Controls & Automation Engineer (PLC/SCADA/IIoT)

VIVEK RAMANAND PAMULAPATI

Controls & Automation Engineer PLC · SCADA · HMI · Industry 4.0

***********************@*****.*** · 216-***-**** · https://www.linkedin.com/in/vivek-ramanand-pamulapati-3a665a260/ Results-driven Controls Engineer with 3+ extensive hands-on experience in automotive and industrial automation. Skilled in multi-vendor PLC programming (Rockwell Allen-Bradley Studio 5000/ControlLogix/GuardLogix, RSLogix 500; Siemens TIA Portal; B&R), control-system design, and HMI/SCADA development, anchored by ISO 13849 and IEC 61508 safety compliance. Proficient in IIoT and data analytics (Python, SQL, Power BI, Tableau) to enable enterprise visibility, predictive maintenance, and continuous improvement. Demonstrated success delivering meaningful OEE gains, MTTR reductions, and throughput improvements through legacy migrations, modernized architectures, and data-driven decision making. Certifications include Rockwell, Siemens, ISA CAP, and OSHA 10. CORE COMPETENCIES

PLC Programming: Ladder Logic, Allen-Bradley Studio 5000 · RSLogix 500 · Siemens TIA Portal, B&R

Control Systems: Control System Design & Integration · PID Tuning & Diagnostics · HMI Development · SCADA · I/O Systems (Digital/Analog) Industrial Systems: Motor Control & Interlocks · Conveyor Automation · P&ID Interpretation · Wiring Diagram Review · Commissioning Support

Reliability & CI: Root Cause Analysis · Preventive & Predictive Maintenance · MTBF/MTTR · Continuous Improvement · Lean Principles

Industry 4.0 Tools: Python · SQL · Power BI · Tableau · Anomaly Detection · Time-Series Analysis · Functional Specification Documentation

Design Tools: AutoCAD · SolidWorks · EPLAN Electric P8 · ePlan / Electrical Schematics · Control Panel Design

Safety Standards: IEC 61508, ISO 13849, OSHA Standards, SIL (Safety Integrity Level). PROFESSIONAL EXPERIENCE

Controls Engineer General Motors Arlington, TX Aug 2025 – Present Job Responsibilities

• Enterprise Control Architecture: Design, program, and maintain centralized plant-wide control architectures utilizing Allen-Bradley ControlLogix and GuardLogix hardware platforms via Studio 5000.

• Safety Matrix Design & Compliance: Draft complex control panel layouts, electrical schematics, and safety-critical instrumentation using EPLAN Electric P8 and AutoCAD adhering to ISO 13849 PLd and IEC 61508 standards.

• Industrial Data & IIoT Pipelines: Develop and maintain Python-based edge data extraction scripts to stream real-time PLC tags via OPC-UA protocols into relational SQL databases for enterprise-level visibility.

• Cross-Functional Commissioning: Lead on-site commissioning, factory acceptance testing (FAT), and site acceptance testing (SAT) across multi-station assembly environments alongside cross-functional production teams.

Key Achievements

• Automotive Line Modernization: Refactored disparate PLC logic across a 45-station assembly line from 5 separate OEM machinery scopes into a master GuardLogix safety network; eliminated systemic cycle-time bottlenecks to boost plant OEE by 8.5% and scale throughput from 248 to 270 units/hour.

• Downtime Minimization via Analytics: Built an automated telemetry pipeline to log real-time controller alarm diagnostics, developing root-cause dashboards that accelerated MTTR by 40% and slashed unplanned line downtime to less than 15 minutes per shift.

• Quality & Validation Excellence: Programmed overhead Power & Free (P&F) conveyor tracking, zone accumulation, and automatic jam-recovery logic in Ladder Diagram (LD), securing a 99.2% First-Pass Yield (FPY) during final Production Part Approval Process (PPAP). Controls and Automation Engineer Siemens · Karnataka, India Mar 2021 – July 2023 Job Responsibilities

• Platform Migrations & Upgrades: Refactored legacy industrial codebases and converted outdated, unmapped control logic into structured, modular, and tag-based architectures.

• Multi-Protocol System Integration: Engineered physical network interfaces and software translation layers to bridge third-party industrial hardware into centralized SCADA platforms using Modbus TCP/IP and industrial Ethernet.

• Process Loop Optimization: Conducted advanced loop tuning, sensor calibration, and diagnostic profiling on critical analog I/O loops tracking high-frequency thermal, flow, and pressure variations.

• Predictive Maintenance Frameworks: Designed business intelligence interfaces using Power BI and Tableau to map machine operation baselines, tracking continuous improvement and reliability milestones.

Key Achievements

• Brownfield Legacy Migration: Migrated legacy RSLogix 500 "spaghetti" code from obsolete SLC 500 processors into modern Studio 5000 Add-On Instructions (AOIs), accelerating machine cycle times by 12% and pushing production throughput from 250 to 280 units/hour.

• Predictive Asset Reliability Deployment: Engineered a plant-wide data pipeline streaming over daily high-frequency time-series PLC data points into optimized databases, executing an anomaly detection script that cut unplanned downtime by 22% and extended MTBF from 120 to 154 hours.

• Network & Hardware Cost Optimization: Interfaced specialized B&R Control Systems into a unified industrial network to eliminate multi-platform data drops—boosting overall OEE by 8.2% while overhauling panel layouts to save in annual maintenance costs. TECHNICAL PROJECTS

Multi-OEM Integration & Modernization of a 45-Station Assembly Line - Allen-Bradley ControlLogix/GuardLogix, Power & Free Conveyor Logic, Panel Design, & Industrial Analytics.

• Engineered & Unified Control Architecture: Refactored disparate PLC logic from 5 separate OEM machinery scopes into a centralized Allen-Bradley ControlLogix/GuardLogix network using Studio 5000; eliminated cycle-time bottlenecks to boost OEE by 8.5% and increase throughput from 248 to 270 units/hour.

• Developed Dynamic Conveyor & Safety Logic: Programmed overhead Power & Free (P&F) conveyor tracking, accumulation, and jam-recovery logic in Ladder Diagram (LD) while using EPLAN/AutoCAD to design an ISO 13849 PLd compliant safety matrix (light curtains/E-stops), securing a 99.2% First-Pass Yield (FPY) during final PPAP.

• Implemented Industry 4.0 Analytics: Built an automated data pipeline using Python and SQL to log real-time controller alarm diagnostics from the line; developed root-cause analysis dashboards that accelerated MTTR by 40% and slashed unplanned line downtime to less than 15 minutes per shift. Brownfield Legacy Migration & OEE Optimization - RSLogix 500 to Studio 5000 Migration, B&R Systems, & Continuous Improvement.

• Executed Legacy Migration & Code Optimization: Refactored and migrated legacy RSLogix 500

"spaghetti" code from obsolete SLC 500 hardware into modular, tag-based Studio 5000 Add-On Instructions (AOIs), accelerating cycle times by 12% and increasing throughput from 250 to 280 units/hour.

• Integrated Multi-Platform Networks: Bridged specialized B&R Control Systems into a unified Allen-Bradley Ethernet network via Modbus TCP/IP for centralized SCADA control; eliminated communication bottlenecks to boost OEE by 8.2%.

• Redesigned Electrical Hardware Architecture: Utilized EPLAN Electric P8 and AutoCAD to overhaul electrical schematics, optimize digital/analog I/O distribution, and design updated control panels—modernizing legacy hardware to save $45,000 in annual maintenance costs and eliminate obsolete spare-part reliance.

IoT-Enabled Smart Conveyor & Sortation System - PLC/SCADA Integration, Python Data Pipelines, & Predictive Maintenance.

• Developed Industrial IoT Data Pipelines: Engineered a plant-wide data extraction pipeline using Python to stream real-time PLC tags (current, temperature, cycle times) via OPC-UA into optimized SQL databases handling over daily data points; deployed a time-series anomaly detection script that cut unplanned downtime by 22%.

• Designed Live Reliability Dashboards: Built customized Power BI asset health dashboards to track machine trends and automatically compute key operational metrics, successfully extending Mean Time Between Failures (MTBF) from 120 hours to 154 hours via data-driven preventive maintenance.

• Streamlined Fault Diagnostics & SCADA Integration: Integrated automated SCADA alarm diagnostics to drastically accelerate root-cause analysis, successfully reducing Mean Time to Repair

(MTTR) by 35% and cutting average line troubleshooting times from 45 minutes to under 15 minutes.

EDUCATION

M.S. Information Technology · Cumberland University, Tennessee Jan 2024 – Aug 2025 B.Tech in Computer Science · New Horizon University, India Jul 2018 – Jul 2022 CERTIFICATIONS

• Rockwell Automation Certified ControlLogix System Maintainer / Programmer

• Siemens Certified Automation Engineer (TIA Portal)

• OSHA 10-Hour General Industry Certification

• ISA Certified Automation Professional (CAP)

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