Automation Engineer Industrial Controls & IT Integration

RISHIKA VAJRALA

Cincinnati, Ohio *******************@*****.*** +1-224-***-**** LinkedIn

PROFESSIONAL SUMMARY

Automation Engineer with 3+ years of experience designing and implementing corporate-side automation solutions supporting manufacturing operations across automotive, controls systems, and industrial equipment sectors. Skilled in PLC/SCADA integration, HMI development support, and industrial control system architecture with quantifiable achievements: 35% reduction in manual data workflows, 40% improvement in automation system reliability, and 30% faster engineering documentation delivery. Expert in bridging controls engineering with IT infrastructure through industrial communication protocols, automation data management, and control system integration. Specialized in supporting Controls Engineers, Manufacturing Engineers, and Plant Operations with automation architecture design, system commissioning support, and process automation solutions. Core Competencies: Industrial Automation Architecture, PLC/SCADA System Integration, HMI Development Support, Control System Data Management, Process Automation Design, Industrial Communication Protocols, Automation System Validation, Manufacturing Controls Support, Industrial IoT Integration, Automation Documentation, Control Panel Design Support, Corporate Engineering Coordination TECHNICAL SKILLS

PROGRAMMING & AUTOMATION TOOLS

• Python Automation: Industrial Data Collection, Process Scripts, System Integration

• SQL: Manufacturing Databases, Historian Queries, Data Validation & Reporting

• Workflow Orchestration: Apache Airflow, Automation Job Scheduling, Dependency Management

• Data Visualization: Power BI, Tableau, Automation Dashboards, Operational Reporting

• DevOps for Automation: Git, Version Control, Deployment & Change Tracking INDUSTRIAL COMMUNICATIONS & NETWORKING:

• Industrial Protocols: OPC UA, Modbus, EtherNet/IP, Profinet, MQTT

• Control Networks: Industrial Ethernet, DeviceNet, Network Architecture & Diagnostics

• PLC–Database Connectivity: Real-Time Data Exchange, Production Data Logging, Interface Design

• Industrial IoT: Gateway Configuration, Sensor Integration, Secure Data Transmission

• Edge Computing: On-Prem Data Processing, Latency Reduction, Manufacturing Analytics AUTOMATION & PROCESS CONTROL:

• Process Automation Design: Workflow Definition, Control Strategy Development, Automation Standard

• Material Handling Automation: Conveyor Systems, Automated Storage & Retrieval, System Integration

• Robotics Integration: FANUC, ABB, Robot-to-PLC Communication, Production Data Exchange

• Vision Systems: Cognex, Keyence, Inspection System Integration, Quality Automation INDUSTRIAL CONTROL SYSTEMS:

• PLC Integration Support: Allen-Bradley, Siemens, Mitsubishi, Control System Commissioning, Troubleshooting

• SCADA & HMI Systems: Wonderware, Ignition, FactoryTalk View, Siemens WinCC, Operator Interface Design

• Historian Systems: OSIsoft PI, Wonderware Historian, Time-Series Data Management, Production Analytics

• DCS Integration: Distributed Control Systems, Plant-Wide Control Integration, System Interoperability WORKING EXPERIENCE

Automation Engineer General Electric Boston Feb 2025 – Jan 2026 Automation System Integration & Controls Support:

• Designed automation data integration solutions connecting PLC systems, SCADA platforms, and corporate databases across 12+ manufacturing sites, eliminating 35% of manual data collection workflows

• Engineered real-time data collection systems from Allen-Bradley and Siemens PLCs using OPC UA and industrial Ethernet protocols, enabling corporate engineering teams to monitor production equipment status, alarm conditions

• Developed automated data pipelines extracting process data from Wonderware and Ignition SCADA systems into SQL databases for production analysis, quality tracking, and equipment performance monitoring

• Built automation system dashboards in Power BI visualizing PLC alarm history, SCADA trends, equipment utilization, and process parameters across production lines, reducing troubleshooting time by 30% Process Automation & Industrial Systems:

• Architected industrial data warehouse consolidating control system data from PLCs, HMIs, vision inspection systems, and robotic controllers, supporting predictive maintenance initiatives and process optimization studies

• Implemented automated alarm management and notification systems for critical control points, processing real-time events from SCADA platforms and distributing alerts via email and SMS, improving incident response time by 25%

• Established data validation frameworks for control system datasets ensuring accuracy of process measurements, setpoint tracking, and alarm logs, reducing data quality issues by 30% for engineering analysis

• Configured automated deployment pipelines for SCADA screen updates, HMI modifications, and database schema changes using Git and Jenkins, achieving 99% deployment success rate and minimizing production disruptions Engineering Support & Technical Documentation:

• Delivered 200+ automated control system reports including alarm summaries, process trend analysis, equipment runtime logs, and batch production records with 99.5% on-time delivery supporting daily operations

• Optimized historian database queries and time-series data retrieval through indexing strategies and query optimization, reducing data extraction time from 90 seconds to under 30 seconds

• Standardized automation documentation templates including P&IDs markup, I/O lists, network diagrams, and control narratives, improving cross-functional communication between Controls, IT, and Manufacturing teams

• Developed Python-based automation tools for PLC tag database generation, HMI screen validation, and control system health monitoring, reducing engineering overhead by 25% Systems Engineer HCL Technologies India Jun 2022 – Jul 2024 Industrial Automation Development & System Integration:

• Engineered 50+ automation projects for automotive OEM and Tier-1 supplier clients, connecting shop floor control systems with corporate engineering platforms and processing data from 100+ PLCs, 20+ SCADA systems

• Designed and deployed control system data pipelines integrating Allen-Bradley ControlLogix, Siemens S7, and Mitsubishi PLCs with SQL Server databases using OPC UA and Python

• Implemented centralized SCADA data repository consolidating process data from Wonderware InTouch, GE iFIX, and Ignition platforms across 20+ manufacturing sites Process Automation & Controls Engineering Support:

• Created automated workflow for control system routine tasks using Apache Airflow, improving Controls Engineering productivity by 30% through automated alarm analysis, trend data preparation, and batch report generation

• Optimized SQL Server and Oracle databases supporting SCADA historians and MES applications through query tuning and partitioning strategies, improving real-time data access speed by 40% and saving $250K annually

• Established automated metadata management for PLC tag databases, I/O configurations, and control loop documentation, improving system traceability and facilitating faster troubleshooting during production issues Automation Analytics & Industry 4.0 Support:

• Partnered with Controls Engineers and Plant Automation Teams to design analytics platforms supporting control system optimization, including loop tuning analysis, alarm rationalization, and equipment performance monitoring

• Delivered automation dashboards visualizing control system health metrics (PLC CPU utilization, network traffic, SCADA server performance, alarm rates), enabling proactive maintenance and reducing unplanned downtime by 15%

• Implemented control data quality frameworks ensuring accuracy of process variable logging, recipe parameters, and batch records, achieving 99% data integrity for FDA 21 CFR Part 11 and IATF 16949 compliance EDUCATION

Master of Science in Information Technology – University of Cincinnati, USA, 3.89 CGPA Bachelor of Science in Computer Engineering – Gurunanak Institutions of Technology, India, CERTIFICATIONS

• Python & SQL for Industrial Automation Systems

• Industry 4.0 & Industrial IoT (IIoT) – Smart Manufacturing, Edge Computing Systems

• Lean Six Sigma Green Belt

• Robotics & Automation Fundamentals

• Industrial Communication Protocols – OPC UA, Modbus, EtherNet/IP

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