Controls & Automation Engineer (PLC/SCADA)

Bhavya Nenavath Controls & Automation Engineer

TX, USA +1-214-***-**** ***************@*****.*** LinkedIn

PROFESSIONAL SUMMARY

Controls and Automation Engineer with 5+ years of progressive experience spanning PLC programming, SCADA development, and industrial process automation across manufacturing environments in India and the United States. Hands-on track record delivering uptime improvements, reducing scrap rates, and cutting commissioning timelines through practical engineering and cross-functional teamwork. Comfortable owning projects end-to-end — from I/O design and panel integration to HMI development and site acceptance testing.

PROFESSIONAL EXPERIENCE

B&R Industrial Automation TX, USA Sep 2022 – Present

Controls & Automation Engineer

Designed and deployed Allen-Bradley ControlLogix PLC programs for 2 new packaging lines at a regional food & beverage facility, achieving a 99.1% uptime average over the first 8 months of operation.

Developed FactoryTalk View SE SCADA application covering 240+ I/O points, enabling remote monitoring of 4 production cells and reducing operator rounds by approximately 30%.

Led panel design review and UL 508A compliance verification for a $420K capital project, catching 3 design conflicts early and saving an estimated $18,000 in field rework costs.

Configured Ethernet/IP and Modbus TCP/IP network architecture for plant-floor devices, resolving intermittent communication faults that had previously caused 2–3 nuisance shutdowns per week.

Supported continuous improvement efforts by building a PLC-based OEE data collection routine, giving engineering management real-time visibility into availability, performance, and quality metrics.

Collaborated with process engineers and electrical contractors during brownfield retrofits, managing scope changes and ensuring all HMI touchscreens, VFDs, and safety relays were commissioned on schedule.

Authored standard operating procedures and PLC coding standards adopted across 3 active project sites, reducing onboarding time for new project engineers by roughly 2 weeks.

Precision Industries Pvt. Ltd. Pune, Maharashtra, India Feb 2020 – Dec 2020

Automation Engineer

Led PLC upgrade of 5 legacy Siemens S5 units to S7-1500 platform, eliminating a recurring spare-parts shortage that had caused an average 11 hours of unplanned downtime per month.

Developed Wonderware InTouch SCADA screens for a stamping and welding cell, giving operators real-time visibility into 14 process parameters and cutting operator error reports by 35%.

Coordinated Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT) for a robotic welding integration project, completing commissioning 9 days ahead of the scheduled go-live date.

Designed and implemented an automated reject-tracking module in RSLogix 5000, enabling the quality team to trace root-cause defects to specific shift windows — scrap rate dropped from 4.2% to 2.6% over two quarters.

Mentored two junior technicians on PLC I/O troubleshooting and HMI tag configuration, reducing escalation tickets to senior engineering by approximately 40% within 3 months.

Collaborated with the maintenance team to build a structured PM checklist for 6 robot controllers, cutting mean-time-to-repair (MTTR) by an average of 22 minutes per incident.

Precision Industries Pvt. Ltd. Pune, Maharashtra, India Jun 2019 – Mar 2020

Junior Automation Engineer

Programmed Allen-Bradley MicroLogix PLCs for 3 semi-automated assembly lines, cutting manual intervention time by roughly 28% within the first production quarter.

Built ladder logic and function block routines for conveyor sequencing and reject handling, directly improving line throughput by an estimated 15% on the trim-and-form cell.

Assisted senior engineers in panel wiring reviews and I/O mapping for a new press-brake automation project, helping the team meet a tight 6-week delivery window.

Calibrated proximity sensors, encoders, and VFD drives on packaging lines, reducing unplanned stoppages from roughly 9 per month to about 3.

Maintained detailed redline documentation and updated as-built drawings after each field change, improving audit-readiness during two ISO 9001 surveillance visits.

TECHNICAL SKILLS

PLC Platforms:

Allen-Bradley (ControlLogix, CompactLogix, MicroLogix), Siemens S7-300/400/1500, B&R X20, Omron CP/CJ Series

Programming:

IEC 61131-3 (Ladder Logic, Structured Text, Function Block, SFC), RSLogix 5000 / Studio 5000, TIA Portal, B&R Automation Studio

SCADA / HMI:

FactoryTalk View SE/ME, Wonderware InTouch, Ignition (Inductive Automation), B&R APROL, WinCC

Networking:

Ethernet/IP, Modbus TCP/IP, PROFIBUS, DeviceNet, OPC-UA, OPC-DA

Drives & Motion:

Allen-Bradley Kinetix, PowerFlex VFDs, Siemens SINAMICS, servo tuning, multi-axis coordinated motion

Electrical:

Panel design (UL 508A), I/O mapping, loop drawings, P&IDs, NEC code compliance, AutoCAD Electrical, EPLAN

Industry Tools:

Factory Talk Diagnostics, Asset Centre, Git (version control), MS Project, JIRA

Soft Skills:

Cross-functional collaboration, technical documentation, client-facing project management, mentoring junior engineers

EDUCATION

Master of Science in Health Informatics

Governors State University University Park, Illinois, USA January 2021 – August 2022

CERTIFICATIONS

Rockwell Automation — Studio 5000 Logix Designer Level 1 & 2 (2022)

Siemens — SIMATIC S7-1500 PLC Programming Fundamentals (2021)

B&R Industrial Automation — Automation Studio Structured Text Programming (2023)

OSHA 10-Hour General Industry Safety (2024)

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