Systems & Controls Engineer

Vishnu Vardhan G

Systems & Controls Engineer

United States +1-314-***-**** ****************@*****.*** www.linkedin.com/in/vishnu-reddika Professional Summary

Systems & Controls Engineer with 4+ years of experience supporting industrial automation and manufacturing operations. Experienced in PLC programming, machine startup, commissioning, troubleshooting, and production support across manufacturing and automotive environments. Hands-on experience with Siemens and Allen-Bradley PLCs, HMI/SCADA systems, VFDs, industrial communication networks, motor controls, and field instrumentation. Skilled in diagnosing control issues, performing I/O validation, supporting FAT/SAT activities, and working closely with maintenance, production, and engineering teams to improve equipment reliability, reduce downtime, and support continuous process improvements.

Technical Skills

• PLC & Automation: Allen-Bradley Studio 5000, ControlLogix, CompactLogix, Siemens TIA Portal, STEP 7, Ladder Logic, Function Block Diagram (FBD), Structured Text (ST), PLC Programming, PLC Troubleshooting

• Commissioning & Startup: Machine Commissioning, System Startup, FAT, SAT, I/O Checkout, Loop Testing, Functional Testing, Interlock Validation, Root Cause Analysis

• HMI / SCADA: FactoryTalk View SE/ME, Siemens WinCC, HMI Development, SCADA Systems, Alarm Management

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

• Electrical & Controls: PowerFlex VFDs, SINAMICS Drives, Motor Controls, MCCs, Control Panels, Field Instrumentation, Sensors, Pneumatic Systems, Safety Circuits, Emergency Stops (E-Stops), Lockout/Tagout (LOTO)

• Engineering Tools: AutoCAD Electrical, FactoryTalk Linx, Siemens TIA Portal, Studio 5000 Logix Designer, Multimeters, Oscilloscopes

• Soft skills: Communication, Collaboration, Cross-functional Collaboration, Decision Making, Problem Solving, Time Management, Analytical Thinking & Numerical Accuracy Professional Experience

Systems & Controls Engineer – Modineer, USA March 2025 – Present

• Develop and modify PLC programs using Allen-Bradley ControlLogix/CompactLogix (Studio 5000) and Siemens S7 PLCs (TIA Portal) to support production equipment, improve machine sequencing, and resolve control system issues.

• Supported commissioning and startup activities by performing I/O checkout, loop testing, interlock validation, and functional testing to ensure smooth equipment startup and system handover.

• Troubleshoot PLC logic, HMI alarms, and field devices to identify root causes of production issues, minimizing downtime and improving equipment reliability.

• Implement control logic enhancements for alarms, equipment sequencing, interlocks, and machine operation while following change management procedures and validating updates before deployment.

• Support manufacturing and maintenance teams by diagnosing electrical and controls issues related to sensors, VFDs, motor controls, and industrial communication networks during production.

• Work closely with mechanical, electrical, and process engineers during equipment upgrades to integrate new devices, update PLC programs, verify I/O, and support successful system commissioning.

• Maintain and update control system documentation, including PLC backups, I/O lists, electrical drawings, and operating sequences to support maintenance activities and future system modifications.

• Updated I/O lists, control narratives, sequence documentation, and field markups to ensure accurate system records and support future maintenance activities. Systems Engineer -Metrix Engineers, India June 2020 – July 2023

• Supported the development, testing, and commissioning of automated control systems for manufacturing equipment and production processes.

• Performed troubleshooting of PLC logic, HMI applications, and industrial communication networks to identify and resolve control system issues during startup and production.

• Executed functional testing, I/O validation, and interlock verification to ensure reliable operation of machines under both normal and fault conditions.

• Verified communication between PLCs, HMIs, remote I/O, field instrumentation, sensors, and actuators to ensure reliable system operation during testing and commissioning.

• Assisted with system integration activities by validating controller communication, field instrumentation, and machine interfaces before production release.

• Investigated control system faults, communication issues, and equipment failures using electrical drawings, PLC diagnostics, and engineering tools to determine root causes.

• Supported commissioning and startup by performing loop checks, functional testing, and system validation while working closely with electrical and mechanical teams.

• Tested and validated PLC programs, sensors, control valves, VFDs, and other field devices to ensure proper machine operation and process performance.

• Collaborated with controls, electrical, and production teams to implement control system improvements, verify corrective actions, and improve equipment reliability.

• Maintained technical documentation, including test records, validation results, troubleshooting logs, and engineering changes to support ongoing maintenance and future system upgrades.

• Supported preventive maintenance activities by troubleshooting PLC-controlled equipment, verifying control system performance, and assisting with equipment upgrades to improve system reliability. Education

Master of Arts in Information Technology Management. Webster University, USA.

May 2025

Bachelor of Technology May 2022

Telangana University, Telangana, India

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