THOKAIMAYIL VENKATESAN

Developed detailed electrical schematics and layouts for automated control systems, ensuring accurate and efficient designs.

Designed electrical panels and wiring diagrams for industrial machinery, adhering to industry standards and safety regulations.

Selected and integrated electrical components such as sensors, actuators, and relays into control systems, optimizing performance and reliability.

Conducted electrical load calculations and ensured proper sizing of components to prevent overloading and ensure system stability.

Performed electrical testing and validation of control systems, identifying and resolving issues to ensure optimal functionality.

Designed and developed safety matrices to identify and mitigate potential hazards, enhancing overall system safety and compliance.

Stayed updated with the latest electrical design standards and technologies, continuously improving design practices and system performance.

Documented all electrical design processes, creating detailed manuals and diagrams for future reference and maintenance.

Designed and implemented PLC control systems for BIW assembly lines, enhancing automation and production efficiency.

Programmed and commissioned PLCs for robotic welding and assembly stations, ensuring precise and reliable operations.

Integrated PLCs with various sensors and actuators to monitor and control critical BIW processes, improving quality and consistency.

Conducted on-site troubleshooting and maintenance of PLC systems, minimizing downtime and ensuring continuous production.

Developed HMI interfaces for BIW control systems, providing operators with intuitive and user-friendly controls.

Performed system validation and acceptance testing for new BIW equipment, ensuring compliance with industry standards and customer requirements.

Designed custom VBA solutions for quality control applications, enhancing data accuracy and process efficiency.

Automated QC data collection and analysis using VBA macros, resulting in more timely and accurate quality assessments.

Created user-friendly Excel dashboards with VBA macros to visualize QC metrics and trends, aiding in decision-making.

Developed comprehensive safety matrices to identify and mitigate potential hazards in manufacturing processes, ensuring a safer work environment.

Implemented and maintained DIFOT metrics, achieving a consistent on-time delivery rate of 100 percent.

Collaborated with cross-functional teams to design and update safety matrices, enhancing overall workplace safety and compliance.

Conducted regular customer meetings to discuss project requirements, progress, and address any concerns, ensuring customer satisfaction.

Trained junior engineers on electrical design principles, PLC programming, and safety standards, fostering their professional development

Designed and programmed PLC systems for custom-built machinery, ensuring precise control and functionality tailored to client specifications.

Led the commissioning of special purpose machines, overseeing the installation, testing, and validation of control systems to ensure optimal performance.

Developed HMI interfaces for special purpose machines, enhancing user interaction and operational efficiency.

Integrated various sensors and actuators into PLC systems, ensuring accurate data acquisition and control for complex machinery.

Conducted on-site troubleshooting and debugging of PLC programs during the commissioning phase, resolving issues promptly to meet project deadlines.

Collaborated with mechanical and robotics engineers to design and implement control systems for bespoke machinery, ensuring seamless integration and operation.

Performed system validation and acceptance testing for special purpose machines, ensuring compliance with industry standards and client requirements.

Provided comprehensive training and support to end-users on the operation and maintenance of PLC-controlled special purpose machines.

Implemented safety protocols and fail-safes within PLC programs to ensure the safe operation of custom machinery.

Documented all design and commissioning processes, creating detailed manuals and reports for future reference and maintenance.