PLC Programming
Structured, documented control logic you can maintain.
We write, modify, and migrate PLC programmes across the major platforms:
- Siemens (S7-300, S7-400, S7-1200, S7-1500, TIA Portal),
- Allen-Bradley (RSLogix 5000/Studio 5000),
- Mitsubishi (GX Works).
Whether it's a new machine build, a legacy system upgrade, or a platform migration, we deliver clean, structured code with full documentation. All programmes are written to IEC 61131-3 standards and handed over with version-controlled project files.
Capabilities:
- New machine and process control programmes.
- Legacy PLC migration and modernization.
- Siemens, Allen-Bradley, Mitsubishi.
- IEC 61131-3 structured programming.
- Full documentation and handover.
HMI Development
Operator interfaces that reduce error and improve visibility.
We design and develop HMI screens that give operators clear, accurate process information and intuitive control. Platforms include Siemens WinCC (TIA and standalone), Ignition, FactoryTalk View. Screen layouts follow ergonomic and ISA-101 principles alarm management, navigation hierarchy, and colour standards are applied consistently. We also carry out HMI audits and redesigns on existing systems where poor interface design is contributing to operator error or production loss.
Capabilities:
- Siemens WinCC, Ignition, FactoryTalk View .
- ISA-101 compliant screen design .
- Alarm rationalisation and management .
- HMI audits and redesign .
- Remote access and historian integration .
Robot Integration
Robots integrated safely, reliably, and to production spec.
We integrate industrial robots into new and existing production lines handling the full scope from cell design and PLC interfacing through to safety interlocking, operator HMI, and commissioning to production-ready status. We work with Kuka and FANUC. Safety integration is carried out in line with EN ISO 10218 and EN ISO 13849, with formal risk assessment and safety validation included where required.
Capabilities:
- FANUC, KUKA.
- PLC and safety system interfacing.
- Cell design and guarding specification.
- EN ISO 10218 / EN ISO 13849 compliance.
- Commissioning and operator training.
Functional Safety
TÜV Rheinland Certified FS Technician #5334/25 – Machinery.
Functional safety work is carried out by a TÜV Rheinland Certified Functional Safety Technician (Certificate #5334/25 – Machinery). We provide safety function specification, SIL/PL determination, SISTEMA analysis, safety-related control system design, and formal safety validation. We work to EN ISO 13849 and IEC 62061 standards and can support both new installations and the assessment of existing safety systems. Documentation is produced to a standard suitable for regulatory submission and third-party audit.
Capabilities:
- TÜV Rheinland Certified FS Technician #5334/25.
- Safety function specification (SRS).
- SIL/PL determination and SISTEMA analysis.
- EN ISO 13849 and IEC 62061.
- Safety validation and documentation.
Electrical Design
Panel schematics and circuit design to IEC standards.
We produce electrical design documentation for control panels, machine installations, and process plant from concept schematics through to approved-for-construction drawings. Work is carried out using EPLAN Electrical and delivered in formats suitable for panel builders, site installation teams, and long-term maintenance. Designs comply with IEC 60204-1 (Safety of Machinery Electrical Equipment) and relevant BS/EN standards. We also carry out design reviews and produce as-built documentation for existing installations.
Capabilities:
- EPLAN Electrical.
- IEC 60204-1 compliant designs.
- Control panel schematics and layouts.
- Cable schedules, I/O lists, loop diagrams.
- As-built documentation and design reviews.
Fault Finding & Diagnostics
Systematic diagnosis to root cause, not just symptom treatment.
We carry out structured electrical and control system fault diagnosis on production plant, process equipment, and machine tools. Using a methodical approach fault tree analysis, signal tracing and PLC diagnostic monitoring we identify root causes rather than masking symptoms. We work across a wide range of control architectures and are experienced in diagnosing intermittent faults, drive and servo issues, sensor and field device failures, and communication network problems.
Capabilities:
- PLC diagnostic and online monitoring.
- Drive and servo fault analysis.
- Sensor, field device, and network faults.
- Intermittent and recurring fault investigation.
- Written fault reports with root cause analysis.
Breakdown Response
Responsive on-site support when production is down.
When critical plant stops, speed and accuracy matter. We provide responsive on-site breakdown support for electrical and automation systems arriving with the tools, test equipment, and technical knowledge to diagnose and resolve faults efficiently. We are experienced across a broad range of plant environments including food and beverage, pharmaceutical, automotive, and general manufacturing. Where a permanent repair requires parts or planned downtime, we will implement a safe interim solution and provide a clear scope for the full repair.
Capabilities:
- Responsive on-site attendance.
- Electrical and control system breakdowns.
- Food, pharma, automotive, manufacturing.
- Interim solutions and full repair scoping.
- Post-breakdown reports and recommendations.
Commissioning & Upgrades
From FAT through to SAT structured, documented, signed off.
We carry out structured commissioning of new and upgraded automation systems from factory acceptance testing (FAT) through to site acceptance testing (SAT) and production handover. We also deliver control system upgrades, software updates, and hardware retrofits on live and shutdown plant, managing the change process to minimise risk and production impact. All commissioning work is documented with test records, punch lists, and handover packs suitable for the client's quality management system.
Capabilities:
- FAT and SAT planning and execution.
- Control system upgrades and retrofits.
- Software version management.
- Live plant change management.
- Commissioning documentation and handover packs.