Sanketkumar — Controls Engineer

KEPEX/RS LINX

Rockwell Products- PLC/HMI/DRIVES/SERVO ETC.

Saftey Devices/Safety PLC

ROBOT

PLC/HMI

PLC/HMI

SQL Data Base Configuration/Script Writing/Config with PLC/DATA Transaction to PLC

Weld Controller and Weld Robot

Automated Welding Process

Debug/troubleshooting/Continous Improvement/Throughput Improvement/Process Optimization/ Minimizing Downtime

Automated

As a Controls Engineer Program and support PLC-based automation systems for vehicle assembly at build shop and on-site operations, focusing on system power-on, Integration and real-time production troubleshooting. Collaborate with cross-functional teams to ensure reliable equipment performance from initial debug through launch support on the plant floor. Serving as a subcontractor PLC Programmer at General Motors, specializing in the installation, commissioning, and integration of complex automation equipment in high-volume automotive manufacturing environments. Executed PLC programming, commissioning, and integration of Body Shop automation systems at GM Oshawa LA and LC Zones, consistently meeting project milestones within scheduled timelines both in the build shop and on-site. Managing milestone progression through G-Comply tags: Performing power-on and initial system start-up validation, verify equipment build standards based on Power on checklist, GCCB checklist at build shop and at plant floor. SCS verification, Support MPS validation, Debug try-out mode, and Complete 4-hour dry cycle runs to verify throughput, motion accuracy, and system stability. Finalized buy-off book documentation and checklists to confirm production readiness and system compliance. (G comply: RED tag/Yellow tag/Green Tag) Utilized detailed checklists (Power-On, GCCB, GCCS, SAT SCS, NAX) for systematic verification and quality assurance across build shops and on-site environments. Proactively identified and resolved integration issues, enabling on-time project completion and achieving key milestones without delays. Ensure precise integration, conduct rigorous validation, and provide technical production support to troubleshoot and optimize control systems, minimizing downtime and enhancing process reliability. Responsible for developing, modifying, and debugging PLC programs to control and coordinate robotics, conveyors, motion systems, vision systems, and safety devices. Power-on activities, I/O verification, and system bring-up, ensuring seamless communication between electrical and mechanical components. Collaborate closely with cross-functional teams to support production launch, resolve field issues, and fine-tune system logic for cycle time optimization, fault recovery, and operational stability. Proficient in interpreting electrical schematics, troubleshooting on the plant floor, and delivering robust, production-ready automation solutions aligned with GM's manufacturing standards. Provide on-site production support to quickly resolve downtime issues, optimize control logic, and ensure consistent throughput. Work alongside maintenance and engineering teams to monitor system performance and implement long-term corrective actions.

As a Controls Systems Engineer operating as an Individual contributor with recognized expertise, tasked with responsibilities throughout the entire vehicle development lifecycle, including requirements definition, systems design and implementation, testing, and problem resolution. Supporting Commissioning and integration Activities during Battery Plant Launch PLC programming Debugging on newly installed Automation equipment Worked on AGC in RESS Shop (Pack main line), debugging during integration for improving cycle times. Debugging Cart Tools Programming, Setup and worked on System Automation Manager (SAM Server), KEPserverEx6 setup, and troubleshooting, Debug AGC PLC for destination setup, decision setup and path configuration. AGC Troubleshooting during Production support, worked with AGC Software, AGC PLC's and OPC server for data transfer. Performed activities like AGC Destination setup, AGV traffic control software debugging, AGV Field shape implementation etc. Set up and implement AGC's, AGC path improvisation, modifying and debugging AGC programming as needed. Attended Daifuku AGC Training at Daifuku build Shop. Worked on Throughput improvement projects in GA and RESS shop. TIP work with cross functional team to meet the production target, executed given task and TIP project in timely manners. Supporting and monitoring G-comply Activities for Operation Readiness Verifying and supporting Buy-off Activities like NAX, GCCS, SAT, SCS, GCCB, and power-on Checklist. Working with Contractors/Third party suppliers/Vendors to achieve desired goal on timely manner Following upon the status of Equipment build/ Commissioning/integration to achieve SORP timeline. Participating in N build/ Tag status/ Type study / Error proofing and Operation Readiness check off. Develop and document prerequisites are essential for constructing an automotive system design. Plan and oversee critical interfaces within systems to facilitate component reusability and ensure adherence to standard methodologies for consistency. Supervise requirement development alongside other project activities. Offer assistance to specialists in conducting root cause analyses. Exhibit expertise in accurately capturing and analyzing empirical data. Create testing methodologies to effectively pinpoint areas for design enhancement. Keep abreast of emerging industry trends, technologies, and best practices. Identify and document potential weaknesses within systems, devising action plans for mitigation and monitoring corrective measures.

As a member of an initiative-taking, dynamic, multidisciplined team, design and develop world-class automation solutions. Duties involve contributing to machine concepts, design of control software, integration of software with electrical and mechanical systems, process development, and machine installation at customer sites worldwide. Programming and integration assignments involve leading-edge technologies and processes utilizing PLCs, PCs, robotics, motion controllers, vision systems, laser, and other controllers. Design and Develop Safety standard Code from Industrial safety standard and robotics safety standard ISO 10281-1 & 2, designing control safety programming with different PLC'S like SICK Safety, Rockwell AB. Design and develop software programs (PLC and/or PC based) specific to customer and project requirements based on standard ATS programming methods. Debug and commission control systems at our facility, during the system integration stage and then at the customer's site during installation. Travel as required to customer and supplier sites to perform installation, commissioning, and training duties. Select, evaluate, and integrate hardware and software components such as robots, analog devices, motion controllers, sensors, vision systems and lasers. Collaborate with other members of the control systems design department and other groups to continuously improve methods of integrating controls technology, with the goals being enhanced safety, enhanced functionality, and reduced cost. Collaborate with other members of the control systems design department and other groups to ensure that labor and material budgets as well as scheduled delivery dates are adhered to or improved upon. Collaborate with customers, project managers, designers, toolmakers, and electricians to solve problems to provide the customer with a complete, functional automation system.

Commissioning: Manage priorities and support commissioning Activities like Programming, teaching servo and Robots, Panel Wiring, obtaining Accuracy and Effective cycle time with Maintaining standard Quality, Developing, and documenting SOP for new Cell or Updated weld cell. Preventive Maintenance: Planning PM Checklist as per the requirement of equipment, Implementing PM Schedule, Activities for New Equipment's, Documentation of training procedure of PM, inventory of equipment etc. Project Management: Enhance maintenance project tracking, manage maintenance project % and KPI's, documenting daily progress report, managing Cell PFS, Documenting Projected timeline, manpower, cost, location for new installation of robots, Automation System, Designing new weld cell. Maintaining and working on Project management tools like to do list, collaboration, Detail Reporting, Time tracking. Review Customer Requirements and Performing Project commissioning through designing, testing, installation, trail, and launch. Manage and provide direction to multiple contractor (AUTOMATION) to closure of PFS. Working with Production specialist to prioritize task and PFS item closure, Developing Automation Scope for cost and higher production i.e., Andon Project, Machine escalation concept, Data collection for records. Addressing Varied issue Related to H&S like Ergonomics, Hazards, and safety Concern. For Resolving it, Develop and modify Standard Work Procedure, Implement Ergonomics Management, and techniques. New Installation and implementation: Install and test performance of robotic system and other mechanical automation equipment, perform engineering change point if needed, Camera (vision system) implementing, modifying weld schedule as per quality standard. Designing and programming weld assembly lines, designing robotics cell for weld operation. Develop and modify robotics weld cell design, configuration, and programming. Robotics and Vision system Programming: Modifying and creating New Programming methods for Assembly operation, Robot Programming from scratch, Programming Cognex (Insight explorer), Keyence (IV-Navigator), Practices Robotics maintenance for component replacement, engaging supplier for complex problems of Robotic. PLC&HMI Programming and troubleshooting: Developing new Programs for Automation control, troubleshooting logics for line break-down, Programming Data collection and Automation scope, Configuring Communications, I/O Cards, Analog Card etc. Creating and modifying SCADA programming, DATA acquisition and logging. Developing new Programming technique i.e., De-bounce, Sequence Programming with MITSUBISHI GX, Omron CX. Designing New HMI for new cell, Updating HMI, I/O wire commissioning of HMI, Modification of HMI Design, and programming, Adding, or updating new Faults for Safety and Quality perspective (MITSUBISHI, OMRON) Creating Documentation for Perform Cell start up, running and electrode/tip change at certain intervals and lockout/tag out on varied location over WELD ASSEMBLY CELL, Managing Quality Revision Logs. Practice tooling changeovers, robotic programs, EOAT, electrical modifications, and Implementing Kaizen (INDUSTRIAL APPLICATIONS) to enhancement of Quality, Cost Reduction and Cycle time.

Technical Leading: Train and supervise a team of internship field technicians, responding to inquiries, assigning tasks, and resolving conflicts. Lead role in Automation line start-ups, monitor machine performance. Prepared Training Programs for Fanuc LRmate200IC and ABB IRC5 Controller and PLC Troubleshooting and Programming. Project Management: Performed Project Lunch implementation i.e., Final Buy-off (Run-time) Equipment for weld assembly, Installment, Testing, Commissioning, and scheduling i.e., guideline and time function, minute of meetings, QPR meeting, Calculating Budget function with MRO Purchase team etc. Design and developing Automation control system and participated in F.M.E.A(Design and process), perform Kaizen Activities to Reduce cost, cycle time and enhancement of Quality Standards and Logistics requirement, coordinating projects from awarding through completion. Responsible for monitoring schedule and activities to achieve project success. Manage Maintenance projects (CapEx), leading a cross-functional team to identify & mitigate risk, ensuring attainment of Project. Production Engineering: Examine on-site Control system and equipment, recognizing ideal faults in machines and perform root-cause analysis to maintaining equipment, collaborating maintenance team for PM Implementation. Deploy, maintain, and continually improve site CMMS to ensure timely completion of all scheduled PM's & MWO's, optimize spare parts inventory, and leverage data/analytics to systematically reduce maintenance costs & downtime, Responsible for Equipment Manufacturing by executing 3D DAP, BOM study, Buyoff & Shipping follow-up. Hydraulic and Pneumatic: Read and prepared blueprints and schematic drawing to determine work procedures and equipment functions, list out and suggest new equipment changeover for long life cycle. VBA Programming, EXCEL-PLC communication via OPC Server, Excel Macros, Writing SQL Query when required. PLC Programming: Developing the AB-PLC (RS LOGIX5000) programming using sequence, FBD, ladder logic. Robot Programming and Servo: A hands-on experience of Programming and teaching the Denso, ABB, and Fanuc robot to pick and place operation of assembled parts, Simulating and designing work cell, Implementing New Robots, Vision system, Modifying EOAT, payload for higher Robot accuracy.