Automation Engineer with 4+ Years in Manufacturing Automation

VENKATA CHATRATHI

Automation Engineer

*****************@*****.*** +1-716-***-**** linkedin.com/in/venkatachatrathi United States PROFESSIONAL SUMMARY

Automation Engineer with 4+ years of experience deploying robotic work cells, PLC-controlled systems, and machine vision integration across medical device, consumer products, and electrical manufacturing environments. Delivered a 40% improvement in defect detection at Clorox, 35% reduction in quality escapes at Zimmer Biomet, and zero major non-conformities across ISO audits at Schneider Electric. Combines deep hands-on expertise in FANUC, Allen-Bradley, and Cognex with a strong foundation in IQ/OQ/PQ validation, PFMEA, and Lean Six Sigma to lead automation projects from concept through production launch in regulated, high-volume environments. TECHNICAL SKILLS

Automation & Controls: Allen-Bradley Studio 5000 / RS Logix 5000, Siemens TIA Portal, SCADA (FactoryTalk, Ignition), FANUC & Universal Robots, Cognex & Keyence Machine Vision, EOAT Design, Multi-Axis Motion Control Manufacturing Engineering: PFMEA, Control Plans, FAI, GD&T, DFM/DFA, BOM Management, ECO Implementation, Production Line Balancing, NPI, Validation (IQ/OQ/PQ) Quality & Continuous Improvement: Lean Six Sigma Green Belt, DMAIC, RCA, SPC, Gage R&R / MSA, CAPA, 8D Problem Solving, Kaizen, 5S, ISO 9001 / ISO 14001, FDA 21 CFR, ISO 13485 Design & Data Tools: SolidWorks, Creo, CATIA, AutoCAD, Power BI, Minitab, MES, OEE Tracking, SAP, Arena Simulation, Advanced Excel

PROFESSIONAL EXPERIENCE

Zimmer Biomet Jan 2025 – Present

Automation Engineer Warsaw, IN

• Deployed Cognex automated vision inspection systems on the orthopedic drive unit line, reducing manual inspection headcount by 30% and improving structural defect detection by 15%.

• Optimized PLC logic sequencing (Allen-Bradley Studio 5000) across 3 production lines, increasing overall throughput by 12% with no additional labor investment.

• Implemented closed-loop feedback system between final assembly testing and sub-assembly cells, reducing quality escape recurrence by 35% within the first quarter.

• Directed 8-member cross-functional team through full automation integration and validation of new assembly equipment, ensuring on-time commissioning and production readiness.

• Authored and executed IQ/OQ/PQ validation protocols for new automated assembly equipment in compliance with FDA 21 CFR and ISO 13485 requirements.

• Developed real-time SPC dashboards within MES to monitor process stability and equipment health, reducing unplanned downtime by 20% by flagging drift before failures occurred.

• Led root cause analysis for intermittent electrical continuity failures traced to ultrasonic welding contamination; implemented corrective actions eliminating the failure within 2 weeks.

• Spearheaded scrap reduction initiative by analyzing torque failure trends across 500+ units; recalibrated DC tools reducing torque-related scrap by 20%.

• Owned PFMEA and Control Plan updates for new battery pack enclosures, proactively identifying potential leak paths prior to high-rate production launch.

The Clorox Company Feb 2024 – Jan 2025

Automation Engineer Oakland, CA

• Designed and deployed robotic work cells (FANUC, Universal Robots) for material handling, assembly, and inspection, increasing line productivity by 18% and reducing manual intervention by 25%.

• Automated manual inspection using Cognex and Keyence machine vision systems, increasing defect detection accuracy by 40% and cutting inspection time by 25%.

• Programmed PLC-based multi-axis motion control systems, improving equipment synchronization and increasing throughput by 15%.

• Led 3 automation integration projects from RFQ through commissioning, delivering on time and within budget with full production readiness.

• Developed EOAT and custom automation tooling, improving process repeatability and reducing process variation by 20%.

• Applied DFM/DFA principles to automation system design, reducing component rework by 15%.

• Delivered continuous improvement initiatives across automated lines, improving equipment uptime and OEE by 16%.

Schneider Electric Jan 2021 – Aug 2023

Process & Automation Engineer Hyderabad, India

• Automated inspection of silver-plating thickness using DMAIC methodology, reducing material waste by 18% and improving first-pass yield.

• Led process improvement initiatives across high-voltage assembly lines, developing standardized Work Instructions and visual controls that reduced process deviations by 20%.

• Conducted Gage R&R and MSA studies across 5 measurement systems, reducing measurement uncertainty and improving inspection repeatability to within 10% acceptable variation.

• Facilitated 8D problem-solving and CAPA implementation for internal quality escapes, reducing recurring defects by 25% within 6 months.

• Led Kaizen initiatives focused on point-of-use tooling and workstation optimization, reducing non-value-added movement by 18%.

• Managed 20+ Engineering Change Orders for updated PCB and breaker designs, maintaining uninterrupted production schedules and preventing inventory obsolescence.

• Coordinated MRB disposition of 150+ non-conforming units per quarter, reducing hold time by 30% through structured corrective action workflows.

• Achieved zero major non-conformities across all ISO 9001 and ISO 14001 external compliance audits. EDUCATION

University at Buffalo, The State University of New York Aug 2023 – Dec 2024 Master of Science, Industrial Engineering Buffalo, NY JNTU Kakinada Jun 2019 – Jul 2023

Bachelor of Technology, Mechanical Engineering India CERTIFICATIONS

• Lean Six Sigma Green Belt – AIGPE

• Lean Six Sigma Yellow Belt – AIGPE

• Self-Charged Hybrid Electric Vehicles – Toyota Motor Corporation

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