saravanan sampath

 Electronics & Automation leader with 18+ years of experience in high-volume manufacturing environments, specializing in SMT electronics assembly, industrial robotics, PLC controls, and maintenance strategy. Proven track record managing automated production lines, improving equipment reliability, and leading cross-functional technical teams in global organizations including Michelin and Nokia. Deep expertise in FUJI SMT systems, PCB assembly, robotics (ABB/FANUC), PLC platforms (Allen Bradley, Siemens, Omron), and predictive maintenance frameworks. Strong background in ISO compliance, TPM/WCM, Lean Six Sigma, and cost-optimized maintenance operations. Recognized for translating business goals into technical execution, driving uptime, OEE improvement, and continuous improvement culture. Safety-focused, audit-ready, and experienced in customer-facing manufacturing environments. 

Key Skills

PLC: Allen Bradley PLC&HMI Panelview
PLC:siemens PLC & simatic wincc
Fanuc (M900i – 4 & 6 Axis), ABB IRB 4600
Drives: Emerson, Control Techniq, Kinetix, Siemens
IBM Maximo CMMS, SAP PM
Ethernet/IP, Profibus, AS-i, Modbus, Ethernet
Allen Bradley ControlLogix, CompactLogix,
Tools: SAP, Minitab, six sigma black belt
PanelView, FactoryTalk View, Siemens WinCC, Wondwr
Networks: Ethernet, Profibus, AS-i, mod
TPM, Kaizen, Six Sigma, 5S, Lean Manufacturing
Hight speed routers and jigs

Professional Experience

Jul 2011
Present
Asst manager -Automation &Industrial Robots
MICHELIN TYRES INDIA LTD Chennai, IN
Global leader in the tire industry—manufacturing Aerospace, Car, Truck, and Military tires.
 
Automation Engineer Electrical & Automation 

Duration: ~2011 2019 (8 Years) 

Key Responsibilities: 

  • Led robotics and control systems for highly automated tire manufacturing lines (car, truck, specialty production).

  • Programmed, debugged, and commissioned Allen Bradley PLCs, HMIs, SCADA systems, drives, conveyors, and robotic cells.

  • Performed ABB & FANUC 4/6-axis robot teaching, path optimization, and interlock validation.

  • Executed installation, FAT/SAT, commissioning, and production handover of automation systems.

  • Developed structured PLC architecture, I/O mapping, reusable standards, and fault diagnostics.

  • Supported CNC/PLC-based special purpose machines, assembly equipment, and automated production lines.

  • Coordinated with OEMs and system integrators for procurement and machine acceptance.

  • Maintained automation equipment to ensure high uptime and reliability.

  • Implemented predictive maintenance and TPM practices to reduce breakdowns.

  • Enforced electrical safety, robotic safety, LOTO procedures, and statutory compliance.

  • Documented maintenance procedures and prepared technical reports.

 
 
Assistant Manager Automation & Maintenance 

Duration: 2019 Present 

Key Responsibilities: 

  • Managed automation strategy from design review through installation, qualification, and sustained production.

  • Led cross-functional teams to improve equipment efficiency and manufacturing uptime.

  • Translated business strategy into automation execution plans.

  • Oversaw preventive, predictive, and corrective maintenance programs.

  • Tracked maintenance expenses and optimized repair budgets.

  • Managed machine qualification, upgrades, and new installations.

  • Coordinated customer audits and compliance with ISO 9001 / 14001 / 45001 standards.

  • Implemented WCM / TPM initiatives to improve operational excellence.

  • Reported automation KPIs, downtime analysis, and reliability metrics to leadership.

  • Developed maintenance procedures and ensured documentation discipline.

  • Managed spare parts inventory and vendor coordination.

  • Inspired teams, encouraged skill development, and supported continuous improvement culture.

  • Ensured ethical standards, safety compliance, and operational discipline.

 
Jun 2011
Jul 2012
Automation engineer-Trainee
MICHELIN NORTH AMERICA INC Spaturnburg,south Carolina., US
Global leader in the tire industry—manufacturing Aerospace, Car, Truck, and Military tires.
Training & Technical Exposure (Rockwell, USA) 
 
Trained at Rockwell Automation on PLCs, drives, and HMI.
Hands-on exposure to global automation standards and documentation.  Allen Bradley Certification & Technical Training in USA Rockwell Training Center-Greenville -south Carolina. Allen Bradley PLCs -Control Logix fundamentals Project Development Rockwell Kinetics Drives 6000 motion control & Trouble shooting . RS Logix 5000 -level 4 -Motion Programming Logics HMI -Factory Talk ME and PanelView Plus Programming. PID -Instrumentation Loop development Training. Programming standards-Grafcet -ST395/ST265 IMS SCHOOL Greenville -south Carolina. Electrical technical Training& Mechanical technical Training. RCM-Reliability centered maintenance Training CMMS IBM-Maximo maintenance software training. PROACT-RCA analysis Training. Planning & scheduling for maintenance training. IQS-Quality standard and Process training & digitalized Projects. Electrical Automation Technician- MICHELIN Truck tire Plant Spaturnburg.SC Troubleshooting of tire assembly manufacturing Process machines. AB PLC Programming of Process requirement in automated machine SLC to Control Logix conversion Projects in Obsolete machines. Kinetix Drives replacement and attending technical breakdowns 

Sep 2007
Jun 2011
Associate Engineer – SMT Automation
Nokia India Pvt Ltd, Chennai, India Chennai, IN
mobile Phones manufacturer
 
Electronics / High-Speed Manufacturing Environment 
 
Managed shift operations independently and led a team of technicians to troubleshoot high-speed automatic machines, SMT lines, and industrial robotic systems.

Performed preventive and corrective maintenance on robotic hardware, mechanical assemblies, and electronic systems to ensure maximum equipment reliability.

Installed, programmed, and troubleshot FUJI SMT systems for PCB/component mounting, Cencorp routers, automated soldering, paste filling, and mobile packing lines.

Installed and maintained Reflow Oven machines and PCB assembly equipment to support stable production output.

Troubleshot and maintained PLC systems (OMRON, MELSEC) for PCB conveyor routing and automated screwing machines.

Modified HMI  screens to support variable PCB product configurations and production flexibility.

Created and taught robotic programs for Baumann robots/routers for pick-and-place, screwing, and cutting operations with precision depth and positioning control.

Applied robotic programming using Visual Basic and ladder logic for automation system tasks and machine integration.

Developed and implemented AGILENT vision system programs for inspection accuracy, defect risk reduction, and OEE improvement.

Applied strong mechanical and electrical troubleshooting skills for equipment setup, repair, and production support.

Implemented Lean, Kaizen, and Kanban initiatives to improve semiconductor mounting machine performance.

Delivered measurable improvements in OEE, cycle time, product quality, cost efficiency, and production throughput.

Supported continuous improvement culture and cross-functional collaboration on shop-floor automation projects. 

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- USA
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
FMEA-AIAG VDA
OMNEX
MSA-AIAG
OCTAGEN
CAE-English assessment -C2-Band 8
Cambridge
OSHA STANDARD Certification
Udemy

Achievements

2011
Performance
 Developed a power backup solution for PLCs and robots, significantly reducing product scrap and startup loss.
Consistently exceeded production support KPIs by optimizing preventive maintenance strategies. 

Quote

Self-motivated, resilient, and skilled in leading and working with teams.

Languages

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

Career Aspiration

To contribute as a Robotics & Controls / BIW Automation Engineer in leveraging deep hands-on experience in robotics, PLCs, safety, and large-scale automated manufacturing systems.

Get in touch with saravanan