Services
The whole control layer: from the sensor on the floor to the operator screen, and on to the report management actually reads.
PLC Programming & Fault Diagnosis
Program development, online fault diagnosis and reverse engineering of inherited code on Siemens S7, Allen-Bradley, Schneider and Omron platforms.
- Program development and correction in TIA Portal, Step 7 and Step 5
- Fault diagnosis through online monitoring — without stopping the line
- Reverse engineering and re-documentation of undocumented programs
Retrofit & Control System Modernisation
Migrating discontinued S5, S7-300 and legacy operator panels to current hardware. The mechanics stay; only the control layer is renewed.
- Program conversion from S5 and S7-300 to S7-1500 / TIA Portal
- Replacement of operator panels with no spare parts left on the market
- Existing field wiring preserved; changeover fitted into a shift break
HMI & SCADA Systems
Operator screen redesign, alarm management, recipe systems and SCADA that shows the whole line on a single screen.
- WinCC, WinCC Flexible and panel-based HMI applications
- Meaningful alarm management — prioritised, not a wall of warnings
- Product recipe management: single-touch format changeover
Remote Maintenance & Teleservice
Connecting to the PLC through a secure tunnel. Most faults resolved within the hour, without waiting for travel time.
- Encrypted, logged access over an industrial router and VPN
- Key-switch controlled setup — the link is live only when you enable it
- Remote upload and verification of program changes
Production Monitoring & MES
Collecting real data from the line to make OEE, downtime causes and shift performance measurable. Managing with numbers, not guesses.
- Direct data collection from the PLC — no extra counters or manual entry
- OEE calculation: availability, performance and quality tracked separately
- Downtime reason classification and a top-five loss report
ERP Integration
Closing the gap between the shop floor and ERP: work orders flow down, actual production flows back automatically.
- Work orders pushed from ERP down to the line
- Actual output, scrap and downtime written back to ERP automatically
- Stock and consumption movements matched to production
Energy Monitoring & EMS
Which machine consumes what, and how much energy per unit produced? You cannot reduce what you do not measure.
- Selection and commissioning of machine-level energy analysers
- Consumption per unit produced — for example kWh per 1,000 bottles
- Compressed air, water and electricity monitored together
Panel Design & Commissioning
From control panel design through to the line producing its first good unit on site.
- Control panel engineering and bill of materials
- Field wiring inspection and labelling
- Sensor, drive and motor commissioning