Six disciplines, delivered as one system
Every engagement below can run on its own, but most sites need two or three of them working together — the control logic, the network it sits on, and the people who support it once it's live. Jump to a discipline for scope, deliverables, and the platforms we work in.
PLC Programming & Panel Design
Ladder logic, structured text, and function block programs written for the technician who has to troubleshoot them at 3am, not just the engineer who wrote them. We also design and build the panels the logic runs in.
- Ladder, structured text, and function block programming
- Control panel design, drawings, and bill of materials
- Safety circuit design (E-stops, interlocks, guarding)
- Factory acceptance testing before anything ships to site
- On-site commissioning and loop checks
- As-built documentation and program backups handed over to your team
SCADA System Integration
Operator screens, tag databases, and alarms built around how your operators actually work a shift — not a default template. Includes historian setup so the data outlives the project.
- HMI screen design following high-performance HMI principles
- Tag database architecture and naming standards
- Alarm rationalization aligned to ISA-18.2
- Historian configuration, trending, and reporting
- Redundancy and failover setup for critical servers
- Operator training and screen walkthroughs before go-live
DCS Migration & Support
Legacy DCS platforms rarely get replaced overnight. We plan migrations around your shutdown windows, migrate control narratives module by module, and stay on for support once you're live on the new system.
- Legacy system assessment and migration roadmap
- Control narrative review and rewrite
- Phased migration planned around shutdown windows
- Loop checks and staged cutover, module by module
- Operator retraining on the new system
- Ongoing DCS support and patching contracts
Industry 4.0 & IIoT
Getting data off the plant floor and into a dashboard someone actually opens. We start with a single pilot line rather than a plant-wide rollout, so you can see the value before scaling it.
- Edge device selection and deployment
- OPC-UA and MQTT data pipelines from PLC to cloud
- Dashboarding for production, downtime, and OEE
- Predictive maintenance models for critical assets
- Digital twin pilots for new lines or retrofits
- Retrofit connectivity for machines with no native network port
OT Cybersecurity
Control-system security is a different discipline from office IT security — patching a PLC on the wrong schedule can stop production. We design around uptime first, then harden from there.
- Asset inventory and network topology mapping
- IEC 62443 zone-and-conduit segmentation design
- Firewall and DMZ architecture between OT and IT networks
- Vulnerability assessment scoped to avoid process disruption
- Incident response planning specific to control systems
- Security awareness training for plant and control-room staff
IT Support & Infrastructure
The corporate and plant IT systems that sit alongside your control network still need a helpdesk, patched servers, and someone to call when a laptop won't boot. We run that support on an SLA, not an as-available basis.
- Remote and on-site helpdesk support
- Server and network administration
- Patch management scheduled around plant operations
- Backup and disaster recovery planning
- Microsoft 365 / Google Workspace administration
- Hardware procurement and lifecycle management