of automation limits. As Michael put it, “When you build a resume on wood products, you develop a good sense for the limits of automation, and it gives you perspective when looking at automation challenges in other industries.”
Bob’s early expertise with Allen-Bradley control systems made him a go-to engineer for regional lumber mills automating high-speed stackers, headrig controls, and large retrofit projects. His work has included upgrading systems from ControlLogix to RSView32 (and today, leading FactoryTalk View conversions of those same systems), supporting long-time customers like Weyerhaeuser, USNR, and Collins Pine. Many of these mills still rely on Bob to maintain and modernize equipment he installed nearly 20 years ago.
As the wood products sector evolved, so did Bob. Today, he is known for retrofitting aerospace hangars and equipment throughout the Seattle region and continuing to push the envelope of controls engineering while staying close to the rugged landscapes that have always shaped his career.
One of Bob’s most memorable roles has been on the greenfield food & beverage projects based in the PNW, where the sheer scale and energy of the site created a unique kind of excitement.
“It’s like being a kid in a playground,” he said. “You work two weeks straight, 12 hours a day, running around like a maniac solving problems. You don’t even realize you’ve been running on adrenaline until you get home and just melt.”
These projects offered the kind of hands-on, field-intensive problem solving Bob thrives on full of movement, climbing staircases to check instrumentation, and troubleshooting in real time.
Mentorship, Mountains, and a Mind for Balance
Bob brings the same tenacity to mentorship as he does to engineering. Inside the office, he is a steadfast resource to junior engineers, helping them develop clarity in their problem-solving and confidence in their technical decision-making.
One junior engineer reflected:
My first impression of Bob when I joined Concept was that he was incredibly blunt and would tell a situation exactly like it is to prevent any type of misconception. He is incredibly passionate about his work and what he has accomplished. As one of my main mentors, it was incredibly useful to know exactly what Bob is thinking, and it helped me interpret him better as we had more conversations.
You can learn a lot just by listening to him and as my skills and experience keep advancing, I find myself seeking out these conversations now that I can translate what he is saying (sorta). His teaching approach is themed around getting things done in a timely and efficient manner.”
Bob’s passion for programming is one of the reasons his mentorship resonates so strongly.
“I love programming because when I make a mistake, all I have to do is change the code,” he explained. “When a mechanical engineer makes a mistake, they’ve got to order parts, wait two weeks, and live with the burn marks for 20 years. I just tweak the program, and no one ever knows the difference.”
It’s that kind of adaptability and perspective that defines how Bob approaches engineering with speed, efficiency, and a deep understanding of the systems he’s working with.
Outside of the office, Bob is just as driven. Whether hiking with his dogs, taking his kids on mountain adventures, or exploring the forests near remote mill sites, he always finds ways to blend work, nature, and curiosity.
A colleague recalls a visit to a facility in Colville, Washington. Bob glanced at a distant hill and offhandedly said, “I need to climb that.” After a long day and night of startup work, the team reunited the next morning — only for Bob to casually mention, “You should’ve come. The views were incredible.” He had climbed it at sunrise.
A few summers ago, Bob also led a full moon hike in the Willamette Valley, guiding a small group of teammates to a ridge overlooking Three Finger Jack and the Three Sisters. It was an experience talked about long after — another example of Bob’s knack for blending adventure, camaraderie, and appreciation for the outdoors.
A Steady Force in an Evolving Industry
Bob O’Brien exemplifies what it means to be a Principal Engineer at Concept Systems. With a career rooted in the rugged challenges of wood products automation and evolving into cutting-edge work in aerospace, he brings depth, adaptability, and clarity to every project he touches. His approach blends technical expertise with hard-earned perspective built over decades in the field and countless conversations mentoring the next generation.
Whether scaling a hillside at sunrise, navigating a complex retrofit, or guiding a young engineer through a tricky controls issue, Bob brings the same steady mindset: get it done, do it right, and enjoy the process along the way. His presence continues to shape the way Concept Systems delivers engineering solutions — grounded, resourceful, and built to last.
Core Competencies
Technical Expertise
- PLC programming
- HMI configuration
- Motion control systems
- Machine vision & 3D laser scanning
- PC-based & custom programming
- Control panel design, testing, & QC
- Safety system integration
Project Capabilities
- Field installation & commissioning
- Troubleshooting & wiring diagnostics
- Customer training & support
- Proposal estimation & technical research
- Project leadership & multi-discipline coordination
- Mentorship of junior engineers
Industry Experience
- Extensive background in wood products automation
- Hot mill controls & metal processing systems
- Aerospace facility retrofits
- Food manufacturing (including Greenfield startups)
Application Experience
High-Speed Lumber Stacker
Bob served as the lead controls engineer on a high-speed lumber stacker project that pushed both motion performance and system reliability. He designed the entire Allen-Bradley ControlLogix-based control system, which included seven motion axes, ranging from hydraulic cylinders with Temposonic SSI probes to full vector PowerFlex 700 drives with encoder feedback. Under Bob’s leadership, the system consistently achieved stacking speeds of 24 tiers per minute, meeting the mill’s high throughput demands with precision and control.
Particle Board Press Controls Upgrade
In one of his more technically demanding retrofits, Bob reengineered a legacy TI555 discrete PLC system into a fully analog control system with continuously variable hydraulic pressure and volume control. He integrated Bulletin 150 SMC-Flex soft starters and Temposonic probes onto a Profibus network and performed a major HMI upgrade to Wonderware. Bob also implemented a Delta RMC100 controller for precise press loader and unloader motion — utilizing the Delta Compact Profibus protocol for seamless integration. His work not only modernized the line but also set the foundation for improved press performance and operator usability.
Battery Gigafactory Startup
Bob was selected as part of a four-person senior engineering team to support the commissioning and startup of a high-volume battery production line at a U.S.-based gigafactory. He worked alongside multiple integrators and internal teams to bring A-B ControlLogix PLCs, Kinetix 5700 Servo Motion Controllers, and an Ignition-based HMI online. In addition to startup support, Bob played a key role in troubleshooting field anomalies, validating wiring, and improving system performance — applying his hands-on approach and fast problem-solving skills to help get the line running efficiently under tight timelines.
Have an automation challenge? Let’s solve it.
The project stories and technical insight shared here are just a glimpse into the depth of talent behind Concept Systems. From retrofitting legacy systems to leading large-scale automation design, our Principal Engineers, like Bob, bring decades of experience, practical problem-solving, and cross-industry expertise to every solution.
Whether you’re modernizing outdated equipment, launching a new facility, or tackling a tricky integration, our team is ready to engineer a solution that works.
Contact us to start the conversation.