Vivek Desale

INDUSTRIAL ENGINEER · 12 YEARS

From machines and controls to industrial data and AI.

I work at the boundary between factory equipment and software — connecting PLCs, CNCs and industrial systems, investigating difficult OT problems, validating performance, and turning machine data into usable engineering context.

12Years across automation, IIoT & industrial systems
10kTags tested in scalability workloads
OT→AICurrent engineering direction

IMPACT DASHBOARD

Engineering across the industrial stack.

Connectivity

PLC, CNC, edge and industrial protocol integration across brownfield environments.

Evidence-led RCA

Wireshark/PCAP, logs, controlled experiments and repeatable performance tests.

Manufacturing delivery

Automotive, OEE, energy, traceability, machine connectivity and production systems.

Industrial AI

RAG, engineering knowledge systems and AI-assisted troubleshooting with human verification.

ENGINEERING SHOWCASE

Selected systems and engineering stories.

Not just a project list: each item is framed around the problem, constraints, engineering decisions, evidence and outcome.

Industrial Engineering

Industrial Connectivity & Performance Lab

Built a controlled OT environment for connectivity validation, driver testing, scalability characterization and protocol-level root-cause analysis.

EtherNet/IP · S7 · OPC UA · Modbus · MQTT · Wireshark · Python

Industrial AI

AI-Assisted OT Troubleshooting

Engineering workflow combining manuals, configurations, logs and PCAP evidence to support traceable root-cause investigation.

RAG · AI Agents · Python · Industrial Networking

Engineering Data

PLC/CNC Parser & Engineering Data Platform

Multi-vendor parsing workflows that turn controller projects and configuration files into structured, reusable engineering context.

Siemens · Rockwell · Mitsubishi · FANUC · Python

Manufacturing Quality

Automotive Rubber Curing Quality & Traceability

Used process instrumentation and production evidence to identify unauthorized parameter changes, then added access control, interlocks and traceability.

PLC · HMI · Python · SLMP · RCA · MES

Automation

Turbocharger Journal Bearing Verification

Automated loading, rotation, barcode verification and reject handling for visually similar journal-bearing variants under real production constraints.

Siemens S7-300 · Cognex · Servo · OPC · LabVIEW

Portfolio Build

Automotive Production Line Simulator

A reusable manufacturing environment for production flow, OEE, quality, rework, industrial data and FDE/Industrial AI experimentation.

Manufacturing · UNS · IIoT · Simulation · AI

CASE STUDIES

Real constraints. Clear ownership.

01 — Journal Bearing Verification

Problem

Near-identical bearing variants, reflective surfaces and unreliable manual barcode scanning created assembly risk.

Approach

Enclosed scan cell, controlled lighting, servo rotation, Cognex reader and PLC/LabVIEW verification handshake.

Engineering

PLC/HMI sequencing, scanner communication, interlocks, reject confirmation and retry/timeout logic.

Outcome

1,000+ trial cycles, approximately 95–98% read/verification accuracy depending on bearing wear, 20–30 s cycle.

02 — Rubber Curing Quality Escape RCA

Problem

Export quality failures persisted despite SOPs and inspections.

Evidence

Instrumented temperature/pressure and production behavior across shifts; repeated the observation across multiple machines.

Finding

Production parameters were being changed to accelerate cycles, particularly during night shifts.

Control

Password protection evolved into automatic parameter restoration and management-cleared alarms.

ENGINEERING JOURNEY

Materials → controls → machines → factories → data → intelligence.

LitmusIndustrial Engineer

Industrial connectivity, driver validation, performance/scalability, protocol troubleshooting and lab infrastructure.

TrimasysAssistant Project Manager — IIoT

OT/IT integration, machine connectivity, OEE, energy, traceability and customer delivery.

Wipro PARISolution Engineering / IIoT Pre-sales

Automotive production-line concepts, RFQs, architecture, BoQ/estimation and customer discovery.

Quaint TechnomationPartner / Technical Leadership

Industrial automation business, PLC/HMI systems, machine retrofits, quality controls and IIoT projects.

Early Automation RolesApplication & PLC Engineering

Controls, sensors, drives, PLC programming, commissioning and industrial application engineering.

TU ChemnitzM.Sc. Electrical & IT Systems

Micro & Nano Systems; AFM/SEM, TERS and semiconductor/material characterization.

TECHNICAL EXPERTISE

Industrial systems first. Software and AI where they create leverage.

OT & Connectivity

EtherNet/IP/CIP, Siemens S7, OPC UA, Modbus TCP/RTU, MQTT, MTConnect, FANUC FOCAS, Beckhoff ADS, DNP3.

Engineering & Data

Python, Node-RED, SQL, InfluxDB, Grafana, Wireshark/PCAP, REST/GraphQL, industrial edge and UNS patterns.

AI & Applications

RAG, AI agents, FastAPI, React, Docker, engineering knowledge systems, evaluation and human-in-the-loop workflows.

INDUSTRIAL AI

AI grounded in machine context and engineering evidence.

My focus is not AI replacing engineering judgment. It is AI helping engineers retrieve the right evidence, understand industrial context, investigate faster and make better-supported decisions.

Connect→Normalize→Contextualize→Reason→Verify→Act

PROFESSIONAL HUB

Building toward Industrial AI & Forward Deployed Engineering.

Open to roles where manufacturing-domain depth, customer-facing engineering, industrial data and AI deployment meet.