ABDELLAH HILALI
Arlington,TX
Summary
Controls and Commissioning Engineer specializing in designing and commissioning automated manufacturing systems and safety controls. Skilled in Safety Logix development, GuardLogix PLC programming, and integrating multi-vendor robotic cells, enhancing production efficiency and safety compliance.
Overview
1
1
Certification
15
15
years of professional experience
Work History
CONTROLS & AUTOMATION ENGINEER
Howmet Aerospace
Fullerton, CA
08.2025 - 04.2026
- Oversee automated manufacturing line controls and field commissioning, providing direct engineering and technical troubleshooting support to skilled maintenance technicians across multi-shift operations.
- Lead Safety Logix development and GuardLogix Safety PLC programming in Studio 5000, configuring safety task routines, safety tags, and safe zone interlocks for active production lines.
- Configure and troubleshoot Allen-Bradley ControlLogix/GuardLogix PLCs, PowerFlex VFDs, ArmorStart controllers, and FANUC robotic cells on active production lines.
- Integrated and troubleshot hardwired safety circuits with Banner (SC10 / SC26) and Allen-Bradley Guardmaster safety relays, ensuring compliance and operational safety with safety light curtains, E-stops, and door interlocks.
- Designed, reviewed, and updated electrical control panel layouts, safety loop diagrams, and field I/O interconnects for plant retrofits using AutoCAD Electrical, enhancing system reliability.
- Executed 4D root-cause failure analysis on unscheduled downtime events, eliminating recurring machine faults and achieving 100% FAS08 and OSHA safety compliance.
CONTROLS & MAINTENANCE TECHNICIAN
IAC Group
Arlington, TX
03.2025 - 08.2025
- Provided controls technical support and real-time troubleshooting for high-volume automotive interior components, including door panels, headliners, center consoles, and instrument panel trims.
- Maintained cell safety integrity by diagnosing dual-channel safety circuit faults across Allen-Bradley Guardmaster relays, Banner safety modules, and guard interlock switches.
- Directed real-time troubleshooting, logic modifications, and maintenance of industrial controls, Allen-Bradley PLCs, drive systems, and heavy-duty sensors to support JIT supply output.
- Programmed Siemens HMIs using the PAL framework to streamline machine control and operator diagnostic screens on assembly cells.
- Applied AutoCAD Electrical for Automation Engineering to maintain accurate redline drawings and electrical wiring diagrams for assembly cells.
- Integrated and calibrated Cognex vision systems and error-proofing gates to validate assembly tolerances prior to final shipment.
AUTOMOTIVE CONTROLS & MAINTENANCE ENGINEER
Magna International
Liberty, MO
01.2024 - 01.2025
- Led commissioning engineering for unionized skilled trades technicians in a high-speed automotive metal chassis and structural body plant.
- Built automated FANUC robotic cells from scratch, taking full charge of GuardLogix Safety PLC development, Safety I/O mapping, and hardware integration between Allen-Bradley PLCs, FANUC robots, and Siemens HMIs.
- Designed and wired hardwired safety loops featuring Banner safety controllers and AB Guardmaster relays to enforce emergency stops, robot safety fence interlocks, and light curtain mute zones.
- Executed full programming and integration of multi-vendor hardware across complex 3-brand vendor environments, establishing EtherNet/IP communications and cell interlocks.
- Programmed and tuned FANUC robots utilizing Weld Spot Tool, Dispense Tool, and path teaching to maintain high-precision chassis weld integrity.
- Referenced EPLAN 8 drawings and modified AutoCAD Electrical schematics for troubleshooting hardware faults and safety loop faults on welding lines.
ROBOTICS & ELECTROMECHANICAL SPECIALIST III-B
Oceaneering International
Houston, TX
11.2022 - 12.2023
- Conducted electrical diagnostics, circuit-level troubleshooting, and preventive maintenance on complex robotic systems, motor drives, safety relay panels, and main control panels.
- Utilized oscilloscopes, multimeters, and specialized software to diagnose signal integrity and safety circuit faults.
- Authored standard operational procedures (SOPs) and maintenance documentation to maximize equipment reliability.
CONTROLS & COMMISSIONING ENGINEER
Dogus Engineering
MO
02.2014 - 10.2022
- Led turnkey commissioning engineering projects, designing and building electrical control panels using Allen-Bradley PLCs and integrated safety systems for hydraulic automation and process control setups.
- Developed Safety Logix routines and panel wiring schematics utilizing Banner and Allen-Bradley safety relays to manage hardwired E-stop circuits, safety mats, and enable switches.
- Integrated motor actuators, beam sensors, motor valves, and advanced field devices into automated production equipment.
- Installed, commissioned, calibrated, and maintained advanced pressure transmitters and flow meters to ensure precise process measurement.
ELECTRICAL AUTOMATION ENGINEER
MENSOY SARL
MO
03.2011 - 01.2014
- Developed control logic, HMI interfaces (including Siemens HMI / PAL programming), and PLC code using Allen-Bradley Studio 5000, FactoryTalk View, and Siemens TIA Portal.
- Wired, tested, and commissioned hardwired safety control circuits with Allen-Bradley and Banner safety relays across multi-brand automation lines.
- Designed, installed, and maintained electrical control panels, VFD motor control circuits, and soft starter systems for optimized machinery performance.
- Commissioned backup power generators featuring auto-start functionality and automatic load-sharing capabilities.
Education
Bachelor's Degree - Systems Engineering (Complex Systems)
High Institute of Advanced Industrial Technologies
Associate Degrees (3) - Robotics & Automation | Industrial Instrumentation | General Electricity
Skills
- Safety system design
- GuardLogix and GuardMaster programming
- Hardwired safety solutions
- Emergency stop integration
- Safety gate and light curtain systems
- Dual-channel loop configurations
- OSHA compliance
- Python and SQL programming
Personal Information
- Availability: Shift Availability: Full flexibility for 3-Shift Rotation (1st, 2nd, 3rd), Overtime, Weekends & Holiday Downtime
- Work Permit: U.S. Permanent Resident (Green Card Holder) — Authorized to work in the U.S. without sponsorship
- Residence Permit: U.S. Permanent Resident (Green Card Holder) — Authorized to work in the U.S. without sponsorship
- Visa Status: U.S. Permanent Resident (Green Card Holder) — Authorized to work in the U.S. without sponsorship
Certification
Rockwell Automation: Advanced Studio 5000 Logix Designer Formal Certificate, FANUC Robotics Academy: Advanced Teach Pendant Operation & Programming Formal Certificate, FANUC Robotics Academy: Integrated Systems Allen-Bradley PLC & FANUC Robot Training Formal Certificate
TECHNICAL SKILLS & CORE COMPETENCIES
Languages: English (Fluent), French (Fluent), German (Professional/Technical), Arabic (Fluent).
Timeline
CONTROLS & AUTOMATION ENGINEER
Howmet Aerospace
08.2025 - 04.2026
CONTROLS & MAINTENANCE TECHNICIAN
IAC Group
03.2025 - 08.2025
AUTOMOTIVE CONTROLS & MAINTENANCE ENGINEER
Magna International
01.2024 - 01.2025
ROBOTICS & ELECTROMECHANICAL SPECIALIST III-B
Oceaneering International
11.2022 - 12.2023
CONTROLS & COMMISSIONING ENGINEER
Dogus Engineering
02.2014 - 10.2022
ELECTRICAL AUTOMATION ENGINEER
MENSOY SARL
03.2011 - 01.2014
Bachelor's Degree - Systems Engineering (Complex Systems)
High Institute of Advanced Industrial Technologies