Machine Overhaul and Modernization

On machines that are mechanically sound but have outdated control infrastructure, the PLC and HMI, motion control, drives and motors, control panel and software are renewed. The decision to overhaul rather than buy a new machine is assessed based on cost, parts availability, mechanical condition and production needs.

Up-to-date schematics, backups and a list of the existing system may be requested at the technical team stage. No staged before/after photos are used; the diagram is a simple illustration of the transition.

• Parts unavailableNo spare parts are available for the existing control system.
• Mechanically soundThe frame and mechanism are in usable condition.
• Production needs have changedHigher expectations for speed, precision or traceability.
• Frequent downtimeFaults caused by the old control infrastructure.

A symptom is not a diagnosis; the cause becomes clear during laboratory diagnosis.

Process: site survey → goals and scope → design → implementation → trial production → training and documentation. No “definitely cheaper” outcome is promised; the decision is made together, based on data.

1. 01

   Requirements meeting

   Goals and constraints are clarified.

2. 02

   Site survey

   The current situation on site is documented.

3. 03

   Design

   The scope and solution are designed.

4. 04

   Quotation and scope approval

   A written scope is prepared and your approval obtained.

5. 05

   Implementation

   Carried out in the planned period.

6. 06

   Acceptance and handover

   Testing, documentation, handover.

Machine type and age (if known), existing control system, the problem experienced, production goal, location and planned downtime window.