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Proportional - Integral - Derivative (PID) controller performs well for linear systems. For systems with nonlinearity, controller parameters need to be tuned every time for new operating point to obtain `local gain parameters'. These local gain parameters are not sufficient to get satisfactory performance at other operating points. In this paper a novel approach `Aggregate Fitness Function' is presented to obtain the `global gain parameters' that works satisfactorily at various operating points. Online optimization scheme with Genetic Algorithm (GA) is adopted to tune the Proportional-Integral (PI) controller parameters for setpoint tracking of DC Motor by minimizing Integral-Time-Absolute-Error (ITAE). Hardware validation of the results is presented and studied. The plant under study is DC Motor Control Module (MS15) from M/S LJ CREATE™. M/S National Instrument (NI) based software and hardware components i.e …