ARUN KUMAR

Lead PLC programming (Mitsubishi FX5U), MES implementation, and Poka-Yoke deployment for assembly lines, integrating with HMIs and IT systems for real-time monitoring.

Direct multidisciplinary O&M teams in operations, maintenance, and troubleshooting of MES/Poka-Yoke/PLC systems, ensuring minimal downtime and safety compliance.

Design sensor-based Poka-Yoke solutions (barcodes/QR, interlocks) to eliminate defects and reduce rework on tractor aggregates.

Drive shop-floor digitization and Industry 4.0 initiatives, integrating MES, PLCs, and IoT devices for data-driven decision making and improved OEE.

Analyze MES/PLC data (OEE, alarms) for root cause analysis and permanent corrective actions with production and quality teams.

• Analyzed customer specifications and requirements to develop, modify and maintain PLC programs.
• Tested newly developed PLC programs to ensure proper functioning before deployment.
• Programmed HMI, SCADA systems using various software packages such as Rockwell, Siemens, Omron.
• Configured communication networks between PLCs and other automation devices via Ethernet and IP or other protocols.
• Provided technical support for customers regarding their PLC programming issues.
• Maintained detailed documentation of all programming efforts including changes made over time.

- Verified electrical control design and panel buyoff with the supplier for equipment including the overhead conveyor, floor conveyor, RGV, sub-assembly conveyor, EOL equipment, shower tester, and filling machine in the TCF shop.

- Finalized network design and IP scheme as per project requirements.

- Installed and commissioned equipment in alignment with the design specifications and discussions.

- Developed HMI and PLC programs according to Mahindra standards, ensuring seamless integration with MES and other equipment handshaking.

• Analyzed customer requirements and proposed technical solutions.
• Developed detailed design specifications for complex software applications.
• Created comprehensive documentation including user manuals, system diagrams, flowcharts and other materials related to software development projects.
• Debugged existing PLC programs in order to identify errors and optimize performance.
• Programmed PLC, HMI, SCADA systems using various software packages such as Studio 5000, RsLogix 500/5000, RSView32, FactoryTalk View SE, ME, Studio.
• Configured communication networks between PLCs and other automation devices via Ethernet and IP or other protocols.

• Developed PLC code and HMI interface as per specific process requirements.

• Implemented high-level control strategies for conveyor system, resulting in 15% increase in operational efficiency.

• Created, read, and edited logic diagrams, wiring diagrams, overhead conveyor, and floor conveyor for BIW/PaintShop and TCF assembly operations.

• Supported Level I and Level II Technicians and Equipment Operators in resolving machine issues, reducing downtime by 20%.

• Executed overhaul and installation of new equipment to enhance production capabilities.

• Verified data system operation and ensured seamless HMI functionality.

• Installed and troubleshooted 240V and 480V motors, VFD’s, and Servo drives, contributing to uninterrupted operations.

• Documented on-site work and provided valuable assistance during client inspections, maintaining high quality standards.

• Delivered automation support to plant operations 24/7, ensuring smooth functioning of manufacturing, facilities, and utilities, including shutdowns.