Technical audit
Program backups, device versions, I/O, communications and critical process functions.
Existing system development
Machine and production line modernisation
We renew control systems, extend machine functions and prepare migrations so that the change remains predictable, testable and properly documented.
Control migrationMoving from legacy PLC and HMI solutions
Functional extensionNew devices, recipes and operating variants
Risk controlBackups, testing and a commissioning plan
Service scope
Modernisation based on understanding the current system
Before replacing hardware or restructuring software, we review process logic, documentation, communications and dependencies between devices. This separates hardware, software and operational issues.
- Program, signal and connection inventory
- PLC controller or HMI panel migration
- Machine sequence and feature extension
- Alarm and diagnostic improvement
- Integration of new drives, sensors and devices
- Updated project backups and documentation
Controlled change
A plan designed to limit shutdown risk
We separate work that can be prepared offline from tasks that require machine access. The test order and rollback conditions are agreed before commissioning.
Preparation
New code, configuration, signal mapping, test plan and work schedule.
Changeover
Staged commissioning, function tests, acceptance and project file handover.
When to modernise
Signs that a control system needs a planned change
Unavailable components
Controllers, panels or modules are discontinued and spare stock is difficult to maintain.
Unclear diagnostics
Operators can see the effect of a fault but receive little guidance towards its cause.
Legacy software limits
Every change is risky because the software lacks structure or reliable documentation.
New production needs
The process requires more formats, production data, reporting or higher-level integration.
FAQ
Common questions
Does modernisation require replacing the entire control system?
Not always. We identify the components that limit reliability or future development. A staged migration is possible when interfaces between old and new sections are clearly defined.
Can the familiar operator workflow remain unchanged?
Yes, if it works well for production. Diagnostics and screen clarity can be improved while preserving the established process logic.
How should we prepare for an audit?
Collect current project files, electrical diagrams, known issue lists, planned process changes and information about available service windows.
Trust PLC Solution
Prepare the upgrade without unnecessary risk
We will start with the current state, the objective and the project's time constraints.