Installation engineers, like me, experience life in a very unique way.
We’re often away from our homes and families for four to six weeks at a time. We can find it a challenge to establish real roots and stable relationships. And only the most resilient of us tend to make it past the first few months (let alone the first few years).
But I love it. And there are many reasons why I do.
I’m Kevin.
I’m an experienced lead engineer, proudly working at IES since March 2021.
I never quite know where my job will take me. But here’s what a typical job looks like as an installation engineer working closely with high-technology equipment, along with the challenges I face on a daily basis.
Travelling Heavy
I live in Arizona in the US. But most of the work I do is in Europe.
So, if a job starts on a Monday in Germany, then I leave on the Saturday before.
Although each job is typically scheduled for around four weeks, I’ve found that anything can happen. And I’ve learned from experience to pack enough clothes, power adapters, cables, assembly books, and necessities for a six-week stay.
There really is no such thing as travelling light when you’re an installation engineer.
That can make it tough to keep my bag under the airline weight limit (those pesky overweight bag charges!) but sometimes it just can’t be helped. Between my luggage, laptop bag and backpack, I’m toting 130-150 lbs (59-68 kg) around the world. You really should see me!
Lessons Learned the Hard Way
Carrying tools is probably the most challenging thing about travelling.
They’re heavy (bad for bag weight limits and my back) and need to be kept in a durable travel-type toolbox. Tools like precision measuring equipment need extra protection, as they’re particularly sensitive to impacts and vibrations. And between rolling on gravel and cobblestone streets, and being thrown around as checked baggage, engineer toolboxes take a serious beating.
The logistics of bringing tools and other items on flights and through security can also be really complicated.
For example, you can’t put rechargeable batteries in your checked luggage because of fire safety concerns, so you must bring them in your carry-on. On the flip side, you’re not allowed to bring electric drills, hand tools longer than seven inches and anything used to cut or poke in your hand luggage, so you must stow them in your checked bags.
Those rules also vary by region. And you can get caught out if you’re not careful.
I remember after one particular job I found a great deal on cobalt drill bits and a 12-inch carpenter level.
My bags were packed, and common sense said neither of those tools would be a security threat. So, I brought them in my carry-on bag. Boy, was that the wrong decision.
Both set off the security alarms. And although I debated with the officer (and then the security chief) that a pen from my laptop bag would pose a bigger threat than a four-inch drill bit or a 12-inch plastic level, they decided to confiscate them anyway.
While, on another trip, I was allowed to fly from the USA to Taiwan to Europe with a 20,000 mAh power bank in my carry-on. Only for it to be confiscated in Turkey for being above the regulated mAh.
So it goes. Even questionable lessons can be learned the hard way.
Settling In
Travelling from Arizona to my European destination will typically take around 17 hours. But I lose another eight or nine hours just from switching from Mountain Standard Time to Central European Time.
That means between getting to the airport, navigating connecting flights, and hiring cars, I arrive at my hotel around 20–30 hours after I leave my house, which can be tough.
If all has gone well with my travel and the fab coordination, we start the project on time.
Some fabs are massive. That means it can take 20 to 30 minutes to walk from the car to the dressing area—with a further 20 to 30 minutes to get suited up and walk to the work area.
The first day involves badging and onboarding. I start by checking crates and assessing the floor and pathway for readiness.
If I can, I’ll get ahead of the game by laying mylar and marking the floor for module placement. That involves verifying the datum point with the local field service engineer (FSE), as well as the engineer responsible for automated material handling system (AMHS) alignment.
I’ll then spend lunchtime with the local FSE at the in-house cantina, and have a quick meeting with them at the end of the day to discuss progress and report to our manager and tool vendor.
Evenings are important for our team's integrity. It’s where we can unwind and talk about our days, our previous experiences and just spend time generally bonding and getting to know each other.
We might even get cleaned up and head out for dinner, before getting some rest.
Facing Challenges on the Go
When installing complex, high-technology tools, you need to be able to manage your time effectively.
Some engineers prefer to pace themselves and play catchup at the end—but that can really push the schedule when inevitable delays occur. Me? I prefer to start heavy to create a buffer on time, so I can then pace myself until the end. But everyone manages their time differently.
No job comes without its fair share of challenges. But they can be a lot of fun to solve.
For example, at one job, we weren’t allowed to bring a painted two-meter prybar into the fab to shift a nine-ton module 30 centimetres to the mark. We were, however, allowed a nickel-coated, 60-centimetre crowbar.
So, we improvised.
Using blocks, we controlled the leverage and walked the module one or two millimetres at a time to the mark. That took a lot more time to complete, of course. But it worked.
A more common problem is floor variation.
Most of the time, large modules sit on floor deviations that cause alignment issues with the enclosure trusses, doors or roof components. That means we have to use precision lasers, plumbs and transit optical tools to align the modules.
These types of challenges come up a lot, and we have to adapt to overcome them on the fly. But solving them is part of what keeps the job fresh and new.
Ready to Head Home
You never know if a job is going to run long or end early until the last few days.
If tasks become problematic, the last few days run long.
But if all goes well, the last day involves tool cleanup and inspection with the FSE and a fab representative. Essentially, it’s a day to verify the accuracy of the work and note any inherent issues with the tool, fab, floor or other.
We finish by cleaning the area, wiping down the tool and reorganising our kits for our next trip.
I say goodbye to my teammates and new-found friends, ready to see my family and friends at home once again.
Making the Impossible, Possible
Life as a travelling engineer involves being able to adapt to any unexpected challenges that come your way. Being able to communicate tactfully and meaningfully through different cultural norms and languages. And being able to manage physical logistics in fabs with different rules and regulations.
We’re the navigators of unknown places and faces. We must transcend language barriers and find comfort in revolving hotels. We feel proud of the work we do and the teams we’re a part of, however fleetingly.
And we make the impossible, possible.
- Kevin Shockency, an installation engineer abroad
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