About me

Automation and Controls Engineer specializing in industrial automation, PLC/SCADA systems, real-time manufacturing data, and robotics control. Currently at Trusscore, I develop and deploy production-critical automation solutions in a high-volume PVC extrusion environment, integrating PLCs, vision systems, databases, and enterprise software into unified control and monitoring systems.

I design end-to-end industrial solutions using Ignition, Studio 5000, FactoryTalk, SQL, and Python, including SCADA/HMI applications and real-time production monitoring platforms. I have built multi-threaded industrial software integrating Keyence barcode systems with custom OCR pipelines for real-time part validation across multiple extrusion lines. I also support PLC integration, electrical troubleshooting, and OPC UA-based communication between machines and enterprise systems.

My work extends into manufacturing intelligence, including inline quality systems for dimensional inspection, defect detection, and color/gloss analysis. I evaluate and deploy industrial sensing technologies (Micro-Epsilon, Cognex, LMI, X-Rite) and build SQL pipelines with Power BI/Power Apps dashboards for traceability and operational analytics.

Previously, during my MSc at Ontario Tech University, I focused on robotics and automation, developing an RGB-D 3D scanning system (95% accuracy), a hybrid trajectory optimization method (51% energy reduction, 33% cycle time improvement), and ROS-based robotic control frameworks with web HMIs. I also developed automated trajectory planning for industrial spray-painting systems validated across FANUC, KUKA, and ABB robots.

Expertise

  • Electromechanical Modelling

    Electromechanical Modelling

    Model system dynamics for deeper process understanding.

  • SCADA

    PLC and SCADA

    Studio 5000, Ignition, FactoryTalk.

  • ROS

    ROS

    Deep understanding of ROS1 and ROS2 topics, services, actions, launch, rviz, gazebo, nav2 etc.

  • Deep Learning

    Deep Learning

    Create custom Deep Neural Networks in Python tensorflow.

Publications

  • Gabbar, H.A.; Idrees, M. ARSIP: Automated Robotic System for Industrial Painting. Technologies 2024, 12, 27. https://doi.org/10.3390/technologies12020027

  • Idrees, M.; Gabbar, H.A. A hybrid optimization scheme for efficient trajectory planning of a spray-painting robot. In Proceedings of the 3rd International Conference on Robotics, Automation, and Artificial Intelligence (RAAI), Singapore, 14–16 December 2023

Resume

Education

  1. MSC IN ELECTRICAL AND COMPUTER ENGINEERING, ONTARIO TECH

    Jan 2022 — Jan 2024

    GPA: 4.20/4.30, Thesis: https://hdl.handle.net/10155/1718, Courses: Power Electronics, Manipulator and Mechanism Design, Machine Learning and Data Mining, Intelligent Systems Applications, Real Time Data Analytics IOT, Adaptive Control.

  2. BS IN MECHANICAL ENGINEERING, GHULAM ISHAQ KHAN INST OF ENG SCIENCES

    Aug 2016 — Sep 2020

    GPA: 3.91/4.0, Capstone: Design and Fabrication of a Bipedal Robot. Courses: Calculus, Physics, Dynamics, Control Systems, Vibrations, Robotics, Digital Logic Design, Microprocessor Systems, Design of Machines, Mechanism Design, Finite Element Methods, Stress Analysis, Thermodynamics, Heat Transfer, Project Management, Total Quality Management.

  3. NON-DEGREE CULTURAL EXCHANGE, UNI OF MISSOURI COLUMBIA, USA

    Jan 2019 — May 2019

    A Cultural Exchange Semester sponsored by IREX and UGRAD. Courses: American History, College Seminar, Internship and Career Exploration. Presented my country and did community service work in a Food Bank

Experience

  1. Automation and Controls Engineer, Trusscore

    May 2024 — Present

    1. - Working with key cross-functional stakeholders to create technical requirements/RFQ packages, assess automation integration capabilities and estimate automation costs.
    2. - Developing HMI, SCADA systems and backend services for real-time equipment control, production monitoring, and data visualization using Ignition, Studio 5000, and FactoryTalk.
    3. - Interpreting electrical schematics and wiring diagrams to understand equipment behavior, troubleshoot control systems, and support PLC and SCADA integration across PVC manufacturing lines.
    4. - Leading development of an inline QC system for extruded PVC panels covering dimensional, visual defect, and color/gloss inspection.
    5. - Evaluating 3D profiling systems (Micro-Epsilon, Cognex, LMI Technologies) and color/gloss measurement tools (X-Rite, Spectro Pro) for production deployment.
    6. - Developed a 2000+ line multi-threaded Python service integrating Keyence barcode readers with an in-house OCR pipeline to validate PVC panel part markings in real time across 8 extrusion lines.
    7. - Implemented industrial system integration across PLCs, extrusion equipment, and vision systems using OPC UA and communication protocols, enabling centralized data exchange and control.
    8. - Participated in cross-functional discussions to support ERP workflow integration from NetSuite through database, PLC, and SCADA systems for work order management and production execution.
    9. - Built and optimized SQL-based data pipelines and analytics queries for production traceability, reporting, and operational insights by utilizing MySQL, Power Apps, and PowerBI.

  2. GRADUATE RESEARCH ASSISTANT, ONTARIO TECH

    Jan 2022 — Jan 2024

    1. - Designed a 3D scanner and Calibrator to register point clouds of complex surfaces using an RGBD sensor with 95% capture accuracy.
    2. - Developed a novel hybrid trajectory optimization algorithm and programmed it in Python reducing energy and process time by 51% and 33%.
    3. - Developed a ROS and Python based software framework with an integrated web-based HMI/GUI for user control.
    4. - Designed the integrated system in SolidWorks, simulated it in Python, tested and debugged the prototype in real-time.
    5. - Analysed industrial robot post-processors in RoboDK to convert the trajectory to robot programs.
    6. - Paid industry visits and demonstrated the system to see how it can be extended to industrial robots like FANUC, KUKA, ABB

  3. Engineering Intern Controls & Instrumentation, GIKI

    June 2019 — Aug 2019

    1. Designed a low-cost control system for early failure detection of a power transformer using GSM, GNSS, Arduino, Thermocouple & SONAR.
    2. Designed a low-cost 3 phase PWM inverter for a force-controlled linear actuator & simulated it in Proteus

  4. Student Ambassador, U.S. Department of State

    Jan 2019 — May 2019

    1. Presented my country in Missouri to bridge cultural gaps.
    2. Participated in volunteer work to help the local community, wrote personal blogs, and attended festivals to celebrate cultural diversity.

Portfolio

Blog