Samy Timalsina

About Me

ML-Driven Automation,
Factory Floor to Cloud

Six years replacing manual labor and downtime with measurable throughput, cost, and safety gains — across PLC, vision, machine learning, and cloud stacks.

I'm a Controls & Software Engineer with 6+ years delivering end-to-end automation solutions at an ISO 13485 / FDA-registered contract manufacturer. My track record centers on shipping complete systems — from the PLC sequence and electrical panel to the ONNX inference server and Azure dashboard — that replace manual labor and recurring downtime with quantifiable gains.

I work fluently across the full automation stack: Allen-Bradley ControlLogix & CompactLogix (Studio 5000), Siemens TIA Portal / WinCC, ISA-88 machine architectures, Keyence / Cognex / Omron vision, YOLO / ONNX models running on NVIDIA GPUs, C# REST services on Azure, and AutoCAD Electrical schematics. Whether it's a lights-out press cell, a 99%-accurate defect detector, or an 8-second automated cycle that eliminated a full operator shift — I deliver the complete solution.

Prior to Auer Precision I designed power and controls systems for induction heating equipment at Ajax Tocco Magnethermic, and hold an M.S. in Electrical & Electronics Engineering (GPA 4.0) from Youngstown State University.

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6+ Years Experience

9+ Projects Shipped

99% ML Vision Accuracy

25 hrs Recovered / Week / Machine

Industrial Controls

Allen-Bradley ControlLogix & CompactLogix (Studio 5000), Siemens TIA Portal / WinCC, ISA-88 architectures, FactoryTalk, RSLogix 500, HMI, SCADA, and AutoCAD Electrical panel design.

Studio 5000TIA PortalISA-88FactoryTalk

Automation Systems

Designing and commissioning complete machine cells — UR robot integration, Promess servo press, IPG laser, stepper / servo motion, vibratory feeders, and safety integration.

UR RobotsPromess PressIPG LaserMotion Control

Computer Vision

Deploying YOLO / ONNX defect detection on NVIDIA GPUs alongside Keyence, Cognex, Omron, and Zeiss CMM vision — inline quality inspection at production speed.

YOLOONNXKeyenceCognexOmron

Software Development

Production-grade systems in C# and ASP.NET Core — REST services, Windows Services, FastAPI inference servers, real-time dashboards, T-SQL, and Razor Pages web apps.

C#ASP.NET CoreFastAPIT-SQL

Azure Cloud

Architecting cloud-connected factory solutions with Azure SQL, Blob Storage, and DevOps pipelines — bridging Ignition / PLC data to real-time cloud dashboards.

Azure SQLAzure BlobAzure DevOpsIgnition

Machine Learning

Shipping end-to-end ML systems: acoustic anomaly detection with ONNX + FastAPI, YOLO defect detection on RTX 3000 GPUs, and image classification pipelines for industrial sorting.

ONNXYOLONVIDIA GPUFastAPI

Experience & Education

Career & Academic Background

Software & Controls Engineer

Auer Precision · Mesa, AZ

Sept 2019 – Present

ML Acoustic Anomaly Detection: shipped end-to-end ONNX + FastAPI + PLC system enabling lights-out press operation; recovered ~25 unattended production hours/week per machine.
Automated Leak Tester: designed ISA-88 PLC architecture and UR robot interface for an 8-second cycle, eliminating a dedicated 8-hour operator shift/day.
ML Vision Quality Inspection: deployed YOLO defect detection on RTX 3000 for semiconductor carriers — 99% accuracy, inference cut from seconds to milliseconds.
Automated Fuse Tapping (Defense): delivered PLC-driven tapping line with steppers and Keyence XGX vision, removing manual labor and repetitive-motion hazards.
Robotic CMM Integration: built C# service linking Zeiss CMM to UR robot for automated bin-sorting, cutting manual inspection time 60%+.
High-Speed Vision & Control: integrated PLC mastic dispenser with Omron inline vision, lifting throughput 50% to 1,500 parts/hour.
Servo Press Retrofit: modernized a medical-tape line with Promess servo press, full panel rewiring, safety integration, and servo tuning in-house.
Data Integration & Dashboards: built ASP.NET Core production dashboard with Ignition/PLC + Azure SQL/Blob pipelines for real-time flatness inspection.
Legacy Equipment Recovery: restored a 1973 mechanical press from original schematics by isolating a faulty NOTO timing relay, avoiding OEM dispatch fees and downtime.

Allen-BradleySiemens TIA PortalONNXYOLO C#ASP.NET CoreAzureUR RobotsFastAPI

Controls Engineer

Ajax Tocco Magnethermic · Warren, OH

Sept 2018 – Aug 2019

Power & Controls Design: produced AutoCAD Electrical schematics and BOMs for induction heating power supplies; troubleshot 800–1200 A breakers, SCR/diode rectifiers, and IGBT inverters.
HMI & PLC Programming: developed FactoryTalk View, WinCC, and TIA Portal interfaces and ladder/FBD logic for induction heating, forging, and quenching lines.

AutoCAD ElectricalFactoryTalkWinCCTIA PortalLadder Logic

Graduate Assistant

Youngstown State University · Youngstown, OH

Aug 2016 – Aug 2018

Lab Instructor: taught Control Systems (16 seniors) and Digital Circuits (16 sophomores).
Research Assistant: applied nonlinear MATLAB analysis to detect agglomeration in boiler furnaces (M.S. thesis).

Control SystemsMATLABResearch

Education

M.S. Electrical & Electronics Engineering

Youngstown State University, OH

Rayen College of Engineering (ABET) · Thesis: Detection of agglomeration in a fluidized bed using structure-function

GPA 4.0 2016 – 2018

B.E. Electrical Engineering

Tribhuvan University, Nepal

GPA 3.77 2009 – 2013

FE Engineer Trainee · NCEES ID 18-708-69 · May 2018 – Present

Technical Skills

Full-Stack Automation Expertise

Controls / PLC

Allen-Bradley ControlLogix Allen-Bradley CompactLogix Studio 5000 RSLogix 500 Siemens TIA Portal WinCC FactoryTalk ISA-88 Micro 820 Structured Text Ladder Logic Function Block HMI Design SCADA

ML / Vision

ONNX YOLO NVIDIA Cosmos Reason 2 Cognex Keyence Omron Vision Zeiss CMM FastAPI (inference) Defect Detection Acoustic Anomaly Detection

Software / Cloud

C# ASP.NET Core T-SQL JavaScript HTML / CSS Azure SQL Azure Blob Storage Azure DevOps SSMS Git Visual Studio

Hardware

NVIDIA GPUs (RTX 3000) Raspberry Pi UR Robots Promess Servo Press IPG Laser AutoCAD Electrical SCR / IGBT Power Electronics

Architecture & Patterns

SOLID Principles Repository Pattern MVC / MVVM ISA-88 Machine Control Observer Dependency Injection REST API Design

Process & Methodology

Agile / Scrum ISO 13485 FDA-Regulated Env. Electrical Panel Design Safety Integration Servo Tuning AutoCAD BOMs

Projects

Engineering & Software Portfolio

Measurable results across controls, vision, ML, and cloud — from semiconductor inspection to lights-out press operation.

ONNX · FastAPI · PLC

ML Software

ML Acoustic Anomaly Detection

Shipped an end-to-end ONNX + FastAPI + PLC system enabling fully lights-out press operation. The ML model detects acoustic anomalies in real time, automatically stopping the press on bad cycles. Recovered ~25 unattended production hours/week per machine.

25 hrs/week recovered per machine

ONNXFastAPIPLC IntegrationAllen-BradleyPython

YOLO · RTX 3000 · Semiconductor

ML Vision

ML Vision Quality Inspection

Deployed YOLO defect detection on an RTX 3000 GPU for semiconductor carrier inspection. Achieved 99% detection accuracy with inference time cut from seconds to milliseconds — enabling inline, production-speed quality control.

99% accuracy · seconds → milliseconds inference

YOLOONNXNVIDIA RTX 3000PythonFastAPI

ISA-88 · UR Robot · 8-Second Cycle

Controls

Automated Leak Tester

Designed ISA-88 PLC architecture and UR robot interface for an automated leak testing cell. The 8-second cycle completely eliminated a dedicated 8-hour manual operator shift per day, delivering immediate labor cost savings.

8-second cycle · eliminated 8-hour operator shift/day

ISA-88Allen-BradleyUR RobotsStudio 5000

Controls Vision

Automated Fuse Tapping (Defense)

Delivered a PLC-driven tapping line with stepper motors and Keyence XGX vision for a defense contractor application (bomb fuses). Removed manual labor and repetitive-motion injury hazards while achieving a 20-second automated cycle.

PLC IEC 61131-3Keyence XGXStepper ControlHMI

Software Controls

Robotic CMM Integration

Built a C# service linking a Zeiss CMM to a UR robot for fully automated bin-sorting based on inspection results. Eliminated manual measurement and part handling, cutting inspection time by 60%+.

60%+ reduction in manual inspection time

C#Zeiss CMMUR RobotsOmron SDK

Omron Vision · 1,500 parts/hour

Vision Controls

High-Speed Vision & Control

Integrated a PLC-controlled mastic dispenser with Omron inline vision for real-time dispensing verification. Lifted production throughput by 50% to 1,500 parts/hour by eliminating manual inspection bottlenecks.

50% throughput increase → 1,500 parts/hour

Omron VisionPLCInline InspectionStudio 5000

Controls

Servo Press Retrofit — Medical Device

Modernized a medical-tape production line by retrofitting a Promess servo press with full panel rewiring, safety integration per ISO 13485, and in-house servo tuning. Eliminated OEM dependency and delivered a fully documented, validated system.

Promess Servo PressAllen-BradleyAutoCAD ElectricalISO 13485

Software Cloud

Production Dashboard & Data Pipeline

Built an ASP.NET Core production dashboard consuming live Ignition / PLC data via Azure SQL and Blob Storage pipelines. Provides real-time flatness inspection results and production metrics across multiple lines.

ASP.NET CoreAzure SQLAzure BlobIgnitionT-SQL

Controls Vision

Automatic Welding System

Automated a manual welding process using Keyence vision to verify correct part alignment before the operator proceeds. Programmed PLC in Structured Text, designed the vision logic, and produced the full electrical schematic.

PLC Structured TextKeyence VisionAutoCAD Electrical