Service scope
PLC Programming & Logic Development
Structured, modular control logic for discrete manufacturing written to be maintained.
- Ladder Logic, Structured Text & FBD per IEC 61131-3
- Siemens, Rockwell, Mitsubishi & Schneider platforms
- Modular, reusable function block libraries
- Structured tag naming and symbol conventions
- Written for plant maintenance readability
PackML / ISA-88 Machine Programming
A common state model so every machine on the line behaves and reports the same way.
- OMAC PackML state model and mode handling
- Standardized unit-to-line integration
- Consistent machine states across OEM equipment
- PackTags for line-level data exchange
- Faster integration of third-party equipment
PLC Code Refactoring & Optimization
Legacy logic restructured and documented without changing machine behaviour.
- Restructuring legacy logic without changing behaviour
- Removing dead code, duplicate rungs and bypasses
- Rebuilding tag naming and symbol standards
- Scan-time optimization on constrained processors
- Documentation rebuild for undocumented systems
PLC Migration & Platform Conversion
Obsolete processors replaced and re-commissioned inside available production windows.
- Platform-to-platform logic conversion
- Legacy processor and IO replacement strategy
- Cutover planning within production windows
- Re-commissioning against original behaviour
- Obsolescence risk assessment and roadmap
Simulation & Virtual Commissioning
Logic and HMI validated offline so start-up time is spent on production, not debugging.
- Offline logic and HMI validation before site work
- Fault-path testing without physical equipment
- Reduced on-site debugging and start-up time
- Simulation-based FAT sign-off
- Operator training ahead of line availability
HMI Design & Visualization
Diagnostics-first operator screens on OEM standards or your own template library.
- OEM standards: GM GCCS 1 & 2, Ford FAST & GVOSS
- Native: WinCC, FactoryTalk View, Ignition Perspective
- Custom client templates and style guides
- Diagnostics-first fault, IO and sequence screens
- ISA-101 high-performance HMI principles
- Multi-language and shift-handover support
Machine & Plant Automation
Work-cell through multi-station line architecture, sequence design and fault recovery.
- Work-cell through multi-station line architecture
- Sequence of operations and control philosophy
- Safety interlock coordination with control logic
- Robot, vision and third-party device integration
- Station-level fault handling and recovery
- Cycle time and bottleneck analysis
Motion Control & Servo Systems
Servo axis configuration, coordinated motion sequences and safe travel strategy.
- Servo axis configuration and tuning
- Indexing, positioning and cam profile logic
- Motion-to-PLC data interface design
- Coordinated multi-axis sequence development
- Torque, position and homing diagnostics
- Safe motion and travel limit strategy
Industrial Networking & Communication
Plant-floor topology, addressing and protocol architecture up to the enterprise layer.
- EtherNet/IP, ProfiNET, ProfiBUS, Modbus TCP/IP
- IO-Link device integration and diagnostics
- OPC UA and MQTT for plant-to-enterprise data
- Topology, addressing and segmentation design
- Managed switch and VLAN configuration
- Network fault diagnosis in live production
Standards applied
to this discipline.
Work in this category is developed against the published standards below, applied consistently regardless of the hardware vendor on the line.
Defines the standard programming languages for programmable logic controllers Ladder Diagram, Function Block Diagram, Structured Text, Instruction List and Sequential Function Chart together with common data types and the program organisation units that structure a project.
- Language selected per routine rather than by habit
- Reusable function block and POU libraries
- Structured tag, symbol and comment conventions
ISA-88 establishes the procedural, physical and recipe models for controlled equipment. PackML applies its state model to discrete and packaging machines as a fixed set of machine states and modes, with PackTags as the standard data interface for line-level exchange.
- State and mode engine implemented per machine
- Consistent behaviour across mixed OEM equipment
- PackTags interface for line and MES data exchange
Covers the HMI lifecycle from philosophy and style guide through design, implementation and change management. Specifies display hierarchy, colour discipline and alarm indication conventions intended to shorten operator time-to-detection and reduce response error.
- Display hierarchy from line overview to device diagnostics
- Muted process graphics, colour reserved for abnormal states
- Common navigation and screen standards across the plant
Twelve steps.
Every engagement.
Each engagement follows the same sequence from discovery through post-commissioning support, so scope, documentation and validation are never negotiated mid-project. Every step closes on a named deliverable.
Discovery
Review of existing equipment, process requirements and production constraints, including what is already installed and what cannot be interrupted.
Requirements Definition
Requirements captured and documented against client specifications and applicable process standards, so scope is agreed before design begins.
Functional Design Specification
Control philosophy, sequence of operations, interlocks and interface requirements written and approved before any software is developed.
IO List Development
A structured input/output list establishing the interface between field hardware and control software, and the reference for both wiring and logic.
System Architecture
Control network, hardware and communication architecture defined across the PLC, HMI, SCADA and MES layers, including addressing and segmentation.
Software Development
PLC, HMI and MES application development to IEC 61131-3 conventions against the approved FDS, using modular and documented code structures.
Simulation
Offline validation of logic and operator screens, including fault paths, before any equipment is available moving debugging off the production floor.
Factory Acceptance Testing
Structured functional validation against the FDS prior to shipment or site deployment, with defects logged and closed before mobilisation.
Site Acceptance Testing
On-site validation against the approved FDS under live equipment conditions, confirming behaviour matches what was specified and tested.
Commissioning
Equipment energization, sequence validation, interlock proving and production ramp-up support through to stable output.
Training
Operator and maintenance training on system operation, screen navigation and diagnostics, so the plant can run and troubleshoot the system itself.
Support
Post-commissioning remote and on-site support for optimization, change requests and issue resolution, with scheduled system health reviews.
Talk to the
engineer,
not a sales desk.
Production challenges involving unplanned downtime, retrofit planning, MES integration or new line commissioning can be reviewed directly with engineering leadership. Initial technical consultations are used to understand current control architecture, process constraints and desired outcomes before a proposal is issued.
Industrial Automation Project Engineer with 8+ years designing and developing PLC, HMI, SCADA and MES solutions for the automotive and material handling industries.