Controls/Automation Engineer with experience in PLC programming, commissioning, troubleshooting, and plant-floor integration for industrial automation and material handling systems. Strong hands-on with Siemens PLCs (S7-1200/S7-1500, TIA Portal V18) and Beckhoff TwinCAT 3.1 (EtherCAT, distributed I/O), plus limited collaboration exposure to Rockwell Studio 5000 / FactoryTalk View / PowerFlex. Experienced integrating PLC/OT data with higher-level systems using OPC UA/DA and industrial Ethernet (PLC–IPC–WMS/Web). Interested in expanding into MES connectivity, downtime/traceability, and plant system integration in assembly/machining/fabrication environments.
Hi, I’m
PRASANNA UMAK
Pune
Summary
Overview
7
years of professional experience
1
Certificate
7
years of post-secondary education
Work History
Wipro PARIPune
Control Engineer
03.2024 - Current
Job overview
- Developed and modified Siemens PLC logic (TIA Portal V18) and HMI functionality for automation/material handling systems (Conveyors, ASRS, ATLS, AMR).
- Commissioned and troubleshot systems on-site: I/O checkout, functional testing, diagnostics, issue closure; supported FAT/SAT activities.
- Implemented industrial communication via PROFINET and EtherNet/IP and enabled OPC UA/DA data exchange between PLCs, IPCs, WMS, MES and web servers to support real-time visibility and integration.
- Supported drive integration and commissioning (SINAMICS, SEW) during ramp-up and shutdown/start-up support.
- Coordinated with project stakeholders and maintained test/commissioning documentation and change records.
Career Break (Full-time Government Exam Preparation)
07.2021 - 02.2024
Job overview
- Full-time competitive exam preparation; resumed full-time automation role in 2024.
Alligator Automations Pvt. Ltd.Pune
Jr. Control Engineer
05.2019 - 07.2021
Job overview
- Delivered controls engineering for 5 bagging machine projects (3 semi-automatic, 2 automatic), from PLC development to commissioning and troubleshooting.
- Programmed Beckhoff CP6066 using TwinCAT 3.1, implemented EtherCAT network, and configured Beckhoff distributed I/O for sensors/actuators.
- Built/modified HMIs and improved alarm/diagnostic usability; contributed reusable templates/logic blocks.
- Assisted in one Rockwell collaboration (limited scope): Studio 5000 logic support, FactoryTalk View screens, PowerFlex VFD setup/troubleshooting.
Education
Sant Gadge Baba Amravati University
B.E./B.Tech from Electronics and Power
05.2014 - 08.2018
University Overview
Independent Rural Institute CollegeAmravati, India
HSC
07.2012 - 05.2014
University Overview
GRKV School Amravati, India
SSC
07.2011 - 05.2012
University Overview
Skills
- PLC & Automation: Siemens S7-1200/S7-1500 (TIA Portal V18), Beckhoff TwinCAT 31 (IEC 61131-3 ST/Ladder, EtherCAT)
- Rockwell (Collaboration Exposure): Studio 5000, FactoryTalk View, PowerFlex VFD (limited scope)
- OT Integration: OPC UA/DA, PLC–IPC connectivity, real-time data exchange, third-party system interfacing
- Industrial Networking: PROFINET, EtherNet/IP, EtherCAT
- Drives/Motion: SINAMICS G120/G115D, SEW (commissioning support)
- Execution: FAT/SAT support, commissioning, shutdown/start-up support, troubleshooting
- Documentation: change logs, commissioning reports, test records, handover notes
Certification
- Industrial Automation Course
- AutoCAD 2018
Languages
Marathi
First Language
English
Upper Intermediate
B2
Hindi
Upper Intermediate
B2
Timeline
Control Engineer
Wipro PARI
03.2024 - Current
Career Break (Full-time Government Exam Preparation)
07.2021 - 02.2024
Jr. Control Engineer
Alligator Automations Pvt. Ltd.
05.2019 - 07.2021
Sant Gadge Baba Amravati University
B.E./B.Tech from Electronics and Power
05.2014 - 08.2018
Independent Rural Institute College
HSC
07.2012 - 05.2014
GRKV School
SSC
07.2011 - 05.2012
Relevant Integration
Relevant Integration
- Real-time OT Data Connectivity: OPC UA/DA integration between PLCs, IPCs, and WMS/Web applications
- Traceability/Downtime (Foundation): alarm/fault handling, event-based diagnostics, and system status capture via PLC/HMI + server integration
- Third-party System Integration: handshakes and interface validation with higher-level applications (WMS/MES interfaces where applicable)
Latest Projects
Latest Projects
- COCA-COLA | ASRS + Conveyor + ATLS (Automatic Truck Loading System) — Gujarat
Client: Hindustan Coca-Cola Beverages (HCCB) | Status: Ongoing (Production Support)| Dates: Dec 2024 – Present Controls engineering for ASRS and conveyor system including lifts, cross transfers, and turntables (~200 units) and ATLS.
Developed/modified PLC logic and HMI for sequencing, interlocks, alarms and fault handling.
Commissioned equipment on-site; supported FAT/SAT, troubleshooting, and performance stabilization during ramp-up.
Integrated system signals/data with WMS and Actiw Management system via industrial communication/OPC (as applicable).
Coordinated with mechanical/electrical/site teams and customer for technical closure and issue resolution. - TATA MOTORS (TML), Sanand | ASRS + Conveyor + AMR Integration — Gujarat
Client: Tata Motors | Status: Completed | Dates: Oct 2024 – Dec 2025 Controls support for ASRS + conveyor + turntables and AMR workflows for engine/parts transport.
Assisted PLC/HMI changes, commissioning activities, and troubleshooting during deployment.
Integrated interfaces with WMS and MES for production/logistics visibility and control handshakes.
Executed testing/validation with site team; supported documentation and handover. - Bagging/Packing Machines (Beckhoff PC-based Control) | Alligator Automations, Pune 3 Semi-Automatic Bagging Machines + 2 Automatic Bagging Machines Beckhoff CP6066, TwinCAT 3.1, EtherCAT, Beckhoff distributed I/O, HMI development, commissioning and troubleshooting