Automation/Controls Engineer

PARASHAR MERAPALA

+1-713-***-**** Email: ************@*****.*** https://www.linkedin.com/in/parashar-merapala-2297a017b/ PROFESSIONAL SUMMARY

Diligent Controls/Electrical Engineer with over 4+ years of self-motivated and dedicated with knowledge of controls systems and testing, schematics, and troubleshooting. A hard-working and driven professional with a strong understanding of mixed signal concepts, PLC programming hardware and software (RSLogix500, RSLogix5000). Adaptive at design, testing and troubleshooting of existing systems and new control systems. Talents in project management and programming languages. Friendly and organized with familiarity with safety and health regulations. TECHNICAL SKILLS

Industry Skills: Tool Design & Development, Schematic Interpretation & Design, Reporting & Documentation.

Project Skills: Project Management, Critical & Analytical Thinking, Troubleshooting.

Soft Skills: Leadership & Teamwork, Organizational Skills.

Programming Languages: C, SQL, Python.

Protocols: PCIe; AXI; MSI.

MS OFFICE (word, excel, power point)

EDUCATION

Master’s in Computer engineering 01/2022 – 05/ 2023 University of Houston- Clear Lake, Houston, Texas. Bachelor’s in Electrical & Electronics Engineering 07/2016 – 11/2020 Mahindra University, INDIA

PROFESSIONAL EXPERIENCE

Lear Corporation (Grand Prairie, TX)

Controls Engineer 05/2025 – Present

Managed full project lifecycle for automation systems and robotics, including proof-of-concept builds, DFx (Design for Manufacturing/Assembly/Serviceability), and field commissioning.

Programmed, debugged, and optimized PLC/HMI systems (Allen-Bradley, Siemens, etc.) for automated machinery to minimize cycle time and improve system uptime.

Analyzed and modified PLC routines and HMI tags to correct sequence interruptions, improving part flow and reducing machine stoppages.

Conducted root cause analysis of system faults by monitoring live HMI screens, reviewing alarm history, and tracing logic using Studio 5000.

Implemented recovery routines in PLC logic for common failure scenarios, reducing Mean Time to Recover (MTTR) during shift operations.

Modified the final testing program of the Pods tester, resulting in a 20% reduction in testing time and a significant increase in overall production efficiency.

Integrated new sensors, vision systems (Keyence/IR), and I/O modules into existing control systems to support product changes and quality improvements.

Led troubleshooting and root-cause analysis of electrical, mechanical, and software-related faults on production lines, minimizing downtime and improving throughput.

Led end-to-end design, development, and deployment of embedded control systems for autonomous robotic platforms, integrating hardware and firmware to support motion, sensing, and communication. ADIENT US LLC (RIVERSIDE, MO)

Controls Engineer 11/2023 – 04/2025

PLC Programming & Troubleshooting: Developed and implemented control systems using Allen Bradley RSLogix 500/ RSLogix 5000/ Studio 5000 software for automation processes. Experienced in diagnosing PLC program logic errors, such as input/output or communication faults.

Configured and integrated Allen Bradley PLCs with various industrial networks such as Ethernet/IP, ControlNet, DeviceNet.

HMI Design & Configuration: Designed and configured HMI applications using FactoryTalk View to interact with Allen Bradley PLCs for real-time monitoring and control.

Troubleshooting & Optimization: Performed I/O checks, communication troubleshooting (Ethernet/IP, DeviceNet, Modbus, and Profibus), and fault recovery.

Integration & Communication Established connections between automation systems and Manufacturing Execution Systems

(MES) and collaborated on design, programming, testing, and deployment of automation solutions.

Industrial Communication Protocols: Proficiency in Ethernet/IP, Profinet, Modbus TCP/RTU, BACnet, DeviceNet for PLC, HMI, and SCADA communication.

Robotic Programming (FANUC, ABB & UR10): Developed and implemented complex robotic programs using proprietary software (e.g. Roboguide, Handling Tool) for various applications such as material handling and assembly.

SCADA & Remote Connectivity: Configuring SCADA systems (FactoryTalk, Ignition, WinCC) to communicate with PLCs via OPC UA or MQTT.

Vision System Integration: Configured and installed Cognex scanners, Keyence vision cameras (e.g., IV Series, CV-X Series) for various inspection, measurement, and quality control applications in automation environments.

PID Control Design: Designed and implemented PID control loops for a variety of applications, such as temperature control, pressure regulation, flow control, and speed regulation.

VFD Configuration: Configured VFD communication with PLCs using industrial protocols such as Ethernet/IP or Modbus, enabling real-time control and monitoring of motor parameters.

Implemented soft-start and braking functions using VFDs to reduce mechanical stress on motors and connected equipment, extending the lifespan of components.

DeltaV DCS Configuration: Configuring, troubleshooting and maintaining Emerson DeltaV Distributed Controls System

(DCS) for process automation, including control module design & integrating field devices.

BMS Configuration: Configured BMS for real-time monitoring and control of mission-critical systems, including HVAC and access control systems.

EPMS, HVAC & Power Redundancy Management: Worked on EMPS to maintain power redundancy and facilitate uninterrupted power supply via generators and battery systems in case of power failures. Designed and configured HVAC control systems for commercial and industrial applications, ensuring optimal temperature regulation and energy efficiency. Alphasmart Solutions LLC (Cumming, GA)

Controls Engineer 08/2023 – 11/2023

Understood the feature requirements shared by the controls engineer and design the software using MATLAB.

Tested continuity of the software developed as well as to match the requirements.

Conducted Design Review Board (DRB) review with the team once the testing is completed.

Provided various development services to clients based on request. University of Houston – Clearlake (Part-time) – (Houston, TX) Graduate Teaching Assistant 08/2022 – 05/2023

For Linear Circuits lab used lumped constants and integrated circuits to deliver lab content during AC/DC circuit experiments using oscilloscopes, logic analyzers, basic debug.

Graduate Teaching Assistant for Telecom and Networks lab Evaluated system requirements after working on WANs and LANs, circuit and packet switching networks, error detecting and correcting codes, multiplexing, data communications, routing, and network security.

Techbium (Client: Johnson Electric) (Hyderabad, INDIA) Controls Engineer 06/2020 – 12/2021

Accomplished control systems professional with expertise in designing, developing, and optimizing automation solutions and developed PLC and HMI programs from scratch for diverse automation equipment.

Applied in-depth knowledge of Electrical Standards (NFPA79, National Electric code, UL508A) to ensure compliance and safety in all automation projects.

Designed, Evaluated and Implemented SCADA systems and other automated tasks used to collect data in a controlled environment. Maintained relationships with vendors to ensure quality materials.

Designed and maintained control systems for various energy solutions projects, emphasizing safety and compliance.

Managed & planned equipment upgrade projects to optimize manufacturing processes and design electrical schematics for new automation cells.

CERTIFICATIONS

Certified FANUC Robot Tool Handling & Programming from FANUC FA AMERICA

Certified CB3 e-learning from Universal Robots

ADDITIONAL INFORMATION

HONORS & AWARDS: Mahindra Ecole Centrale – Scholarship Award.

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