Uthkala Mallavarapu
Automation & Systems Engineer | PLC-SCADA-HMI Integration | Controls to IT Data Pipelines | Industrial Communications | MES & Manufacturing Platforms | Python & SQL | Industry 4.0
- Role
- Business Analyst at FCCI Insurance Group
- Location
- Washington, PA, US
- LinkedIn followers
- 500 followers
About Uthkala Mallavarapu
Automation & Digital Systems Engineer with 3+ years of experience delivering plant-floor and enterprise level automation solutions across automotive and industrial manufacturing environments. Specialized in bridging Controls, Manufacturing, and IT by designing PLC, SCADA, HMI, and manufacturing systems integrations that improve operational reliability, commissioning efficiency, and production visibility.At General Electric and Ford Motor Company, supported and implemented automation and digital manufacturing solutions across multi-line and multi-site operations, achieving 20-30% reduction in automation related faults and 25% faster commissioning cycles. Integrated Allen-Bradley and Siemens PLC systems with SCADA, historian, and manufacturing data platforms, enabling real time decision making and reducing troubleshooting response time for operations, quality, and engineering teams.Experienced in architecting end to end industrial solutions integrating PLCs, robotics (FANUC, ABB), vision systems (Cognex, Keyence), MES and historian platforms (OSIsoft PI, Wonderware), and industrial communication networks. Applied systems thinking and Industry 4.0 principles to design scalable automation architectures, manufacturing data pipelines, and standardized documentation supporting reliable operations and cross functional collaboration.Core Expertise:Industrial Control Systems: PLC & SCADA integration, HMI configuration, control architecture, alarm diagnosticsManufacturing Systems & Integration: MES connectivity, production data management, commissioning supportIndustry 4.0 & Digital Manufacturing: Industrial IoT, edge data processing, smart manufacturing analyticsTechnical Stack: Python, SQL, OPC UA, Modbus, MQTT, Apache Airflow, Power BI, Tableau, Git
Experience
Business Analyst
Aug 2023 — Present
Education
Robert Morris University
Master's degree, Information Science/Studies
Christ University, Bangalore
Bachelor of Technology - BTech, Computer Science
2018 — 2022
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