Industrial Controls & Process Optimization Engineer

Akhil Prasad Enabothula

Controls Engineer Industrial Automation Engineer

Georgia, USA +1-470-***-**** ***********.**@*****.*** SUMMARY

Controls/ Industrial Engineer with 5+ years of experience supporting manufacturing optimization, Lean initiatives, and data-driven operational improvements across aerospace and high-volume production environments. Skilled in time studies, OEE analysis, capacity planning, workflow balancing, and DMAIC problem-solving using tools such as Advanced Excel, SQL, Power BI, Minitab, Tableau, AutoCAD, and Visio. Proven track record of improving throughput, machine availability, first-pass yield, and on-time delivery performance by identifying bottlenecks, stabilizing process variation, and supporting cross-functional Kaizen and maintenance initiatives. Adept at collaborating with production, quality, maintenance, and controls teams to implement practical, sustainable process improvements aligned with business and operational targets.

SKILLS

Industrial Engineering & Process Improvement: Lean Manufacturing, Six Sigma (DMAIC), Continuous Improvement, Kaizen, Value Stream Mapping (VSM), Time & Motion Studies, Line Balancing, Capacity Planning, Root Cause Analysis Project & Operations Management: Project Planning, Scheduling & Tracking, Resource Allocation, Risk Assessment, Change Management, Stakeholder Coordination, Budget Monitoring, Process Documentation Data Analysis & Performance Monitoring: Advanced Microsoft Excel (Pivot Tables, VLOOKUP, Solver), Minitab, Power BI, Tableau, SQL, Statistical Process Control (SPC), KPI Reporting, Trend Analysis Controls & Automation Exposure: PLC Platforms (Allen-Bradley, Siemens), SCADA Monitoring, HMI Interface Understanding, Ladder Logic, Process Control Basics, Preventive Maintenance Support, Ethernet/IP Manufacturing & Supply Chain: Production Planning, Inventory Optimization, OEE Monitoring, Quality Improvement Support, Workflow Optimization, Safety & Compliance Awareness

Engineering Software & Systems: AutoCAD, MS Project, Visio, SAP / ERP Systems, Basic Python for Process Automation EXPERIENCE

Control Engineer / Industrial Automation Engineer Raytheon Technologies USA Jan 2024 – Present

• Supported PLC-based electronic assembly line troubleshooting by analyzing SCADA production alarms and coordinating with maintenance teams, helping restore stable cycle performance during recurring stoppage conditions.

• Analyzed PLC and SCADA production data to identify downtime drivers and improve OEE across automated assembly lines

• Assisted in HMI logic validation and operator interface improvements during automation optimization reviews, helping reduce manual intervention and improve workstation task clarity across production shifts.

• Participated in Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT) activities by documenting control sequence performance and supporting integration verification prior to production ramp-up.

• Performed industrial control system troubleshooting using Allen-Bradley (Rockwell) PLCs by analyzing I/O signals, SCADA alarms, and sensor/actuator behavior to stabilize automated assembly line performance

• Validated control sequences, interlocks, and system responses during FAT/SAT and HIL activities on Rockwell / Siemens-based systems, ensuring reliable automation deployment

• Monitored automation performance trends using SQL production extracts and Power BI dashboards, helping identify sensor response inconsistencies and improving throughput stability across primary assembly stations.

• Evaluated production flow using value stream mapping (VSM) to identify non-value-added activities and optimize process efficiency

• Applied Lean Manufacturing and Six Sigma (DMAIC) methodologies to improve process stability and reduce variation in high-volume production

• Contributed to Hardware-in-Loop (HIL) simulation preparation and execution support, assisting controls teams in validating minor PLC logic updates before deployment to live manufacturing environments.

• Supported evaluation of sensor-based and vision-assisted inspection points by analyzing defect trends and validating signal integration with PLC logic for automated quality checks.

• Assisted in execution of FAT/SAT validation activities by documenting test cases, verifying control sequences, and ensuring system compliance with defined operational requirements.

Controls Engineer Cimpress India Sep 2021 – Jul 2022

• Supported packaging automation line stability by assisting in PLC logic monitoring and HMI alarm reviews, coordinating with maintenance teams to resolve recurring sensor faults and reduce minor stoppages.

• Analyzed SCADA production logs and cycle-time variation trends using Tableau and Excel, helping supervisors identify throughput bottlenecks and improve on-time order completion performance by nearly 10%.

• Assisted in time studies, line balancing, and process analysis to improve throughput on pilot automation lines

• Supported analysis of production KPIs, SCADA trends, and performance metrics to identify inefficiencies

• Participated in Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT) for new conveyor modules, documenting test observations and supporting technicians during functional validation and commissioning activities.

• Troubleshot PLC-controlled conveyor and packaging systems using Siemens and Allen-Bradley PLC platforms, diagnosing sensor faults, motor issues, and control signal failures to reduce downtime

• Performed I/O mapping and signal validation between PLCs (Siemens / Rockwell) and field devices to ensure accurate automation response during production operations.

• Assisted controls engineers in basic Hardware-in-Loop (HIL) simulation validation and I/O signal verification, helping ensure actuator response accuracy before deployment on live production lines.

• Conducted structured workflow observation and AutoCAD layout reviews for semi-automated packing zones, contributing to zone reorganization initiatives that reduced operator walking distance by approximately 17%.

• Contributed to Six Sigma root cause workshops using fishbone diagrams and Minitab control charts, supporting teams in addressing recurring print quality deviations affecting rework levels and schedule adherence.

• Participated in validation of automated conveyor and packaging systems during commissioning by supporting functional testing, I/O verification, and documenting system behavior against expected conditions. Junior Controls Engineer HCLTech India Apr 2019 – Aug 2021

• Supported controls engineers in basic PLC logic troubleshooting and signal validation activities on pilot automation lines, helping reduce minor stoppage response time by approximately 12%.

• Performed basic PLC troubleshooting on Siemens and Allen-Bradley systems by analyzing I/O signals, HMI alarms, and control system behavior on pilot automation lines.

• Assisted in validating control logic flow and signal response on PLC-based systems (Rockwell / Siemens) during system testing and debugging.

• Assisted in monitoring SCADA dashboards and logging recurring HMI alerts into Excel trackers, enabling maintenance teams to prioritize corrective actions improving equipment utilization stability.

• Updated process flow and control sequence documentation in Visio following engineering modifications, helping operators understand automated station behavior and reducing operational clarification needs during shifts.

• Maintained line balancing timing sheets and workstation utilization summaries in Advanced Excel, supporting minor sequencing adjustments that improved pilot throughput consistency by nearly 7%. EDUCATION

Master of Science in Engineering Management

Trine University, United States May 2024

Bachelor of Technology in Electronics and Communication Engineering (ECE) Vidya Jyothi Institute of Technology, Hyderabad, India May 2020 PROJECTS

Electronic Assembly Line Productivity Improvement

• Conducted structured time studies on electronic assembly tasks, identifying imbalance patterns and improving shift output efficiency by 11%.

• Built workstation workload comparison sheets in Excel, helping supervisors redistribute operator tasks and stabilize takt adherence during peak demand.

• Reviewed OEE dashboards with engineering teams, highlighting micro-stoppage drivers that impacted throughput consistency across primary assembly lines.

• Supported pilot workflow adjustments validated through daily performance tracking, reducing backlog carryover occurrences across two consecutive production cycles.

Downtime Reduction and Equipment Availability Optimization

• Analyzed downtime trends using SQL production extracts and Power BI dashboards, helping reduce minor stoppages by approximately 8%.

• Coordinated preventive maintenance follow-ups with controls technicians, improving machine availability reliability across high- utilization stations during quarterly reviews.

• Developed capacity planning trackers incorporating staffing variability, enabling production leads to reduce reactive overtime scheduling by 13%.

• Assisted DMAIC improvement initiatives using Minitab statistical validation, stabilizing scrap variation patterns and improving first- pass yield performance.

Order Fulfillment Flow Optimization and Layout Improvement

• Conducted workflow observations using stopwatch tracking and AutoCAD layout analysis, reducing operator walking distance by approximately 17% across packing zones.

• Evaluated fulfillment cycle dashboards in Tableau, helping supervisors identify backlog buildup stages and improve on-time completion performance by 10%.

• Maintained production KPI trackers in Excel pivot reports, supporting planners in balancing workloads during fluctuating order demand periods.

• Participated in Six Sigma workshops analyzing print quality deviations, helping reduce recurring rework volumes impacting shipment scheduling reliability.

Line Balancing and Process Documentation Improvement

• Supported workstation timing data collection and updated Excel line balancing sheets, improving pilot production throughput consistency by approximately 7%.

• Revised SOP flow diagrams in Visio after engineering change requests, reducing operator onboarding clarification time by nearly 15%.

• Monitored SPC trend charts in Tableau dashboards, enabling supervisors to detect early process deviation signals before escalation events.

• Assisted preventive maintenance planning by compiling HMI alert summaries, helping technicians schedule inspections without disrupting daily commitments.

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