Manufacturing Automation
Industrial automation solutions for manufacturing environments, designed to improve reliability, reduce downtime, and support long-term operational performance.
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At Stratos Control Systems, we deliver standards-based automation systems that help manufacturers maintain efficiency, improve system visibility, and extend the lifecycle of critical control infrastructure.
From PLC programming and SCADA systems to control panel building, E-PLAN control panel design and system upgrades, our solutions are built to support both current production demands and future growth.
Automation Designed for Modern Manufacturing
Modern manufacturing environments rely on automation systems that can deliver consistent performance, adapt to changing production demands and support continuous improvement. As production lines evolve, manufacturers need automation that is reliable, scalable and easy to maintain.
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At Stratos, we combine PLC Programming, Machine Control Systems, SCADA & HMI Systems and industrial control panels to create integrated automation solutions that improve operational efficiency and reduce downtime. Our structured engineering approach ensures systems remain supportable throughout their lifecycle, helping manufacturers maximise productivity while preparing for future expansion.
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Whether you're upgrading legacy equipment, integrating new machinery or standardising automation across multiple production lines, we deliver practical engineering solutions designed for long-term performance.
Manufacturing Automation Challenges
Manufacturing environments often face a range of automation challenges, including:
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Downtime caused by failing or obsolete control systems
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Inconsistent PLC and HMI standards across machines
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Ageing control panels and unsupported hardware
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Limited visibility into system performance
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Difficult fault finding and reliance on specific individuals
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Integration challenges between machines and processes
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By addressing these challenges at the control system level, we help manufacturers improve reliability, efficiency, and control.
Supporting Manufacturing Systems Throughout Their Lifecycle
Manufacturing automation is continually evolving. Equipment ages, production requirements change and new technologies become available, making lifecycle planning essential for maintaining reliable operations.
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Stratos supports manufacturers throughout the complete lifecycle of their automation systems. From new control panel design and PLC programming to SCADA integration, automation fault finding, control system upgrades and electrical documentation, we help engineering teams extend asset life, improve maintainability and reduce operational risk.
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By taking a long-term approach to automation, manufacturers can reduce unexpected failures, simplify future upgrades and improve overall production resilience.
How We Support Manufacturing Operations
Control Panel Build & Design
We design and manufacture industrial control panels for manufacturing environments using AutoCAD and E-Plan, focusing on clarity, safety, and long-term support.
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Control panel design and build
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Panel refurbishment and upgrades
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MCCs and machine control panels
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Full documentation and testing
PLC & Machine Control Systems
We deliver structured PLC programming and machine control systems designed for reliable manufacturing operation.
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PLC programming and upgrades
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Machine control and integration
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Legacy PLC replacement
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Structured, maintainable software
SCADA, HMI & System Monitoring
We design SCADA and HMI systems that provide visibility across manufacturing processes and production lines.
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SCADA system design and integration
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Alarm management and diagnostics
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Trends, reporting, and performance monitoring
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Platforms including Ignition, WinCC, InTouch, FactoryTalk View SE
Control System Upgrades & Refurbishment
We modernise manufacturing automation systems while minimising risk and downtime.
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Control panel refurbishment
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Phased upgrades and migration strategies
Building Management Systems & Utilities Integration
We integrate building management and utility systems to support manufacturing automation and operations.
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Utility and energy monitoring
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Integration with production systems
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Centralised visibility and control
Automation Platforms We Support
Stratos Control Systems primarily deliver manufacturing automation solutions using trusted industrial platforms:
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Siemens
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Allen Bradley
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Mitsubishi
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We also support a wide range of legacy and specialist control systems, particularly as part of upgrade and refurbishment projects.
Industrial Control Panels for Manufacturing
Industrial control panels provide the foundation for reliable manufacturing automation. They bring together PLCs, drives, safety devices, HMIs and field equipment into a structured system that supports safe, efficient production.
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Our Control Panel Design, Build & Manufacture service delivers robust control panels engineered for manufacturing environments. Supported by detailed EPLAN documentation, comprehensive testing and clear labelling, our panels simplify installation, improve fault finding and provide a scalable platform for future automation upgrades and production expansion.
Automation Designed for Real-World Manufacturing Operations
Manufacturing automation systems must operate reliably across multiple machines, processes, and production lines, often with varying ages and technologies.
Poor integration, obsolete PLCs, or undocumented systems create ongoing challenges for engineering and maintenance teams.
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Stratos Control Systems delivers automation systems that are:
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Reliable and maintainable
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Consistent across machines and sites
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Easy to fault find and modify
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Scalable for future expansion
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Our focus is on practical, long-term automation solutions that support continuous manufacturing operations.
Manufacturing Applications We Support
Our experience covers a wide range of manufacturing environments, including:
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Discrete manufacturing
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Process manufacturing
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Multi-line production environments
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OEM and site-based machinery
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Brownfield and greenfield projects
Testing and Commissioning for Reliable Manufacturing
Successful automation projects depend on thorough testing before production begins. Factory Acceptance Testing (FAT) verifies that control panels, PLC software, HMI interfaces and communications perform as intended before equipment leaves the workshop.
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Following installation, Site Acceptance Testing (SAT) confirms that the complete automation system integrates correctly with live manufacturing processes and operates reliably under real production conditions. This structured testing approach reduces commissioning risk, minimises production disruption and helps ensure a smooth transition into operation.
Manufacturing Applications We Support
Our automation engineers support a wide range of manufacturing processes, from standalone machines to fully integrated production facilities.
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Typical manufacturing applications include:
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Production and assembly lines
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Automated machine cells
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Conveyor and transfer systems
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Robotic integration
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Process control systems
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Utilities and energy monitoring
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Packaging and end-of-line automation
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Material handling and product movement
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Batch and continuous manufacturing processes
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Plant-wide monitoring and reporting
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By designing automation around the specific needs of each manufacturing process, we help organisations improve productivity, increase reliability and build systems that are easier to maintain and expand.
Common Manufacturing Automation Challenges We Help Solve
Manufacturers face increasing pressure to improve productivity while reducing downtime, managing ageing automation systems and maintaining consistent production standards. Addressing these challenges requires structured engineering, reliable automation platforms and long-term lifecycle planning.
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Our specialist resources can help you overcome common manufacturing automation challenges:
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Reduce Downtime – Learn how proactive automation improvements, better diagnostics and structured maintenance reduce production interruptions.
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Replace Obsolete Systems – Discover practical approaches to upgrading legacy PLCs, SCADA systems and industrial control panels while minimising operational risk.
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No Visibility Into Automation Systems – Explore how SCADA systems provide real-time monitoring, improved diagnostics and better production visibility.
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Poorly Documented & Inconsistent Control Systems – Understand how standardised PLC programming and accurate documentation simplify maintenance and future upgrades.
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Automation Projects Overrunning – See how structured planning, testing and engineering governance help deliver successful automation projects.
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Whether you're modernising a single production line or standardising automation across multiple manufacturing sites, Stratos provides practical solutions that improve reliability, maintainability and long-term operational performance.
Why Choose Stratos Control Systems
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Experienced industrial automation engineers
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Strong focus on reliability, maintainability, and standardisation
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Expertise across PLC, HMI, SCADA, and control panels
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Proven capability in upgrades and legacy systems
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Practical, site-focused engineering approach
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We deliver automation systems that work reliably today and remain supportable in the future.
Frequently Asked Questions
Talk to Us About Manufacturing Automation
Whether you are upgrading legacy control systems, improving system visibility, or planning new manufacturing automation projects, Stratos Control Systems can help.​