Gary Cantrell
Manufacturing & Electrical Project Planning
&
Estimating
Licensed Industrial Electrician
Helping industrial organizations improve reliability, reduce risk, and extend the life of critical electrical assets.
Manufacturing & Electrical Project Planning | Industrial Electrical Systems | Asset Modernization
With more than 20 years of experience in industrial electrical maintenance, controls, manufacturing project planning, and electrical project execution, I bring a field-based perspective to complex industrial projects and critical electrical infrastructure.My career has progressed from hands-on industrial electrical maintenance and controls into electrical maintenance planning, project planning and estimating, capital projects, reliability, asset lifecycle management, and equipment modernization. I work at the intersection of maintenance, engineering, operations, procurement, contractors, vendors, and manufacturing execution—turning technical requirements into practical, executable work.I currently support complex electrical infrastructure and industrial projects in aerospace aluminum manufacturing, developing project scopes, labor and material estimates, BOMs, procurement requirements, contractor and shop scopes, work packages, schedules, and execution plans from initial concept through installation, commissioning, and closeout.My experience also includes coordinating repair and fabrication work with in-house machining, welding, and fabrication operations, developing scopes of work, material requirements, labor estimates, schedules, and execution plans for equipment repairs, modifications, and fabrication. This gives me a practical understanding of how engineering requirements translate into real-world manufacturing and maintenance work.Electrical Modernization & ObsolescenceA major area of my expertise is industrial electrical obsolescence and Form-Fit-Function (FFF) replacement analysis. I evaluate aging and unsupported electrical equipment, research current-production replacements, determine compatibility and required modifications, and support procurement, installation, commissioning, and long-term lifecycle planning.This work extends across medium- and high-voltage power distribution, substations, switchgear, transformers, MCCs, VFDs, motor-generator systems, industrial controls, PLCs, HMIs, and other critical electrical equipment.I have also supported modernization of legacy industrial control systems, including DC crane controls and other critical material-handling equipment, where obsolete technology must be replaced while maintaining existing functionality, reliability, and operational requirements.Project Planning & ExecutionMy approach combines practical field experience with disciplined project planning. I understand what it takes to move a project from an initial problem or concept into a defined scope, estimate the resources required, coordinate the people and materials involved, execute the work safely, and return the equipment to service.My experience includes:Project Scoping → Estimating → Procurement → Contractor & Shop Coordination → Installation → Commissioning → CloseoutI specialize in projects where electrical knowledge, maintenance experience, manufacturing operations, and project execution all intersect.Building Better Lifecycle StrategiesBeyond individual projects, I focus on the larger questions that affect industrial assets over time:What is becoming obsolete? What should be replaced? What can be modernized? What will it cost? What resources are required? And how can the work be executed with the least operational risk?Whether the need involves manufacturing project planning and estimating, electrical infrastructure modernization, controls upgrades, repair and fabrication planning, critical electrical equipment replacement, outage planning, or long-term asset lifecycle strategy, I bring a practical, field-informed approach focused on safety, reliability, maintainability, and successful execution.Core Expertise: Manufacturing & Electrical Project Planning • Project Estimating • Industrial Electrical Systems • Controls & Automation • Electrical Obsolescence • Form-Fit-Function Replacement • Capital Projects • Repair & Fabrication Planning • Medium- & High-Voltage Power Systems • Electrical Reliability • Asset Lifecycle Management • Outage & Shutdown Planning • Technical Procurement • Contractor & Vendor Coordination • Commissioning & Startup
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Electrical Project Planning & Scope Development
Utility Power & Distribution: Scoping for outside power work — poles, feeders, and transformers.
Substations & High-Voltage: Planning upgrades, retrofits, and new installations.
Controls & Automation: PLC, HMI, and drive installation projects — from design to commissioning.
Facility Electrical: Lighting upgrades, new installations, and energy-efficiency projects.
Major Equipment Projects: Large-scale systems such as overhead DC cranes and other critical equipment upgrades.
Machine & Equipment Upgrades: Modernization and retrofitting of motors, generators, pumps, compressors, and other rotating machinery to improve reliability, efficiency, and lifespan.
Maintenance Planning & Reliability Programs: Develop preventive, predictive, and corrective maintenance strategies; optimize equipment availability and reduce unplanned downtime.
Develop accurate budgets, schedules, and risk assessments for projects of all sizes.
Prepare RFIs and funding requests to secure capital approval.
Create detailed execution plans that minimize downtime and maximize safety.
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Retrofit & Retrofill Solutions
Sourcing OEM-certified equipment from ABB, Eaton, Schneider, and other trusted suppliers.Upgrade obsolete breakers, MCC buckets, switchgear, and substations to extend system life.Ensure compliance with UL, NFPA, and other industry safety standards.Deliver cost-effective modernization solutions that avoid full replacement of critical assets.
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PLC & Automation Controls Upgrades
Design and implement PLC, HMI, and automation system upgrades.Integrate controls with existing systems for seamless operation.Support facility automation projects that improve operational efficiency and reliability.Troubleshoot and optimize control systems to minimize downtime.
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High-Voltage & Substation Projects
Upgrades and modernization of high-voltage distribution systems (5kV–15kV).Ensure safe installation and operation of substations and switchgear.Conduct system assessments to improve reliability and operational efficiency.Coordinate with engineers and contractors to meet compliance and safety standards.
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Full Lifecycle Project Execution
Owner’s representative from concept through commissioning.Manage contractors, vendors, and internal teams to deliver projects on schedule and budget.Oversee procurement, logistics, and material delivery to optimize workflow.Ensure successful project completion with minimal disruption to operations.
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Outage Planning & Reliability Optimization
Develop detailed outage schedules to minimize downtime.Coordinate across operations, maintenance, and reliability teams.Identify areas for reliability improvement and implement solutions.Balance production needs with safe execution of electrical projects.
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Manufacturing Repair, Machining & Fabrication PlanningTurning Maintenance Requirements Into Executable Shop Work
Repair & Modification Scoping — Define the work required to repair, modify, or restore industrial equipment and components.
Machining Requirements — Coordinate machining work such as shaft repairs, keyways, dimensional modifications, and other component work requiring lathes or CNC equipment.
Fabrication & Welding — Develop scopes and coordinate fabrication and welding work for equipment modifications, repairs, supports, structural components, and custom industrial solutions.**
Labor & Material Estimating — Develop estimates based on the required work, materials, shop resources, outside services, and execution requirements.
Shop Scheduling — Coordinate work with in-house machining, welding, and fabrication resources while balancing production, maintenance, outage, and equipment availability requirements.
Procurement & Materials — Identify material requirements and coordinate procurement of components, raw materials, replacement parts, and outside services.
Electrical Integration — Incorporate electrical, controls, instrumentation, and power requirements into broader mechanical repair and fabrication projects.
Execution Planning — Develop work packages, schedules, and execution plans that allow skilled trades to perform the work efficiently and safely.
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High-Voltage Rotating Equipment
(MG Sets & Large Motors)
Provide full-scope project planning and coordination for Motor-Generator (MG) sets, synchronous motors, and other high-voltage rotating equipment.Condition assessments & upgrade planning for aging MG sets.Retrofit and modernization projects to improve reliability and efficiency.Outage planning & contractor coordination for motor rewinds, alignment, and commissioning.Integration with power distribution systems and controls/automation upgrades.Safety compliance for high-voltage work (NFPA 70E, OSHA.
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DC Industrial Crane Systems & ControlsCritical Electrical Systems for Heavy Industrial Material Handling
Evaluating legacy DC crane control systems and identifying obsolete or unsupported componentsDeveloping Form-Fit-Function (FFF) replacement strategies for aging electrical and control equipmentSupporting PLC and HMI modernization projects
Developing project scopes, material requirements, BOMs, labor estimates, and execution plans
Coordinating electrical contractors, controls personnel, maintenance, engineering, and operations
Supporting equipment commissioning, startup, troubleshooting, and operational validationIdentifying required modifications when modern components cannot directly replace legacy equipment
Planning electrical work around production requirements and major shutdown windowsDeveloping long-term replacement strategies to reduce the risk associated with obsolete controls and drives
Project Planning & ExecutionCrane modernization and repair work often involves coordination across multiple disciplines and work groups. I have supported projects requiring electrical, controls, mechanical, fabrication, procurement, and operations coordination, with work planned around production schedules and planned outages.My planning responsibilities can include:Scope Development → Engineering & Technical Review → Cost & Material Estimating → Procurement → Contractor / Shop Coordination → Installation → Commissioning → CloseoutThis provides a direct connection between my field experience as an industrial electrician and my current role in electrical maintenance planning and project execution.Reliability in Critical Industrial ApplicationsIndustrial cranes operate in environments where electrical reliability is critical. A failure can stop production, delay major maintenance activities, or prevent the movement of equipment necessary to restore other systems.My experience with crane electrical systems therefore extends beyond troubleshooting individual failures. It includes identifying systemic reliability risks, addressing obsolete equipment, planning modernization projects, developing replacement strategies, and coordinating the work necessary to keep critical material-handling systems operational.
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Vendor Management & Procurement
Source and manage OEMs and specialty contractors.Ensure compliance with safety, quality, and project requirements.Negotiate and coordinate contracts to meet budget and timeline expectations.Serve as the single point of accountability for project delivery.
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Cross-Industry Expertise
Experienced in aluminum manufacturing, utilities, marine, and heavy industrial facilities.Ability to adapt solutions to each client’s unique operational and regulatory environment.Skilled in balancing technical, operational, and budgetary requirements.