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saravanan sampath

 Senior Automation Engineer with 18+ years of experience in manufacturing and 24/7 environments, specializing in Controls & Drives, PLC/SCADA, and electrical production systems. Experienced in tyre manufacturing with Michelin (India & Thailand – Laem Chabang, Nong Khae, Rayong), supporting automated lines and maintenance. Expert in troubleshooting, RCA, and continuous improvement, reducing downtime, cost, and scrap. Skilled in preventive, predictive, and breakdown maintenance, plus installation & commissioning. Hands-on with Rockwell ControlLogix, adaptable to Siemens (TIA Portal, Step7, WinCC), and CMMS (Maximo/SAP PM). Strong in team collaboration, supplier coordination, drawings, and projects.

Key Skills

PLC: Allen Bradley PLC&HMI Panelview
PLC:siemens PLC & simatic wincc
Robotics: ABB IRB 4600, Fanuc M900i (4 & 6 Axis)
Drives: Emerson, Control Techniq, Kinetix, Siemens
SCADA & HMI: Rockwell, WinCC, FactoryTalk, PanelVw
Systems: IBM Maximo, TPM, FMEA, RCA, MTBF/MTTR
Planned &Preventive maintenance
Maximo -CMMS,Autocad,SAP
Tools: SAP, Minitab, six sigma black belt
Wonderware SCADA,RCM Trained in USA
Industrial Networks: Ethernet, Profibus, AS-i, mod
TPM, Kaizen, Six Sigma, 5S, Lean Manufacturing

Professional Experience

Jun 2011
Present
Sr engineer -Automation
MICHELIN TYRES INDIA LTD Chennai, IN
Global leader in the tire industry—manufacturing Aerospace, Car, Truck, and Military tires.
 Expereince :
  • Delivered electrical engineering support in 24/7 manufacturing environments, maintaining and improving electrical production equipment and Controls & Drives systems to reduce downtime, maintenance cost, and scrap levels. 
  •  Executed preventive, predictive, and reactive maintenance (PPM) strategies to ensure high equipment availability and reliability, aligned with plant maintenance objectives. 
  •  Performed advanced fault diagnosis, root cause analysis, and rapid breakdown recovery, ensuring quick restart of production machinery and minimizing operational disruptions. 
  •  Worked extensively with PLC, SCADA, and industrial automation systems, supporting troubleshooting, modifications, and continuous optimisation of control systems. 
  •  Contributed to installation, testing, commissioning, and startup of new equipment, ensuring compliance with electrical standards and operational requirements. 
  •  Designed and upgraded MCCs, LV distribution systems, control panels, and automation architectures, improving system performance and safety. 
  •  Reviewed and interpreted electrical drawings, schematics, and technical documentation to ensure accurate implementation and compliance. 
  •  Collaborated with suppliers and cross-functional teams (Production, Quality, Maintenance, Purchasing) to resolve technical issues and implement system improvements. 
  •  Managed maintenance activities using CMMS (Maximo) for planning, tracking, and performance analysis (transferable to SAP PM environment). 
  •  Implemented continuous improvement initiatives, including cost reduction, downtime reduction, and reliability enhancement through engineering modifications and optimisation. 
  •  Maintained technical documentation, troubleshooting guides, and system records, ensuring up-to-date and structured engineering data. 
  •  Supported control system backup, protection, and maintenance (PLC/SCADA systems and related devices). 
  •  Participated in risk assessments, FMEA, and reliability programs, enhancing system safety and operational efficiency. 
  •  Demonstrated technical leadership, mentoring junior engineers and leading engineering tasks and improvement projects 
Jun 2011
Jul 2012
Automation engineer-Trainee
MICHELIN NORTH AMERICA INC Spaturnburg,south Carolina., US
 Experience :
  • Completed advanced training at Rockwell Automation in PLC, Drives, and HMI programming, supporting industrial automation systems in a tire manufacturing environment. 
  •  Worked as an Automation Engineer in shift operations, handling preventive and breakdown maintenance to ensure continuous production in 24/7 plant operations. 
  •  Performed troubleshooting, fault diagnosis, and system upgrades on legacy systems, including migration to ControlLogix PLC platforms. 
  •  Supported tyre assembly machines and automated production lines, ensuring high equipment availability and process reliability. 
  •  Contributed to L2/L4 automation implementation, improving process control, monitoring, and system integration. 
  •  Executed root cause analysis (RCA) and implemented corrective actions to reduce recurring failures and improve system performance. 
  •  Utilised CMMS (Maximo) for maintenance planning, work order management, and performance tracking. 
  •  Gained hands-on experience in electrical and mechanical maintenance, supporting cross-functional troubleshooting and system optimisation. 

Sep 2007
Jun 2011
FAP Technician – SMT &Building services
Nokia India Pvt Ltd, Chennai, India Chennai, IN
mobile Phones manufacturer
 Relevant Experience 
  • Managed shift-based maintenance activities in a high-volume manufacturing environment, supporting 24/7 operations and ensuring continuous equipment availability. 
  •  Executed planned preventive maintenance (PPM) and reactive breakdown support, troubleshooting high-speed SMT lines, robotic systems, and automated production equipment. 
  •  Installed, programmed, and maintained electrical and automated systems including SMT machines, reflow ovens, conveyors, and robotic equipment, ensuring reliable system performance. 
  •  Performed fault diagnosis, repair, and system recovery, prioritising issues to minimise downtime and maintain production continuity. 
  •  Worked with control systems (HMI/SCADA), modifying and supporting system interfaces to meet operational and production requirements. 
  •  Conducted routine equipment inspections, measurements, and system checks, ensuring safe and efficient operation of electrical and control systems. 
  •  Followed Safe Systems of Work (SSoW), company safety procedures, and risk assessments to maintain a safe working environment. 
  •  Supported compliance and quality standards, including safe handling of electrical components, proper use of tools, and adherence to operational procedures. 
  •  Collaborated with cross-functional teams and contractors, supporting maintenance, troubleshooting, and improvement activities. 
  •  Delivered continuous improvement initiatives using Lean, Kaizen, and Kanban to improve equipment uptime and operational efficiency. 
  •  Maintained clear communication, supported shift handovers, and trained junior technicians to enhance team capability and performance. 


Education

Mar 2007
Mar 2011
Bachelor in electrical & electronics engineering in A.V.I.T. Engineering college
VMRF
Mar 1997
Mar 2000
Diploma in Electrical & Electronics Engineering in A.M.S POLYTECNIC
DOTE -Tamilnadu

Certifications

2012
Certified in Allen Bradley PLC &HMI
Rockwell Automation center-greenville -USA
Certification in ABB Robot 6&4 Axis ,IRC5
ABB -Training center-Banglore ,India
Certification Emerson -SP&M drives.
NIDEC-Control Technique training center
2025
Certified Lean six sigma -black belt
MSME-Govt of india
2025
FMEA-MSA -AIAG
Octagon
2026
Project Management Professional (PMP)
MSME-PMI

Achievements

Performance
 
  • Applied Six Sigma methodology in the tyre curing process, reducing process variation and improving curing consistency, resulting in enhanced product quality and reduced defects.

  • Led data-driven root cause analysis in curing operations, improving cycle stability and increasing equipment reliability through structured process optimisation.

  • Improved curing process capability and uptime by implementing continuous improvement actions aligned with Lean and Six Sigma principles, supporting higher production efficiency.


Quote

Self-motivated, focused, with a strong sense to lead, take initiative, show resilience, collaborate, and engage with the team

Languages

Tamil
(Native)
French
(Basic)
English
(Fluent)

Career Aspiration

Having experience in manufacturing & energy industry and expecting good Position in same industry in Europe/UK

Get in touch with saravanan