Pranjali Ramtekkar
Sanjose
Summary
Controls Engineer with 7+ years of experience bridging automation, data systems, and manufacturing execution platforms. Skilled in MES development, PLC/HMI/SCADA integration, and building data-rich, traceable production environments.
Overview
9
9
years of professional experience
1
1
Certification
Work History
Manufacturing Controls Engineer
Tesla Inc., Fremont, CA
12.2023 - Current
- Served as Controls Point of Contact for Robotaxi Battery Pilot Program upgrades, ensuring build readiness across RC builds.
- Owned program controls execution, aligning production with engineering and quality standards while minimizing deviations.
- Led process development, supplier collaboration, and equipment validation for modules, packs, and ancillary components.
- Directed FAT, commissioning, and process optimization activities, delivering stable, production-ready systems.
- Implemented AutoPackout automation on Model S/X battery packs, reducing labor by 2 HC per shift and saving $10.80 per car.
- Integrated Fanuc Robot Dynamic Rack Placement with Keyence 3D Vision, achieving >99% vision accuracy.
- Developed and integrated MES solutions to synchronize production events with controls systems, enabling real-time traceability and visibility.
- Configured MES interfaces to capture test results, equipment downtime, and OEE data for high-volume battery pack production.
- Acted as controls liaison for Cybertruck Battery Pack Potting, reducing scrap costs (≈ $4K per module) and ensuring compliance with Tesla controls standards.
- Developed Python- and Java-based automation applications, including hardware design, operator GUIs, and workflow documentation.
Project Engineer
Factory Technologies Inc., Modesto, CA
06.2020 - 12.2023
- Experience in the Food and Beverage industry has led to an in-depth knowledge of Fillers, Labelers, DE palletizers, Palletizers, Bag-in-a-Box and Conveyance systems.
- Developed and integrated MES solutions to synchronize production events with controls systems, enabling real-time traceability and visibility.
- Configured MES interfaces to capture test results, equipment downtime, and OEE data for high-volume battery pack production.
- Asset Centre Server and Client Commissioning which allowed the plant to archive and track changes for PLC Code, HMI Code and VFD parameters.
- Design and Development of Ignition systems using MySQL and MSSQL databases.
- Seasonal Production Support for Receiving, Processing, Production and Delivery including after hours support to minimize downtime.
- Controls commissioning engineer for automated logistics systems, with a focus on Amazon Fulfillment Centers.
Controls Engineer
Pearson Packaging Systems, Spokane Valley, WA
02.2019 - 05.2020
- Robot programming (Fanuc), PLC programming & vision system programming for secondary packaging processes, palletizing, and 3D scanner system.
- Case Sealer and Case Erector machine development.
- Travel to customer sites for installation of the system, perform system startup and provide robot training to the operator.
- Design complete 2D electrical schematics and assembly drawings for control panel.
- Release Controls Bill of Material.
- Generated User Centric Design graphical HMI screens for complex machinery while providing sufficient feedback for troubleshooting. Provide UL certification to the control panel and machine.
- Inspect, operate and test completed products to verify functioning, machine capabilities and conformance to product manager conformance.
- Integrate 3D scanner system with Fanuc robot using socket messaging.
Robotics Integration/Controls Engineer
iA-Robotics, Murrieta, CA
08.2017 - 01.2019
- Robot programming (Fanuc Roboguide), PLC programming (GE) & vision system programming (IR vision) for assembly, machine load and unload, inline wheel de-burring & material removal system, wheel machining and palletizing, packaging, drill and 3D scan system.
- Generated simple HMI screens for complex machinery while providing sufficient feedback for troubleshooting.
- Implement controls reliable safety systems for safeguarding robots, conveyors, and other high volume manufacturing equipment.
- Programming safety controllers, install light curtains & design fence safety and OSHA compliant safety circuits.
- Integrating vision guided application in robotic systems: precision, alignment, pick & place, dispense, part inspection.
- Select appropriate circuit protectors, wire and cable, sensors, safety hardware, PLC hardware, remote I/O, VFD and servosystems.
- Generate field reports of technical analysis, quality check analysis, help manuals and other documentation.
Controls Engineer Intern
Jabil Chad Automation, Anaheim, CA
02.2017 - 06.2017
- Designed AC and DC electrical controls for robotic and pick & place automation equipment for consumer products, semiconductor industry, multi-station parallel processing and custom automation.
Education
MSE - Electrical Engineering
Arizona State University
12.2016
Skills
- Programming languages: C, C, MATLAB, Python
- Manufacturing Execution Systems (MES), Ignition, SQL, ISA-95, OEE, Traceability, MySQL, Clickhouse, Seeq, Splunk, Minitab
- Tools: AutoCAD Electrical, AutoCAD vault, Solidworks, Simulink, Minitab, Microsoft Office, Epicore ERP System
- Vision: iRVision, Keyence Vision, Cognex In-sight and VisionPro, 2D & 3D vision System, Halcon
- PLC: Rockwell, Beckhoff, Siemens, Beckhoff Motion, Rockwell Motion Control, Siemens Motion
- Communication Protocol: OPCUA, EtherNet/IP, EtherCAT, TCP/IP
Certification
- Inductive Automation 8.1 Gold Cert, 8.1 Core Cert.
- Fanuc Advanced IR Vision Operation and Programming - 2D, Fanuc Advanced TPP Programming, HandlingTool Operation and Programming, IR Pick Tool, Pallet Tool Setup And Programming
Timeline
Manufacturing Controls Engineer
Tesla Inc., Fremont, CA
12.2023 - Current
Project Engineer
Factory Technologies Inc., Modesto, CA
06.2020 - 12.2023
Controls Engineer
Pearson Packaging Systems, Spokane Valley, WA
02.2019 - 05.2020
Robotics Integration/Controls Engineer
iA-Robotics, Murrieta, CA
08.2017 - 01.2019
Controls Engineer Intern
Jabil Chad Automation, Anaheim, CA
02.2017 - 06.2017
MSE - Electrical Engineering
Arizona State University