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saravanan sampath

 Senior Electrical & Automation Engineer with 18+ years’ experience in PLC automation, maintenance, and reliability improvement. Expert in fault finding, GMP, Six Sigma, and CMMS systems, delivering improved uptime, reduced breakdowns, and efficient high-speed manufacturing operations. 

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, GMP
Wonderware SCADA,RCM Trained in USA
Industrial Networks: Ethernet, Profibus, AS-i, mod
TPM, Kaizen, Six Sigma, 5S, Lean Manufacturing

Professional Experience

Jul 2011
Present
Sr.Electrical engineer-Automation
MICHELIN TYRES INDIA LTD Chennai, IN
Global leader in the tire industry—manufacturing Aerospace, Car, Truck, and Military tires.
Technical Experience
Performed reactive maintenance (24/7 breakdown support) ensuring minimum downtime and improved MTTR/MTBF 
  •  Executed planned preventive maintenance (PPM) using SAP / IBM Maximo CMMS to maximise equipment uptime 
  •  Conducted fault finding and repair on: 
    •  PLC systems (Allen-Bradley, Siemens) 
    •  Motors, VSD/servo drives (PowerFlex, Kinetix, Unidrive) 
    •  Control panels, MCCs, LV systems 
  Automation & Equipment 
  •  Troubleshooting and modification of Allen-Bradley PLCs (ControlLogix, CompactLogix, GuardLogix, SLC) 
  •  HMI modification using PanelView 1500
  •  Maintenance of conveyors, pumps, gearboxes, motors, sensors, barcode systems, weighing systems
  •  Worked on servo-controlled and automated material handling systems
  •  Supported robot maintenance (FANUC, ABB) and program modifications 
  Installation & Commissioning 
  •  Installation, modification, and commissioning of electrical systems and machinery 
  •  Integrated new circuits, MCC panels, and automation systems 
  •  Supported machine ramp-up to achieve production targets 
  Maintenance & Reliability 
  •  Performed advanced fault diagnosis and implemented corrective actions to reduce downtime 
  •  Conducted root cause analysis (RCA) and implemented CAPA
  •  Analysed equipment performance data and improved reliability 
  GMP & Compliance 
  •  Applied Good Manufacturing Practices (GMP) in manufacturing environment 
  •  Maintained calibration control for sensors (temperature, pressure, timers)
  •  Ensured documentation: maintenance logs, breakdown reports, audit readiness 
  Electrical & Automation Improvements 
  •  Improved PLC reliability, sensor accuracy, and alarm systems
  •  Reduced false trips and undetected failures 
  •  Performed servo/VFD parameter tuning for process optimisation 
 Safety 
  •  Followed LOTO, permit-to-work, and risk assessment procedures
  •  Ensured safe working practices and compliance with standards 
  Operations & Team Support 
  •  Supported production teams for quick breakdown recovery 
  •  Managed shift maintenance activities and prioritised critical issues 
  •  Coordinated with cross-functional teams and contractors 
  Additional Responsibilities 
  •  Managed spare parts inventory using CMMS 
  •  Performed preventive maintenance for conveyors and tyre handling systems
  •  Worked on factory systems including LAN support and automation integration
 
Jun 2011
Jul 2012
Automation engineer-Projects
MICHELIN NORTH AMERICA INC Spaturnburg,south Carolina., US
 Trained at Rockwell Automation in PLCs, VFD drives, and HMI programming 
  •  Worked in Michelin North America, supporting high-speed manufacturing operations 
  •  Provided shift-based maintenance support, handling both reactive and preventive maintenance
  •  Ensured machine uptime through timely breakdown response and corrective actions 
 PLC & Automation Projects
Troubleshot and upgraded legacy systems from Allen-Bradley SLC PLCs to ControlLogix platforms
  •  Executed PLC migration projects including: 
    •  Program conversion and validation 
    •  Hardware replacement and system integration 
  •  Installed and commissioned upgraded PLC systems in tyre assembly shop
 Fault Finding & Reliability 
  •  Performed advanced troubleshooting on PLC-controlled systems and automation equipment 
  •  Conducted Root Cause Analysis (RCA) for recurring failures 
  •  Implemented corrective actions to improve system reliability 
 Maintenance & CMMS 
  •  Trained in IBM Maximo CMMS for maintenance planning and execution 
  •  Managed preventive maintenance schedules and breakdown records 
  •  Supported maintenance planning to improve equipment performance 

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

Apr 2007
Mar 2011
Bachelor in electrical & electronics engineering in A.V.I.T. Engineering college
VMRF
Apr 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
2026
Food Safety: Good Manufacturing Practices (GMP)
Alison

Achievements

2024
GMP & Six Sigma Driven Curing Process Improvement
Project:  
  • GMP: Implemented GMP-based maintenance and calibration control for curing presses, improving reliability, traceability, and reducing breakdowns through RCA & CAPA. 
  • Six Sigma:  Applied DMAIC in curing process, reducing variation, improving Cp/Cpk, and increasing equipment uptime and 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

I aim to build my career in the FMCG sector in the UK/Europe, specializing in electrical and automation roles, contributing to process reliability, efficiency, and continuous improvement.”

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