Diya Chaudhari

Automation & Control Engineer with hands-on experience in PLC programming, HMI development, electrical control panel design, machine commissioning, FAT/SAT, and pharmaceutical machinery automation. Proven expertise across Mitsubishi, Delta and Xinjie PLC platforms, VFDs, servo systems, industrial communication protocols and machine validation. Skilled in electrical system design, technical documentation, root cause analysis and cross-functional project execution, with exposure to automation projects across multiple manufacturing sites in India.

Graduate Trainee Engineer at Bharat Forge Ltd. (2025-02 – Present)

• Developed PLC ladder logic and operator-friendly HMI screens for Delta, Mitsubishi and Xinjie-based automation systems, covering machine control, alarms, diagnostics and production monitoring.
• Configured and commissioned servo drives, VFDs, closed-loop stepper drives and BLDC motor applications for production equipment.
• Performed electrical troubleshooting, safety interlock verification, I/O checking and functional testing to maximize machine availability and uptime.
• Led root cause analysis (RCA) and corrective action implementation for machine breakdowns, and monitored OEE, downtime and production efficiency metrics.
• Diagnosed PLC-based automation faults including I/O diagnostics, sensor validation and control-system fault identification on MCCs, VFDs, control panels and power distribution systems.
• Supported Lean Manufacturing, 5S, TPM and Kaizen initiatives to improve plant performance, alongside calibration and testing of sensors, transmitters and actuators.
• Prepared electrical BOMs, control panel layouts, PLC I/O lists, SOPs, BUSOPs and breakdown analysis reports; participated in FAT, SAT and machine validation activities.
• Supported automation projects across Pune, Bangalore, Chennai and Hyderabad, coordinating with production and cross-functional teams.

Automation & Control Engineer at Exenity Systems Pvt. Ltd. (2024-01 – 2025-02)

• Designed and developed electrical and pneumatic automation systems for pharmaceutical and process-industry machinery based on URS and approved project scope.
• Prepared detailed Electrical BOM, Pneumatic BOM, Sensor Lists, PLC I/O Lists and Control Panel Design documentation for multiple automation projects.
• Engineered electrical control panel layouts including component selection, panel sizing, cable routing, terminal arrangements and power distribution architecture.
• Designed and validated pneumatic control systems comprising cylinders, solenoid valves, FRLs, manifolds, pressure regulators and pneumatic actuators.
• Configured, tested and commissioned Mitsubishi FX5U PLCs and GOT2000 HMIs, including I/O verification, hardware diagnostics, communication setup and program management.
• Configured and optimized Mitsubishi VFDs (FR-D, FR-E, FR-A) for motor control, including speed control and acceleration/deceleration parameters.
• Conducted FAT, alarm validation, user access testing and real-time machine commissioning across pharmaceutical production equipment.
• Developed alarm management systems, machine interlocks and fault-handling logic to improve reliability and operator safety.
• Created and maintained electrical schematics, wiring diagrams, SOPs, FAT reports and commissioning reports; collaborated with mechanical, process and validation teams.

Diploma in Electrical Engineering – Shivajirao Jhondhale College of Polytechnic (2019 – 2020)

B.E. in Electrical Engineering – Zeal College of Engineering & Research (2023 – 2024)