Automation Controls Engineer
Kyaw Min Thu
20 years building and commissioning industrial control systems — PLC programming, instrumentation, and controls across offshore drilling, R&D, manufacturing, and warehouse automation.
// System Overview
Experience
20+ Years
Specialization
PLC / Controls
PLC Platforms
Rockwell, Siemens
HMI / Visualization
NI LabVIEW / CompactDAQ
Domains
MFG, Offshore, R&D
Degree
BS Computer Science
Location
Bay Area, CA
Core Competencies
SYS.01
PLC Platforms — Rockwell ControlLogix, Siemens S7-300/1500, Mitsubishi FX, Omron
Data Acquisition — NI CompactDAQ, LabVIEW, Keyence sensors, Python / SQL
Protocols — OPC UA, Modbus TCP, Ethernet/IP, MQTT, SECS/GEM
Programming — Python, SQL, C, Ladder Logic, Structured Text, FBD
Hardware — Fanuc Robotics, VFDs, Servo Drives, NI CompactDAQ, Safety circuits
Root Cause Analysis
SYS.02
Two cases that demonstrate structured debugging across different failure types — process layer failure and human-system interaction failure.
Case 01 · Process Failure
Fire Training Simulator — Intermittent Ignition Failure
Symptom
Ignition failed intermittently — no alarms, control logic correct
Isolation
Control, electrical, and mechanical layers verified. Air supply uninstrumented — no visibility
Root Cause
Clogged air filter → insufficient pressure at ignition phase
Fix
Replaced filter, added pressure transmitter, integrated into monitoring, PM schedule implemented
Outcome
Ignition immediate and stable · Zero recurrence
Case 02 · Human-System Interaction
Amazon Fulfillment — Intermittent System Shutdown
Symptom
Random system stops — no alarms, no deterministic pattern, not reproducible
Challenge
PLC trending insufficient for rare events — no logging, trigger source unknown
Approach
Built Python monitoring system capturing all stop conditions, permissives, and interlocks 24/7 with real-time Slack alerting
Root Cause
Unintentional manual input — intermittent button trigger by associate, invisible without logging
Outcome
Root cause confirmed · Full event visibility · Zero recurrence
Professional Experience
SYS.02
Automation Engineer / Controls Lead
- Controls lead for Rockwell ControlLogix PLCs across conveyor and sortation systems in 24/7 fulfillment centers.
- Primary Fanuc robot technical lead — troubleshooting, system recovery, and commissioning support.
- Built Python monitoring tools for fault trending and downtime analysis.
- Commissioned a conveyor inspection system integrating sensors, PLC logic, and HMI diagnostics.
Electrical Technician | Automation & Controls Systems
Performed full engineering scope: system design, PLC programming, commissioning, and validation
- Owned full engineering lifecycle — concept design, component specification, sourcing, installation, testing, commissioning, and ongoing maintenance.
- Designed and built NI-based control systems (CompactDAQ, LabVIEW) for in-house R&D and field-deployed applications.
- Programmed Allen-Bradley PLCs (ControlLogix, CompactLogix) for high-pressure pump, valve, and instrumentation control.
- Integrated Keyence sensors and vision systems into automated test and measurement workflows.
- Designed electrical schematics, specified and sourced components, built control panels, and wired safety interlocks.
- Used Python and SQL for data acquisition, experiment traceability, and test repeatability across R&D projects.
Maintenance Technician (Automation & Controls)
- Supported high-volume manufacturing automation including Fanuc robotics and Rockwell PLCs.
- Performed predictive maintenance and root cause analysis on production lines.
- Improved Mean Time Between Failures (MTBF) through data-driven reliability programs.
- Modified control logic and supported production startups and line expansions.
Field Service Engineer (Controls & Automation)
- Led full control system conversion for offshore drilling top drive — Mitsubishi to Siemens S7 PLC.
- Managed all project phases: architecture, I/O mapping, interlock logic, ATEX-certified cabinet fabrication.
- Tuned hydraulic PID loops and verified control performance under live offshore load conditions.
- Commissioned systems offshore with live troubleshooting in hazardous environments.
- Full lifecycle ownership from design to production handover.
Tooling Center Technician
- Maintained and calibrated industrial electrical equipment to safety and performance standards.
- Managed inventory and tool preparation for field maintenance teams.
System Engineer
- Designed and commissioned automated firefighter training systems for Singapore Civil Defence Academy.
- Programmed PLCs and built SCADA interfaces for fire, gas, and hydraulic control systems.
- Integrated LPG and kerosene fire effects with the highest safety standards.
- Delivered documentation and operator training for end users.
Associate Engineer — Computer Integrated Manufacturing
- Maintained CIM systems (IBM SiView) and factory automation data platforms.
- Troubleshot server logs and optimized data collection workflows for production control.
- Improved reliability and uptime of automation data systems.
Engineering Assistant — Mixed Signal Logic Testing
- Maintained pneumatic controlled chip handling systems.
- Troubleshot mixed signal logic processing test equipment and minimized downtime.
- Performed tester and handler setup, preventive maintenance, and calibration.
Project Highlights
SYS.03
Offshore · Controls Conversion
Full PLC Conversion — Hydraulic Top Drive, Offshore Drilling
Led a complete control system conversion for an offshore drilling top drive from Mitsubishi PLC to Siemens S7.
Covered the full project lifecycle — architecture, I/O mapping, interlock logic, ATEX-certified cabinet fabrication,
and on-site commissioning. Tuned hydraulic PID loops under live load conditions in a hazardous-area environment.
Siemens S7
TIA Portal
PID Control
ATEX
Hydraulics
R&D · Test Automation
High-Pressure Test Rig Automation — Water & Wastewater R&D
Owned full engineering scope — concept design through commissioning — for in-house and field-deployed NI-based control systems.
Programmed Allen-Bradley PLCs and NI CompactDAQ for pump, valve, and instrumentation control. Integrated Keyence sensors for measurement and feedback.
Specified and sourced components, designed electrical schematics and safety interlocks. Used Python and SQL for data acquisition and experiment traceability.
Allen-Bradley
NI CompactDAQ
LabVIEW
Keyence
Python
SQL
Safety interlocks
Personal Tool · Standards Reference
Control System Standards Atlas
Personal engineering reference for industrial control system standards — navigate NEC, NFPA 79,
IEC 60204-1, functional safety (IEC 61511), cybersecurity, and hazardous area standards across
lifecycle stages without opening PDFs. Built a RAG browser for cross-standard lookup and comparison.
IEC 60204-1
NFPA 79
IEC 61511
NEC
Jekyll
Python
Warehouse · Control Monitoring
PLC & IPC Control Monitoring — Amazon Fulfillment Centers
Built monitoring dashboards reading live PLC and IPC data across conveyor and sortation systems in 24/7 fulfillment centers.
Covered commissioning and maintenance of control panels and IPCs. Developed Python-based tools for fault trending
and downtime analysis.
Rockwell ControlLogix
FactoryTalk
Python
IPC
System Thinking
SYS.04
Control system behavior ≠ system behavior. Physical process determines the actual outcome.
Failures often originate outside the control system — in the mechanical, process, or human layer.
When existing tools lack visibility, build the instrumentation layer before attempting diagnosis.
Isolate domains independently. Do not replace components until the root cause is confirmed.
// Failure Path — Fire Ignition RCA
Compressor — Air source
Air filter — Heavily clogged
Pressure drop — Insufficient at ignition phase
Burner — Ignition fails
Fix: filter replaced + pressure transmitter added
// Monitoring System — Intermittent Shutdown
PLC signals — Stop cmds, permissives, interlocks
Python monitoring — 24/7 continuous capture
Slack alerting — Real-time on any stop event
Root cause captured — Unintentional button input
Full visibility established · Issue resolved
Education
SYS.05
Bachelor of Science in Computer Science
California State University, East Bay — Hayward, CA
Jun 2018 — Dec 2024
Diploma in Electronics, Computers & Communication Engineering
Singapore Polytechnic
Jun 2001 — Apr 2004
Let's Connect
Open to automation engineering roles, consulting, and collaboration opportunities.