Prasad Uday Joshi
Plant Engineer at Cardinal Glass Industries.
Robotics & Automation Specialist | MS in Robotics & Autonomy
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Engineering Innovation Across Continents
I am a Plant Engineer at Cardinal Glass Industries and a recent M.S. in Robotics and Autonomy graduate from Drexel University. My career is built on a dual foundation: the hands-on precision of process control and the forward-thinking potential of intelligent systems.
With deep experience in Honeywell Experion PKS, Siemens PCS7, and Allen-Bradley PLCs, I specialize in bridging the gap between legacy industrial infrastructure and modern automation. My work spans the full spectrum of control, from the fine-tuning of PID loops to the deployment of complex robot navigation algorithms. I am driven by a single goal: leveraging data-driven process control and robotics to make manufacturing environments safer, smarter, and more efficient.
Having worked and studied across India, the United States of America, and Europe (Poland), I've developed a global engineering perspective. I thrive in cross-functional, multicultural environments, translating complex customer needs into robust automation solutions.
Contact Information
📍 Mountain Top, PA 18707
📞 +1 (215) 240-5080
Work Authorization
U.S. work-authorized: F-1 STEM OPT

Professional Expertise
Results-driven engineer specializing in industrial automation, control systems, and robotics integration. Experienced in developing PLC/HMI programs, optimizing PID control loops, and commissioning automated systems. Proficient in Honeywell Experion PKS, OSIsoft PI Vision, and ROS 2, with strong analytical and communication skills.
Process Control
Expert in DCS configuration, PID tuning, and loop optimization for industrial manufacturing environments
Robotics Integration
Autonomous navigation, SLAM algorithms, and ROS 2 development for intelligent mobile robots
Data Analytics
PI Vision dashboards, KPI tracking, and performance monitoring for operational excellence
Safety Systems
Safety interlock validation, process safety compliance, and secure control modifications
Professional Journey
Plant Engineer
Cardinal Glass Industries | Mountain Top, PA
Dec 2025 – Present

System Maintenance & Troubleshooting:
• Support automated manufacturing lines via PLC-based control systems to ensure stable, continuous, and high-efficiency plant operations.
• Monitor and troubleshoot PLC logic, I/O signals, sensors, actuators, and HMI interfaces to proactively minimize unplanned downtime.
• Diagnose complex control system issues involving motors, Variable Frequency Drives (VFDs), conveyors, industrial heaters, and pneumatic systems.
Collaboration & Process Optimization:
• Partner with maintenance and controls teams to execute logic modifications, perform system validation, and resolve deep-seated technical bottlenecks.
• Analyze process and machine data to identify recurring faults, cycle time inefficiencies, and systemic gaps in production throughput.
• Facilitate commissioning and change management, ensuring all control system updates and process improvements are thoroughly documented.
Safety & Compliance:
• Maintain strict compliance with safety interlocks, Lockout/Tagout (LOTO) procedures, and established plant safety standards.
• Validate fail-safe mechanisms within the automated environment to protect both personnel and equipment integrity.
Process Engineering Co-op
SYENSQO (Solvay Specialty Polymers) | West Deptford, NJ
Nov 2024–Mar 2025
• Strengthened automation performance across a fluoropolymer facility by diagnosing control issues, tightening loop behavior, and improving day-to-day process stability.
• Elevated key unit operations through precise PID tuning, cutting oscillations and sharpening system responsiveness.
• Designed cleaner, faster, operator-centered Honeywell Experion PKS graphics, updated control logic, and improved module functionality for safer, smarter plant operation.
• Drove the PI Vision modernization effort: rebuilding tag structures, streamlining databases, and converting old displays into intuitive dashboards used by engineering and operations.
• Supported a major DCS upgrade with point verification, control strategy refinement, and troubleshooting during integration.
• Worked hands-on with Allen-Bradley and Siemens PLCs, reviewing logic, solving field issues, and ensuring smooth interaction between PLCs, DCS layers, and plant equipment.
Creative Director (Co-op)
Fason De Viv | Philadelphia, PA
Sep 2024 – Oct 2024
  • Managed social media content, visual branding, and campaign materials using Adobe Creative Suite and Canva.
EV Design Intern
Capabl (Elite Techno Groups) | Bengaluru, India
May 2021 – Jun 2021
  • Built and simulated electric vehicle models, designed battery management systems, and optimized powertrain performance
Recent Role: Process Engineer at SYENSQO (Co-Op)
Solvay Specialty Polymers | West Deptford, NJ | Nov 2024 – Mar 2025
As a Process Engineering Co-op at SYENSQO (Solvay Specialty Polymers), I'm driving operational excellence in fluoropolymer production through advanced control systems optimization and data infrastructure modernization.
My work focuses on diagnosing and optimizing control loops to stabilize production processes, updating and configuring Honeywell Experion PKS DCS graphics and logic for improved operator usability, and leading the PI Vision migration project — restructuring PI tags and dashboards for enhanced data transparency across the organization.
01
Control Loop Optimization
Diagnosed and stabilized critical control loops in fluoropolymer production, improving process consistency and reducing variability
02
DCS Configuration
Updated Honeywell Experion PKS graphics and logic, enhancing operator interface usability and system responsiveness
03
PI Vision Migration
Led data infrastructure modernization, restructuring PI tags and dashboards for improved transparency and decision-making
04
Automation Sequences
Automated startup/shutdown procedures and validated safety interlocks, reducing manual intervention and enhancing safety
05
DCS Upgrade Project
Contributed to major system upgrade, verifying module functionality and maintaining point conversion databases
Breakthrough Projects
Autonomous Mobile Robot Simulation
TurtleBot3 – ROS 2 & Gazebo (2025)
  • Developed a complete autonomous navigation stack using SLAM and sensor fusion, achieving greater than 95% localization accuracy and a 30% efficiency gain via optimized path planning.
  • Implemented modular PLC/HMI-like control logic for real-time decision-making and multi-robot coordination.
AI-Driven Defect Detection using TensorFlow & PyTorch 2024
  • Created synthetic datasets and auto-annotation pipelines to train YOLOv8 for surface defect classification.
  • Fine-tuned models and performed ablation testing on lighting and pose variations to improve precision by 19 %.
  • Integrated trained models into ROS2 for real-time QA and validation on robotic inspection stations.
Autonomous Robotic Arm with PID Motion Control (ROS2 + Gazebo) 2023
  • Developed ROS2 simulation integrating Gazebo physics and PID controllers for multi-axis robotic manipulation.
  • Implemented camera-based pose estimation and object tracking using OpenCV and Python scripts.
  • Optimized motion trajectories with reinforcement learning, achieving 95 % placement accuracy.
Industrial Microwave Temperature Monitoring
Real-Time Control System (2022)
  • Engineered a real-time temperature monitoring and control system for industrial ovens.
  • Integrated sensors and feedback loops to improve thermal regulation accuracy by 30% and automated data acquisition, reducing manual intervention by 25%.
>95%
Localization Accuracy
Achieved in autonomous robot navigation using advanced SLAM algorithms
30%
Efficiency Improvement
Gained through optimized path planning and thermal regulation systems
25%
Reduced Manual Work
Automation of data acquisition and monitoring processes
Academic Excellence
Drexel University
Philadelphia, USA
M.S. in Robotics and Autonomy
Expected Graduation: September 2025
GPA: 3.44 / 4.00
Advanced coursework in autonomous systems, robot kinematics, control theory, computer vision, and machine learning. Hands-on experience with ROS 2, Gazebo simulation, and real-world robotics applications.
NMIMS University
Mumbai, India
B.Tech (Honours) in Mechatronics Engineering
Graduated: August 2022
GPA: 3.66 / 4.00
Comprehensive foundation in mechanical systems, electronics, control systems, and automation. Specialized in integrating mechanical, electrical, and computer engineering principles for intelligent systems design.
Technical Skill Portfolio
Process Control & Automation
  • Honeywell Experion PKS
  • Siemens PCS7
  • Allen-Bradley PLCs
  • PID Tuning & Loop Optimization
  • HMI/SCADA Development
  • AutoCAD Electrical
Programming & Simulation
  • Python
  • MATLAB & Simulink
  • C Programming
  • ROS 2 (Robot Operating System)
  • Gazebo Simulation
  • Algorithm Development
Data Acquisition & Visualization
  • OSIsoft PI System
  • PI Vision Dashboards
  • KPI Tracking & Analytics
  • Performance Monitoring
  • Real-Time Data Processing
Design & Modeling
  • SolidWorks CAD
  • Siemens TIA Portal
  • AutoCAD Mechanical
  • System Architecture Design
  • Technical Documentation

Soft Skills That Drive Success
Analytical Thinking • Teamwork & Collaboration • Creative Problem Solving • Attention to Detail • Adaptability • Cross-Cultural Communication
Certifications & Continuous Learning
Committed to staying at the forefront of automation, robotics, and data science through continuous professional development and industry-recognized certifications.
Lean Six Sigma Black Belt
The Council for Six Sigma Certification (CSSC)
November 2025
Process improvement methodologies and quality management principles

Certification Number : rC2rLRh1TW
Certification Date : November 15th, 2025


Lean Six Sigma White Belt
The Council for Six Sigma Certification (CSSC)
July 2025
Process improvement methodologies and quality management principles.

Certification Number: VyhCQu1bCJ
Certification Date: July 7th, 2025
Modern Robotics Specialization
Northwestern University (Coursera)
April 2022
Mechanics, Planning & Control: comprehensive robotics theory and applications.

Certificate: https://coursera.org/verify/specializat ion/YALEQ7GA4DW9
IBM Data Science Specialization
IBM (Coursera)
April 2022
Developed practical expertise in data collection, analysis, visualization, and data-driven decision-making using Python and real-world projects.

Certificate: https://coursera.org/verify/profession al-cert/P5SZ5ABBL4A3
IBM Machine Learning Specialization
IBM (Coursera)
April 2022
Machine learning algorithms, data analysis, and predictive modeling techniques.

Certificate: https://coursera.org/verify/profession al-cert/DDAVT2RN55A6
Industrial IoT on Google Cloud Platform
The University of California, Irvine: Cloud-based industrial automation and data management solutions
Interfacing with the Arduino
University of London: Microcontroller programming and sensor integration
Introduction to Virtual Reality
University of London: Immersive technology fundamentals and applications
Computational Vision
University of Colorado Boulder: Computer vision algorithms and image processing
Let's Build the Future Together
I'm motivated by technology that improves how we make, move, and manage things from factory floors to autonomous robots. My technical focus areas include:
  • Distributed Control Systems (Honeywell DCS) configuration and graphics engineering
  • Process loop tuning and automation optimization
  • Data analytics & visualization through PI Vision and SCADA
  • Autonomous navigation and robot simulation (ROS2, Gazebo)
  • PLC programming for industrial automation and safety interlocks
I enjoy working in multicultural teams and contributing to projects that combine engineering innovation with environmental sustainability. Having worked across continents, I bring a global perspective to solving complex automation challenges.
"Technology that improves how we make, move, and manage things — that's what drives my passion for automation and robotics engineering."
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