Upgrade to modern control systems before legacy failures cause unexpected downtime.
- Control system upgrades including rewritten PLC logic and redesigned HMI visualisation
- Compliance with the latest Machinery Directive and industrial safety regulations
- Seamless integration with existing infrastructure and higher-level MES/ERP platforms
Upgrading the control system reduces cabinet footprints and cuts overall energy consumption across power and drive systems. Operators and maintenance teams gain immediate operational transparency and actionable diagnostics, allowing direct connectivity into plant-wide SCADA and factory monitoring networks.
- Control system migration — High-performance PLC hardware, re-engineered control architecture, and modern HMI visualisation. Resulting in lower operator vulnerability and dependable cycle stability.
- Safety and compliance — Integrated safety system redesign, strict alignment with the Machinery Directive, and complete technical documentation. Minimises human presence in hazardous operating zones.
- Optimisation and throughput — Line cycle optimisation and overall productivity gains paired with superior workstation ergonomics. Ensures predictable operation and eliminates control-related breakdowns.
We delivered an extensive retrofit of an automated assembly and soldering line for a Tier-1 automotive component manufacturer. Scope included redesigning functional safety circuits, overall line optimisation, electrical rewiring, new PLC architecture with tailored HMI visualisation, machine compliance for Total Productive Maintenance (TPM), and on-site commissioning with personnel training.
Maintenance Department
Automotive Component Supplier
The line was aligned fully with Machinery Directive standards. The soldering cell was entirely re-engineered with automated part feeding, eliminating manual intervention in dangerous zones. Redesigned manual assembly stations maintained nominal output while improving operator ergonomics, supported by an integrated Andon system for clear machine state visualisation. Control optimisation delivered stable cycle performance and significantly reduced troubleshooting times for plant maintenance.
We provide a comprehensive engineering approach.
The pathway to full automation: from initial needs analysis to ongoing lifecycle support.
Frequently Asked Questions
More questions? Contact our engineering team to discuss technical feasibility.
It depends on the modernisation scope. Where compliance with the Machinery Directive requires introducing safety interlocks or light curtains, specific manual cycles may require minor deceleration for operator safety. Conversely, retrofits incorporating automated sub-modules accelerate takt times and alleviate operator workload. The exact performance goals are defined during the initial audit.
Depending on work scope—historically ranging from one to three weeks. We engineer and pre-commission off-site to execute installation strictly within your planned maintenance shutdown window.
Not in every case. If kinematic and mechanical components are intact, replacing the control platform costs significantly less than buying new capital equipment. However, when an asset is severely degraded and demands widespread component overhauls, we transparently advise investing in a new custom machine—backed by complete warranties and domestic engineering support.
We pre-assemble and validate modules so mechanical and electrical drop-in takes minimal time. Keeping line downtime to an absolute minimum directly protects your operational margins.
Yes. We work on third-party installations, adapting legacy control programs, drive hardware, and electrical distribution to meet modern technical and safety requirements.
Yes. Ensuring compliance with the Machinery Directive and delivering updated mechanical and electrical schematics is an integral part of the retrofit scope.