Our Method

System Definition

• Functional Description of the Process

  Write the narrative of how the process actually runs: sequences, modes (auto/manual/jog), recipes, start-up and shutdown, fault handling, and operator actions. This document becomes the contract between operations and controls engineering and is the source of truth for PLC logic and HMI design.

• I/O Definition

  List every field signal: digital and analog inputs/outputs, safety I/O, network devices, and smart instruments. Assign tag names, descriptions, ranges, engineering units, and PLC addresses. The I/O list drives hardware sizing, panel design, wiring drawings, and checkout procedures.

Hardware

• 3D Panel Design with SolidWorks

  Model the enclosure in 3D so layout, heat, wireway, and door swing are proven before metal is cut. Place DIN rail, terminal blocks, drives, and cooling so the panel is buildable and serviceable. The model feeds fabrication drawings, cut sheets, and sometimes collision checks against the machine skid.

• Electrical Drawing Submittal

  Issue the design package for review: power distribution, control schematics, I/O drawings, network diagrams, panel layouts, cable schedules, and bills of material. The customer or AHJ reviews and comments; approved drawings become the official build and as-built baseline.

• Procurement

  Buy long-lead and specified parts against the approved BOM: PLC hardware, drives, enclosures, terminals, wire, sensors, and third-party devices. Track lead times, substitutions, and incoming inspection so fabrication is not delayed by missing or wrong components.

• Panel Fabrication

  Build the enclosure to the drawings and applicable codes (typically UL 508A). Cut and punch the box, mount devices, wire to the schematic, label every conductor and terminal, and document deviations. A well-built panel shortens later testing and field commissioning.

• Testing

  Prove the assembled panel on the shop floor before it ships. Typical work includes point-to-point wiring checks, power-up, PLC/HMI download, simulated I/O or loopback, safety-circuit validation, and a factory acceptance test (FAT) against the functional description.

Software

The executable control application and the tools used to create, test, and maintain it.

• PLC Code

  Structured programs (ladder, structured text, function blocks) for sequencing, PID, motion, safety, and communications. Follow a consistent tag standard and modular structure so the code can be simulated, commissioned, and supported years later.

• HMI Screens

  Graphic pages for overview, equipment detail, trends, alarms, and recipes. Screens should follow plant HMI standards (color, navigation, alarm philosophy) so operators can run the line safely with minimal training.

• Simulation

  Exercise PLC logic and HMI against a process model or I/O simulator before the real machine is available. Simulation finds sequence errors, interlock gaps, and screen issues in the office instead of on the plant floor.

Commissioning

Install, connect, and bring the system live at the site. Work includes mechanical/electrical tie-in, network configuration, program download, and stepwise introduction of real product until the line runs at intended rate.

• I/O Checkout

  Verify every field device against the I/O list: correct point, polarity, scaling, and description. Force or stroke devices, confirm HMI feedback, and sign off each point so later process problems are not hidden wiring faults.

• Site Acceptance Test

  Run the agreed SAT procedure with the customer present: modes, sequences, faults, safety functions, production rate, and documentation. Successful SAT is typically the contractual handover from project team to operations.

• Plant Support

  After handover, keep the system running: troubleshooting, spare parts, program backups, small enhancements, and training. Support may be on-call, remote, or scheduled visits and is what turns a commissioned system into a reliable production asset.