Automation & Controls Engineer

Pavan Sai Kakani

+1-659-***-**** Email: **************@*****.***

PROFESSIONAL SUMMARY

Automation & Controls Engineer with over 3+ years of experience specializing in the design, programming and deployment of complex industrial control systems. Expert in Allen-Bradley (ControlLogix/CompactLogix) and Siemens (S7-1200/1500) environments, with a strong focus on optimizing high-speed manufacturing and material handling operations. Proven ability to lead full-cycle engineering projects, from initial P&ID development to final commissioning and site acceptance testing. TECHNICAL SKILLS

• PLC Platforms: Allen-Bradley ControlLogix/CompactLogix, RSLogix 5000; programming and troubleshooting.

• SCADA & HMI: Ignition, Wonderware InTouch, FactoryTalk View, Siemens WinCC, GE iFIX.

• MHE & Robotics: Conveyors, sortation, automated storage, print/apply, scanners; FANUC/ABB robotics, PLC integration and data exchange.

• Industrial Networks: EtherNet/IP, ControlNet, DeviceNet, Profibus, AS-i, Modbus, OPC UA, MQTT.

• Drive & Vision Systems: Servo/VFD motor controls; Cognex/Keyence vision integration and quality automation.

• Electrical & Controls: Distribution systems, panel troubleshooting, I/O configuration.

• Data & Reporting: OSIsoft PI, Wonderware Historian, SQL Server, Power BI, Tableau.

• Software & Docs: Python, MS Office; P&IDs, I/O lists, network diagrams. PROFESSIONAL EXPERIENCE

Automation Engineer Johnson Controls Milwaukee, WI Jan 2024 – present

• Programmed and maintained Allen-Bradley ControlLogix and CompactLogix PLCs using Studio 5000/RSLogix 5000 for manufacturing and MHE systems.

• Provided 24/7 troubleshooting and support for PLC, HMI, SCADA, VFD and control systems, minimizing downtime.

• Managed industrial networks including EtherNet/IP, DeviceNet, ControlNet, ProfiBus, Modbus TCP/IP and OPC UA.

• Integrated PLCs with Ignition, Wonderware and FactoryTalk View for real-time monitoring and control.

• Deployed alarm management and diagnostics solutions, improving incident response by 25%.

• Developed Python automation tools for PLC tag generation, HMI validation and engineering workflow optimization.

• Built Power BI dashboards using SCADA and historian data to monitor OEE, runtime and downtime trends.

• Supported commissioning, startup, FAT, SAT and validation activities for automation projects.

• Maintained control documentation including P&IDs, FDS, I/O Lists and network architecture diagrams.

• Performed root cause analysis (RCA) and implemented continuous improvement initiatives to enhance system reliability.

Automation Engineer Orbit Technologies Hyderabad, India June 2021 – Aug 2022

• Programmed and commissioned Allen-Bradley, Siemens S7 and Mitsubishi PLCs for conveyor and assembly automation.

• Developed SCADA/HMI applications using Ignition, Wonderware, GE iFIX and FactoryTalk View.

• Integrated FANUC and ABB robots with PLC systems for automated material handling and production processes.

• Configured industrial communication protocols including EtherNet/IP, Profinet, ProfiBus, Modbus TCP/IP and OPC UA.

• Executed FAT, SAT, installation, startup and commissioning activities across multiple customer sites.

• Established process data collection frameworks supporting IATF 16949 compliance and operational reporting.

• Led troubleshooting and emergency support efforts, minimizing production impact during critical equipment failures.

• Coordinated emergency technical resources to resolve equipment failures and minimize production impact. EDUCATION

Masters of Science in University of Alabama at Birmingham, USA

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