Charan Vaidya

Experience Summary

• Designed and delivered client-specific industrial automation solutions, covering PLC, HMI, and SCADA systems to meet tailored operational needs.
• Developed real-time MES dashboards in Ignition SCADA for effective production monitoring, enabling proactive decision-making.
• Successfully optimized processes, leading to reduced downtime and enhanced production efficiency across multiple projects.
• Hands-on expertise in FAT and SAT commissioning for PLC, HMI, and SCADA systems, ensuring smooth integration and performance validation.

Key Projects:

• TIN Sorting with Data Tracking – Implemented using fail-safe Siemens PLC, Keyence hand scanner, RFID, Ignition SCADA, stoppers, VFDs, servo drives, and other devices for robust automation and traceability.
• Ignition-Based Warehouse Visualization – Developed on Ignition 8.1.3 Perspective module, providing real-time fault detection on conveyors, and machine status monitoring for seamless warehouse operations.
• AMR Robot Application – Engineered a fail-safe Siemens PLC solution with PLC-to-PLC API interfacing, client-side interface development, safety programming, advanced HMI design, and SCL logic for smart machine integration and autonomous mobility support.

Experience Summary:

• Designed and implemented advanced control systems for digital, discrete manufacturing engineering.
• Executed virtual commissioning using digital technologies to optimize processes before physical deployment.
• Managed full-stack PLC programming, HMI/SCADA development, SQL database management, Python scripting, process simulation, on-site commissioning, and system integration.

Key Project:

• Ignition Dashboard – Developed a comprehensive KPI dashboard, including frontend and backend tasks, Perspective Module implementation, MSSQL integration, Siemens PLC connectivity, and real-time data tracking.

Experience Summary:

• Integrated robots, PLCs, vision systems, and MES across multiple production lines, ensuring seamless automation and data-driven operations.
• Successfully delivered four large-scale automation projects, optimizing efficiency, accuracy, and throughput.

Key Projects:

• Tyre Handling System – Developed PLC logic for four Mitsubishi PLCs managing conveyors and stoppers; integrated Keyence barcode scanner for automated tracking.
• Car Battery Assembly Line – Implemented automation using 4 Siemens fail-safe PLCs and 3 Fanuc robots for material handling and tightening; integrated Cognex hand scanner and vision system.
• Two-Wheeler Battery Assembly Line – Programmed three Siemens fail-safe PLCs, integrated ABB robots for handling, data tracking, RFID, drives, and additional automation features.
• Powertrain Assembly Line – Managed approximately 148 Siemens Fail-Safe PLCs with OEM-standard programming; implemented station-wise PLC-to-PLC interfacing, recipe-based operations, and data tracking applications.