Siemens STEP 7 TIA Portal, Allen-Bradley Studio 5000; HMI, development, I/O commissioning, sensors, actuators, VFDs, motor controls, and safety systems; wiring verification, signal tracing, and root-cause analysis
Controls Technician • Automation • Electrical Troubleshooting
Controls-focused technician for automation, machines, signals, and uptime.
Electrical & Computer Engineer with hands-on experience in industrial controls troubleshooting, automotive EMC testing, and instrumentation. Skilled in PLC Fault tracing, VCU flashing and testing, electrical schematic design, and CAN bus diagnostics. Experienced at troubleshooting electrical systems,validating sensors and actuators, and supporting machine reliability and safe production operations.
Using ladder logic, electrical schematics, multimeters, wiring verification, continuity checks, signal tracing, and root-cause analysis to isolate downtime causes, reduce repeat failures, and restore equipment safely.
NFPA 70E, NFPA 79, LOTO, UL 508A; ISO26262 awareness, FMEA/DFMEA; technical reporting, downtime analysis, and CAPA documentation.
Positioning
Controls Technician Focus
This site is built around the story that matters: troubleshoot machines, verify signals, isolate faults, support production, and document fixes clearly.
PLC Controls & Production Troubleshooting
Troubleshooting PLC-controlled production equipment using Siemens STEP 7/TIA Portal and Allen-Bradley Studio 5000, including HMI alarms, I/O checks, sensors, actuators, relays, motors, VFDs, safety systems, and industrial control panels.
Electrical Diagnostics & Root-Cause Analysis
Using ladder logic, electrical schematics, multimeters, wiring verification, continuity checks, signal tracing, and root-cause analysis to isolate downtime causes, reduce repeat failures, and restore equipment safely.
Validation, SCADA & Machine Reliability
Supporting HMI/SCADA visibility, SQL/Python scripting, machine startups, changeovers, equipment testing, post-repair validation, EMC setup verification, corrective actions, and reliable production recovery.
ECU, CAN & Embedded Systems
ECU/VCU flashing, CAN bus diagnostics, DTC analysis, ETAS INCA, Vector CANoe/CANalyzer, CANape, ESP32 sensing, UART, I2C, ADC workflows, and embedded hardware/software validation.
Background
About
I earned dual BSE degrees in Electrical Engineering and Computer Engineering from the University of Michigan-Dearborn. My work connects controls, instrumentation, embedded systems, automotive validation, circuit analysis, and robotics.
The value I bring is practical execution: verify the setup, check the signal, isolate the fault, document the evidence, and keep the system reliable.
Education
University of Michigan-Dearborn
Dual BSE in Electrical Engineering and Computer Engineering
September 2019 – April 2024
Relevant technical foundation: Control Systems, Automatic Control Systems, Circuits, Electronic Circuits, Digital Signal Processing, Microprocessors, Embedded Systems, Computer Networks, Robotics, and Vision Systems.
Core Stack
Controls-Focused Skills
Prioritized for industrial controls, PLC troubleshooting, automation support, electrical diagnostics, and production reliability.
PLC Troubleshooting & Controls
Siemens STEP 7TIA PortalAllen-Bradley Studio 5000
PLC programmingLadder logicPLC troubleshooting
HMI developmentHMI alarmsI/O commissioning
I/O checksNachi Ax PLC & I/O
Industrial Automation & Machine Controls
PLC-controlled equipmentIndustrial automationSensors & actuators
VFDsMotor controlsRelays
Safety systemsIndustrial control panelsMachine startups
ChangeoversMachine commissioningEquipment testing
Electrical Diagnostics & Troubleshooting
Electrical schematicsWiring verificationSignal tracing
MultimetersContinuity checksPolarity checks
Impedance checksSignal integrityRoot-cause analysis
Downtime reductionOscilloscopesVector Network Analyzers(VNA)
SCADA, Validation & Reliability
SCADA systemsSQL scriptingPython scripting
Equipment monitoringPost-repair validationInstrumentation setup
Instrumentation setupTechnical documentation
Corrective actionsCAPA documentationDowntime analysis
Automotive & EMC Testing
ETAS INCAVector CANOEVector CANalyzerdSPACE ControlDesk
LabVIEWECU/VCU FlashingDTC diagnostics
Instrumentation setupTechnical documentation
CAN bus analysisBCI testing EmissionsRadiated & Immunity
ESD testingTest setup validationOEM procedures
Design Software
AutoCADAutoCAD ElectricalEPLAN Electric P8Autodesk Fusion 360
Work History
Experience
Machines, signals, diagnostics, reliability, and documented evidence.
Controls Technician — AAM Oxford Forge
Oxford, MI
- Troubleshot and diagnosed faults on PLC-controlled production equipment using Siemens STEP 7/TIA Portal and Allen-Bradley Studio 5000, including HMI alarms, sensors, actuators, relays, motors, VFDs, and industrial control panels.
- Supported HMI/SCADA interface development and data visibility using SQL and Python scripting for equipment monitoring and troubleshooting support.
- Used ladder logic, electrical schematics, multimeters, and I/O checks to identify root causes of machine downtime and reduce repeat equipment failures.
- Supported machine startups, changeovers, equipment testing, and post-repair validation to restore production safely and minimize interruptions.
- Documented repairs, downtime causes, troubleshooting steps, and corrective actions.
- Collaborated with maintenance, production, and engineering teams to quickly diagnose equipment issues, restore machine operation, and reduce downtime impact on production.
EMC Lab Test Technician — Applus+ Reliable
Madison Heights, MI
- Executed automotive EMC validation testing (BCI, radiated emissions/immunity, ESD) following OEM procedures, delivering traceable pass/fail engineering data.
- Configured and validated EMC test setups including instrumentation, harnesses, fixtures, and DUT mounting to ensure repeatable and reliable test conditions.
- Performed signal integrity, impedance, continuity, and polarity checks on test setups to minimize invalid data and reduce unnecessary retesting. runs and prevent bad data.
- Troubleshoot test failures by isolating setup-related issues from DUT behavior, documenting corrective actions and validated retest resultswith retest evidence.
- Maintained detailed test logs, screenshots, plots, and documentation to meet compliance.
Junior Electrical Engineer Intern — Robert Bosch
XC-Multimedia Department • Plymouth, MI
- Supported ECU validation workflows through flashing, post-flash verification, CAN checks, and tool-based data review.
- Used ETAS INCA and Vector CANoe/CANalyzer to log, review, and validate CAN signal behavior and communication quality.
- Reviewed signals including speed, torque, temperature, pressure, throttle, boost, and lambda/AFR for plausibility and data integrity.
- Diagnosed DTCs, CAN timeouts, sensor dropouts, and configuration mismatches using traces, logs, and measurement data.
- Maintained structured notes and run documentation to support repeatable validation workflows.
Technical Evidence
Controls-Relevant Projects
Curated to support controls engineering: feedback systems, embedded sensing, robotics control, signal analysis, circuits, FPGA logic, and networked systems.
PLC Project
Allen-Bradley PLC Logic — Studio 5000 / Ladder Logic
Developed and reviewed Allen-Bradley ladder logic concepts using Studio 5000, including start/stop motor control, seal-in logic, timers, counters, interlocks, permissives, fault conditions, HMI alarm logic, and basic I/O troubleshooting. Focused on production-style troubleshooting, safe machine recovery, and reducing downtime.
PLC Project
Siemens PLC Logic — TIA Portal / STEP 7
Built and analyzed Siemens PLC logic using TIA Portal and STEP 7 concepts, including ladder logic, function blocks, timers, counters, memory bits, I/O mapping, Profinet device communication, HMI tag structure, alarm logic, and machine sequence control. Emphasized electrical diagnostics, PLC fault tracing, and structured troubleshooting for automated equipment.
PLC Project
Arduino Opta PLC Logic — Industrial Control / Ladder Logic
Built and reviewed PLC control logic using the Arduino Opta PLC for industrial-style automation applications, including digital I/O control, ladder logic concepts, timers, counters, interlocks, permissives, memory bits, alarm handling, and machine sequence logic. Focused on electrical troubleshooting, input/output verification, fault tracing, safe machine recovery, and structured diagnostics for automated equipment.
Priority Project
Control Systems & Signal Analysis — MATLAB / Simulink
Modeled dynamic systems using transfer functions, feedback blocks, poles and zeros, step response, sinusoidal response, Bode/Nyquist analysis, Simulink workflows, aliasing analysis, and notch-filter response.
Senior Design
Smart Shoe System — Embedded Sensors, ESP32 & Mobile Dashboard
Designed a wearable sensing system using pressure/force sensors, ESP32 communication, serial data readings, and a Flutter mobile dashboard. Demonstrates sensor integration, embedded reads, mobile visualization, hardware/software integration, and physical prototype iteration.
Robot Vision Line Follower & Proportional Control
Developed robot vision software for line following using ROS image acquisition, Canny edge detection, Hough line extraction, and proportional steering control.
Embedded Development Boards & Microcontroller Platforms
Hands-on embedded systems work across Arduino, Nexys A7 FPGA, DragonBoard, and TM4C123GXL platforms. Used these boards for sensor integration, digital logic, UART/I2C communication, embedded debugging, and hardware/software validation.
UART, I2C, ADC & Embedded Debugging
Configured UART communication, ADC conversion, I2C accelerometer reads, and LED control logic. Used serial output and debugging tools to verify embedded behavior.
Alcohol Detection System — FPGA, VHDL & Decision Logic
Developed VHDL logic for sensor-driven decision logic with simulation waveforms for intoxication, distance, speed, and display outputs.
Image Transmission Network
Built a socket-based image transmission system using client/server networking concepts and file-transfer workflows.
Operational Amplifier Circuit Analysis
Simulated and tested op-amp configurations in LTspice and lab measurements. Compared gain, clipping, waveform response, and measured hardware results.
MOSFET Amplifier Simulation & Validation
Investigated common-source and source-follower MOSFET amplifier behavior through LTspice simulation and lab comparison.
Continuous Learning
Professional Certificates
Completed programs across web development, data analytics, AI, automation, robotics, PLC fundamentals, MATLAB/Simulink, and engineering tools.
Nachi Robotics Systems INC Robot Programming & PLC • 2 certificate
IBM / Coursera AI • Data Science • Prompt Engineering • 12 certificates
IBM Certificate
AI, data science, Python, and software engineering training.
IBM Certificate
Technical training in data, AI, and programming fundamentals.
IBM Certificate
Applied learning in artificial intelligence and data tools.
IBM Certificate
Software engineering, analytics, and technical development.
IBM Certificate
Machine learning and data science training.
IBM Certificate
AI concepts, technical workflows, and applied data skills.
IBM Certificate
Python, automation concepts, and data-driven development.
IBM Certificate
Professional technical training in AI and software tools.
IBM Certificate
Data science, analytics, and machine learning foundations.
IBM Certificate
Technical learning across AI, Python, and data systems.
IBM Certificate
Software, analytics, and AI-focused professional training.
IBM Certificate
Prompt engineering, AI tools, and technical problem solving.
LinkedIn Learning PLC • Automation • Technical Training • 12 certificates
LinkedIn Learning Certificate
PLC, automation, software, and technical training.
LinkedIn Learning Certificate
Industrial automation and controls-related learning.
LinkedIn Learning Certificate
Technical development and engineering workflow training.
LinkedIn Learning Certificate
Software, automation, and technical problem-solving skills.
LinkedIn Learning Certificate
PLC concepts, automation, and engineering support skills.
LinkedIn Learning Certificate
Professional training in technical systems and software tools.
LinkedIn Learning Certificate
Industrial automation, troubleshooting, and systems learning.
LinkedIn Learning Certificate
Controls-related training and technical skill development.
LinkedIn Learning Certificate
Automation, engineering tools, and professional development.
LinkedIn Learning Certificate
Technical training supporting automation and diagnostics work.
LinkedIn Learning Certificate
PLC, automation, and engineering workflow development.
LinkedIn Learning Certificate
Professional technical training for automation-focused roles.
MATLAB / Simulink Engineering Simulation • 1 certificate
Microsoft Career Essentials • 1 certificate
Google / Coursera Data Analytics • 2 certificates
Codecademy Web Development • 5 certificates
Codecademy Certificate
Web development training and front-end foundations.
Codecademy Certificate
HTML, CSS, and website-building concepts.
Codecademy Certificate
Front-end development and web structure.
Codecademy Certificate
Interactive website and programming fundamentals.
Codecademy Certificate
Web development practice and technical learning.
Next Step
Contact
For controls engineering, automation, validation, test systems, embedded systems, and automotive systems opportunities.
Email
samkalaf@umich.edu
Phone
(586) 224-3245
LinkedIn
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GitHub
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Resume
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Website
samkhalaf.org