Industrial Automation Control Engineer (4+ yrs)

Naga Anil

Control Engineer

Email: **********************@*****.*** Contact: +1-832-***-****

Professional Summary:

With over 4+ years of experience in the industrial automation sector, developed a deep expertise in designing and deploying end-to-end industrial automation solutions focusing on PLC, HMI, and SCADA integration, proficient in developing complex logic using Ladder, Structured Text, and Function Blocks across major platforms like Studio 5000 and TIA Portal, complemented by a strong background in tuning PID loops for high-precision control in continuous process environments. My hands-on experience extends to managing industrial networks such as EtherNet/IP and PROFINET, and proven track record of leading Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT) for large-scale capital projects, thorough understanding of machine safety standards (ISO 13849), specializing in Safety PLCs, and I am skilled in integrating multi-axis motion control systems and robotic cell integration for high-speed applications. Beyond core programming, interpreting P&IDs and electrical schematics, utilizing Python scripting for data analysis, and driving Industry 4.0 initiatives through IIoT and OPC UA implementation. excel at troubleshooting "ghost" issues in live production environments, collaborating with cross-functional teams, and ensuring high-quality technical documentation. My professional approach is defined by a commitment to mentoring junior staff and maintaining peak performance during highpressure commissioning phases while upholding strict safety compliance. Technical Skills:

PLC Platforms Allen-Bradley (Studio 5000), Siemens (TIA Portal), Omron (Sysmac Studio, CXProgrammer)

HMI / SCADA FactoryTalk View, Ignition, GE iFIX, Omron NB/NA Series, WinCC Communication EtherNet/IP, PROFINET, EtherCAT, Modbus TCP/RTU, OPC UA Motion & Drives PowerFlex VFDs, Kinetix Servos, Omron 1S/G5 Series, Siemens SINAMICS Software/Scripting Python, MATLAB, Simulink, Git, SQL for Historians Design Tools AutoCAD Electrical, EPLAN, Bluebeam Revu Safety & Compliance SIS (Safety Instrumented Systems), HAZOP, SIL Ratings, ISO 13849 Professional Experience:

Client: Siemens – USA Jun 2025 - Present

Role: Control Engineer

• Spearheaded the modernization of a legacy SCADA system using GE iFIX, enabling high-resolution trending and historical data retrieval for plant-wide analysis.

• Developed custom Add-On Instructions (AOIs) to standardize motor and valve control across multiple production lines, reducing code development time for new projects.

• Resolved a critical synchronization issue between distributed I/O racks and the main controller by optimizing the RPI (Requested Packet Interval) settings.

• Engineered a robust alarm management strategy that filtered nuisance alarms, allowing operators to focus on high-priority system criticalities during upsets.

• Led the integration of smart power meters into the automation backbone via Modbus TCP to track real-time energy consumption per machine unit.

• Designed a failsafe interlock system for a high-pressure testing rig, ensuring all safety parameters were met before the system could be energized.

• Collaborated with the IT/OT department to implement secure remote access for troubleshooting, utilizing VPN tunnels and managed firewalls.

• Provided technical leadership during a plant-wide upgrade, coordinating with electrical contractors to ensure field wiring matched the revised schematics.

• Conducted Advanced PID tuning for a thermal process, successfully stabilizing temperature fluctuations within a

$\pm$ 0.5 C margin.

• Authored a comprehensive Control Narrative for a new chemical dosing system, detailing every logic state from startup to emergency shutdown.

• Implemented automated data logging using SQL database triggers, providing the client with precise batch reports for regulatory compliance.

• Facilitated weekly technical reviews with the project stakeholders to demonstrate progress and finalize HMI screen navigation flows.

Client: Honeywell - USA Jan 2024 – May 2025

Role: Control Systems Engineer

• Developed high-speed motion control logic using Sysmac Studio for a multi-axis packaging machine, utilizing EtherCAT for sub-millisecond synchronization.

• Integrated Omron FQ2 vision sensors for real-time label inspection, significantly reducing the scrap rate for a major FMCG client.

• Configured Safety over EtherCAT (FSoE) to manage emergency stops and light curtains, ensuring the machine reached a "Safe State" instantly upon breach.

• Custom-built HMI dashboards on NA-series terminals that included interactive troubleshooting guides and PDF viewer tools for maintenance crews.

• Optimized VFD acceleration and deceleration ramps for a heavy-duty conveyor system to prevent mechanical wear and tear during frequent starts.

• Performed field loop checks and instrumentation scaling for various analog sensors, ensuring 4-20mA signals accurately reflected physical values.

• Diagnosed and fixed a persistent communication dropout caused by electromagnetic interference (EMI) by rerouting signal cables and improving shielding.

• Supported the client during Factory Acceptance Testing (FAT), simulating complex fault conditions to prove the robustness of the auto-recovery logic.

• Conducted on-site training sessions for client operators, focusing on alarm reset procedures and manual override protocols.

• Streamlined the BOM (Bill of Materials) process for control panels, ensuring all Omron components were compatible with existing plant power specs.

Jhon Deere - India Jan 2020 – Dec 2022

Role: Control Engineer

• Assisted in the configuration of industrial PCs (IPCs) and server environments to host SCADA applications for offshore manufacturing clients.

• Performed system integration testing (SIT) for enterprise-level automation software, documenting bugs and verifying patches before deployment.

• Developed SQL queries and stored procedures to extract production KPIs from industrial databases, supporting management-level reporting.

• Maintained Active Directory permissions for shop-floor HMI terminals, ensuring only authorized personnel had access to critical control setpoints.

• Collaborated on the deployment of a Version Control System (Git) for PLC code, standardizing how the global team managed multi-user software edits.

• Provided Level 1 technical support for client network issues, troubleshooting connectivity problems between field gateways and cloud-based historians.

Education:

Masters in Information technology from Cumberland University, USA – 2025

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