Open to collaboration & research opportunities

SUNISH SURESH

Software Engineer R&D

Bridging Control Engineering with AI-driven Automation — building the intelligent factories of tomorrow.

Rheinböllen, Germany  ·  HAHN Automation Group R&D
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Years Experience
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Projects Delivered
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PLC Platforms
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The Engineer Behind the Code

Sunish Suresh — Software Engineer R&D

I'm a Software Engineer R&D at HAHN Automation Group, where I work at the intersection of advanced control theory and next-generation industrial software. My journey started in Mumbai programming PLCs on the factory floor — and has evolved into designing AI/ML-powered systems that redefine industrial automation.

Holding a Master's in Control Engineering from Technische Hochschule Mittelhessen (Germany) and with a published paper on Automotive Cybersecurity (ISO/SAE 21434), I bring both theoretical depth and real-world engineering pragmatism to every challenge.

I speak the language of both factory floors (IEC 61131-3, SCADA, VFDs, FAT/SAT) and research labs (Python, C++, EKF, adaptive control, ML) — making me uniquely effective at bridging the OT and IT worlds.

Industry Verticals Oil & Gas · Pharma · Food & Beverage · Automotive · Ceramics
R&D Focus Areas Next-gen PLCs · AI/ML for automation · Control algorithms · IIoT
Global Engineering Journey India (Mumbai) → Germany — international R&D teams, multilingual

Career Timeline

Software Engineer R&D

HAHN Automation Group
Jun 2025 – Present Current Role
Rheinböllen, Germany · Hybrid
  • Exploring and implementing cutting-edge automation technologies within R&D
  • Integrating and testing next-generation PLCs and industrial controllers
  • Designing and deploying custom control algorithms for advanced machine behavior
  • Developing AI and ML-based solutions for industrial automation challenges
  • Programming in Structured Text (IEC 61131-3), Python, and C++ across projects
  • Driving cross-functional research projects from concept through to prototype
PythonC++IEC 61131-3 AI/MLNext-Gen PLCControl Algorithms

Junior Software Engineer R&D

HAHN Automation Group
Feb 2024 – Jun 2025 1 yr 5 mos
Rheinböllen, Germany · Hybrid
  • Contributed to R&D initiatives in advanced industrial automation software
  • Developed software solutions in C++ and Python for real automation challenges
  • Collaborated on projects bridging traditional PLC logic with modern software architectures
C++PythonR&DIndustrial Automation

Master Thesis Student – R&D

HAHN Automation Group
Aug 2023 – Jan 2024 6 mos
  • Conducted master's thesis research embedded in the R&D department
  • Developed HMI programming solutions and control system prototypes
  • Documented all research findings formally in LaTeX
HMI ProgrammingLaTeXControl SystemsResearch

Student Research Assistant

Technische Hochschule Mittelhessen (MND Dept.)
Oct 2022 – Jul 2023 10 mos
Friedberg, Germany · Hybrid
  • Developed and implemented control algorithms (EKF, PID, Adaptive) in MATLAB & Python
  • Tutored students in both Linear and Non-Linear Control Engineering modules
  • Implemented and improved Arduino-based hardware for inverted pendulum experiments
  • Produced comprehensive teaching materials and academic documentation
PythonMATLABArduino Control TheoryC++Adaptive Control

Industrial Automation Engineer

Freelance · Remote
Jan 2021 – Sep 2021 9 mos
  • Delivered PLC and HMI programming solutions for industrial clients remotely
  • Provided expert consultation on automation system design and integration
PLCHMI ProgrammingRemote

Industrial Automation Engineer

Allied Electricals, Mumbai
Sep 2018 – Dec 2020 2 yrs 4 mos
Mumbai Metropolitan Region, India
  • PLC and SCADA/HMI programming across Oil & Gas, Pharma, and Food & Beverage industries
  • Programmed and configured VFDs and Servo Drives for motion control applications
  • Implemented IIoT solution (Siemens IOT2040 + Thingsboard + PostgreSQL) for DAQ from chart recorders
  • Developed SQL-based SSRS reports for production data analysis
  • Executed Factory Acceptance Tests (FAT) and Site Acceptance Tests (SAT)
  • Led SCADA migration of 4,000+ process tags for a major oil & gas pipeline (Panipat)
Siemens TIAWonderwareSCADA IIoTSQLThingsboardFAT/SAT

Technical Expertise

PLC & SCADA Platforms

Siemens TIA Portal WinCC Advanced MicrowinSmart Wonderware InTouch Aveva Edge Studio Wonderware ITME Schneider Unity Pro EcoStruxure Control Expert Zeliosoft Codesys Rockwell RSLogix 500 Factory Talk Indusoft SCADA Cimplicity

Programming Languages

Python MATLAB / Simulink Structured Text (IEC 61131-3) Ladder / FBD / STL C++ C / Arduino SQL JavaScript LaTeX

Control Engineering

PID Control (Discrete & Continuous) Extended Kalman Filter (EKF) State Space Analysis Adaptive Control State Observers Motion Control (VFD/Servo) Non-Linear Control Optimal Control

AI / ML for Automation

ML-based Control Solutions Data-Driven Modeling Predictive Analytics Neural Networks Computer Vision (Industrial)

IIoT & Connectivity

OPC-UA MQTT Node-RED Thingsboard Siemens IOT2040 LoRaWAN / TTN PostgreSQL MSSQL / SSMS / SSRS Docker

Cybersecurity & Tools

ISO/SAE 21434 TARA (Threat Analysis & Risk Assessment) MS Threat Modeling Tool Ansys Medini AutoCAD CST Studio Suite STM32 / CubeIDE
Expert
Advanced
Intermediate

Featured Projects

Featured Industrial

Panipat Pipeline SCADA Migration

Complete SCADA overhaul for a major oil & gas pipeline system — migrating 4,000+ process tags from legacy Indusoft to modern Cimplicity architecture with zero operational downtime.

4,000+Tags Migrated
ZeroDowntime
Indusoft SCADACimplicityOil & Gas
Featured Industrial

IoT DAQ for Chart Recorders

Designed a customized, cost-effective IIoT solution to digitize analog chart recorder data using Siemens IOT2040, enabling real-time cloud monitoring via Thingsboard — eliminating manual paper-based logging.

100%Digitized
CostEffective
Siemens IOT2040ThingsboardPostgreSQLPython
Industrial

PET Blowing Machine Automation

PLC and HMI programming for 2 and 4 cavity PET blowing machines using Siemens S7-1200 and S7-200, achieving a measurable 5% improvement in production throughput.

+5%Efficiency Gain
Siemens S7-1200TIA PortalTP700 HMI
Industrial

Atomiser Spray Dryer Control

Developed SCADA and PLC control for an atomizer spray dryer producing 500 kg/hr of fine ceramic powder, ensuring precise temperature, pressure, and flow control throughout the drying process.

500kg/hr Capacity
Wonderware ITMESiemens S7-1200Ceramics
Industrial

Triple Effect Evaporation Plant

Full PLC and SCADA implementation for a continuous solvent recovery process using triple-effect evaporation, ensuring safe and efficient chemical plant operation with full alarm management.

Siemens ET200TIA V15WinCC AdvancedChemical
Research

Extended Kalman Filter — Inverted Pendulum

Designed and implemented an EKF for real-time non-linear state estimation of an inverted pendulum system. Validated theoretically and against physical hardware with measurable accuracy improvements.

PythonMATLABEKFState Estimation
Research

Adaptive Current Control & Speed Observer — DC Motor

Simulated adaptive current control strategy and speed observer for DC motor, demonstrating robustness against parameter variations and load disturbances through Python-based simulation.

PythonAdaptive ControlMotor Drives
Research

Induction Machine State Observer

Developed a state observer simulation for an induction machine to estimate rotor flux and speed without direct measurement, enabling sensorless control strategies for motor drives.

PythonMATLABControl TheoryInduction Motor
Academic

RF Velocity Sensor & Coil Accelerator — GraviTrax

Simulated and optimized an RF velocity sensor and electromagnetic coil accelerator for a GraviTrax marble run. Involved EM simulation (CST Studio Suite) and embedded firmware on STM32.

STM32CubeIDECST StudioMATLAB
Academic

Automated IoT Glasshouse

End-to-end IoT greenhouse automation — integrated sensor arrays, LoRaWAN connectivity via The Things Network (TTN), and cloud-based monitoring for fully autonomous climate management.

ArduinoLoRaWANTTNIoT Sensors

Publications & Research

MDPI October 2022 Open Access Peer Reviewed

Cybersecurity Comparison of Brain-Based Automotive Electrical and Electronic Architectures

A comprehensive comparative analysis of four automotive E/E architecture types — evaluating their cybersecurity threat landscape, vulnerabilities, and recommended mitigation controls in alignment with ISO/SAE 21434. The paper provides a clear comparative framework and suggests design improvements for security-by-design in next-generation automotive systems.

Key Contributions

  • Mapped threat models across federated, centralized, domain, and zonal E/E architectures
  • Applied ISO/SAE 21434 TARA methodology systematically to each architecture type
  • Identified security strengths and weaknesses with a comparative scoring framework
  • Proposed concrete improvement possibilities for security-by-design in automotive systems

Academic Journey

Master's in Control Engineering

Technische Hochschule Mittelhessen (THM), Friedberg, Germany Oct 2021 – Jan 2024

Advanced studies in linear/non-linear control, state space methods, adaptive control, and digital signal processing. Master's thesis completed within HAHN Automation Group R&D.

Automotive Cyber Security Academy (ACSA 2022)

Continental Engineering Services & Universitatea Politehnica Timișoara Jun 2022 – Oct 2022

Specialized training in automotive cybersecurity, TARA methodology, and ISO/SAE 21434. Culminated in a peer-reviewed publication in MDPI.

Wonderware InTouch & ITME Training

SSM InfoTech Solutions Pvt. Ltd., India Jul 2019 – Aug 2019

Certified training on Wonderware InTouch SCADA and ITME platform for industrial HMI development.

Post Graduate Diploma in Industrial Automation

Prolific System & Technologies PVT. LTD., India Jul 2018 – Dec 2018

Intensive training across Siemens, Schneider, Allen-Bradley PLC platforms, SCADA systems, industrial networking, and drive configuration.

B.Tech in Electrical and Electronics Engineering

MBCCET (Mahatma Gandhi University), Kerala, India Jul 2014 – May 2018

Foundation in electrical machines, power systems, analog & digital electronics, and microcontrollers. Served as IEEE Student Branch Link Representative.

Let's Connect

Whether it's a collaboration, a research discussion, or a conversation about the future of industrial automation — I'd love to hear from you.

Location Rheinböllen, Germany 🇩🇪
Open to collaboration, research partnerships & new opportunities