Controls & Automation Engineer with PLC/SCADA Expertise

Professional Summary

Kavya A

Controls Engineer Automation Engineer

*****************@*****.*** 708-***-**** Sterling, VA Controls & Automation Engineer with 4+ years of experience delivering high-performance automation solutions across water

& wastewater systems, pharmaceutical manufacturing, and automotive assembly. Expert in developing and troubleshooting PLC-based control systems (Allen-Bradley, Siemens), SCADA platforms (FAST/TOOLS, FactoryTalk, Ignition), and real-time data interfaces using OPC UA, Modbus TCP/IP, and SQL. Proven track record in automating critical processes such as municipal water treatment, engine drop and alignment, and GMP-regulated batch production. Adept at scripting SCADA logic for reporting, fault tracking, and system integration. Skilled in aligning automation systems with industry standards including IEC 61131-3, ISO 24512, ISO 13849, and 21 CFR Part 11 to ensure safety, compliance, and system reliability. Technical Skills

PLC Hardware: Siemens S7-300, S7-1200, S7-1500, Allen-Bradley ControlLogix, CompactLogix

HMI & SCADA Development: Siemens WinCC, Rockwell FactoryTalk View, Ignition, Yokogawa FAST/TOOLS

Web & Programming Languages, IDEs: Ladder Logic, Structured Text, Function Block Diagram, SQL, Python, C, C++, HTML, CSS, Java, Visual Studio, Eclipse.

PLC Programming Platforms: Siemens TIA Portal, Rockwell Studio 5000, CODESYS

Industrial Communication Protocols: Profinet, Ethernet/IP, Modbus TCP/IP, Profibus, OPC UA, MQTT.

Automation & Motion Control: Servo drives, Allen-Bradley Kinetix 5500 Drives, Fanuc, KUKA, G-120 & S-120 drives, VFDs.

Electrical Design & Other: AutoCAD Electrical, MS Office Suite, JDBC, AI, ML, Power BI.

Standards & Compliance: IEC 61131-3, ISO 24512, ISO 13849, 21 CFR Part 11, GMP, IATF 16949, IEC 62443 Professional Experience

ESPO Corporation Willowbrook, IL Jan 2023 – Present Automation Controls Engineer

Responsibilities:

Designed and programmed Siemens S7-1500 PLCs using TIA Portal and IEC 61131-3 languages (Ladder Logic and Structured Text) to automate high-speed Accu-Chek test strip production lines. Performed I/O validation and sequencer logic testing to ensure real-time responsiveness. Optimized cycle times to support 24/7 FDA-compliant manufacturing operations.

Developed and tuned closed-loop PID control strategies for reagent dispensing and temperature-controlled curing ovens critical to strip chemistry. Calibrated control parameters based on sensor feedback and process trends to maintain accuracy. Delivered consistent process control within narrow tolerances to meet product quality specifications.

Integrated high-resolution encoders, capacitive sensors, and Siemens G120/S120 drive via Profinet for coordinated motion applications including web handling, strip feeding, and rejection systems. Aligned PLC motion logic with mechanical sequences to avoid misfeeds and jams. Partnered with mechanical engineers to optimize motion profiles for throughput.

Designed intuitive WinCC HMI interfaces with recipe management, fault diagnostics, and animated graphics to simplify operations for cleanroom technicians. Enabled touchscreen navigation for guided troubleshooting and alarm acknowledgment. Reduced operator training time and improved first-time-right batch performance.

Deployed Ignition SCADA dashboards to visualize real-time OEE, batch status, fault history, and machine KPIs across multiple production lines. Established OPC UA connections to Siemens PLCs and external OPC UA servers to enable secure, high-speed tag communication. Developed filtered views for operators, supervisors, and maintenance teams to focus on role- specific data. Supported shift handoffs and corrective actions with visual performance indicators.

Integrated WinCC and Ignition systems with SQL Server for structured data logging and batch reporting across regulated process steps. Enabled time-stamped audit trails of operator actions and setpoint changes in support of 21 CFR Part 11.

Used Python scripts within Ignition to automate production summaries, traceability reports, and downtime analysis on a per- batch basis. Configured secure data handoff to MES and QA systems for review and approval. Reduced manual reporting time while improving data accuracy for quality audits.

Implemented all automation and control changes under GMP, change control, and 21 CFR Part 11 frameworks to support FDA-regulated manufacturing.

Client: Larsen & Toubro (L&T), India Feb 2020 - Jul 2021 Role: Process Control Engineer

Responsibilities:

Developed and deployed Allen-Bradley ControlLogix-based automation systems using Studio 5000 and FactoryTalk View SE to support automated truck assembly processes including cab mounting, chassis component installation, and engine drop. Programmed sequencer logic per IEC 61131-3 standards with attention to safety interlocks and takt-time- based cycle coordination.

Configured torque tools, lift-assist devices, and barcode scanners over EtherNet/IP to verify torque specs, part presence, and VIN-based build sequencing. Supported real-time data capture for each truck unit in compliance with IATF 16949 quality standards, enabling traceability and error prevention.

Assisted with engine drop and chassis integration automation, using PLC-controlled hoists and fixture sensors to ensure accurate alignment and fastening of PACCAR engines. Verified mount position feedback to reduce misalignment errors and support safe handling per ISO 13849 guidelines.

Designed FactoryTalk View SE dashboards for operator stations to display real-time build steps, torque results, and fault messages. Configured station-specific problem tracking to help operators identify root causes and notify maintenance, improving station availability and reducing downtime.

Implemented OPC UA communication using Kepware to bridge ControlLogix PLCs and torque controllers, enabling centralized data monitoring and KPI tracking across the assembly line. Structured tag namespaces to support MES handoff and SCADA reporting.

Troubleshot intermittent torque verification failures at a front suspension station, where torque tool confirmation signals were not being registered by the PLC. Resolved the issue by identifying a loose I/O terminal block and updating the fault detection logic to include a heartbeat signal from the tool controller, restoring accurate torque validation and preventing false station rejections.

Education

Masters in Computer Science from Governance State University, Chicago, IL, USA

Bachelors in Computer Science from JNTUK– India.

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