Process requirements
Functional description, operating modes, sequences, recipes, start and stop conditions and system responsibilities.
From concept to detailed engineering
Industrial automation system design
We design control solutions for machines and production lines: system architecture, electrical schematics, I/O lists, PLC, HMI and SCADA selection, plus interfaces to MES, ERP and TraceSmart.
Complete automation engineering
Technical decisions documented before work begins
A sound design reduces changes on site, makes implementation easier to quote and leaves maintainable documentation. We adapt the scope to a new machine, an upgrade or integration of an existing line.
System structure
PLC, distributed I/O, drives, HMI panels, SCADA, industrial networks and integration layers.
Schematics and hardware
Power and control diagrams, protection, cabinet hardware, cables, sensors and actuator selection.
PLC, HMI and SCADA
Programming standards, data structures, operator screens, alarms, reporting and diagnostic strategy.
MES, ERP and TraceSmart
Data exchange, APIs, OPC UA, SQL databases and product identification using OCR, codes and RFID.
Testing and commissioning
FAT and SAT criteria, test lists, backups, manuals and a safe transition plan for the new solution.
Single responsibilitydesign, build and commissioning
Technology fitselected for the process
Maintainable documentsclear for maintenance teams
Ready to expandcapacity and common standards
Engineering workflow
From process audit to implementation support
Each stage ends with a deliverable that can be reviewed before moving forward.
Process review
We analyse technology, cycle time, quality, safety and the information needed by operators and production.
Site inventory
We inspect the existing PLCs, networks, documentation, signals, cabinet capacity and integration options.
Concept and options
We compare architectures, upgrade scope, migration methods and production continuity risks.
Detailed design
We prepare schematics, I/O lists, equipment specifications, the functional description and software assumptions.
Design review
The solution is agreed with production, maintenance, IT and safety before equipment is ordered.
FAT, SAT and as-built
We support tests, commissioning and the update of documentation to the final installed condition.
Coherent architecture
The complete path from field signal to production data
We design more than a control cabinet. Field equipment, control, visualisation and data exchange are treated as one maintainable system.
Sensors, OCR and RFID
Drives and actuators
Safety systems
Control system designPLC · I/O · network · software standard · diagnostics
Documentation scope
What the completed design can include
The final set depends on the project, plant standards and whether SystemSmart is also responsible for implementation and commissioning.
| Area | Typical deliverables |
|---|---|
| Control concept | Functional description, sequences, operating modes, architecture diagram and safety assumptions. |
| Electrical design | Schematics, bill of materials, cable list, component layout, calculations and protection selection. |
| Automation | I/O list, addressing, network topology, drive, sensor, alarm and interlock lists. |
| Software | PLC standard, HMI/SCADA structure, recipes, reports, users and project backups. |
| Interfaces | Data map, interface description, protocols, buffering and loss-of-communication scenarios. |
| Acceptance and service | FAT/SAT procedures, test records, manuals, spare-parts list and as-built documentation. |
Engineering proven in production
Selected industrial projects
Examples cover PLC and OPC integration, industrial software and the combination of automation with OCR and traceability.
Technical questions
Industrial automation design — FAQ
The design can cover a new investment or an upgrade of a live production system.
What should an industrial automation design include?
At minimum: a functional description, architecture, electrical schematics, an I/O list, hardware selection, PLC/HMI assumptions and a test plan. Integrated systems also require a data map and interface specification.
Can an upgrade be designed around a short shutdown?
Yes. The design then includes inventory, migration steps, off-line preparation, pre-shutdown tests and a rollback scenario.
Can the design use the plant's preferred hardware?
Yes, provided it is technically suitable and available. Common PLC, HMI, drive and component standards reduce spares and simplify support.
Can SystemSmart also build and program the system?
The scope may include design, cabinet assembly, PLC/HMI/SCADA programming, commissioning, as-built documentation and ongoing service.
How is MES or ERP integration specified?
We define data ownership, message formats, protocols, buffering, confirmations and system behaviour when communication is lost.
What is needed to quote the design?
A process description, available documentation, equipment list and expected scope are enough to start. If materials are incomplete, we begin with a site audit and inventory.
First step
Send your project assumptions or arrange a site audit
We will assess the scope, integration risks and the information needed for detailed engineering.