Balaji Narayana Perumal
Mes Engineer || PLC Programmer || Embedded Engineer
chennai
Summary
Experienced Automation Engineer with a strong background in PLC programming, MES, and SCADA system implementation. Proficient in database administration, Kepware integration, and OPC communication, with expertise in IIoT applications using AVerMedia, Linux, and ESP32. Skilled in vision systems, robotics with Omron cobots and Fanuc robots, and various control systems. Adept at optimizing industrial processes through SCADA solutions (Iconics, FactoryTalk View SE), Node-RED, and MSSQL. Holds a background in Electrical and Electronics Engineering
Overview
4
4
years of professional experience
6
6
years of post-secondary education
Work History
IIOT Engineer
Saint Gobain India Private Limited
06.2024 - Current
- Developed and deployed ESP32-C3-based IIoT solutions for real-time industrial data acquisition, monitoring, and control.
- Interfaced multiple sensors using I2C and SPI protocols (e.g., MPU6050, GNSS L89) for motion and location tracking in forklifts and shop-floor systems.
- Implemented UART and USB communication between ESP32 and Jetson (AVerMedia Linux) boards for synchronized data exchange.
- Wrote Linux-side Python scripts on AVerMedia boards for Jetson telemetry extraction, camera detection (USB/FFC), and GPIO status feedback via serial/USB protocols.
- Implemented multi-topic MQTT telemetry publishing for speed, acceleration, motion, and system health using JSON format, compatible with SCADA dashboards and Phoenix/Neo platforms.
- Developed computer vision-based human detection algorithms using Jetson and OpenCV to enhance operator safety, and trigger system-level actions (e.g., buzzer, relay control).
- Designed MQTT-based telemetry protocols for edge-to-cloud data transfer, integrating with MES and SCADA dashboards.
- Programmed ESP32-C3 using Arduino IDE (C++) and Python, optimizing for reliability, watchdog recovery, and real-time processing.
- Worked extensively in Linux environments (Ubuntu/Jetson) for deploying, debugging, and managing computer vision and GPIO applications.
- Configured Ethernet and OPC-UA communication for high-speed data exchange between IIoT devices and MES infrastructure.
- Led PoC, UAT, and PSAT testing to validate system functionality, ensure plant readiness, and meet operational safety standards.
Automation Engineer - Mes
Dalisoft Technologies Private Ltd
02.2024 - 05.2024
- Designed and developed MES solutions tailored to specific manufacturing workflows, ensuring alignment with operational goals and production KPIs.
- Integrated MES with Kepware, OPC-UA, and Iconics SCADA, enabling seamless communication between PLCs, SCADA, and MES platforms.
- Customized MES logic and UI using tools like BridgeWorks and AssertWorks, optimizing production visibility and traceability.
- Developed PLC programs for real-time data acquisition from machines, ensuring structured data flow into MES/SCADA systems for monitoring and analytics.
- Established cross-platform communication between Siemens PLCs and Mitsubishi PLCs, enabling data exchange and coordinated control between production lines and downstream equipment.
- Configured Mitsubishi F-Series PLCs, including logic for automation control, data sampling, and alarm/event handling.
- Integrated MS SQL databases for structured logging, reporting, and batch-level traceability of production events.
- Provided ongoing MES troubleshooting, support, and optimization, minimizing downtime and ensuring system reliability.
- Collaborated with production, IT, and automation teams to validate MES workflows, support change management, and drive digital transformation.
- Documented MES system architecture, PLC tag mappings, and integration processes to support future upgrades and compliance audits.
Electrical Engineer - L2
Tata Electronics Private Ltd
07.2023 - 02.2024
- Conducted preventive maintenance and diagnostics on PLCs, robotic systems, and automation equipment using TIA Portal, Omron PLCs, Delta PLCs, and GE Fanuc, ensuring consistent system uptime and reliability.
- Troubleshot and resolved PLC, SCADA, and robotic malfunctions, utilizing tools like TIA Portal, Ignition SCADA, and Omron Cobots to restore optimal performance with minimal downtime.
- Calibrated and fine-tuned CCD cameras, laser sensors, and PLC-controlled robotic components, maintaining precision in critical automation processes.
- Developed and optimized PLC programs to enhance machine logic, streamline workflows, and meet dynamic automation requirements.
- Configured and managed Ignition SCADA systems for real-time visualization, process control, and data logging, integrating with existing MES infrastructure.
- Executed robotic maintenance and fault diagnosis for Omron collaborative robots, improving uptime and safety in automated work cells.
- Led machine bring-up and validation activities, including CPK and GRR studies, to ensure accuracy, repeatability, and process stability.
- Maintained detailed logs of PLC revisions, robot servicing, SCADA configurations, and equipment upgrades for compliance, audits, and continuous improvement.
- Enforced electrical and industrial automation safety protocols, adhering to global standards in robotic and PLC-controlled system environments.
PLC Programmer
Apollo Tyres Private Ltd
04.2021 - 07.2023
- Diagnosed and resolved issues in PLC and SCADA systems, ensuring high equipment uptime and supporting MES-driven root cause analysis using structured fault diagnostics.
- Developed and modified PLC programs on Allen-Bradley CompactLogix using Studio 5000, integrating machine-level data into MES and SCADA platforms.
- Designed and deployed SCADA systems using FactoryTalk View SE, Iconics, and Kepware OPC-UA/DA, enabling real-time process visibility and control across production systems.
- Built Node-RED dashboards for machine health monitoring, power/utility usage tracking, and real-time condition monitoring, integrated with MS SQL and MQTT-based IIoT flows.
- Used JavaScript and Node-RED logic to automate MES reporting, notification triggers, and machine status visualizations.
- Executed automation strategies to reduce scrap, optimize runtime efficiency, and enhance OEE (Overall Equipment Effectiveness).
- Planned and performed preventive and corrective maintenance of PLCs, HMIs, and networked control systems, reducing Mean Time to Repair (MTTR) and increasing MTBR.
- Designed and implemented HMI screens to improve operator interaction and enhance MES-related manual entry points and fault logging workflows.
- Created technical documentation, SOPs, and structured training programs on MES interfaces, PLC/HMI maintenance, and data logging best practices.
- Managed spare part planning and codification for automation hardware in alignment with MES asset hierarchies and maintenance schedules.
- Ensured alignment with corporate automation standards and effectively communicated MES data integration expectations to multidisciplinary teams.
- Developed standardized programming practices and templates for PLC code development, streamlining future projects and enabling consistent quality across all control systems.
Education
Bachelors - Electrical and Electronics Engineering
Ponjesly College of Engineering
07.2015 - 05.2019
Hsc - Maths & Biology
kootalmooodu matriculation
03.2013 - 04.2015
Skills
- PLC programming - Studio 5000,Tia portal,Gx Works
- Ignition Scada,Iconics, Factory talkview Se,Node red
- Python programming, Mssql, C,Embedded C, C programming
- Nvidia Jestson modules, Esp32,
- Linux systems - Nvdia jetson modules, Eagle Board
- Vision Systems - Opencv, Object detection
- Communication Protocols - Ethernet Ip, OPU-Ua , Modbus, Tcp Ip, Uart, Spi, I2c,
Interests
Exploring distant lands
Learning about Astrology
Quantum physics
Capturing moments
Feeling the music
Playing Guitar
Personal Information
- Date of Birth: 11/14/97
- Nationality: Indian
Timeline
IIOT Engineer
Saint Gobain India Private Limited
06.2024 - Current
Automation Engineer - Mes
Dalisoft Technologies Private Ltd
02.2024 - 05.2024
Electrical Engineer - L2
Tata Electronics Private Ltd
07.2023 - 02.2024
PLC Programmer
Apollo Tyres Private Ltd
04.2021 - 07.2023
Bachelors - Electrical and Electronics Engineering
Ponjesly College of Engineering
07.2015 - 05.2019
Hsc - Maths & Biology
kootalmooodu matriculation
03.2013 - 04.2015
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