Avadh Nagaralawala

Avadh Nagaralawala

Automation, Control System Consultant & Project Management Professional

PLC/SCADA Integration | Digital Twins | Advanced Control Systems

About

Experienced Automation and Control System Consultant with 12+ years of expertise in industrial automation & control system developement. Skilled in system integration, team leadership, coaching stakeholders, and managing high-stake projects while delivering innovative, cost-effective solutions. Passionate about advancing digitalization and sustainable development in the mining & automative industry.

🎓 Education

M.S. Information Assurance
Wilmington University, Delaware
GPA: 3.5 | May 2016

B.E. Electronics & Communication
Sardar Patel University, India
June 2010

📜 Certifications

• Project Management Professional (PMP)
• Professional Scrum Product Owner (PSPO)
• MineStar Health Equipment
• UL-891 & NFPA 70 Standards

🎯 Mission

Revolutionizing mining operations through data-driven automation, sustainable practices, and innovative digital solutions that enhance safety, efficiency, and environmental responsibility.

💡 Innovation Focus

Developing novel digital-twin frameworks for rare-earth mineral extraction, achieving over 5% recovery improvement through adaptive, model-driven control systems.

Technical Expertise

Automation Platforms

  • PLC: RS Logix Series, Siemens TIA, Honeywell
  • SCADA: Factory Talk, Studio 5000, WinCC
  • CAT Tools: Technician Toolbox, VIMS
  • Product Link Elite, MHEI, Vision Link

Communication Protocols

  • ControlNet & DeviceNet
  • IP Ethernet Communication
  • RS232, J1939, CAN
  • CDL, TCP/IP

Monitoring & Analytics

  • Vibration-Based Condition Monitoring
  • Real-Time Surveillance Systems
  • Predictive Maintenance
  • Smart Sensor Integration
  • Data-Driven Optimization

Mining Technology

  • Tailings Management Systems
  • Mining Electrification
  • Rare-Earth Mineral Processing
  • Sustainable Mining Practices
  • Risk Mitigation Strategies

Project Management

  • Agile for Engineering Projects
  • PMI Methodologies
  • Cross-Functional Leadership
  • NPI (New Product Introduction)
  • Strategic Planning

Professional Experience

Feb 2020 - Present

Automation & Control System Consultant

Caterpillar Inc., Tucson, Arizona

  • Delivered 95% of Electric Rope Shovel projects on time and within budget by developing detailed project plans and schedules
  • Improved PLC program logic, reducing errors by 20% and aligning requirements for 10+ key stakeholders
  • Enhanced shovel performance by 10% annually through NPI packages including Cycle Segmentation, Payload, and Vibration Condition Monitoring
  • Led quality improvement and cost-reduction initiatives, boosting operational efficiency and customer satisfaction
  • Increased team productivity by 15% through mentoring and structured training for junior engineers
Oct 2017 - Feb 2020

Electrical Project Engineer

Eaton Corporation, Sumter, South Carolina

  • Designed switchboards adhering to UL-891 and NFPA 70 standards, achieving a 95% on-time delivery rate
  • Reduced audit findings by 10% through compliance with regulatory standards
Jul 2017 - Oct 2017

Automation Engineer

Ethnic Food Inc., Port Washington, NY

  • Increased operational efficiency by 25% through warehouse automation solutions in food producing industry
  • Streamlined HVAC Systems by reducing equipment errors by 10%
Dec 2012 - Nov 2013

Automation Engineer - Plant Engineering

Jindal Saw Ltd., Mundra, India

  • Optimized system integration for 3+ production assembly lines through instrumentation and control devices
Sep 2010 - Nov 2012

Automation and Control Engineer

Videocon Industries Ltd., Bharuch, India

  • Troubleshot and debugged Allen Bradley PLC and RSView32 SCADA systems, minimizing downtime and ensuring seamless operations in glass manufacturing continuous production plant

Achievements

IEEE Senior Member Elevation

Institute of Electrical and Electronics Engineers (IEEE)

Elevated to IEEE Senior Member grade, recognizing significant professional experience and technical accomplishments in the advancement of technology.

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Featured Speaker - PMI Arizona Chapter

Project Management Institute

"Digital Twin-Enabled Project Delivery: A Structured Framework for Reducing Execution Risk and Accelerating Outcomes" - Educational presentation on leveraging digital twin technology in project management.

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IRCE 2026 Special Session Organizer

9th International Conference on Intelligent Robotics and Control Engineering

Invited to organize and host special session at IEEE/IEEE RAS co-sponsored conference in Urumqi, China.

ICCAD 2026 Special Session Co-Chair

10th International Conference on Control, Automation and Diagnosis

Invited as Session Co-Chair for special session on "Advanced Automation, Control, and Diagnostics for Large-Scale Industrial Machinery and Complex Operational Systems" at ICCAD 2026 in Lisbon, Portugal.

View Call for Papers →

Accepted Speaker - Cephalocon 2025

Linux Foundation, Vancouver, Canada

Talk accepted: "Edge-Aware Ceph Deployments for Harsh Industrial Environments: Design, Lessons and Optimization" at Cephalocon 2025.

Oral Presentation - MEMO 2025

Canadian Institute of Mining, Calgary, Canada

Abstract approved for oral presentation: "Driving Innovation and Best Practices in Mining: The Role of Automation and Robotics" at MEMO 2025 Conference.

Featured: "How Smart Sensors Are Changing Mining Maintenance"

The American Reporter

Published article on sensor-based condition monitoring and predictive maintenance benefits.

PMI Arizona Board of Directors Candidacy

Project Management Institute - Arizona Chapter

Interviewed for Board position; developed signature speaking topic "Agile Beyond IT: Applying Agile Principles to Engineering & Industrial Projects"

Expert Speaker - Technology Advancement in Mining

Birla Vishvakarma Mahavidyalaya Engineering College, India

Delivered expert session on "Technological Advancement in Mining Vehicles and Role of EC Engineering" organized by Electronics and Communication Engineering Department.

Invited Webinar Presenter - CIM Knowledge Exchange

Canadian Institute of Mining, Metallurgy and Petroleum

"Revolutionizing Tailings Management: Practical Strategies for Sustainable Mining Operations"

Peer Review Activity

African Journal of Environmental Science and Technology (AJEST)

Reviewed manuscripts on geospatial assessment and digital structures in emerging economies.

IEEE VTS Industry Engagement Webinar

IEEE Vehicular Technology Society

"Electric Rope Shovels: History, Product Overview and Applications" - Industry engagement webinar on ERS technology and innovations.

PMI CCRS Registered Education Provider

Project Management Institute - Continuing Certification Requirements System

Course registered in PMI's official education system for professional development units.

Certified Peer Reviewer

Elsevier Researcher Academy

Successfully completed every module within the Certified Peer Reviewer Course, demonstrating expertise in academic peer review processes and standards.

Publications & Media Features

Automation and Control Systems: Powering the Next Era of Mining

AI Journal

Comprehensive exploration of how automation and control systems are revolutionizing modern mining operations, enhancing efficiency, safety, and sustainability.

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Navigating PLC Migration: From Siemens S7-300 to S7-1500

Digital Journal

Expert guide on PLC migration strategies, addressing technical challenges, best practices, and implementation approaches for upgrading legacy Siemens control systems.

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Australia Has Minerals and Miners, but Can It Loosen China's Grip on Rare Earths?

California Insider / The Epoch Times

Expert analysis on Australia's rare earth opportunity and the challenges of building a competitive supply chain outside of China's dominance.

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Safety Share: A Personal Lesson on Workplace Safety

North American Mining Magazine

Personal narrative highlighting the critical importance of adhering to safety protocols in mining and manufacturing operations.

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How Smart Sensors Are Changing Mining Maintenance

The American Reporter

Comprehensive analysis of sensor-based condition monitoring, predictive maintenance strategies, and their impact on cost reduction and safety improvements in mining operations.

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The Silent Revolution in Shovel Intelligence

FoxInterviewer

Exploration of intelligent Electric Rope Shovel systems, cycle-based analytics, and performance optimization techniques transforming mining equipment efficiency.

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How Smarter Monitoring is Reshaping the Future of Mining

Daily Scanner

Feature article on advanced monitoring technologies, data-driven maintenance approaches, and real-time condition monitoring innovations in the mining sector.

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Upgrading for Industry 4.0: How Siemens S7-1500 Migration Solves Hidden Legacy Challenges

Manufacturing Tomorrow

Comprehensive guide explaining why migration to the S7-1500 platform is becoming urgent, the hidden challenges engineers face during transition, and how modern PLC architecture supports Industry 4.0 readiness, improved reliability, and long-term performance.

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Driving Sustainable Growth in African Mining: The Role of Automation and Electrification

African Research Magazine

Research article examining the integration of automation and electrification technologies to promote sustainable mining practices across the African continent.

PLC and SCADA Integration in the Mining Industry

Technical Research Paper

Comprehensive academic paper analyzing PLC and SCADA integration methodologies, challenges, and best practices in modern mining operations.

Leadership & Professional Roles

Consultant

Caterpillar ERS Product Group

Leading advanced control and PLC-SCADA integration projects for Electric Rope Shovel automation. Specializing in Siemens S7-300 to S7-1500 migrations, cycle segmentation strategies, and vibration-based condition monitoring systems.

Government Affairs Committee Member

Colorado Mining Association (CMA)

Serving on strategic policy-level committee monitoring mining-related legislation and regulation. Contributing to policy recommendations for CMA Board during 2025 legislative cycle.

Member

Women in Mining (WIM)

Active member of international organization promoting women's leadership and visibility across the global mining sector.

Special Session Organizer

IRCE 2026 Conference (IEEE/IEEE RAS)

Invited to organize and host special session at the 9th International Conference on Intelligent Robotics and Control Engineering in Urumqi, China.

Board Nominee

PMI Arizona Chapter

Official nominee for Board of Directors position. Developed signature speaking topic on applying Agile principles to engineering and industrial projects. Recognized for leadership in project management community.

Peer Reviewer

Academic Journals

Providing peer review services for African Journal of Environmental Science and Technology (AJEST) and economic research publications.

Mentor

University of Arizona - Earn to Learn Mentorship Program

Providing mentorship to University of Arizona students through the Earn to Learn Mentorship Program, offering guidance on career development, professional skills, and industry insights.

Scholarship Judge

Arizona Women in Mining Institute

Appointed to review student profiles as a judge for scholarship awards. Evaluated candidates and contributed to scholarship selection decisions through the Arizona Women in Mining Institute.

Speaker

PMI Tucson Chapter

Speaker and presenter at PMI Tucson Chapter events, sharing expertise on project management, automation, and engineering leadership.

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Speaker

PMI Tucson Chapter

Presenting "Digital Twin-Enabled Project Delivery: A Structured Framework for Reducing Execution Risk and Accelerating Outcomes" - January 13, 2026.

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Get In Touch

Open to collaboration opportunities, speaking engagements, and consulting projects in mining automation and digital transformation.

📧 Email Me
💼 LinkedIn
🎤 Sessionize
📍 Marana, Arizona, USA

Professional Links & Credentials

PMI Arizona Board Nominee Profile

Official nomination for Project Management Institute Arizona Chapter Board of Directors.

View Profile →

PMI CCRS Registered Course

Continuing Certification Requirements System - Registered Education Provider course for professional development.

View Course →

IEEE VTS Industry Webinar

Industry Engagement Webinar on Electric Rope Shovels: History, Product Overview and Applications.

View Webinar →