AMAli MahmoudAutomation Engineer, Accenture
75 HardDayLet's talk

Automation Software Consultant Engineer at Accenture

Build systems.Build self.

I build the software that runs robots and conveyor lines. Off the clock, I work on the system that matters most: me.

Ali standing on a bridge over the Chicago River

Why I build

It started with LEGO.

As a kid, I'd pour a bag of LEGO onto the floor: hundreds of scattered pieces and no idea where to start. Hours later it stood finished, every brick exactly where it belonged.

That feeling, taking something scrambled and turning it into something whole that works, is why I fell in love with engineering.

Now I build with bigger pieces.

  • 01

    Robotic systems

    Programming robots to take on the heavy, repetitive work, so people don't have to.

  • 02

    Conveyance systems

    Building the lines that move product through a plant, and every bit of logic that keeps them flowing.

  • 03

    Automation solutions

    Finding the slow, manual steps in a process and engineering them out for good.

  • 04

    AI workflows

    Bringing AI into the flow, so systems don't just run. They get smarter.

Different pieces, same goal: make people's lives easier.

I didn't figure that out overnight.

It took five years, a pandemic, a few rejections and a steel mill. Here's how it happened.

The climb

From a Hamilton high school to building robots at Accenture. Every year added a rung.

  1. Ali holding a Class of 2020 graduation sign at home
    2020

    Class of 2020, on a screen

    Sir Allan MacNab Secondary, then McMaster University2020

    Graduated from Sir Allan MacNab in the middle of a pandemic, then began Automation Engineering Technology at McMaster from my bedroom. My entire first year of engineering happened through a screen.

  2. 2021

    Figuring it out

    McMaster University2021

    Year two came down to one goal: land my first co-op. I rebuilt my resume, applied everywhere and even interviewed for a research role. Honestly, I didn't yet know what I wanted, so I kept applying until a door opened.

  3. Ali in a hard hat and safety vest during his Honda co-op
    2022

    LEGO, life-size

    Honda Canada, Alliston, OntarioMay to Aug 2022

    My first internship, and my first time living away from my family. On Honda's plant floor I watched a car come together from nothing: thousands of scattered parts becoming one finished machine. It was LEGO again, life-size. Behind it ran the PLC logic and software that keep every line moving, where even a few minutes of downtime counts. It showed me what an engineer could be, and that's where I fell in love with engineering.

    • First internship
    • Manufacturing + PLC logic
    • Alliston, ON
  4. 40%more accuratemultivariate LSTM vs. traditional forecasts
    2023

    Where data clicked

    Stelco, Machine Learning Engineer Intern, HamiltonJan to Sep 2023

    Eight months as a Machine Learning Engineer Intern inside a steel plant. I built a TensorFlow tool with LSTM models to forecast aluminum droplets on the Z-line, and SQL pipelines that fed Power BI and automated customer reports. It's where I learned that good data is the foundation of every good system.

    • +40% forecast accuracy
    • -30% data processing time
    • TensorFlow
    • SQL
    • Power BI
  5. A big crowd gathered outside on a sunny day, from Ali's Accenture internship
    2024

    A no, then a yes

    Tesla said no. Accenture said yes.2024

    I've always loved cars and building things from scratch, and Tesla led the world at both. I wanted to work on their robotic systems. They said no. In May, Accenture said yes: I joined as an Automation Analyst intern, the day after running a half marathon.

    • Automation Analyst Intern
    • Half marathon the day before
  6. Ali at his McMaster graduation with his mother
    Ali's father holding up Ali's McMaster degree
    2025

    Graduated. Hired.

    McMaster University, then Accenture full time2025

    Finished my degree in Automation Engineering Technology at McMaster, with Mama and Baba there to see it. Accenture made a return offer, and I came back full time as an Automation Software Consultant Engineer.

    • Automation Engineering Technology
    • Return offer
  7. Now

    Building with AI

    AccentureToday

    Today I design and develop robotic and conveyance systems and write the logic behind them, working directly with clients and vendors. The next rung: bringing AI into every flow I build.

Every rung came with something I built along the way.

Things I've built

At work, at school and at home. I've always loved building things from scratch.

Personal automation / AI

Automating My Own Life

AI is the most powerful tool we've ever had. The real skill is knowing how to use it, so I practice on my own life first.

  • Email on autopilot: workflows that sort, route and handle my inbox so I don't have to.
  • A finance app I built that tracks everything I spend and every investment I'm working on.
  • My basement, controlled by Alexa. In progress.
  • AI workflows
  • Email automation
  • Alexa
  • Finance app
Screenshot of this website's opening screen: Build systems. Build self.
McMaster capstone / IoT

Smart Aquaponics System

Built for people who keep a fish tank but work overseas. The whole ecosystem runs and reports to their phone while they're away.

  • A mobile app shows live temperature, nutrients, pH, humidity and light readings.
  • Automatic water exchange pumps out the dirty water and cycles clean water back in to keep the tank clean.
  • A 3D-modelled fish feeder, so owners can feed their fish from anywhere.
  • Closed loop: fish waste feeds the plants, and the plants filter the water. Runs on an Arduino Mega with a JavaScript + Node.js app.
  • Arduino Mega 2560
  • IoT
  • Node.js
  • 3D modelling
  • Mobile app
The aquaponics capstone build with a lit tank and laptop
Digital + analog circuits / FPGA

FPGA Elevator Control System

An elevator controller built from the logic up, designed for efficiency, safety and reliability.

  • Core control logic written in Verilog and running on an FPGA.
  • Analog and digital circuits for motor control, sensor interfacing and the floor display.
  • Verilog
  • FPGA
  • Motor control
  • Oct to Dec 2023
Model elevator tower wired to an FPGA board on a lab bench
McMaster / Predictive maintenance

CNC Vibration Monitoring

Catch the warning signs before a machine fails. A sensor system that tracks CNC vibrations, so maintenance can be proactive instead of reactive.

  • An Arduino Mega reads a vibration sensor mounted straight onto the machine with a two-magnet mount I designed.
  • A 3D-modelled enclosure houses the Arduino and the electronics.
  • Data streams over Ethernet into Excel, collected across long production runs.
  • The patterns reveal irregularities early, cutting surprise downtime.
  • Arduino Mega
  • Vibration sensor
  • 3D modelling
  • Ethernet
  • Data analysis
The Arduino and vibration sensor mounted on the CNC machine bed

Certified

  • FANUC Industrial Robot Operation and ProgrammingFANUC
  • AVEVA IDEAVEVA

Building systems was never the hard part. Building myself was.

75 Hard

75 Hard is a 75-day mental toughness challenge. Five rules, every single day, no exceptions. Miss one and you start over at day 1.

  1. 01Two 45-minute workouts, one of them outside
  2. 02Follow a diet
  3. 03Drink a gallon of water
  4. 04Read 10 pages of a non-fiction book
  5. 05Take a progress photo

Why I started

I wanted more discipline in my work and my routines, and better ways to improve myself. I'd started reading: The Psychology of Money, then Discipline Is Destiny, which became the staple of my library. I was already seeing the benefits, so I thought, why not?

Day 1 to day 10 was easy. After day 10, it got hard. That's where it started teaching me.

Today

Day48

48 of 75. The grid fills one day at a time.

Workouts
96
Pages read
480
Gallons of water
48
Progress photos
48

A line I keep coming back to

What's a man who can't even keep the promises he made to himself?

What it means to me

This line helped me understand what being a man means. How can I make promises to anyone else if I can't keep the ones I make to myself?

What it's teaching me

01

The real start is day 10

The first ten days ran on excitement. Discipline only started when the excitement ran out.

02

Promises to myself come first

If I can't keep the promises I make to myself, my promises to anyone else don't mean much.

03

Read it, then live it

The books gave me the ideas. Seventy-five days of doing them is what made them stick.

Rule four: ten pages a day. These are the pages.

What I'm reading

Ali's copy of Discipline Is Destiny by Ryan Holiday
Ali's copy of The Psychology of Money by Morgan Housel

My favorite. The staple of my library.

In a world of distraction, focusing is a superpower.

Ryan Holiday, Discipline Is Destiny

To procrastinate is to be entitled. It is arrogant. It assumes there will be a later.

Ryan Holiday, Discipline Is Destiny

The fact is, the body keeps score. The decisions we make today and always are being recorded, daily, silently and not so silently, in who we are, what we look like, how we feel.

Ryan Holiday, Discipline Is Destiny

Compounding works best when you can give a plan years or decades to grow. This is true for not only savings but careers and relationships. Endurance is key.

Morgan Housel, The Psychology of Money

The hardest financial skill is getting the goalpost to stop moving.

Morgan Housel, The Psychology of Money

Rule one: one workout has to be outside. This is where I take it.

Trails and peaks

Ontario trails and one Colorado mountain. Where I clear my head and build endurance.

Sitting on white quartzite above the lakes at Killarney
The CrackKillarney Provincial Park, ON
Hikers on a fall forest trail in Killarney
Fall on the trailKillarney, ON
A steep boulder scramble between birch trees
The scrambleKillarney, ON
Ali on the trail up Pikes Peak
Pikes PeakColorado
Clouds over the valleys below Pikes Peak
Above the cloudsPikes Peak, Colorado / 4,302 m

Every so often, I test all of it in one day.

Finish lines

21.1km

May 2024

Half marathon, zero training

The day before my Accenture internship started, I ran a half marathon for cancer research without training for it. It was all between the ears, and one of the biggest challenges of my life.

All between the ears.

Ali and a friend holding up their finisher medals
Ali running the half marathon in the rain
Ali mid-race on a wet road
Ali and his coworkers, muddy and wearing finisher medals, in front of the Tough Mudder finish banner
Ali carrying a keg on his shoulder during the Tough Mudder, one finger in the air

Tough Mudder

I ran it with my coworkers. Obstacle after obstacle, it taught me about teamwork and about reaching back to help the person behind you.

Up next

Triathlon

  • Swim
  • Bike
  • Run

Swim, bike, run. It's next on the list. Keep it locked.

None of it means much if it stays with me.

Giving back

Ali with the youth soccer team he coaches
Youth soccer coachMountain School. Championship-winning team. Teaching effort, teamwork and character, on and off the field.
Ali at the Greenhill Islamic School registration booth
Greenhill Islamic SchoolGiving back to my local community: serving at Greenhill, helping build the school up, and pitching in wherever I'm needed.

Building something with automation or AI? Walking the discipline path too?

Let's build something.

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