Bridging Mission-Critical Industrial OT & Scalable Enterprise IT
Solutions Architect & Technical Lead with 20+ years of end-to-end experience connecting real-time industrial shop-floor telemetry (MES, SCADA, Level 2) with resilient modern enterprise software architectures.
Emanuele Sabbadini
IT/OT Convergence • MES • SCADA • Level 2 • Distributed Systems • .NET & Modern Web
Executive Summary
Two decades of hands-on technical leadership at the intersection of heavy industry and enterprise software.
Software Engineer & OT Specialist with 20+ years of end-to-end experience bridging modern IT architectures (web, desktop, cloud) and industrial automation (SCADA, MES, process control).
Proven track record delivering autonomous on-site commissioning for mission-critical operations, architecting robust enterprise data pipelines, and translating complex client requirements into scalable industrial solutions.
Adept at cross-functional leadership, stakeholder management, and continuous technological modernization. Seeking to drive digital transformation and assume technical leadership responsibilities in high-impact industrial or enterprise environments.
IT/OT Convergence
Unifying PLC edge telemetry, Kepware OPC, and Level 2 process control with enterprise MES, ERP (SAP), and distributed microservices.
Mission-Critical Resiliency
Architecting zero-downtime, multi-threaded event-sourcing engines for continuous steel casting and high-density financial distribution.
Legacy Modernization
Phased migrations from legacy codebases (Delphi, monolithic WinForms) to modern C#/.NET, Clean Architecture, and high-performance APIs.
Technical Team Leadership
Directing cross-functional internal engineers and external vendors, setting architectural standards, and driving autonomous global plant commissioning.
The IT/OT Architectural Stack
How Emanuele connects the raw industrial shop floor directly to enterprise business intelligence.
Enterprise Systems & Analytics
Business logic, production planning, ERP reconciliation, OEE analytics, and executive intelligence dashboards.
Integration & Event Pipeline
Resilient high-throughput pipelines, data normalization, schema modeling, state machines, and bidirectional synchronization.
Level 2 Automation & Diagnostics
Real-time process optimization, automated metallurgical recommendations, edge classification, and dynamic operator consoles.
Edge Telemetry & Hardware
Sub-second sensor ingestion, machine state acquisition, protocol translation, and autonomous plant floor deployment.
Professional Experience
20+ years of high-concurrency software development, industrial automation, and systems architecture.
OT Specialist | MES & Industrial Integration
- Architecture & MES Modernization: Co-design technical continuous improvement for enterprise Delmia Apriso MES, standardizing data models across production lines and work centers to ensure high-fidelity shop-floor tracking.
- Shop-Floor to Enterprise Integration: Configure edge telemetry pipelines via Kepware OPC servers, bridging PLC hardware directly with the MES to capture real-time production, state, and traceability data.
- Process Optimization & OEE Accuracy: Collaborate with Value Stream Leaders to eliminate manufacturing bottlenecks, aligning system business logic with plant operations to improve Overall Equipment Effectiveness (OEE) metrics.
- Vendor & Lifecycle Management: Author technical specifications and functional blueprints for system expansions, managing external software vendors through delivery, integration testing, and successful go-live phases.
- Operational Enablement & Intelligence: Design SQL reporting dashboards for plant management and conduct technical onboarding to drive adoption across plant supervisors and operators.
Lead Software Engineer & Process Control Specialist
- Mission-Critical Level 2 Architecture: Architected and maintained Level 2 automation platforms for continuous casting and steelmaking, leveraging multi-threaded and event-sourcing patterns to process real-time PLC telemetry and deliver automated process optimization recommendations.
- Technical Team Leadership: Directed a cross-functional team of internal software engineers and external contractors in designing and delivering the core software suite for the casting area, managing code reviews, delivery sprints, and architectural alignment.
- Modernization & Refactoring: Co-architected the phased migration of legacy components from Delphi to modern C#/.NET, replacing backend logic and user interfaces to enhance system maintainability and operator throughput.
- Vision System Integration: Co-designed the integration of an intelligent scrap yard management system incorporating computer vision algorithms for real-time operational classification and material tracking.
- Autonomous Commissioning & Field Integration: Executed end-to-end on-site deployment, commissioning, and validation in global plant environments; engineered secure data interfaces connecting Level 2 systems to enterprise ERP/MES layers and mentored junior engineers on industrial protocol standards.
Full-Stack Software Engineer
- Enterprise Financial & Healthcare Engine (2012–2015): Architected and deployed a calculation engine for public welfare institutions handling pension distributions, tax withholding, and healthcare refunds; built high-density WPF desktop interfaces, automated batch reporting, and managed on-site production deployments. (C#, .NET, WPF, WCF, SQL Server)
- Real-Time Remote Support Platform (2014): Engineered a full-stack web application for remote industrial/commercial diagnostics, implementing real-time messaging, ticket lifecycle workflows, and automated image ingestion for field troubleshooting. (Ruby on Rails, AngularJS, PostgreSQL)
- Graph Visualization Engine (2013): Designed and developed an interactive data exploration tool rendering entity relationships using dynamic SVG graph topologies and graph databases. (Node.js, D3.js, OrientDB, AngularJS)
- B2B E-Commerce & Portal (2009–2012): Built scalable backend services for a distributed smart-home franchise network, integrating multi-supplier product catalogs, secure SOAP banking payments, and cross-domain authentication. (Ruby on Rails, PHP, PostgreSQL)
Architectural Case Studies
Representative mission-critical systems and software architectures designed and delivered.
Mission-Critical Level 2 Casting Automation
Engineered a multi-threaded process control platform for continuous steel casting. Ingests high-frequency PLC telemetry, calculates real-time metallurgical cooling parameters, and delivers automated recommendations directly to plant operators with sub-second responsiveness.
Shop-Floor to Enterprise Telemetry Pipeline
Connected industrial shop-floor manufacturing cells directly to Delmia Apriso MES via Kepware OPC servers. Standardized heterogeneous PLC data models into a unified schema, enabling real-time work-in-progress tracking and millisecond accuracy for Overall Equipment Effectiveness (OEE).
Intelligent Scrap Yard Classification & Tracking
Architected the software integration layer for a computer vision scrap yard management solution. Evaluates incoming raw scrap metal feeds, performs operational quality grading, and directs crane automation logistics while maintaining data fidelity with central manufacturing records.
High-Density Welfare & Pension Calculation Engine
Designed and implemented a calculation and disbursement engine for public welfare organizations. Handled multi-tiered tax withholdings, complex healthcare benefit formulas, automated batch schedules, and high-density operator desktop consoles.
Dynamic SVG Topology & Entity Graph Visualizer
Developed an interactive web-based relational visualization engine rendering complex entity-relationship graphs. Allowed real-time exploration, clustered node analysis, and sub-graph isolation powered by dynamic SVG rendering and graph database persistence.
Phased Delphi to Modern .NET Architecture Migration
Strategically decomposed a monolithic legacy Delphi Level 2 process control suite into modular C#/.NET services. Ensured continuous operational uptime during phased rollout without interrupting active 24/7 steelmaking operations.
Technical Skills Matrix
Comprehensive technical proficiency developed over two decades of production deployments.
Architecture & Systems Design
Industrial Automation & OT
Programming Languages & Stacks
Databases, Tools & Platforms
Education & Credentials
Foundational technical training in aeronautical systems and e-commerce technologies.
E-commerce Technician Certificate
2004Advanced coursework in web architectures, e-commerce transaction systems, relational databases, and enterprise networking.
Aeronautical Technician Diploma
2002Rigorous engineering education covering aerodynamics, avionics, precision telemetry, instrumentation, and control theory.
Languages
Get in Touch
Open to discussions regarding Technical Leadership, Solutions Architecture, and IT/OT modernization.
Let's collaborate on mission-critical solutions
Whether you need to architect a new MES integration, modernize legacy process control software, or lead an engineering team through complex digital transformation, feel free to reach out directly.