Automation Project Lifecycle
From Initial Requirements to Commissioning and Lifecycle Support
Industrial automation projects rarely fail because somebody forgot to write a line of PLC code.
Problems more commonly develop when requirements are unclear, interfaces between suppliers are poorly defined, engineering decisions are made too late or testing is left until equipment reaches site.
A successful automation project therefore requires more than control panel manufacture and PLC programming.
The complete lifecycle needs to be considered, from defining the original operational requirement through control system design, software development, testing and commissioning to documentation, handover and long-term support.
While the exact process varies according to the project, understanding the major stages helps manufacturers, project managers and engineers identify what should happen before the next phase begins.
This guide explains a typical industrial automation project lifecycle and the engineering activities involved at each stage.
Define the Automation Requirement
The project should begin with the problem or operational requirement rather than immediately selecting hardware.
The first questions should establish what the automation system actually needs to achieve.
Requirements may include:
Production objectives.
Machine functionality.
Process requirements.
Equipment to be controlled.
Operator requirements.
Existing automation.
Required interfaces.
Production constraints.
Safety requirements.
Data and reporting requirements.
Future expansion.
For modernisation projects, the existing control system also needs to be understood.
This may involve reviewing PLC hardware, software, control panels, drives, networks, electrical drawings and the condition of existing equipment.
The better the requirement is understood at this stage, the less likely major assumptions will emerge later in the project.
Define the Project Scope and Responsibilities
Once the requirement is understood, the project scope needs to establish what will actually be delivered.
Industrial automation projects frequently involve several parties, potentially including:
Manufacturer or end user.
System integrator.
Control panel manufacturer.
Machine builder.
Mechanical contractor.
Electrical installer.
Equipment suppliers.
IT or network teams.
Safety specialists.
The interfaces between these parties need to be clear.
For example:
Who supplies field instrumentation?
Who installs field wiring?
Who provides the PLC network connection?
Who modifies existing machinery?
Who is responsible for safety validation?
Who provides information required for third-party integration?
Who owns commissioning activities?
Many project problems occur between scopes rather than within them.
Clear responsibilities and deliverables therefore need to be established before detailed engineering begins.
Develop the Control System Architecture
The next stage establishes how the automation system will be structured.
Depending on the application, the architecture may include:
PLCs.
Remote I/O.
Control panels.
HMIs.
SCADA.
Variable Speed Drives.
Motor control.
Instrumentation.
Industrial networks.
Safety systems.
External interfaces.
Higher-level systems.
For an existing facility, the design also needs to consider how the new automation will interact with installed equipment.
This is where decisions around PLC platforms, industrial communication protocols and system standardisation become particularly important.
The architecture should support both the immediate project and the longer-term automation strategy of the facility.
Detailed Electrical and Control System Design
Once the architecture has been agreed, detailed engineering can begin.
Electrical design may include:
Control panel schematics.
Power distribution.
Circuit protection.
Motor control.
Variable Speed Drives.
PLC hardware.
I/O.
Terminals.
Field connections.
Industrial networking.
Component selection.
For machinery applications, relevant electrical and assembly requirements also need to be considered as part of the design.
Where EPLAN is used, the project can progress from the initial architecture into structured electrical schematics and manufacturing documentation.
A good design should answer the questions the panel manufacturer, software engineer, installer and commissioning engineer will encounter later.
PLC, HMI and SCADA Development
Software engineering can progress once the required functionality and hardware architecture are sufficiently defined.
PLC development may include:
Machine sequencing.
Process control.
Equipment interlocks.
Automatic modes.
Manual controls.
Alarm handling.
Fault diagnostics.
Communications.
Data handling.
HMI and SCADA development may include:
Operator controls.
Equipment status.
Alarm information.
Setpoints.
Process values.
Diagnostics.
Trends.
User access.
Reporting.
Software development should follow the agreed functional requirements rather than becoming the stage where unresolved operational decisions are finally made.
Clear software structure and naming standards can also make future maintenance and modification considerably easier.
Control Panel Manufacture
Once the electrical design has been approved, the industrial control panel can move into manufacture.
The manufacturing stage may include:
Enclosure preparation.
Component mounting.
Cable duct installation.
Internal wiring.
Termination.
Equipment identification.
PLC installation.
Drive installation.
Network equipment installation.
Inspection.
Electrical testing.
Changes made during manufacture need to be controlled and reflected in the project documentation.
Otherwise, the electrical drawings can begin to diverge from the panel before it has even reached site.
Where possible, software development and panel manufacture can progress in parallel once the relevant design information has been approved.
Factory Acceptance Testing
Factory Acceptance Testing provides an opportunity to test the automation system before equipment is delivered to site.
Depending on the project, FAT may include:
Control panel inspection.
Component verification.
Electrical checks.
PLC I/O testing.
PLC sequence testing.
HMI testing.
Alarm testing.
Drive testing.
Industrial communications.
Simulated fault conditions.
Where the actual machine or process equipment is unavailable, field signals may need to be simulated.
Any limitations of the FAT should be documented so that remaining tests can be completed during commissioning or Site Acceptance Testing.
Finding problems during FAT is generally preferable to discovering them once production equipment is waiting for commissioning.
Installation and Site Preparation
Before commissioning begins, the site needs to be ready for the automation system.
Depending on the project, this may involve:
Control panel installation.
Electrical supplies.
Field wiring.
Instrumentation.
Motors.
Drives.
Network infrastructure.
Machine installation.
Mechanical completion.
Third-party equipment.
Site readiness has a significant effect on commissioning efficiency.
If engineers arrive to find incomplete field wiring, unavailable machinery or unresolved network infrastructure, commissioning can quickly become a sequence of delays.
A pre-commissioning review can therefore be useful before specialist automation engineering resources are mobilised.
Automation Commissioning
Commissioning brings the automation system together with the actual machinery or process.
Activities may include:
Power-up checks.
Field I/O verification.
Instrument calibration checks.
Motor testing.
Drive commissioning.
Equipment direction checks.
PLC sequence testing.
Machine integration.
Network testing.
HMI verification.
Process testing.
Fault testing.
Software may need to be adjusted as real equipment behaviour becomes visible.
The objective is not simply to make the machinery run.
Commissioning should establish that the control system operates according to the defined functional requirements and interacts correctly with the equipment around it.
Site Acceptance Testing and Handover
Once commissioning is substantially complete, Site Acceptance Testing can verify agreed functionality within the actual operating environment.
SAT may include:
Functional operation.
Production sequences.
Equipment interfaces.
Alarm behaviour.
HMI functionality.
Process conditions.
Production testing.
System recovery.
Customer acceptance criteria.
Outstanding issues should be documented and resolved through an agreed process.
Final handover may then include:
Electrical drawings.
As-built documentation.
PLC backups.
HMI backups.
SCADA backups.
Drive parameters.
Equipment documentation.
Network information.
Test records.
Training information.
The organisation should be left with enough information to support the automation system after the project team has left site.
Lifecycle Support and Future Modernisation
Handover should not be considered the end of the automation lifecycle.
The control system may operate for decades.
During that period:
Production requirements change.
PLC software is modified.
Components become obsolete.
New equipment is integrated.
Networks evolve.
Operators change.
Documentation can become outdated.
Original engineers may no longer be available.
Good lifecycle management therefore includes:
Software backups:
Maintain controlled copies of PLC, HMI, SCADA and drive configurations.
Documentation:
Keep electrical drawings and system information aligned with modifications.
Obsolescence monitoring:
Identify ageing equipment before replacement becomes urgent.
Planned maintenance:
Inspect control panels and critical automation infrastructure.
Fault analysis:
Investigate recurring problems rather than allowing temporary fixes to become permanent.
Modernisation planning:
Develop upgrade strategies before unsupported technology becomes an operational risk.
For facilities requiring structured ongoing engineering support, maintenance and service contracts can provide continuity between individual automation projects.
Why Managing the Complete Automation Lifecycle Matters
Each stage of an automation project affects what happens next.
Poor requirements create design changes.
Poor design creates manufacturing and software problems.
Poor documentation makes commissioning harder.
Insufficient FAT pushes problems onto site.
Rushed commissioning creates unresolved issues.
Poor handover makes the system harder to maintain.
The cost of solving a problem can also increase significantly as the project progresses.
A requirement clarified during design may require only a drawing change. The same issue discovered after manufacture could require rewiring, software changes and additional commissioning.
Effective automation project delivery therefore depends on maintaining continuity between requirements, engineering, manufacture, testing, commissioning and long-term support.
Stratos works across the industrial automation lifecycle, including control system design, control panel manufacture, PLC programming, HMI and SCADA development, FAT, commissioning, modernisation and ongoing engineering support.
This allows decisions made during the early engineering stages to be considered in the context of how the system will eventually be manufactured, commissioned and maintained.
Planning an Industrial Automation Project?
The decisions made at the beginning of an automation project influence everything that follows, from control panel manufacture and PLC development to commissioning and long-term maintenance.
Stratos provides automation engineering across the project lifecycle, helping manufacturers move from initial requirements and control system design through manufacture, programming, FAT, commissioning and ongoing support.
Speak to our engineers about planning, delivering or modernising your next industrial automation project.
Frequently Asked Questions
What are the stages of an industrial automation project?
A typical automation project may include requirements definition, project scoping, control system architecture, detailed engineering, PLC and HMI development, control panel manufacture, FAT, installation, commissioning, SAT and final handover.
What should happen before PLC programming starts?
The required machine or process functionality, hardware architecture, I/O, interfaces and major operating requirements should be sufficiently defined. Starting software development before these decisions are understood can result in unnecessary rework.
When should Factory Acceptance Testing take place?
FAT normally takes place after the relevant panel manufacture and automation development have progressed sufficiently for agreed functionality to be tested, but before the equipment is delivered or installed at its final location.
What is the difference between commissioning and SAT?
Commissioning involves configuring, testing and bringing the automation system into operation with the actual equipment. Site Acceptance Testing is the subsequent agreed verification of system functionality and acceptance criteria at the installation site.
What documentation should be provided at automation project handover?
Depending on the project, handover documentation may include as-built electrical drawings, PLC and HMI backups, SCADA files, drive parameters, equipment documentation, network information, FAT and SAT records and other agreed technical information.