Summary
Overview
Work History
Education
Skills
Certification
Timeline
Generic

SAI KRISHNA KOTAGIR

Saint Louis,MT

Summary

MES Engineer with 6+ years of experience in designing, configuring, and supporting AVEVA Wonderware MES solutions across manufacturing environments. Expertise in deploying Operations, Performance, and Quality modules and integrating MES with PLCs, SCADA (InTouch/System Platform), SAP ERP, LIMS, and shop-floor devices for automated production workflows. Skilled in workflow/SFC development, custom scripting, Galaxy Repository management, and application server configuration to support routing, dispatching, and quality control. Proficient in real-time data acquisition, AVEVA Historian, SQL Server performance tuning, Power BI reporting, and KPI dashboarding (OEE, downtime, yield, scrap analysis). Strong background in L2/L3 support, diagnostics, patch management, version control, and change management for validated environments. Experienced in barcode/RFID-based serialization and traceability, reducing investigation time and improving compliance. Knowledgeable in CSV, GMP, FDA 21 CFR Part 11, and ITAR regulations, with proven experience authoring SOPs, IQ/OQ/PQ documentation, validation reports, and architecture diagrams. Successfully led NPIs, multi-site MES deployments, plant expansions, and user training programs, collaborating with cross-functional teams to ensure regulatory alignment and operational excellence.

Overview

7
7
years of professional experience
1
1
Certification

Work History

MES Engineer – AVEVA Wonderware

Grene Robotics
06.2024 - Current
  • Designed and configured AVEVA Wonderware MES modules including Operations, Performance, and Quality to optimize production workflows and enforce quality control.
  • Developed InTouch HMI screens and configured Historian for real-time visibility, KPI tracking, and operator interactions.
  • Integrated MES with PLCs, SCADA, SAP ERP, and automation systems via OPC UA and Ignition for seamless data exchange and process automation.
  • Created and optimized System Platform objects, workflows, and scripts to support production logic, routing, dispatching, and event-driven actions.
  • Built dashboards and reports using AVEVA Historian and Power BI for OEE, downtime, scrap analysis, and long-term performance tracking.
  • Delivered L2/L3 MES support, including patch management, configuration updates, SQL Server query tuning, and issue resolution.
  • Conducted system validation (IQ/OQ/PQ), patch testing, and change management in lower environments prior to production rollout.
  • Automated alerts and notifications for equipment failures and quality events to improve response times and reduce downtime.
  • Authored SOPs, system architecture diagrams, validation documents, and training materials to support compliance and end-user adoption.
  • Supported New Product Introductions (NPIs) and plant expansion projects, ensuring smooth MES configuration and rollout.
  • Maintained backup, restore, and version control of Wonderware components using Git and server-side scripting.
  • Documented change logs, supported ITAR-compliant audits, and provided 24/7 operational support across multiple production lines.
  • Conducted training sessions and digitized manual logs/forms through MES modules to enhance plant-wide adoption.

MES Engineer- AVEVA Wonderware

BOSCH
03.2022 - 05.2024
  • Designed and configured AVEVA Wonderware MES modules (Operations, Performance, Quality) to optimize production workflows and enforce process standards.
  • Developed InTouch HMI screens to provide real-time production visibility, operator interactions, and automated alerts.
  • Integrated MES with PLCs/SCADA via OPC UA for seamless, reliable data collection and process automation.
  • Leveraged AVEVA Historian for time-series data logging, process monitoring, and KPI analytics.
  • Built and optimized System Platform workflows to support routing, dispatching, and quality control.
  • Enabled SAP ERP integration through custom APIs/middleware for work order execution, BOM synchronization, and master data alignment.
  • Developed dashboards and reports (OEE, downtime, scrap analysis) using Historian Client and Power BI. Implemented barcode/RFID traceability, cutting root-cause analysis time by 30%.
  • Authored validation documentation (IQ/OQ/PQ) and supported CSV activities to ensure compliance during deployments.
  • Conducted MES training sessions and led multi-line rollouts during NPIs and plant expansions.
  • Created SOPs, architecture diagrams, and training materials, and delivered 24/7 MES support to resolve downtimes and data synchronization issues.
  • Led cross-functional teams to enhance product development processes, ensuring alignment with project timelines.
  • Developed and optimized engineering standards for design and manufacturing processes, increasing efficiency.
  • Developed positive working relationships with stakeholders to effectively coordinate work activities.

MES Support Engineer

Critical Manufacturing, Inc.
05.2020 - 01.2022
  • Delivered Level 3 support with troubleshooting and root cause analysis for critical production incidents in AVEVA Wonderware MES environments.
  • Collaborated with MES developers and automation teams to resolve issues involving InTouch HMI, Application Server, and System Platform.
  • Assisted in deploying MES modules (Operations, Performance, Quality) across multi-site manufacturing setups, ensuring standardization and compliance.
  • Supported real-time data acquisition from PLCs and SCADA systems using Wonderware Historian for process visibility and performance tracking.
  • Configured MES workflows, SFCs, and integration templates to meet site-specific production requirements and improve system reliability.
  • Improved documentation, SOPs, and knowledge base to reduce resolution times and strengthen support processes.
  • Advised on MES integration with ERP (SAP), LIMS, and shop-floor devices, enabling end-to-end traceability and production intelligence.
  • Provided training and mentorship to junior engineers, fostering skill development and knowledge sharing.
  • Led initiatives to optimize ticketing systems, reducing backlog and improving customer satisfaction scores.
  • Coordinated with development teams on software updates, ensuring seamless integration of new features into existing systems.

MES Implementation Consultant

Bright Machines, Inc.
10.2018 - 03.2020
  • Integrated AVEVA Wonderware MES with PLCs, SCADA (InTouch/System Platform), and SAP ERP to automate and streamline production workflows.
  • Configured MES modules (Operations, Performance, Quality) to meet site-specific manufacturing requirements and compliance needs.
  • Developed and deployed MES workflows and SFCs for real-time process control, traceability, and operator guidance.
  • Designed dashboards and KPIs in InTouch HMI and AVEVA Historian to track OEE, yield, and downtime across production lines.
  • Performed L2/L3 support, including root cause analysis, SQL Server query tuning, and diagnostics for MES incidents.
  • Managed version control and configuration through AVEVA Application Server and Galaxy Repository.
  • Enabled MES-to-ERP and SCADA integration using Boomi, OPC UA, and SuiteLink for seamless data flow.
  • Supported UAT/SIT testing, site deployment, and post-go-live stabilization across multiple facilities.
  • Collaborated with automation and IT teams to align MES deployments with regulatory, quality, and operational standards.
  • Delivered MES training sessions, authored SOPs, and maintained comprehensive support documentation for plant personnel.
  • Led implementation of automated systems to optimize manufacturing processes.
  • Collaborated with cross-functional teams to ensure seamless project execution and client satisfaction.
  • Analyzed customer requirements and developed tailored solutions to enhance operational efficiency.
  • Mentored junior consultants on best practices in project management and system integration.
  • Conducted training sessions for clients on new technologies, improving user adoption rates.
  • Streamlined project workflows by implementing agile methodologies, resulting in faster delivery times.
  • Facilitated workshops to gather feedback and refine solutions based on client needs and challenges.
  • Developed comprehensive documentation for implemented systems, ensuring clarity and usability for future reference.
  • Managed project risks effectively, establishing contingency plans and proactive issue resolution strategies to minimize disruptions during implementation.
  • Provided exceptional remote support to clients during off-site implementations, ensuring minimal downtime during critical transitions.
  • Ensured seamless data migration, developing comprehensive data mapping plans to support accurate transfer between systems.
  • Developed strong relationships with clients, fostering trust and long-term partnerships through professionalism and expertise.
  • Optimized client''s workflows, analyzing existing processes and recommending improvements during system integration.
  • Adapted quickly to new technologies and tools, ensuring the ability to provide top-notch service regardless of the specific systems being implemented.
  • Communicated effectively with third-party personnel involved in implementation efforts, coordinating activities to maximize progress.
  • Exceeded client expectations by delivering customized training sessions that enabled efficient utilization of newly implemented systems.
  • Authored user documentation to help train third-party personnel on newly-implemented [Product or Service].
  • Streamlined project processes for enhanced efficiency and timely completion of implementation projects.
  • Conducted post-implementation reviews for continuous improvement opportunities in future projects.
  • Contributed to sales efforts by participating in pre-sales meetings and presenting compelling demonstrations of consulting capabilities.
  • Studied customers' business processes to customize implementation measures for minimal disruption to operations.
  • Offered client training services via on-site and online interaction to streamline onboarding process for newly implemented systems.
  • Traveled to customer facilities to inspect initial implementation of [Product or Service], directing apparent issues to appropriate engineering staff for correction.
  • Leveraged industry-specific knowledge to offer expert advice on best practices for system design and configuration during consultations with clients.
  • Resolved issues related to operational components for LAN, WAN and voice systems.

Education

Bachelors - Computer Science

Webster University
Saint Louis, MO
05.2018

Skills

  • MES Platforms: AVEVA Wonderware MES (Operations, Performance, Quality), System Platform, InTouch HMI
  • Integrations: SAP ERP, Ignition, OPC UA, Boomi, custom APIs
  • Databases & Scripting: SQL Server, T-SQL, PowerShell, custom MES scripting
  • Visualization: Power BI, AVEVA Historian, real-time dashboards
  • Automation Interfaces: PLCs, SCADA, barcode/RFID systems
  • Deployment Tools: Git, Windows/Linux servers
  • Compliance: ITAR, GMP, SOPs, documentation in regulated environments

Certification

  • Azure Fundamentals (AZ-900)
  • IT Support Professional Certificate - Coursera

Timeline

MES Engineer – AVEVA Wonderware

Grene Robotics
06.2024 - Current

MES Engineer- AVEVA Wonderware

BOSCH
03.2022 - 05.2024

MES Support Engineer

Critical Manufacturing, Inc.
05.2020 - 01.2022

MES Implementation Consultant

Bright Machines, Inc.
10.2018 - 03.2020

Bachelors - Computer Science

Webster University

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