Controls & Automation Engineer (PLC/SCADA)

Professional Summary:

Controls & Automation Engineer with 5+ years of experience in designing, programming, commissioning, and supporting PLC, HMI, and SCADA systems for automotive manufacturing and industrial automation. Proficient in Rockwell Automation (Studio 5000, ControlLogix/CompactLogix) and Siemens (TIA Portal, S7- 1200/1500) PLC platforms, with extensive experience in automotive assembly lines, conveyor systems, robotic cells, material handling, and special purpose machines (SPMs). Skilled in developing control logic, machine sequences, interlocks, fault diagnostics, and automated recovery routines, while integrating field devices and industrial networks including EtherNet/IP, PROFINET, Modbus TCP, and IO-Link. Experienced in FAT, SAT, I/O checkout, commissioning, startup, and production. Support for high-volume manufacturing lines. Strong background in troubleshooting PLC, HMI, drives, and robotic systems, performing root cause analysis to minimize downtime and improve OEE. Proven ability to lead commissioning activities, coordinate with cross- functional teams, mentor junior engineers.

Technical Expertise:

• PLC & SCADA Platforms: Allen-Bradley ControlLogix/CompactLogix (Studio 5000), Siemens S7-1200/1500

(TIAPortal),Schneider Modicon M580 (EcoStruxure/Unity Pro), FactoryTalk View SE/ME, Siemens WinCC.

• Industrial Protocols & Networks: Modbus TCP/RTU, MQTT, EtherNet/IP, OPC UA, PROFINET, Profibus, SNMP, CAN, LIN, and standard TCP/IP networking for secure, interoperable BMS/EPMS and automation system integration.

• Control Logic & Programming: Ladder Logic, Function Block Diagram (FBD), Structured Text, interlocks, fail-safe logic, redundancy, and SOO-based control implementation.

• Manufacturing & Automotive Automation: Conveyor systems, assembly lines, robotic work cells, palletizers, machine vision integration, barcode/RFID tracking, traceability systems, and automated production equipment for automotive and discrete manufacturing environments.

• Motion Control & Drives: Configuration and commissioning of VFDs, servo drives, motion controllers, encoders, safety relays, and distributed I/O systems for high-speed automated machinery and conveyor applications.

• Robotics & Integration: Industrial robot integration, end-of-line automation, safety interlocking, machine-to- machine communication, and coordination of PLC-controlled robotic manufacturing cells.

• Motion Control & Robotics: Servo motion control, robotic cell integration, safety circuits, end-of-line automation, and synchronized machine operation.

• Tools & Utilities: AutoCAD Electrical, EPLAN, Bluebeam, MS Project, Excel (VBA) for schematics, documentation control, reporting, and project scheduling.

• RCA & Documentation: RCA preparation, Breakdown reports,UP time Reports

• Electrical & Instrumentation: Control panel design support, field wiring verification, sensor selection, instrumentation calibration, motor control circuits, MCC integration, and troubleshooting of electrical and automation systems.

• Process Optimization & Continuous Improvement: Cycle-time reduction, throughput improvement, downtime analysis, OEE monitoring, production bottleneck elimination, and implementation of automation enhancements to improve operational efficiency.

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Education:

Master of Science, Computer technology Eastern Illinois Universit IL, USA. (May 2025)

Bachelor of Technology, Information Technology, National Institute of Technology, Durgapur, India. (Jun 2020)

Dheeraj Sai Chakravarthy Akunuri

Location: Austin, TX Email: ****************@*****.*** Phone: +1-512-***-****

Professional Experience:

Client: PACCAR North Texas, US July 2024 – Present Role: Controls Engineer

Responsibilities:

Maintained and supported Allen-Bradley ControlLogix and CompactLogix PLC programs using Studio 5000, implementing logic modifications, troubleshooting production issues, and maintaining version-controlled backups.

Performed online PLC troubleshooting and logic enhancements to support automated manufacturing equipment, conveyor systems, material handling systems, and robotic work cells while minimizing production downtime.

Utilized Studio 5000 Logix Designer, FactoryTalk View SE/ME, FactoryTalk Linx, FactoryTalk AssetCentre, and RSNetWorx for PLC programming, HMI development, diagnostics, system backups, and controls maintenance.

Supported industrial communication networks including EtherNet/IP, PROFINET, DeviceNet, and Modbus TCP, ensuring reliable communication between PLCs, HMIs, VFDs, remote I/O, robots, and field devices.

Integrated and supported FANUC and ABB robotic systems, including robot-to-PLC handshaking, production sequencing, fault recovery, safety interlocks, and automated changeovers.

Developed and maintained FactoryTalk View SE/ME HMI applications, improving operator visibility, alarm management, equipment diagnostics, and maintenance response time.

Supported automated production systems including conveyor networks, robotic stations, assembly equipment, pallet transfer systems, and automated material handling systems, ensuring maximum equipment availability.

Performed preventive and corrective maintenance on PLCs, HMIs, VFDs, servo systems, industrial networks, and automation hardware to improve system reliability and reduce unplanned downtime.

Participated in equipment commissioning and production startup activities, including I/O verification, PLC validation, safety circuit testing, FAT/SAT support, and production readiness testing.

Collaborated with controls, manufacturing, quality, robotics, and maintenance teams to perform Root Cause Analysis (RCA), implement corrective actions, and drive continuous process improvements to increase system performance and Overall Equipment Effectiveness (OEE).

Supported engineering projects involving control system upgrades, equipment modifications, production line optimization, and automation improvements while ensuring compliance with engineering and safety standards.

Implemented OEE, downtime tracking, and production analytics through SCADA and historian integration to enhance visibility and decision-making.

Troubleshooting & Optimization: Diagnosed PLC, robot, and network issues during commissioning; optimized cycle times, robot paths, and conveyor flow to improve throughput.

Documentation & Standards :Prepared control narratives, wiring diagrams, I/O lists, and as-built documentation aligned with customer and industry standards

Managed project schedules, vendor coordination, and installation supervision to ensure on-time delivery of automation milestones.

Worked with cross-functional teams to implement engineering changes, equipment upgrades, and process improvements while maintaining production requirements.

Ensured compliance with industrial standards and customer specifications for automation programming, machine safety, documentation, and commissioning activities.

Performed troubleshooting of automated systems including conveyors, robotic cells, assembly stations, palletizers, packaging machines, and material handling systems.

• Engineering Environment: Allen-Bradley ControlLogix & CompactLogix PLCs,, FactoryTalk View SE/ME, Ignition SCADA, WinCC, Modbus TCP/IP, BACnet/IP, SNMP, MQTT, VLAN/DMZ Network Segmentation, DCIM Integration, Historian Systems.

Client: Dürr India, Chennai,India

Role: Project Engineer

Responsibilities:

Developed and deployed PLC logic in Allen-Bradley ControlLogix/CompactLogix for conveyors, palletizers, case packers, fillers, and high-speed bottle handling equipment.

Managed project schedules, vendor coordination, and installation supervision to ensure on-time delivery of automation milestones.

Led automation engineering activities for large-scale automotive manufacturing automation systems, including conveyor lines, robotic cells, body shop equipment, and material handling systems, covering controls design, integration, and commissioning.

Developed and modified PLC programs using Siemens S7-1200/S7-1500 (TIA Portal V17/V18) and Allen-Bradley ControlLogix/CompactLogix (Studio 5000 Logix Designer) for automotive production equipment, conveyor systems, transfer units, and automated assembly stations.

Configured and maintained HMI/SCADA applications using Siemens WinCC, WinCC Unified, and FactoryTalk View SE/ME for operator control, alarm management, diagnostics, and real-time production monitoring.

Designed and implemented machine sequences, safety interlocks, permissives, fault handling, and automatic recovery logic for automotive conveyors, lift tables, pallet transfer systems, robotic stations, and production cells.

Integrated and supported industrial communication networks including PROFINET, PROFIBUS, EtherNet/IP, CIP Safety, Modbus TCP/IP, and Industrial Ethernet for communication between PLCs, HMIs, robots, VFDs, servo drives, and remote I/O devices.

Supported integration of ABB and FANUC robotic systems, including robot-to-PLC handshaking, cycle sequencing, safety signals, fault recovery, and production changeover activities.

Configured industrial drives and motion systems including Siemens SINAMICS, Rockwell PowerFlex VFDs, and servo systems for conveyor motion control, positioning applications, and synchronized machine operation.

Executed FAT, SAT, I/O validation, loop checks, commissioning, and startup activities for automotive production lines, ensuring equipment reliability and production readiness.

Performed PLC online diagnostics, troubleshooting, and software modifications using TIA Portal, Step 7, Studio 5000, FactoryTalk Linx, RSLogix/Logix Designer, and FactoryTalk AssetCentre to reduce downtime and improve equipment availability.

Collaborated with mechanical, electrical, robotics, and manufacturing teams to validate MCC panels, control cabinets, safety circuits, sensors, actuators, and field instrumentation according to customer automation standards.

Optimized conveyor logic, robot sequences, cycle times, and production flow to improve line efficiency, OEE performance, and manufacturing throughput.

Managed automation project activities including vendor coordination, installation support, controls documentation, I/O lists, electrical drawings, control narratives, and as-built documentation.

Implemented production monitoring solutions using SCADA, historian systems, and industrial analytics platforms for downtime tracking, fault analysis, and continuous improvement initiatives. Engineering Environment: Rockwell Studio 5000, RSLogix 5000, FactoryTalk View SE/ME, FactoryTalk Linx, FactoryTalk Historian, EtherNet/IP, Modbus TCP/IP, BACnet/IP, MQTT, VFDs, Servo Drives, Industrial Sensors, Actuators, AutoCAD Electrical, EPLAN, Python, Siemens Tia Portal V15 to V19, Siemens Drive,Siemens Servo. Jul 2020 – Jul 2023

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