Supraja Byreddy
Jackson,USA
Summary
Controls Engineer with hands-on experience designing, modifying, and supporting PLC-, HMI-, robotic-, and vision-based control systems in manufacturing environments. Strong background in Allen-Bradley PLCs, PanelView HMIs, industrial networking, and electrical troubleshooting, with proven ability to collaborate with engineering, maintenance, and production teams to improve safety, reliability, and machine performance. Experienced in applying Lean Manufacturing principles, performing root cause analysis, maintaining detailed technical documentation, and supporting plant-wide automation initiatives aligned with Industry 4.0 and smart manufacturing concepts.
Overview
4
4
years of professional experience
Work History
Controls Engineer (Contract)
Midwest Automation Solutions, Inc.
Warrensburg, USA
05.2025 - 12.2025
- Designed, implemented, and modified PLC, HMI, and robotic logic for manufacturing equipment using Allen-Bradley platforms to improve machine safety, reliability, and overall production efficiency across multiple assets.
- Updated and maintained electrical schematics, control narratives, and operational documentation to ensure accuracy, traceability, and consistency with current machine configurations.
- Provided hands-on technical support to maintenance and operations teams by troubleshooting electrical, electronic, and control system issues, helping minimize downtime and reduce scrap.
- Coordinated the build, installation, commissioning, and operator training for electrical control equipment, ensuring smooth system startup and effective handover to plant teams.
- Collaborated closely with mechanical engineers, process engineers, and quality teams to optimize machine performance, improve safety compliance, and enhance product quality.
- Applied Lean Manufacturing principles and problem-solving tools to support continuous improvement initiatives focused on reducing downtime and increasing equipment reliability.
- Performed data analysis on machine performance and alarm history to support predictive maintenance strategies and data-driven decision making.
- Executed control system maintenance and software updates to improve long-term system stability, reliability, and operational efficiency.
- Worked with automation vendors and equipment suppliers to resolve technical issues, evaluate component upgrades, and implement control system enhancements.
- Implemented and validated machine safety systems including interlocks, emergency stops, and fail-safe logic in compliance with OSHA, ISO, and internal safety standards.
- Maintained detailed records of all control system changes, updates, and maintenance activities to support audits, troubleshooting, and knowledge retention.
- Explored and supported implementation of Industry 4.0 concepts such as IoT connectivity and improved automation data visibility to enhance plant performance.
Junior Controls & Automation Engineer
Apex Industrial Controls Pvt. Ltd.
Pune, India
07.2021 - 12.2022
- Supported PLC- and HMI-based automation systems for manufacturing equipment by assisting with programming, testing, and validation of control logic during project execution and commissioning.
- Assisted in troubleshooting electrical, automation, and robotic systems by diagnosing faults, analyzing root causes, and supporting corrective actions to restore normal equipment operation.
- Updated electrical schematics, I/O lists, and control documentation to reflect field modifications, ensuring alignment between design documentation and installed systems.
- Supported installation and commissioning of automation equipment including control panels, sensors, drives, and field devices while following electrical safety standards.
- Assisted with Fanuc robotic systems and vision-guided automation by supporting basic programming, calibration, and troubleshooting of robotic motion and vision components.
- Collaborated with mechanical, production, and maintenance teams to support safe operation, improve equipment performance, and reduce unplanned downtime.
- Applied basic Lean Manufacturing and continuous improvement concepts to support efficiency improvements, scrap reduction, and reliability initiatives.
- Supported data collection and analysis related to equipment performance, alarms, and automation reliability to assist senior engineers with decision making.
- Coordinated with vendors, system integrators, and suppliers to support automation upgrades, component replacements, and technical issue resolution.
- Followed electrical safety procedures, lockout/tagout practices, and best engineering practices while working in live manufacturing and commissioning environments.
Education
Master of Engineering - Computer Engineering
University of Cincinnati
Cincinnati, OHBachelor of Technology - Electrical & Electronics Engineering
Malla Reddy Engineering College
Hyderabad, IndiaSkills
- PLC programming
- Allen-Bradley PLCs
- HMI development (PanelView, FactoryTalk View)
- Robotics and vision systems (Fanuc, Cognex, Keyence)
- Electrical troubleshooting
- Industrial control panels and schematics
- GuardLogix and machine safety systems
- Industrial networking (EtherNet/IP)
- Lean manufacturing and continuous improvement
- Predictive maintenance and data analysis
- Root cause analysis and visualization tools
- Technical documentation and change control
- Equipment installation and commissioning
- Vendor coordination
- Industry 40 concepts
- AutoCAD and electrical drawings
- Microsoft Office Suite
Projects
Plant-Wide Controls Optimization Project
- Supported PLC and HMI upgrades across multiple manufacturing machines to improve control standardization, system reliability, and operator usability.
- Assisted in updating documentation, validating safety systems, and supporting commissioning activities to ensure stable and compliant operation.
- Collaborated with cross-functional teams to reduce downtime and improve overall equipment effectiveness.
- Assisted with integration of Fanuc robots and vision-guided systems using Cognex and Keyence tools to improve automation accuracy and throughput.
- Supported testing, calibration, and troubleshooting of robotic and vision systems during commissioning and production ramp-up phases.
- Helped document system configurations, operating procedures, and maintenance guidelines to support long-term system support.
Timeline
Controls Engineer (Contract)
Midwest Automation Solutions, Inc.
05.2025 - 12.2025
Junior Controls & Automation Engineer
Apex Industrial Controls Pvt. Ltd.
07.2021 - 12.2022
Master of Engineering - Computer Engineering
University of Cincinnati
Bachelor of Technology - Electrical & Electronics Engineering
Malla Reddy Engineering College