Automation Engineer with 3.5+ Years of Experience

Mounika Katta

********************@*****.*** +* (978) 200 – 2232

PROFESSIONAL SUMMARY

A highly motivated Engineering professional with 3.5+ years of Control Engineer experience obtained in various production plants and firms. Excellent technical ability, and analyzing skills, with proven leadership in working as a team or individually Strengths are excellent communication, troubleshooting, and solving process issues

● Experienced Controls Engineer proficient in robotics and PLC systems, with a track record of designing and optimizing control systems. Committed to driving innovation and efficiency in engineering environments, seeking opportunities to enhance manufacturing processes and advance automation technologies.

● Experience in Control System Design, hardware, and software (HMI/PLC, Allen Bradley, Siemens, and several others.)

● Well versed in performing complex inspection and evaluation on electrical components.

● Perform factory acceptance test (FAT) of control system using loop simulation to confirm functionality and performance.

● Experience in development and deployment of advanced control systems for manufacturing processes.

TECHNICAL SKILLS

Programming Siemens TIA Portal, Allen-Bradley RS Logix 5000, Schneider Unity Pro, Python Control Systems PLC & DCS Siemens Step 7, HMI/SCADA development (WinCC, Maple Systems, PID control

Robotics & Industrial Auto FANUC, ABB, ROBOGUIDE, iPendant, Ethernet/IP, Modbus, ProfNet, OPC UA

Simulation & Modeling MATLAB/Simulink, Autodesk AutoCAD, SolidWorks Electrical & CSD EPLAN, VFDs, HMIs, Ladder Logic, STL, FBD Testing, Troubleshooting &

Maintenance

FAT, SAT

Data Acquisition SQL databases, MQTT, cloud-based automation, data logging, analytics, TCP/IP and Computer Networks

Others Keyence IM-6020, VFD, PLC Panel Wiring, Hydraulic, SolidWorks. WORK EXPERIENCE

General Electric – Boston, MA Jan 2025 - Present Controls Engineer

Responsibilities:

● Programmed and commissioned PLCs (Siemens, Allen-Bradley) and DCS systems, enabling reliable control and integration of automated industrial processes.

● Designed and implemented control system hardware and software using Siemens Step 7, WinCC Flex, ladder logic, STL, and Telmecanique Unity Pro PLCs, with AutoCAD used for electrical and hardware schematics.

● Developed and debugged PLC and HMI applications for complex conveyor and material-handling systems, supporting diesel engine production operations for Cummins using Unity Pro PLC and Vijeo HMI platforms.

● Designed HMI and SCADA touchscreen interfaces using Maple Systems HMI/SCADA TFT panels to support real-time monitoring and operator interaction.

● Implemented Siemens PLC-controlled conveyor automation systems capable of sorting incoming materials based on component characteristics such as wood and metal.

● Managed and executed multiple automation projects involving PLC and SCADA programming, integrating industrial equipment such as mixers, ovens, and process control systems.

● Ensured automation systems complied with ISA and IEC industry standards, maintaining safety, reliability, and quality throughout system design and deployment. Key Achievements:

● Reduced automation development time by 10% by performing system simulations and control modeling using MATLAB and Simulink during the design phase.

● Improved robot automation setup efficiency by configuring virtual FANUC robot models and installing iPendant on FANUC ROBOGUIDE 3D V9.40220, enabling faster testing and deployment of robotic systems.

● Delivered a PLC-based conveyor sorting system that automated material classification between wood and metal components, improving operational efficiency in material handling.

● Successfully commissioned and started up conveyor systems for diesel engine production lines at Cummins, ensuring stable system integration between PLC controls and HMI monitoring platforms. Siemens Energy – India June 2021 – Dec 2023

Process Controls Engineer

Responsibilities

● Designed and implemented automated control systems for industrial energy and manufacturing processes, ensuring operational efficiency, reliability, and safety.

● Developed dynamic system models and simulated control strategies using MATLAB/Simulink to evaluate performance and validate control logic before deployment.

● Programmed and configured PLC systems using Siemens TIA Portal, Allen-Bradley RSLogix, and Schneider Unity Pro to enable real-time industrial process control.

● Integrated robotic arms, sensors, actuators, and communication interfaces into automated manufacturing systems to support precise material handling and process monitoring.

● Designed and implemented advanced control algorithms for robotic systems, improving accuracy, system responsiveness, and automation performance.

● Implemented fault detection and predictive maintenance logic within control systems to enhance reliability and prevent unexpected equipment failures.

● Conducted Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT) to validate automation system performance prior to deployment.

● Provided on-site and remote technical support for automation systems, including troubleshooting, system upgrades, and emergency repairs.

● Deployed Keyence high-resolution vision inspection systems for automated defect detection and quality assurance in production environments.

● Applied advanced process control techniques and analytics to improve plant performance and optimize operational efficiency.

● Ensured all control system designs adhered to industry safety and compliance standards including ISA, IEC 61131-3, NFPA 70, OSHA, and ISO 13849.

● Led the integration and configuration of PLC control architectures (Siemens and Allen-Bradley) across manufacturing systems to improve operational control and reliability.

● Performed root cause analysis and troubleshooting on malfunctioning automation systems to minimize disruption and maintain production continuity.

Key Achievements:

● Reduced equipment downtime by implementing predictive maintenance algorithms and automated fault detection mechanisms within PLC-based control systems.

● Improved production throughput by 15% by developing and deploying robotics programming for automated assembly line operations.

● Enhanced defect detection accuracy and product quality by implementing high-resolution Keyence vision inspection systems across production lines.

● Reduced operational disruptions by leading comprehensive fault diagnosis procedures, significantly lowering system errors and ensuring 100% safety compliance.

● Strengthened automation reliability by directing PLC system integration initiatives, improving control capabilities and reducing operational downtime across manufacturing processes.

● Improved plant performance and operational efficiency through the implementation of advanced control strategies and analytics-driven process optimization. PROJECTS

Automatic Dip Painting of Automobile Components using Allen-Bradley PLC Integrated with HMI

● Successfully implemented an automated dip painting system using Allen-Bradley PLC and FactoryTalk View. By designing a user-friendly HMI interface, I improved productivity by 20%, significantly minimizing manual intervention and errors.

Designing and implementing a SCADA System for Water Distribution and Monitoring system

● Designed and implemented a SCADA system using Allen-Bradley PLCs, RSLogix 5000, and FactoryTalk View for real-time monitoring and control. Integrated CompactLogix, ControlLogix, and PanelView Plus to enhance water distribution efficiency with high data reliability. Robotic-vision Material Handling System with a Centralized Programmable Logic Controller

● Implemented a material handling system using Fanuc robots with IR vision, accurately identifying and orienting objects for seamless integration. Enhanced user interface with custom HMI controls, improving operational effectiveness and productivity.

EDUCATION:

Master’s of Science in Computer Science – University of Bridgeport, USA Jan 2024-May 2025 Bachelor’s of Engineering in Electronics and Communication Engineering–MVSR College,India June 2018-July 2021 Diploma in Embedded Systems – Government Institute of Electronics, India Aug 2014-Nov 2017 CERTIFICATIONS:

● Lean Six Sigma Green Belt: International Institute of Management Mastery

● Industrial Automation Fundamentals: Siemens Digital Industries

● Advanced PLC Programming: Allen-Bradley/Rockwell Automation

● FANUC Robot Programming Certification: FANUC America Corporation

● Functional Safety for Industrial Automation: TUV Rheinland

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