Kihele Wubineh
Verified Expert in Engineering
Data Engineer and Software Developer
Wheeling, IL, United States
Toptal member since March 13, 2026
Kihele is a dual-discipline engineer and data specialist who helps manufacturing and pharma teams modernize operations by bridging operational technology and IT. He brings hands-on expertise with Siemens, Allen-Bradley, Beckhoff, and Ignition-based SCADA systems, along with OPC UA implementation and cloud data engineering skills that improve visibility, efficiency, and scale.
Portfolio
Experience
- SQL - 5 years
- Studio 5000 - 4 years
- Ignition SCADA - 4 years
- Python 3 - 4 years
- SCADA - 4 years
- Siemens PLC - 2 years
- Beckhoff PLC - 2 years
- TIA Portal - 2 years
Preferred Environment
Siemens PLC, Allen-Bradley PLCs, Beckhoff PLC, Ignition SCADA, OPC UA, MQTT, SQL Server Management Studio (SSMS)
The most amazing...
...system I've built bridged the automation-data gap, tracking OEE in real time by transforming raw PLC data into actionable manufacturing insights.
Work Experience
Senior SCADA Engineer
Flex
- Led the design, implementation, optimization, and maintenance of SCADA systems with Ignition vision and perspective used to monitor automated assembly and manufacturing lines.
- Developed and supported Allen-Bradley PLC integrations using Kepware OPC to connect PLC data with AVEVA System Platform and SCADA systems.
- Partnered with cross-functional teams (automation, process, manufacturing, quality, IT) to define requirements and deliver dashboards and reports that support overall equipment effectiveness (OEE), yield, and control of critical process parameters.
- Configured, programmed, and deployed SCADA components including HMIs, PLC interfaces, servers/clients, and industrial communication protocols such as OPC, Ethernet/IP, Modbus, and EtherCAT.
- Built and maintained SQL-based data models for manufacturing/SCADA data, designing both star and snowflake schemas to support reliable reporting, analytics, and customer-facing data products.
- Implemented and sustained cybersecurity controls with IT access management, secure configuration, backup/restore, and restart/recovery procedures to protect SCADA environments.
- Analyzed real-time and historical data to identify trends, anomalies, and root causes. Recommended actions that improve process stability and throughput.
Automation Engineer
Amneal Pharmaceuticals
- Supported the execution of IQ/OQ/PQ protocols for manufacturing equipment, facilities, utilities, and associated software in a GMP-regulated environment.
- Performed requalification activities for equipment, facility systems, and utilities under supervision to maintain a validated state and compliance.
- Designed and developed control systems in coordination with OEMs to automate upstream/downstream equipment and add visibility using Ignition SCADA.
- Implemented automation projects following GAMP, cGMP, and GxP principles, supporting validation deliverables and lifecycle documentation expectations.
- Drafted and updated SOPs for new operational equipment and automation processes to support safe, consistent, and compliant operations.
Data Engineer
Datanomics
- Built and maintained reliable ETL data pipelines using Azure Data Factory and Azure Synapse, supporting scheduled and near-real-time data integration needs.
- Designed and streamlined data ingestion workflows for structured and semi-structured data, such as JSON and Parquet, processing information from internal systems and external partners.
- Developed efficient transformation pipelines in Databricks using PySpark and Delta Live Tables, making raw data analysis-ready with minimal overhead.
- Managed and organized data in Azure Data Lake Gen2, maintaining raw, integrated, and curated layers to support reporting and analytics.
- Contributed to creating clear, user-friendly documentation, including dataset overviews, data flow diagrams, and usage tutorials to promote self-service analytics.
SCADA Engineer
Dashen Breweries S.C.
- Designed Ignition SCADA dashboards using Python and Jython with Kepware OPC UA, improving brewery visibility 60% and enabling mobile OEE monitoring via Perspective.
- Built FactoryTalk View SE HMIs with role-based security and automated ControlLogix PLCs (Studio 5000), reducing operator errors by 30% and mechanical jams by 35%.
- Upgraded SLC-500 to ControlLogix L72, eliminating 10% obsolete parts costs while optimizing CIP sequences using PhaseManager to cut cycle time 15% and chemical waste 18%.
- Tuned PID loops in PlantPAx for ±0.5°C mash control and developed Power BI dashboards from Ignition data, reducing product rejects.
Experience
Sorting Conveyor System
I oversaw the entire automation software architecture, including PLC logic (structured text, PLCopen motion control), product tracking via a virtual FIFO shift register, and real‑time communication between the control code and the physics‑based 3D model. A key highlight is the integrated SCADA layer built with B&R mapp View: a modern, web‑based HMI that provides live dashboards for system status, production counts, alarm management, and manual override controls. The HMI communicates directly with the PLC and visualizes the sorting process in synchronization with the digital twin, demonstrating a true Industry 4.0 approach.
This project showcased my ability to design scalable, standards‑based automation solutions, validate them through virtual commissioning, and deliver intuitive supervisory interfaces—skills directly transferable to advanced manufacturing and logistics applications.
Education
Master's Degree in Automation Engineering
University of Bologna - Bologna, Italy
Bachelor's Degree in Mechanical Engineering
Addis Ababa University - Addis Ababa, Ethiopia
Skills
Libraries/APIs
PySpark
Tools
Ignition SCADA, MQTT, Beckhoff PLC, Siemens PLC, CAD, AutoCAD, TwinCAT PLC
Languages
SQL, Python 3, Python, Jython
Storage
SQL Server Management Studio (SSMS), Azure SQL, Databases
Platforms
Studio 5000, Databricks, Azure Synapse Analytics, Jupyter Notebook
Frameworks
TIA Portal
Paradigms
Automation
Other
Allen-Bradley PLCs, OPC UA, ignition perspective, PLC, SCADA, Supervisory Control & Data Acquisition (SCADA), PySQL, Azure Stack, FactoryTalk, Computer Aided Facility Management (CAFM), Validation, IQ/OQ/PQ, Human-machine Interface (HMI), Conveyor, Variable Frequency Drive (VFD), IO module, Azure Data Lake, Azure Databricks, Azure Data Factory (ADF), Electrical Schematics, Pneumatics, PID Controllers, Machine Design, Ethernet, Industry 4.0, B&R Automation Software, Sorting Algorithms, Kepware Server (PLC Integration), Electrical Engineering
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