Summary

Overview

Work History

Education

Skills

Timeline

Ramesh Mandal

Irvington,USA

Summary

Automation & Controls Engineer with over 10 years of hands-on experience in PLC/HMI programming, robotics, and vision inspection systems across high-speed, GMP-regulated manufacturing environments. Skilled in troubleshooting complex automation issues, optimizing production performance, and integrating real-time data reporting through OSI PI systems .

Overview

years of professional experience

Work History

Sr. Automation and Control Engineer

Mark Anthony beverage

Hillside,NJ

03.2025 - Current

Led and supported multiple improvement projects across Brewing, Packaging, and Utility systems to increase uptime and production efficiency.
Collaborated with vendors to implement high-speed can code verification systems using Keyence/Cognex vision cameras integrated with Videojet printers.
Optimized conveyor line speeds and PID control loops to maintain smooth product flow and can spacing across split and single-line conveyors.
Created and implemented CO₂ exhaust fan interlocks and safety shutdowns on filler and seamer lines to meet compliance and safety standards.
Coordinated with electrical contractors and validation teams during equipment upgrades.
Provided critical on-call engineering support, including weekends and night shifts.
Documented all changes, backups, and PLC program versions in accordance with internal quality standards.

Sr. Automation Engineer

Roche Molecular Systems, Inc.

Branchburg Township ,NJ

01.2023 - 03.2025

Configured and maintained OSI PI systems, setting up PI tags, managing archives, and troubleshooting issues.
Developed real-time data collection dashboards using PI Vision and PI Datalink to enhance decision-making.
Integrated PLCs and SCADA systems with OSI PI, enabling seamless data flow and system monitoring.
Diagnosed and resolved operational issues with FANUC, Epson, and ABB robot arms, including servo alarms, communication errors, and motion faults.
Performed robot calibration, mastering, and axis alignment, ensuring optimal performance.
Monitored and configured robotic systems using FANUC, ABB and Epson RC+.
Conducted preventive maintenance tasks, including battery replacements and lubrication, and recovered robots from crashes.
Built strong relationships with vendors and suppliers, negotiating favorable terms on components necessary for completing projects on time and within budget constraints.

Automation PLC Programmer

Union Beverage Packer

New Jersey, USA

09.2019 - 01.2023

Waste management Project: Controlled the pH of wastewater tanks before releasing to municipal waste lines.
Synchronized conveyer speeds at various stages of packaging for better production yield and minimal product damage.
Designed patterns for palletizer to meet customer requirements for final product pallets.
Added single and double pallet call options to palletizer for LGV robots.
Programmed sanitary systems for lead and lag operations with two pump stations.
Implemented a safe entry system with manual switches and filler programming for safe maintenance.
Linked Anton-Paar system with the filler to monitor Oxygen, CO2, Real extract, and alcohol levels.
Detected foreign liquids in empty cans to ensure product quality.
Achievements: Waste management project, Line speed synchronization

Sr. Production Engineer

Avone System and Controls Nepal Pvt. Ltd.

Kathmandu, Nepal

01.2017 - 10.2017

Developed electrical load distribution systems for commercial properties.
Installed VFD panels and automated conveyor systems at cement plants.
Achievements: Chaya-Mall Project

Application Engineer & Sales Support

Arihant Elsys Pvt. Ltd.

Delhi (NCR), India and Kathmandu

08.2012 - 01.2017

Verified and tested GE PLC spare parts for Nepal Electricity Authority projects.
Supported Indian Railways and Delhi Metro projects with joystick testing kits for BHEL.
Designed automation for packaging machines, bio-toilet controls, and other PLC-based solutions.
Developed GSM-based alarm systems and automated oil refueling systems for Globe Hi-Fabes.
Achievements: BHEL Projects and MMHPS Tender