Factory Automation
Integrated Factory Automation for Modern Manufacturing
Modern manufacturing depends on machines, control systems and production information working together reliably. From individual automated machinery to complete production lines, factory automation provides the control infrastructure required to coordinate equipment, monitor processes and maintain consistent production.
Effective factory automation is about more than installing individual PLCs or automated machines. Control panels, PLC software, drives, instrumentation, HMIs, SCADA systems and industrial networks need to work together as one coordinated environment.
Stratos develops, integrates and supports factory automation systems for manufacturing and industrial facilities, helping businesses improve production control, equipment visibility and long-term system reliability.
Whether you are automating new production equipment, integrating existing machinery or modernising an ageing factory control system, our engineers develop practical solutions around the requirements of your operation.
What Is Factory Automation?
Factory automation uses industrial control technology to operate, coordinate and monitor manufacturing machinery and production processes.
A factory automation system may incorporate:
PLCs.
Industrial control panels.
Variable Speed Drives.
Motors and actuators.
Sensors and instrumentation.
HMIs.
SCADA systems.
Industrial networks.
Remote I/O.
Production data systems.
These technologies allow equipment to operate automatically according to programmed sequences, process conditions and production requirements.
Factory automation can be applied to an individual machine, a production cell, a complete production line or wider manufacturing operations.
PLC Control for Factory Automation
PLCs provide the control logic behind much of modern factory automation.
PLC software can coordinate:
Machine sequences.
Conveyor systems.
Motors.
Production equipment.
Interlocks.
Process conditions.
Automated start-up and shutdown.
Equipment communication.
Alarm conditions.
Fault handling.
Stratos develops PLC software around the actual machinery and production process, creating structured control logic that can be understood, maintained and modified as production requirements change.
Control Panels for Factory Automation
Factory automation can extend beyond individual machines to coordinate multiple pieces of production equipment.
Production line automation may involve:
Machine-to-machine communication.
Conveyor control.
Product transfer.
Production sequences.
Line interlocks.
Equipment synchronisation.
Fault handling.
Production monitoring.
Automated changeovers.
Process coordination.
Integrating equipment at line level can provide greater control over how individual machines interact and help prevent faults in one area from creating unnecessary disruption elsewhere.
HMI and Operator Control
Operators need clear information about the condition of automated machinery.
HMIs can provide access to:
Machine status.
Operating modes.
Production information.
Setpoints.
Equipment controls.
Alarm conditions.
Fault diagnostics.
Process values.
Maintenance information.
Well-designed operator interfaces make automation easier to understand and can help teams respond more effectively when production problems occur.
SCADA and Factory-Wide Visibility
Individual HMIs provide local machine visibility, while SCADA can provide a broader view across production equipment and factory operations.
SCADA systems can bring information together from multiple PLCs and machines to display:
Equipment status.
Production conditions.
Active alarms.
Production output.
Process information.
Downtime.
Historical trends.
Operational KPIs.
This provides production, maintenance and engineering teams with greater visibility beyond individual machine controls.
Industrial Networking and Machine Integration
Factory automation increasingly depends on reliable communication between equipment.
Industrial networks can connect:
PLCs.
Production machinery.
Remote I/O.
Drives.
HMIs.
SCADA systems.
Instrumentation.
Other control systems.
Depending on the existing equipment, communications may involve technologies such as PROFINET, PROFIBUS, EtherNet/IP or Modbus.
Reliable industrial networking allows machines and control systems to exchange the information required for coordinated factory operation.
Factory Automation Data and Production Visibility
Automation systems generate valuable information about how manufacturing equipment is performing.
This data can be used for:
Production dashboards.
Downtime analysis.
Historian systems.
Industrial reporting.
Alarm analysis.
Equipment performance monitoring.
Production trending.
Remote monitoring.
Making existing automation data more accessible can help manufacturers identify recurring problems and understand where production performance is being lost.
The objective is not simply to collect more data, but to make useful operational information available to the teams that need it.
Factory Automation Upgrades and Modernisation
Many manufacturing facilities contain automation systems introduced over several generations.
This can result in a mixture of:
Obsolete PLCs.
Ageing control panels.
Unsupported HMIs.
Legacy SCADA software.
Older drives.
Multiple network technologies.
Poor documentation.
Difficult-to-source components.
Factory automation modernisation can address these risks through planned PLC upgrades, control panel refurbishment, HMI replacement, SCADA upgrades and industrial network improvements.
Modernisation can also be phased so that higher-risk equipment is prioritised without unnecessarily replacing systems that remain reliable.
Improving Factory Automation Reliability
Automation should make production more reliable and easier to maintain.
Where repeated faults occur, the underlying control system should be investigated rather than continually relying on temporary fixes.
Reliability improvements may include:
PLC code optimisation.
Improved diagnostics.
Better alarm information.
Control panel refurbishment.
Network improvements.
Improved HMI fault information.
Updated software backups.
Improved documentation.
Obsolescence planning.
A more maintainable automation environment can help engineering teams identify faults faster and reduce dependence on knowledge held by individual engineers.
Factory Automation Maintenance and Lifecycle Support
Factory automation requires ongoing support as machinery ages and production requirements change.
Planned support can include:
PLC health checks.
Control panel inspections.
SCADA and HMI reviews.
Industrial network checks.
Software backup verification.
Obsolescence monitoring.
Documentation updates.
Fault investigation.
Planned system improvements.
Where ongoing engineering support is required, maintenance and service contracts can provide a structured approach to maintaining critical factory automation systems and identifying developing risks before they result in unexpected production failures.
Why Choose Stratos for Factory Automation?
Factory automation requires multiple engineering disciplines to work together.
PLC software cannot be considered independently from the control panel. SCADA depends on reliable PLC communications. Production equipment depends on industrial networks, drives and field devices operating correctly.
Stratos combines control panel design and manufacture, PLC programming, SCADA and HMI engineering, industrial networking and automation support within one control systems environment.
Whether you're automating new machinery, integrating an existing production line or modernising ageing factory automation, our engineers develop solutions around the equipment, people and production requirements of the facility.
Build a More Connected Factory Automation Environment
Bring machinery, control panels, PLCs, operator systems and production information together within a coordinated automation environment.
Stratos designs, integrates, modernises and supports factory automation systems for industrial manufacturers, helping improve production control, system visibility and long-term maintainability.
Speak to our engineers about a new factory automation project, integrating existing production equipment or modernising an ageing control system.
Frequently Asked Questions
What is factory automation?
Factory automation uses PLCs, control panels, drives, sensors, HMIs, SCADA and industrial networks to automatically control and coordinate manufacturing machinery and production processes.
What types of factory equipment can be automated?
Automation can be applied to individual machines, conveyors, production cells, material handling equipment, manufacturing processes and complete production lines, depending on the application.
Can existing factory machinery be integrated into a new automation system?
Often, yes. Existing machinery can be assessed to determine whether its PLCs, communications and electrical controls can be integrated with newer automation equipment or whether particular systems require upgrading.
Can an older factory automation system be modernised?
Yes. Modernisation can include PLC migration, control panel refurbishment, HMI and SCADA upgrades, industrial networking improvements and replacement of obsolete equipment. This can often be completed as a phased programme.
Do you provide ongoing factory automation support?
Yes. Stratos can provide automation support covering PLCs, control panels, SCADA, HMIs and industrial networks. Maintenance and service contracts can also provide structured ongoing system reviews, backup management and obsolescence monitoring.