Services

Consultation and Assessment

Engineering services in industrial automation play a crucial role in helping companies modernize their manufacturing processes, increase productivity, reduce costs, and maintain a competitive edge in today's rapidly evolving global market. Engineering has always been a crucial part of the Automation Industry or any business, contributing an essential role in all the steps required to take a project from the concept stage to a finalized reliable, high-quality, productive one that meets your specification.

Approach

• Understanding Client Requirements: Engineers start by meeting with the client to understand their specific needs, objectives, and challenges. This may involve discussions with key stakeholders, such as production managers, maintenance personnel, and quality control teams, to gain insights into the existing workflow, pain points, and areas for improvement.
Process Mapping: Engineers map out the client's existing industrial processes in detail, documenting each step from raw material input to finished product output. This helps identify inefficiencies, bottlenecks, and areas where automation can streamline operations and enhance productivity.
Data Collection and Analysis: Engineers gather relevant data on key performance metrics such as production throughput, cycle times, downtime events, quality defects, and resource utilization. This quantitative analysis provides valuable insights into the overall efficiency and effectiveness of the existing processes, as well as opportunities for optimization through automation.
Technology Assessment: Engineers evaluate the client's current technology infrastructure, including hardware, software, control systems, and communication networks. They assess the compatibility, scalability, and reliability of existing systems, as well as the potential for integrating new automation technologies and components.
Risk Assessment: Engineers conduct a risk assessment to identify potential hazards, safety concerns, and regulatory compliance issues associated with the proposed automation solutions. This involves evaluating factors such as equipment safety, environmental impact, cybersecurity risks, and human-machine interaction.
Cost-Benefit Analysis: Engineers perform a cost-benefit analysis to assess the financial feasibility and return on investment (ROI) of implementing automation solutions. This involves estimating the upfront capital costs of equipment and implementation, as well as ongoing operational costs, maintenance expenses, and potential savings or revenue gains resulting from increased efficiency and productivity.
Recommendations and Roadmap: Based on the findings of the assessment, engineers develop a set of recommendations and a roadmap for implementing automation solutions tailored to the client's specific needs and priorities. This may include phased implementation plans, technology selection criteria, resource allocation strategies, and timelines for project execution.

Read more

Software Development

We develop the software that drives the automated systems, including programming PLCs (Programmable Logic Controllers), SCADA (Supervisory Control and Data Acquisition) systems, DCS (Distributed Control Systems), MES (Manufacturing Execution Systems), and HMI (Human-Machine Interface) applications. They may also develop custom algorithms for tasks such as motion control, machine vision, and predictive maintenance. Our Engineers are well versed with all 5 IEC defined Programming Languages such as Ladder Logic, Functional Block Diagram, Sequential Function Charts, Structred text, instruction List.

Our Engineers are Hands-on with
• Programming Platforms: TIA portal(SIEMENS), GX developer(Mitsubishi), Machine Expert (Schneider), Control Expert (Schneider), CCW (Allen Bradley).
• HMI Platforms - TIA Portal, GT Designer, Vijeo Designer, CCW (Allen Bradley).
• MES Platforms.
• BMS Platforms - TRACER SC, ECOSTRUXURE.
• SCADA Platforms - AVEVA CITECT, AVEVA Edge, WIN CC, IGNITION.
• DCS Platforms.

Read more

Installation, Testing & Commissioning

We oversee the installation of instrumentation & Control equipments and ensure that it operates correctly within the production environment. This involves testing individual components as well as the integrated system to verify functionality and performance.

Approach

• Preparation and Planning : Review the installation plan developed during the earlier phases and ensure that all necessary equipment, materials, and resources are available. Coordinate with contractors, vendors, and other stakeholders to schedule installation activities and minimize disruption to production operations. Prepare the installation site by clearing space, installing mounting hardware, and ensuring that utilities such as power and communication lines are available.
Hardware Installation : Physically install the hardware components of the automation system, including sensors, actuators, controllers, industrial robots, and other devices, according to the specifications and layout defined in the design phase. Mount equipment securely to prevent vibration, misalignment, or other mechanical issues that could affect performance. Connect electrical, pneumatic, hydraulic, and network cables according to wiring diagrams and connection diagrams, ensuring proper grounding and insulation to prevent electrical hazards.
Software Setup : Install and configure the software components of the automation system, including PLCs, SCADA systems, HMI applications, and other control software, on the designated computing platforms. Configure communication protocols, network settings, and data exchange mechanisms to enable seamless communication between hardware devices and software modules. Load configuration files, program logic, and parameter settings onto the appropriate controllers and devices, ensuring consistency with the design specifications.
System Integration : Integrate the hardware and software components of the automation system to form a unified, functional system. Verify communication between sensors, actuators, controllers, and other devices, ensuring that data is transmitted accurately and reliably. Test interlocks, alarms, and safety systems to ensure that they respond appropriately to abnormal conditions and emergency shutdowns.
Functional Testing : Conduct functional testing to verify that the automated system operates as intended and meets the specified requirements. Test individual system functions and scenarios, such as startup/shutdown sequences, production cycles, error handling, and fault recovery procedures. Monitor system performance, including response times, accuracy, precision, and throughput, to identify any issues or deviations from expected behavior.
Calibration and Tuning : Calibrate sensors, actuators, and control loops to ensure accurate measurement and control of process variables. Tune control algorithms, PID parameters, and other control settings to optimize system performance, stability, and responsiveness. Conduct performance tests under different operating conditions and load profiles to validate system behavior and identify opportunities for optimization.
Documentation and Handover: Document the installation and commissioning activities, including as-built drawings, configuration files, test reports, and commissioning checklists. Provide training to operators, maintenance personnel, and other end-users on how to operate, maintain, and troubleshoot the automated system effectively. Hand over control of the system to the client or end-user, ensuring that they have the necessary documentation, training, and support to assume responsibility for ongoing operation and maintenance.
Final Acceptance: Conduct a final acceptance review with the client to verify that the automated system meets all contractual requirements, specifications, and performance criteria. Address any outstanding issues or deficiencies identified during the commissioning process and ensure that they are resolved to the satisfaction of the client. Obtain formal acceptance and sign-off from the client to officially close the installation and commissioning phase and transition to the operation and maintenance phase.

Read more

Training and Support

We provide training to operators, maintenance personnel, and other relevant staff on how to use and maintain the automated systems safely and effectively. We offer ongoing support and troubleshooting services to address any issues that arise during regular operation

Approach

• Requirement Analysis: Engineers review the system requirements gathered during the earlier phases to understand the software functionality needed for the automation project. They collaborate closely with stakeholders to clarify requirements and ensure a comprehensive understanding of user needs.
Architecture Design: Engineers design the software architecture, which includes defining the overall structure of the software, the interactions between different modules or components, and the data flow within the system. This step involves making decisions about the choice of programming languages, frameworks, libraries, and development tools.
Module Design and Development: Engineers break down the software functionality into smaller modules or subsystems, each responsible for specific tasks or functions within the automated system. They design, code, and test individual modules, following best practices for software engineering, such as modular design, encapsulation, and abstraction.
Integration Testing: Engineers integrate the individual software modules to form a cohesive system and conduct integration testing to verify that the components work together as intended. This involves testing data exchange, communication protocols, error handling, and synchronization between different modules to ensure seamless interoperability.
User Interface (UI) Design: Engineers design and develop the user interface (UI) for the human-machine interface (HMI) or operator consoles used to monitor and control the automated system. They focus on creating intuitive, user-friendly interfaces that provide real-time feedback, visualization of process variables, and controls for manual intervention when necessary.
Database Design and Integration: If the automated system requires data storage and retrieval, engineers design and integrate databases to store configuration settings, historical data logs, production records, and other relevant information. They define data schemas, implement database queries, and ensure data integrity and security.
Simulation and Testing: Engineers use simulation tools and emulators to test the software in virtual environments that replicate the behavior of the real-world automated system. This allows them to identify and address potential issues early in the development process, such as performance bottlenecks, edge cases, and error conditions.
Validation and Verification: Engineers validate and verify the software against the specified requirements to ensure that it meets quality standards and regulatory compliance. This involves rigorous testing, including functional testing, performance testing, stress testing, and compliance testing, as well as documentation of test results and validation reports.

Read more

Optimization and Upgrades

We continuously monitor the performance of automated systems and identify opportunities for optimization and improvement. This may involve fine-tuning control algorithms, upgrading hardware components, or implementing new technologies to stay competitive and meet evolving business needs