Project evidence

Industrial Automation Experience

Representative, anonymised examples showing the situation, delivered engineering scope and practical outcome.

RETROFIT / 01

Live-site Siemens controls modernisation

Siemens PLC · TIA Portal · phased commissioning

Situation

A 25-year-old controls installation supporting critical facility infrastructure required replacement while the site remained operational.

Scope

The existing control architecture and operational constraints were reviewed, modern Siemens PLC hardware was introduced, and the changeover was organised as a controlled phased cutover.

Engineering delivered

Legacy hardware assessment and I/O planning
Modern Siemens PLC architecture
Cutover sequencing and commissioning
Coordination with site and integration teams

Outcome

The upgraded controls were commissioned with zero unplanned downtime during the changeover.

MHE / 02

Distribution-centre controls delivery

PLC / HMI · emulation · conveyor & sortation

Situation

Large automated material-handling projects required repeatable PLC/HMI software, early sequence proving and dependable commissioning across UK and European sites.

Scope

PLC and HMI software was generated from project documentation, proven in virtual-PLC emulation, then commissioned against live conveyor tracking, scan points, divert logic and material flow.

Engineering delivered

Structured PLC and HMI software development
Virtual-PLC emulation before deployment
Conveyor tracking, scan and divert validation
WMS/WCS inter-system message testing

Outcome

Logic was proven before deployment to reduce commissioning risk and support a controlled SAT and go-live process.

SCADA / 03

Real-time production monitoring

C# · XAML / WPF · live KPIs · alarm history

Situation

Operations needed a clearer view of line throughput, recurring faults, alarms and production performance without adopting an oversized enterprise platform.

Scope

A focused SCADA application was developed to collect and present live operational information through line-level KPI views, fault dashboards, alarm logging and event history.

Engineering delivered

C# and XAML/WPF application development
Live throughput and line-state views
Fault dashboard and alarm history
Operationally focused interface design

Outcome

Operators received practical production visibility and a clearer route from an alarm to the equipment requiring attention.

MACHINE / 04

Packaging-line controls upgrade

Siemens PLC / HMI · safe speed · production data

Situation

Legacy machine controls limited diagnostics, made breakdown recovery harder and restricted the production information available to operators.

Scope

A modern Siemens PLC/HMI solution was engineered with safe-speed monitoring, production counting, clearer fault information and updated electrical documentation.

Engineering delivered

PLC and HMI design from project requirements
Safe-speed monitoring and drive integration
Production counting and OEE-related data
AutoCAD documentation and revision control

Outcome

The line gained a maintainable modern control system with stronger diagnostics and better support for production recovery.

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