Riccardo — Senior Controls Engineer / Automation Consultant

Forensic troubleshooting, legacy debugging, and retrofitting of obsolete PLC-5 (e.g., PLC-5/11) and SLC 500 systems. Reverse engineering from 1990s electrical schematics, modern 24VDC sensor integration, and complete logic migrations to modern Logix platforms.

Complete lifecycle programming and maintenance on Step 7 Classic, S7-300, and S7-400 systems. Fast-track conversion and code migration from Step 7 to TIA Portal, PROFIBUS DP network troubleshooting, and hardware consolidation.

Advanced programming and commissioning in Studio 5000 / RSLogix 5000. Modular software architecture, GuardLogix CIP Safety integration, EtherNet/IP distributed I/O, Kinetix servo drives, and FactoryTalk View HMI.

Architecture design and execution in TIA Portal for S7-1500, S7-1500F, and ET 200SP controllers. PROFIsafe functional safety, PROFINET IRT, inter-CPU communication via PN/PN Coupler, WinCC Unified, and complex recipe management.

Multi-axis servo motion control via SINAMICS S120, CU320-2 Control Units, and Startdrive. Implementation of Telegram 105 with DSC (Dynamic Servo Control), Safety Integrated Extended functions (SLS, SDI), One-Button Tuning, and frequency resonance filtering via Bode plots.

Remote rescue commissioning and forensic debugging of complex multi-CPU Mitsubishi plants. Real-time code restructuring, PID loop stabilization, and automatic sequence optimization on poorly documented legacy machines.

Controls engineering and plant startup on Omron architectures for food processing and material handling. Autonomous reverse engineering of custom proprietary logic and on-site commissioning

PLC-to-Robot Profinet handshake, spatial synchronization between linear track external 7th axes and robot controllers, gripper tool-change logic, and multi-pallet cell automation.

Senior specialist in industrial predictive and corrective maintenance with nearly 40 years of plant-floor experience. Deep expertise in deep forensic troubleshooting, resolving chronic electrical and software faults, diagnosing legacy PLC hardware failures, and restoring stalled production assets to maximum operational capacity under critical emergency conditions.

Extensive field competence in automated hydraulic power unit (HPU) control, proportional valve interfacing, and fluid-power process tuning. Demonstrated success engineering sequential control for high/low pressure spindle strokes, tooling expansion systems, column clamping, and heavy machine bed movements.

Integration, calibration, and signal conditioning for diverse field instrumentation. Experienced in scaling and diagnosing analog loops, pressure transducers, PT100/RTD temperature probes, draw-wire absolute encoders, and digital safety devices.

Execution of rigorous dynamic testing, I/O verification, and pre-commissioning validation across complex manufacturing lines. Experienced in functional safety circuit checks, safety matrix verification, emergency stop chain validation, and customer buy-off procedures adhering to strict industry standards.

Hands-on electrical troubleshooting and hardware diagnostics in industrial control panels and machine wiring. Competent in power distribution, 24VDC control circuits, sensor retrofits, remote I/O drop installations, and isolating field noise or grounding issues on legacy industrial equipment.

In-depth field commissioning, software service, and retrofitting of multi-station rotary transfer machines and automated CNC-style working cells (e.g., Mikron, Dormakaba). Proven competence coordinating synchronized multi-axis servo positioning, feed rate regulation, and mechanical sequence interlocks on complex metalworking machinery.

Worldwide on-site commissioning lead with full autonomy in multi-brand industrial plants. Specialization in fast-track plant startups, dynamic multi-axis servo tuning (Siemens SINAMICS S120 via Startdrive, Telegram 105, DSC), safety validation, and line buy-offs under strict shutdown windows across North America, Europe, and Asia. Holder of an active USA B1 Visa for immediate US deployment

Nearly 40 years of full lifecycle PLC programming and architecture design across Rockwell Automation (Studio 5000, RSLogix 500/5, legacy PLC-5), Siemens (TIA Portal v13 to v20, Step 7 Classic), Mitsubishi, and Omron. Demonstrated success executing mission-critical legacy migrations, multi-CPU synchronizations, and implementing modular ISA-88/ISA-95 compliant code for high-throughput automotive and industrial lines.

Forensic troubleshooting specialist called in to resolve chronic software instabilities, systemic motion faults, and thermal process bottlenecks where previous technical teams failed. Proven track record executing live code rescue updates remotely via VPN on multi-CPU drying plants in the US and stabilizing legacy transfer lines on-site.

Advanced control of complex thermal and motion processes, including closed-loop PID regulation, synchronized dosing/casting systems, and high-precision hydraulic power unit control (proportional valves, spindle stroke, and high/low pressure regulation). Experienced in integrating analog sensor loops and field devices under harsh manufacturing environments.

Integration and synchronization of industrial robotics with PLC masters over PROFINET. Extensive experience interfacing ABB OmniCore/IRC5 controllers with linear 7th-axis slide mechanisms, automating multi-station material handling, tool/gripper changing, and high-precision automotive part manipulation. Certified in Universal Robots cobot programming and Robotize GoPal AMR integration.

Design and deployment of supervisory control and data acquisition architectures, including Siemens WinCC Unified, WinCC Professional, and Rockwell FactoryTalk View. Deep IT/OT expertise bridging shop-floor automation with enterprise networks, Level 2 tracking systems, recipe management databases (up to 200 recipes), and virtualization via VMware.

Forensic electrical schematic analysis and reverse engineering from legacy paper drawings dating back to the late 1980s and 1990s. Successfully reconstructed functional machine sequences and modernized I/O networks to integrate new 24VDC sensor architectures into legacy machinery without original CAD or source code.

Controls engineering for high-speed automated automotive assembly lines, robotic joining cells, and leak-test stations (e.g., Ford engine assembly, Webasto roof systems, MAN Truck assembly lines).

Worldwide commissioning lead on mission-critical industrial manufacturing lines across North America, Europe, and Asia. Full lifecycle execution: I/O check, bus communication validation (PROFINET IRT, EtherNet/IP), multi-axis dynamic servo tuning, safety zone verification, and line buy-off under tight shutdown constraints. Holder of an active USA B1 Visa for immediate US deployment.

Full turnkey software development for PLC, HMI, and SCADA architectures based on ISA-88 and ISA-95 standards. Senior development authority in Siemens TIA Portal (v13 to v20), Rockwell Studio 5000, Mitsubishi, and Omron, delivering clean, structured, and modular control code

Design and programming of intuitive plant-floor operator interfaces. Extensive implementation of Siemens WinCC Unified (MTP panels), WinCC Comfort/Advanced, and Rockwell FactoryTalk View (ME/SE), including multi-language support, real-time I/O diagnostics, and large recipe databases (up to 200 recipes).

Turnkey cell integration connecting PLC master controllers with industrial robotics (ABB OmniCore / IRC5 over PROFINET), external 7th-axis linear tracks, automated tooling change systems, remote I/O islands, and enterprise Level 2/MES networks

Automation, controls revamping, and commissioning for rotary transfer machines, high-precision machining centers, and lapping/grinding equipment. Experienced in synchronizing spindle drives, automated clamping, tool feed mechanisms, and hydraulic sequence interlocks.

Multi-axis motion control configuration, tuning, and optimization. Deep expertise with Siemens SINAMICS S120 (CU320-2, Startdrive, Telegram 105 with DSC, One-Button Tuning, Bode plot frequency analysis) and Rockwell Kinetix / PowerFlex drive systems.

Forensic-level troubleshooting on chronic, unresolved system faults and software race conditions where previous teams failed. Proven record rescuing stalled legacy rotary transfer machines on-site in the US (Rockwell PLC-5) and executing live code stabilization remotely via VPN on multi-CPU drying plants.

Direct software engineering partner for the Omega 3 automated cell. Developed and configured 9 SINAMICS S120 servo axes across two CU320-2 units in TIA Portal v20 using Telegram 105 with DSC, dynamic One-Button Tuning, and technological objects (TO) on a Siemens 1516TF-3 PN CPU. Integrated PROFINET handshakes with two ABB OmniCore V250XT robots (linear 7th-axis slide coordination, gripper changes, 12-pallet handling), multi-station thermoregulation, and PN/PN Coupler inter-CPU data exchange.

Executed complete software revamping of a complex lapping machine for end-user Copromec, replacing an obsolete 1989 proprietary German PLC and custom HMI. Reconstructed process logic via reverse engineering from legacy paper electrical and hydraulic schematics. Implemented full sequential control on Siemens ET 200SP (CPU 1510SP F-1 PN), Sinamics G120C drive, proportional hydraulic valves (spindle stroke, tooling expansion), and designed modern WinCC Unified (MTP1000) HMI.

Executed a critical remote rescue commissioning for a multi-CPU Mitsubishi drying plant operating in the USA. Stabilized systemic software faults and timing race conditions via high-latency VPN after previous teams failed. Forensically debugged multi-CPU synchronization, resolved a severe closed-loop PID thermal regulation bug, and re-engineered automatic cycles to achieve client buy-off without plant shutdowns.

Owner and principal software consultant managing high-CAPEX automation, commissioning, and legacy revamping projects worldwide. Direct accountability from initial architectural design and reverse engineering to on-site commissioning and line handover. Senior authority across Rockwell Automation (Studio 5000, legacy PLC-5, SLC 500) and Siemens (TIA Portal v13-v20, S7-1500, Step 7 Classic), integrating multi-axis servo drives, industrial robotics (ABB), and IT/OT virtualization.

Appointed by Mikron Corp. USA for an on-site rescue engineering and legacy retrofitting mission at Dormakaba Americas (Indianapolis, IN). Forensically reverse-engineered original 1993 paper schematics to integrate modern 24VDC sensor architectures into an obsolete Rockwell Automation PLC-5/11 rotary transfer line. Performed in-depth PLC code debugging, sequence validation, dynamic cycle tuning, and trained local technical staff, avoiding full equipment replacement.

Deployed as an external specialist to Charleston, South Carolina, to rescue machine commissioning on an automotive production line under tight delivery deadlines. Implemented corporate "Bosch Standard" on Siemens TIA Portal, diagnosed complex mechanical-software interplay errors, resolved critical cycle bottlenecks, and brought the assembly equipment to full production acceptance.

On-site commissioning and programming of an automated sandwich car ceiling/headliner manufacturing line in the Detroit, Michigan metropolitan area (Plymouth). Executed PLC controls debugging, robotic interface interlocks, dynamic cycle tuning, and validation for high-throughput automotive production.

Controls engineering, cycle optimization, and software maintenance on Ford Figo and Ford Dragon engine assembly lines, as well as diesel cylinder head assembly systems. Implemented PLC logic updates, integrated safety interlocks, resolved production line bottlenecks, and supported multiple international plant launches (Chihuahua and Ahmedabad).

Certified System Integrator for Robotize GoPal Autonomous Mobile Robots (AMR), covering fleet management, automated material transport integration, and industrial facility safety layouts

Official certification in Universal Robots collaborative robotics programming, safety boundary configuration, kinematics, and end-effector/gripper integration.

Advanced technical training covering industrial control systems, drive integrations, and fieldbus automation architectures

Comprehensive technical workshops and hands-on advanced training on Siemens TIA Portal architecture, S7-1500 PLC hardware configurations, Motion Control, and diagnostics

Post-graduate master program focusing on industrial business planning, project management, financial viability analysis, and strategic entrepreneurship