Senior PLC Programming - Process Automation

MEL Systems and Services Ltd.; Chennai; On-site; INR 1,200,000 - 2,100,000; Full time

Job summary

MEL Systems and Services Ltd. is seeking a Senior PLC Programmer to lead weighing and batching automation projects in Chennai.

You will design, test, and commission PLC/SCADA/HMI solutions using Siemens and Allen-Bradley platforms, integrate servo motion, load cells, and weighing controllers, and collaborate with mechanical, electrical, and project teams to deliver turnkey installations. Applicants should have hands-on experience with commissioning, FAT/SAT, and customer support, along with a

Qualifications

• Hands-on experience in Siemens S7 and Allen-Bradley PLCs for automation projects.
• Strong experience in HMI/SCADA development and machine commissioning.
• Experience with weighing & batching automation, recipe management and batch control.

Responsibilities

• Develop, test, and troubleshoot PLC programs for weighing and batching systems.
• Design and develop HMI and SCADA applications for process monitoring and control.
• Develop control logic for batch sequencing, recipe management, weighing operations, dosing, and material handling.
• Configure and integrate servo motors, servo drives, VFDs, load cells, weighing controllers, sensors, and industrial networks.
• Integrate PLC with field instrumentation and weighing equipment.
• Perform FAT, SAT, commissioning and machine start-up activities.
• Troubleshoot automation and control issues during commissioning and production support.
• Coordinate with Mechanical, Electrical, and Project Engineering teams.
• Prepare technical documentation, software backups, and commissioning reports.
• Provide customer support during installation and after-sales service.

Skills

Siemens PLC

Allen-Bradley PLC

HMI Development

SCADA Development

Servo Motor Programming

Weighing & Batching

Tools

TIA Portal

S7-1200/1500

RSLogix 5000

Studio 5000

Profinet

Job description

About the Role

We are looking for an experienced Senior PLC Programmer with hands‑on expertise in Process Automation, specifically in Weighing and Batching Systems. The ideal candidate should have strong experience in Siemens and/or Allen‑Bradley (Rockwell) PLCs, along with HMI, SCADA, Servo Motor Integration, and machine commissioning. The candidate will be responsible for developing, testing, and commissioning automation solutions for weighing and batching applications.

Key Responsibilities

• Develop, test, and troubleshoot PLC programs for Weighing and Batching Systems.
• Design and develop HMI and SCADA applications for process monitoring and control.
• Develop control logic for batch sequencing, recipe management, weighing operations, dosing, and material handling.
• Configure and integrate Servo Motors, Servo Drives, VFDs, Load Cells, Weighing Controllers, Sensors, and Industrial Communication Networks.
• Integrate PLC systems with field instrumentation and weighing equipment.
• Perform Factory Acceptance Testing (FAT), Site Acceptance Testing (SAT), commissioning, and machine start‑up activities.
• Troubleshoot automation and control system issues during commissioning and production support.
• Coordinate with Mechanical Design, Electrical Design, and Project Engineering teams.
• Prepare technical documentation, software backups, and commissioning reports.
• Provide customer support during installation and after‑sales service.

Required Skills

Hands‑on experience in:

• Siemens PLC (TIA Portal, S7‑1200, S7‑1500, S7‑300/400)
• Allen‑Bradley (Rockwell) PLC (ControlLogix, CompactLogix, Studio 5000, RSLogix 5000)

Strong experience in:

• HMI Development
• SCADA Development
• Servo Motor Programming & Servo Drive Integration
• Weighing & Batching Automation
• Recipe Management & Batch Control
• Load Cell Integration
• VFD Integration
• Industrial Communication Protocols (Profinet, Profibus, Modbus TCP/RTU, EtherNet/IP)

Preferred Industry Experience

Candidates with experience in the following industries will be preferred:

• Process Automation
• Weighing Systems
• Batching Systems
• Industrial Automation
• Food & Beverage Processing
• Cement
• Chemical Processing
• Material Handling Systems
• Manufacturing Industries

Key Competencies

• Strong analytical and troubleshooting skills.
• Hands‑on experience in Weighing & Batching applications.
• Experience in Servo Motor tuning, commissioning, and motion control.
• Knowledge of industrial instrumentation, load cells, and weighing controllers.
• Good communication and teamwork skills.
• Willingness to travel for commissioning and customer support.

Why Join Us?

• Opportunity to work on advanced Weighing and Batching Automation projects.
• Exposure to Siemens and Allen‑Bradley PLC platforms, HMI/SCADA systems, Servo Motion Control, and end‑to‑end project commissioning.
• Collaborative work environment with opportunities to work on innovative industrial automation solutions.