Controls & Automation Engineer (6+ yrs)

G Nishanth

PLC Controls Engineer

United States +1-469-***-**** nishanthk4325gmail.com

https://www.linkedin.com/in/g-nishanth-s5063/

Professional Summary

• Controls and Automation Engineer with 6+ years of hands-on experience supporting industrial systems across ware- house automation and automotive manufacturing environments.

• Strong background in PLC programming (Siemens, Allen-Bradley), SCADA systems, and real-time troubleshooting of conveyors, robotics, and process equipment.

• Experienced in commissioning, system validation (FAT/SAT), and resolving production-critical issues under time constraints.

• Proven ability to improve system reliability, reduce downtime, and support high-volume operations through practical engineering solutions.

• Comfortable working on-site with cross-functional teams including operations, maintenance, and OEM vendors. Technical Skills

• PLC Programming: Siemens S7-1200/1500 (TIA Portal), Allen-Bradley ControlLogix/CompactLogix (Studio 5000), Ladder Logic, Structured Text

• SCADA/HMI: Ignition, WinCC, FactoryTalk View, basic screen development, alarms, and tag configuration

• Industrial Networks: Profinet, EtherNet/IP, Modbus TCP/IP, OPC UA

• Drives & Field Devices: VFDs, Servo Drives, Sensors, Encoders, Safety Circuits

• Automation Systems: Conveyor systems, sortation systems, robotic cells, automotive production lines

• Testing & Commissioning: FAT, SAT, I/O checks, loop testing, signal validation, startup support

• Troubleshooting: PLC faults, communication failures, sensor issues, production downtime analysis

• Tools: TIA Portal, Studio 5000, AutoCAD Electrical, basic Python, SQL

• Standards & Safety: IEC 61131-3, LOTO procedures, industrial safety practices Professional Experience

Control & Systems Engineer Aug 2024 – Present

Hewlett Packard Enterprise, Texas

• Developed and implemented industrial automation systems using PLCs (Allen-Bradley, Siemens) with IEC 61131-3 programming languages including Ladder Logic, Structured Text, and Function Block Diagram using TIA Portal and Rockwell Studio 5000.

• Designed, developed, and configured SCADA and HMI systems (Ignition, FactoryTalk View) with real-time visualiza- tion, alarms, and historian integration using PostgreSQL and InfluxDB.

• Led end-to-end commissioning activities including Factory Acceptance Testing (FAT), Site Acceptance Testing (SAT), loop checks, I/O validation, and full system startup.

• Developed and executed comprehensive testing strategies including automated test frameworks, simulation-based val- idation, and control logic verification to ensure system reliability.

• Built Python-based automation tools and data pipelines integrated with PLCs, SCADA, and historian systems for real-time data logging, KPI reporting, and analytics.

• Designed and implemented advanced control algorithms including PID tuning and simulation models for thermal and industrial process optimization.

• Configured and troubleshot industrial communication protocols including OPC UA, Modbus, Profinet, and Ether- Net/IP to ensure seamless system integration.

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• Designed electrical schematics, control panels, and wiring diagrams using AutoCAD while ensuring compliance with UL, CE, and NFPA safety standards.

• Developed, tested, and deployed automation solutions including containerized Python services using Docker and CI/CD pipelines.

• Performed on-site troubleshooting during commissioning and post-deployment to resolve complex electrical, mechanical, and control system issues.

• Maintained detailed documentation including control logic updates, commissioning reports, test results, and as-built drawings.

• Collaborated with cross-functional teams, OEMs, and contractors for system integration, upgrades, and project delivery within schedule and budget.

• Provided technical training and mentorship to engineers and technicians on PLC programming, testing procedures, and troubleshooting.

• Supported continuous improvement initiatives by identifying automation opportunities and enhancing system perfor- mance and reliability.

Controls Systems Engineer June 2023 – July 2024

Home Depot, Dallas, Texas

• Developed and maintained PLC control logic for conveyor routing, accumulation zones, and automated sortation systems in a high-throughput distribution environment.

• Troubleshot control system faults across conveyor networks, restoring material flow and minimizing operational down- time.

• Optimized control sequences and sensor logic to improve routing accuracy and system efficiency across multiple distri- bution lines.

• Performed system validation including I/O checks, signal verification, and functional testing prior to production de- ployment.

• Analyzed system diagnostics, alarms, and logs to identify recurring issues and implement corrective control improve- ments.

• Supported reliable operation of VFD-driven motors, sensors, and safety circuits within automated material handling systems.

• Diagnosed and resolved industrial communication issues between PLCs, barcode scanners, and field devices impacting system performance.

• Maintained and updated automation documentation including control narratives, I/O lists, and electrical drawings. System Engineer Feb 2019 – Jun 2021

Smart Squad Digital Solutions LLP, India

• Worked on day-to-day support of automation and control systems, handling issues reported from site and resolving them with minimal downtime.

• Assisted in PLC program modifications and small logic changes based on operational requirements and field feedback.

• Checked field devices like sensors, actuators, and control panels during breakdowns and coordinated fixes with main- tenance teams.

• Supported SCADA screens by updating tags, alarms, and basic visualization changes as per process updates.

• Monitored system performance and flagged abnormal behavior in conveyors, motors, and control systems during oper- ations.

• Helped in testing newly installed equipment by verifying I/O signals, checking wiring, and ensuring proper communi- cation with PLCs.

• Troubleshot communication issues between PLCs and field devices, including basic network checks and cable-level debugging.

• Maintained simple records of issues, fixes, and daily system status for internal tracking. 2

• Worked closely with senior engineers during commissioning and shutdown activities, supporting testing and system checks.

• Followed safety practices while working on panels, including power isolation and basic lockout procedures. Process Controls Engineer Dec 2017 – Jan 2019

Hyundai Motors, India

• Developed and maintained PLC control logic for automated manufacturing processes across body shop, paint shop, and assembly lines, ensuring seamless production flow.

• Supported commissioning and integration of automated systems including robotic stations, conveyor systems, and process equipment within automotive production environments.

• Troubleshot process control issues impacting production lines, minimizing downtime and ensuring continuous operation of critical manufacturing systems.

• Optimized control strategies and interlocks to improve process efficiency, cycle time, and equipment reliability.

• Performed system validation activities including I/O checks, loop testing, signal verification, and functional testing prior to production release.

• Monitored and maintained industrial communication networks (Profinet, Ethernet/IP, Modbus TCP) between PLCs, HMIs, robots, and field devices.

• Analyzed alarms, trends, and system logs to identify recurring faults and implemented corrective actions to improve process stability.

• Supported operation and troubleshooting of VFDs, servo drives, sensors, safety systems, and control panels used in automated manufacturing.

• Collaborated with production, maintenance, and quality teams to resolve process deviations and improve overall equipment effectiveness (OEE).

• Ensured compliance with industrial safety standards including interlocks, emergency systems, and lockout/tagout

(LOTO) procedures.

• Maintained and updated technical documentation including control narratives, P&IDs, I/O lists, and electrical schemat- ics.

Education

Master of Science in Computer and Information Sciences May 2023 Southern Arkansas University, USA

Bachelor of Technology in Mechanical Engineering April 2016 Vardhaman College of Engineering, India

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