Automation Engineer

Automation Engineer PLC/SCADA & IIoT Implementation (FactTwin)

Location: Visakhapatnam / Hyderabad

Experience: 5-10 years in industrial automation (implementation & commissioning)

Role Summary

Implement FactTwin solutions in brownfield plants. Youll interface with existing PLCs/SCADA/DCS, commission gateways, map and scale tags, ensure reliable data collection to enterprise systems, and troubleshoot end-to-end—from instrument to dashboard—while training plant teams.

What You’ll Do

Pre-Implementation

Conduct site surveys: document PLCs, HMIs, drives, instruments, networks, tag lists, panel layouts.

Draft connectivity plan: select drivers/protocols, define IP plans/VLANs, security posture, and data routing via industrial gateways/brokers.

Prepare I/O & tag maps, data models aligned to production lines/units; write FAT test cases.

Build & Commission

Safely connect to control systems; read/write only with authorized permits; configure scan rates, deadbands, scaling & engineering units.

Configure OPC UA/DA, Modbus TCP/RTU, EtherNet/IP, Profinet to integrate PLC/HMI/SCADA with FactTwin collectors and plant historians.

Commission edge gateways (industrial PCs or appliances), enable buffering/store-and-forward, and validate data to time-series/historian/BI.

Set up MQTT/HTTP forwarding where applicable (topic design, QoS/retain), verify end-to-end timestamp fidelity (NTP/PTP).

Operations & Support

Troubleshoot comms, signal noise, grounding/shielding, serial converters, VLAN/firewall rules, gateway/broker/auth issues.

Create runbooks; train operators/maintenance; hand over with SOPs, backups, rollback plans.

Enforce OT change control: request/impact logs, MOC, and versioned backups of PLC/HMI projects.

Must-Have Technical Skills

PLCs (any 2+ strongly): Siemens S7/TIA Portal; Rockwell/Allen-Bradley ControlLogix/CompactLogix (Studio 5000); Schneider M340/M580 (EcoStruxure); Mitsubishi (GX Works).

IEC 61131-3 programming: Ladder, FBD, Structured Text; online/forced I/O procedures and safe edits.

Protocols: OPC UA/DA, Modbus TCP/RTU, EtherNet/IP, Profinet; addressing/diagnostics; packet-level basics (Wireshark).

SCADA/HMI: WinCC / FactoryTalk / Wonderware (AVEVA) / Ignition—tag structures, alarms, historian connectors.

Gateways & data movement: Kepware/Ignition OPC servers, industrial MQTT brokers/clients, buffering & store-and-forward patterns.

Electrical & instrumentation: Read P&IDs, loop diagrams, GA; 24 VDC control, 4–20 mA/RTD/TC, VFDs/servos basics; panel wiring & shielding.

Industrial networking: IP planning, VLANs, NAT, subnetting, managed switches, device naming; firewall rules in OT cells; secure remote access.

Commissioning discipline: FAT/SAT scripts, cause-effect matrices, alarm rationalization basics, punch-list closure.

Structured troubleshooting: From field device I/O PLC logic comms gateway broker application.

Must-Have Professional Skills

Clear written/spoken communication with operations, maintenance, OEM vendors.

Strong documentation: survey reports, I/O lists, tag dictionaries, risk assessments, as-built drawings.

Safety first: LOTO, PPE, arc-flash awareness, confined-space etiquette; escalate before writes to live controllers.

Customer handling: expectation setting, downtime window negotiation, crisp UATs.

Big Pluses

Drives/robot basics (VFD tuning, safe I/O handshakes).

Cybersecurity (ISA/IEC 62443 mindset: zones/conduits, least-privilege, certificate management).

Scripting for tooling (Python/PowerShell) to parse tag lists, normalize CSVs, call vendor APIs.

MES exposure: OEE, reason/DT codes, genealogy/traceability, batch/recipe (ISA-88).

CAD tools: AutoCAD/EPLAN mark-ups; Visio/Draw.io for network & P&ID overlays.

Linux on industrial PCs; Docker basics; time-series databases.

Tools & Tech (indicative; equivalents welcome)

Siemens TIA • Rockwell Studio 5000 • Schneider EcoStruxure • Mitsubishi GX Works • OPC UA/DA • Kepware • Ignition • Modbus TCP/RTU • EtherNet/IP • Profinet • Managed switches (Moxa/Hirschmann/Cisco IE) • Wireshark • AutoCAD/EPLAN • Time-series/historian tools • FactTwin modules.

Education & Certifications

Diploma/B.Tech in EEE/E&I/Mechatronics/Automation (or equivalent). Desirable: Siemens/AB/Schneider vendor certs; OSHA/NEBOSH safety awareness; ISA membership.