Automation Projects
Industrial Automation Projects from Design Through to Commissioning
Successful industrial automation projects require more than selecting the right PLC or control equipment. Electrical design, control panels, software, industrial communications, operator interfaces and production requirements all need to come together within a coordinated engineering programme.
Poorly defined requirements, changes during delivery and weak coordination between engineering disciplines can result in delays, additional costs and automation systems that are difficult to maintain after handover.
Stratos delivers industrial automation projects for manufacturers and production environments, providing engineering support from initial system assessment and design through control panel manufacture, PLC programming, SCADA and HMI development, testing, commissioning and final handover.
Whether you're introducing new automation, upgrading an existing production system or replacing obsolete controls, our engineers focus on delivering practical automation around the requirements of the equipment and production environment.
Industrial Automation Project Planning
A successful automation project starts with understanding what the system actually needs to achieve.
Before detailed engineering begins, project requirements may consider:
Existing equipment.
Production requirements.
Control philosophy.
PLC platforms.
Electrical requirements.
Operator interaction.
SCADA requirements.
Industrial communications.
Safety requirements.
Documentation.
Testing.
Production constraints.
Clearly defining these requirements helps reduce uncertainty later in the project and provides a stronger basis for engineering decisions.
Automation System Design
System design determines how the different elements of the automation solution will operate together.
Depending on the project, this may include:
Control system architecture.
PLC selection.
I/O requirements.
Control panel design.
Industrial networks.
Variable Speed Drives.
Instrumentation.
HMI architecture.
SCADA integration.
Existing system interfaces.
Design should also consider maintainability and future expansion rather than focusing only on getting the equipment operational for initial handover.
Control Panel Design and Manufacture
PLC programming translates the project requirements into the logic that controls the machinery or process.
Development may include:
Machine sequences.
Process control.
Equipment interlocks.
Motor control.
Analogue control.
Alarm generation.
Fault handling.
Operating modes.
Industrial communications.
Diagnostic functions.
Structured PLC software also makes the finished system easier to understand, troubleshoot and modify after the project has been completed.
HMI and SCADA Development
Operators and engineering teams need clear visibility of what the automation system is doing.
Depending on the project, Stratos can develop HMI or SCADA applications providing:
Equipment status.
Process visualisation.
Operator controls.
Setpoints.
Alarm information.
Fault diagnostics.
Production information.
Historical trends.
Operational dashboards.
User access.
The interface should be designed around the people using the system rather than simply displaying every value available from the PLC.
Industrial Network Integration
Modern automation projects frequently require multiple control systems and devices to communicate.
Industrial networking may connect:
PLCs.
Remote I/O.
Drives.
HMIs.
SCADA systems.
Instrumentation.
Production equipment.
Existing control systems.
Depending on the equipment, this may involve PROFINET, PROFIBUS, EtherNet/IP, Modbus or other industrial communication technologies.
Network requirements should be considered during system design rather than introduced after equipment has already been selected.
Integrating New and Existing Automation
Not every automation project begins with a completely new system.
New equipment frequently needs to interact with existing:
PLCs.
Control panels.
Production machinery.
SCADA systems.
Industrial networks.
Drives.
Instrumentation.
Legacy equipment.
Existing systems should therefore be assessed early in the project to understand compatibility, available communications and potential obsolescence risks.
Where suitable, existing equipment can be retained rather than replaced unnecessarily.
Factory Acceptance Testing
Factory Acceptance Testing provides an opportunity to verify automation equipment and functionality before final site implementation.
Depending on the project, FAT may include:
Control panel inspection.
PLC hardware checks.
I/O simulation.
PLC software testing.
HMI testing.
Alarm verification.
Sequence testing.
Communication testing.
Documentation review.
Customer witness testing.
Identifying issues before equipment reaches site can reduce the amount of corrective work required during installation and commissioning.
Site Commissioning and SAT
Once the automation system has been installed, commissioning verifies its operation with the actual machinery, field devices and production environment.
Activities may include:
I/O verification.
Instrument testing.
Drive commissioning.
PLC sequence testing.
HMI and SCADA checks.
Network testing.
Equipment interlocks.
Alarm verification.
Site Acceptance Testing.
Production trials.
Commissioning provides the transition between the engineered system and normal production operation.
Automation Project Documentation and Handover
A completed automation project should leave the customer with sufficient information to understand and maintain the system.
Handover documentation may include:
Electrical schematics.
PLC software.
HMI applications.
SCADA projects.
Software backups.
I/O schedules.
Drive parameters.
Network information.
Test records.
As-built documentation.
Where changes are made during commissioning, documentation should reflect the final installed system rather than the original pre-commissioning design.
Post-Project Automation Support
Automation requirements continue after project handover.
Initial production may identify opportunities for optimisation, while software, hardware and production requirements will continue to change throughout the system's operating life.
Post-project support may include:
PLC optimisation.
HMI modifications.
SCADA changes.
Software backup management.
Control panel inspections.
Automation health checks.
Obsolescence monitoring.
Documentation updates.
Planned system improvements.
Where longer-term support is required, maintenance and service contracts can provide a structured transition from project delivery into ongoing lifecycle support.
Why Choose Stratos for Industrial Automation Projects?
Automation projects involve multiple interconnected engineering disciplines.
Using separate suppliers for control panel manufacture, PLC programming, SCADA development and commissioning can increase the amount of coordination required and make responsibility between different elements of the project less clear.
Stratos brings control panel engineering and manufacture, PLC programming, HMI and SCADA development, industrial networking, testing and commissioning together within one automation engineering environment.
This allows our engineers to consider the complete control system from initial design through to production handover, helping create automation solutions that are practical to operate, maintain and develop over the longer term.
Deliver Your Next Automation Project with Stratos
From initial control system design and control panel manufacture through PLC programming, SCADA integration, testing and commissioning, Stratos brings the key elements of industrial automation project delivery together.
Speak to our engineers about a new automation project, production system upgrade or modernisation programme.
Frequently Asked Questions
What does an industrial automation project include?
Depending on the requirements, an automation project can include system design, control panel manufacture, PLC programming, HMI and SCADA development, industrial networking, FAT, installation support, commissioning and final documentation.
Can Stratos deliver the control panel and PLC programming?
Yes. Stratos provides both control panel manufacture and PLC programming, allowing the electrical hardware and automation software to be developed as part of the same wider control system.
Can you integrate new automation with existing machinery?
Yes. Existing PLCs, machinery, control panels and networks can be assessed to determine how new automation can be integrated and whether particular components require upgrading.
Do you provide Factory Acceptance Testing and commissioning?
Yes. Automation projects can include Factory Acceptance Testing before site implementation and commissioning or Site Acceptance Testing once the system has been installed.
Can you support the automation system after the project is completed?
Yes. Stratos can provide post-project technical support and planned system improvements. Maintenance and service contracts can also provide structured ongoing support after project handover.