Sai Prasada1

Controls and Automation Engineer with 4+ years of hands-on experience supporting industrial systems across warehouse automation and automotive manufacturing environments. Strong background in PLC programming (Siemens, Allen-Bradley), SCADA systems, and real-time troubleshooting of conveyors, robotics, and process equipment. Experienced in commissioning, system validation (FAT/SAT), and resolving production-critical issues under time constraints.

Proven ability to improve system reliability, reduce downtime, and support high-volume operations through practical engineering solutions. Comfortable working on-site with cross-functional teams including operations, maintenance, and OEM vendors.

Control & Systems Engineer - Hargrove Controls Automation - Mobile, Alabama

(2024-02)

• Owned the full lifecycle of industrial automation projects, including system design, PLC/HMI development, testing, commissioning, and post-deployment support.
• Designed and developed PLC-based control systems (Siemens, Allen-Bradley) using IEC 61131-3 languages, ensuring scalable and reliable machine and process control.
• Engineered SCADA and HMI solutions (Ignition, FactoryTalk View) for real-time monitoring, alarm management, and data visualization.
• Defined and executed testing strategies, including simulation, I/O validation, and control logic verification to ensure system functionality and performance.
• Led commissioning activities such as FAT, SAT, loop checks, and system startup, ensuring smooth handover to operations.
• Integrated industrial communication protocols (OPC UA, Modbus, Profinet, EtherNet/IP) to enable seamless connectivity across systems.
• Developed Python-based tools and automation workflows for data logging, reporting, and system analytics.
• Designed electrical schematics and control panels using AutoCAD, ensuring compliance with industry safety standards (UL, CE, NFPA).
• Deployed and maintained automation applications, including containerized services using Docker and CI/CD practices.
• Provided on-site and remote troubleshooting support, resolving issues across control systems, field devices, and network communications.
• Maintained detailed project documentation, including design specifications, test reports, and as-built drawings.
• Collaborated with cross-functional teams and stakeholders to deliver projects on time while meeting quality and performance expectations.
• Drove continuous improvements by optimizing control strategies, enhancing system reliability, and reducing downtime.
• Trained and mentored engineers and technicians on system design, programming, testing, and troubleshooting best practices.

Controls Engineer - Hyundai Motors - India

(2021-05 - 2023-04)

• Developed and maintained PLC control logic for automated manufacturing processes across body shop, paint shop, and assembly lines, ensuring seamless production flow.
• Supported commissioning and integration of automated systems including robotic stations, conveyor systems, and process equipment within automotive production environments.
• Troubleshot process control issues impacting production lines, minimizing downtime and ensuring continuous operation of critical manufacturing systems.
• Optimized control strategies and interlocks to improve process efficiency, cycle time, and equipment reliability.
• Performed system validation activities including I/O checks, loop testing, signal verification, and functional testing prior to production release.
• Monitored and maintained industrial communication networks (Profinet, Ethernet/IP, Modbus TCP) between PLCs, HMIs, robots, and field devices.
• Analyzed alarms, trends, and system logs to identify recurring faults and implemented corrective actions to improve process stability.
• Supported operation and troubleshooting of VFDs, servo drives, sensors, safety systems, and control panels used in automated manufacturing.
• Collaborated with production, maintenance, and quality teams to resolve process deviations and improve overall equipment effectiveness (OEE).
• Ensured compliance with industrial safety standards including interlocks, emergency systems, and lockout/tagout (LOTO) procedures.
• Maintained and updated technical documentation including control narratives, P&IDs, I/O lists, and electrical schematics.

Master of Science - Computer and Information Sciences - Auburn university at Montgomery (2024-08)