Akshay — Automation Engineer

ControlLogix, Factory Talk View Machine Edition, Factory Talk View Site Edition., MicroLogix with software's RSLogix-5000, RSLogix-500. Migration of PLC5/SLC5 to ControlLogix / Compact logix along with HMI. Work experice with controllers like- 1756-L73, L33, 1756-L72, L340ER, etc. Have good experice in offshore development for Allen bradley / Rockwell - PLC, HMI and SCADA and remote / on site commissioning supprots.

Experience in offshore development and remote / on site commissioning support in multiple domains on siemens platform with controllers like- S7-317F, S7-1200, S7-300, S7-1500. S7-1500 with Software's SIMATIC Manager, Siemens: S7-300, TIA Portal.

Developed and comissioned chemical process skid HMI on Wonderware intouch

Having good experince for installtion and commissiong acroos globe in various domains like- Automotive, Manufacturing, Process industirs, Speciality chemicals, Wtaer tretments, etc

Abilities Strong expertise in PLC programming, debugging, and commissioning across Siemens (Simatic Manager, TIA Portal) and Rockwell Automation (ControlLogix, CompactLogix) platforms. Proficient in IEC 61131-3 languages including Ladder Logic, Function Block Diagram (FBD), Structured Text (ST), and STL. Ability to design modular, reusable PLC architectures using FBs, FCs, UDTs, AOIs, and instance data blocks for scalable multi-station systems. Experienced in machine-to-machine interlocks, safety interlocks, and collision-zone logic in automated manufacturing lines. Skilled in online modifications, force testing, and live troubleshooting in running production environments with minimal downtime. Strong understanding of industrial communication protocols (Profinet, Profibus, Ethernet/IP, Modbus, OPC UA) for seamless PLC-to-PLC and PLC-to-IT integration. Capable of implementing diagnostics, alarms, and fault-handling strategies to improve maintainability and reduce mean time to repair (MTTR). Adept at integrating PLC logic with robots, vision systems, drives, barcode/RFID systems, and field instruments. Experience in aligning PLC logic with MES, SCADA, and Industry 4.0 architectures, ensuring reliable data acquisition and traceability. Accomplishments Successfully developed and standardized PLC programs for multiple automotive and manufacturing stations, improving code reusability and reducing commissioning time. Led PLC modifications and optimizations across live production lines, resolving critical issues without impacting plant operations. Delivered complex interlock and handshake logic between PLCs, robots, and upstream/downstream equipment, eliminating collision risks and improving line stability. Played a key role in legacy PLC migration projects, modernizing Siemens and Rockwell platforms while maintaining operational continuity. Implemented diagnostic and fault-logging enhancements, enabling faster root cause analysis and improved maintenance response. Supported global manufacturing sites (USA and India) during commissioning, ramp-up, and post-go-live stabilization phases. Contributed to MES and digital manufacturing initiatives by ensuring PLC data accuracy and consistency for OEE, traceability, and performance analytics. Acted as a technical reference and mentor for junior engineers on PLC standards, best practices, and troubleshooting methodologies. Recognized for problem-solving under time-critical conditions, consistently closing open items and stabilizing production systems.

Abilities Extensive hands-on expertise in SCADA system design, configuration, deployment, and commissioning across automotive, manufacturing, water treatment, and process industries. Proficient in leading SCADA platforms including Ignition (Inductive Automation – Core Certified), Wonderware- Intouch, Siemens WinCC, and Rockwell FactoryTalk View. Strong capability in PLC–SCADA integration using Siemens S7, Rockwell ControlLogix/CompactLogix, and third-party devices. Skilled in SCADA architecture design for plant-level and enterprise-level deployments, including high availability, redundancy, and secure network segmentation. Expertise in real-time data acquisition, alarm management, historian integration. Advanced understanding of SCADA–MES integration, enabling traceability, production reporting, and performance monitoring. Ability to implement ISA-95 and ISA-88 aligned SCADA models for scalable and standardized system design. Experienced in IT/OT integration, including database connectivity (MS SQL), MQTT, OPC UA, and secure data exchange. Strong troubleshooting and optimization skills for live production environments with minimal downtime. Capable of translating customer requirements into functional SCADA designs, including HMI standards and usability best practices. Accomplishments Successfully designed and delivered SCADA solutions for global automotive and manufacturing clients including Stellantis, Cummins, Comau, Stryker, and SEDEMAC. Led development of Ignition-based SCADA applications integrated with PLCs, historians, and MES systems, improving operational visibility and decision-making. Delivered OEE and production monitoring SCADA applications, enabling real-time performance tracking and data-driven improvements. Implemented standardized HMI and SCADA templates, reducing engineering effort and improving consistency across multiple production lines. Played a key role in legacy SCADA system migration and modernization, enhancing system reliability, scalability, and cybersecurity posture. Integrated SCADA systems with Factory Magix MES for end-to-end traceability and production reporting. Supported presales and solution architecture activities by defining SCADA system scope, effort estimation, and technical proposals. Provided on-site and remote commissioning, FAT, and SAT support, ensuring smooth go-live with minimal production disruption. Acted as a technical lead and customer interface, resolving complex SCADA and integration issues in critical production environments. Contributed to Industry 4.0 initiatives, leveraging SCADA as the foundation for digital manufacturing and smart factory implementations

Responsibilities include, but are not limited to, •Driving digital transformation and Industry 4.0 initiatives by leading technical and pre-sales engagements and solution architecture for Industrial Automation, Smart Manufacturing, MES and IIoT implementations across automotive and discrete manufacturing sectors. •Technical Presales & Solution Consulting: Lead end-to-end presales cycle from opportunity qualification to proposal delivery, conduct discovery workshops to assess digital maturity and manufacturing pain points and architect solutions spanning Industrial Automation, MES, SCADA, IIoT platforms and cloud-based manufacturing analytics. •Industry 4.0 Solution Architecture: Design smart manufacturing ecosystems integrating MES, Digital Twin technologies and Real-Time Production Monitoring aligned with ISA-95/ISA-88 standards. •Automotive Manufacturing Expertise: Deliver specialized solutions for automotive Tier-1/ Tier-2 (Line Builders) addressing compliance (STLA CS, FCA US MECR, VASS V6, IEC 61131-3), traceability, Andon systems and cycle time optimization. •Customer Engagement & Value Selling: Collaborate with C-suite, Plant Managers and IT Directors to articulate business value of digital manufacturing initiatives, translating technical capabilities into outcomes such as reduced downtime, improved OEE, enhanced supply chain visibility and regulatory compliance. •RFP/RFI Management & Proposal Development: Drive responses to complex RFPs/RFIs, working with sales, product and delivery teams to create architectures, effort estimates and implementation roadmaps (FRS/FDS). •Partnership & Ecosystem Development: Work with PLC OEMs (Siemens, Rockwell, Schneider) and cloud providers to deliver integrated end-to-end manufacturing intelligence solutions. •Post-Sales Technical Support: Provide technical impact to delivery teams during implementation, support escalations and ensure customer success through solution optimization and enhancement roadmaps.

Responsibilities include, but are not limited to, •Leading high-performing project teams to deliver enterprise-level MES solutions, driving digital transformation initiatives across manufacturing operations while ensuring seamless integration with existing automation infrastructure. I collaborate closely with cross-functional teams to transform customer needs into scalable, high-performance industrial automation and MES solutions. •Project Leadership & Delivery: Lead project teams through the complete lifecycle from engineering design to commissioning and final handover; ensuring on-time, within-scope and within-budget delivery. •Technical Design & Coordination: Oversee and guide the technical design process, fostering collaboration among multidisciplinary engineering teams to achieve seamless solution integration. •Client Engagement & Requirements Analysis: Conduct technical consultations with clients to understand operational needs, translate them into detailed functional specifications and ensure alignment with project objectives. •Project Planning & Change Management: Manage project timelines, resource allocation and change control processes while maintaining comprehensive project documentation. •Quality Assurance & Compliance: Ensure adherence to design standards, testing protocols and delivery quality benchmarks for all MES and automation deliverables

I lead end-to-end project execution from engineering and design to commissioning and handover ensuring technical excellence, timely delivery and customer satisfaction. Key Responsibilities: 1. Manage overall project lifecycle, including planning, design, execution and handover. 2. Coordinate technical design reviews and ensure alignment with engineering standards and customer requirements. 3. Conduct technical discussions to interpret and implement customer inputs effectively. 4. Analyse P&IDs, control philosophies and process documentation to design automation solutions. 5. Develop and test PLC logic and SCADA/HMI applications in line with project specifications. 6. Handle project scheduling, scope management and resource coordination. 7. Lead Factory Acceptance Tests (FAT), on-site commissioning and system handover activities.