Plant Floor Control Solutions
An effective and efficient manufacturing facility relies on accurate, automated control of all processes and equipment. A shop’s floor contains many components requiring careful analysis, configuration and deployment for successful production, from analog transmitters and proximity switches to motor control centers and power supplies. To ensure the highest levels of productivity and product quality, plants must implement a modern shop floor control system that communicates with all these components across each manufacturing line.
Shop Floor Control Tools to Modernize Your Facility
The team at Malisko understands that all plant manufacturing components must work together seamlessly to achieve these goals. We’ll work with you to learn about your existing processes and develop a strategy tailored to your operation’s unique goals and objectives.
Our vast experience in developing shop floor control solutions enables us to offer services for the most critical elements of your operation, including:
- Electrical power distribution with monitoring, including main and sub switchgear.
- Electrical and control panel design, including lighting and utility.
- Instrumentation specifications.
- Controllers, such as programmable logic controllers (PLCs) and distributed control systems (DCSs), for processes, utilities and building services.
- Motor control centers (MCCs) and variable frequency drives (VFDs).
- Inline analytical equipment.
- Machine controllers.
- Human-machine interfaces (HMIs), including standalone and distributed.
- Communication networks for controllers, I/O and special-purpose devices.
- Wiring and cabling, including secure remote telemetry (wireless).
- Process and operational data collection, storage and reporting.
- Web-based SCADA (Supervisory Control and Data Acquisition).
- Secure remote system monitoring for troubleshooting and technical support.
As part of our shop floor control offerings, Malisko offers integration services for hardware, software and other equipment to deliver an efficient and cost-effective solution.
Benefits of Shop Floor Control Software
An effective production and shop floor control software solution is one of the most critical aspects of improving your shop’s efficiency. This software lets you connect all your automated equipment and components from your plant’s operations to streamline production and enable successful manufacturing. Implementing high-quality software allows you to control all your most critical manufacturing elements in real-time.
Integrating a software solution tailored to your company’s unique operation enables you to enjoy benefits like:
- Reducing manufacturing costs.
- Improving product quality.
- Ensuring production consistency and minimizing errors.
- Integrating with existing production software.
An effective and efficient manufacturing facility relies on accurate, automated control of all processes and equipment. A shop’s floor contains many components requiring careful analysis, configuration and deployment for successful production, from analog transmitters and proximity switches to motor control centers and power supplies. To ensure the highest levels of productivity and product quality, plants must implement a modern shop floor control system that communicates with all these components across each manufacturing line.
Shop Floor Control Tools to Modernize Your Facility
The team at Malisko understands that all plant manufacturing components must work together seamlessly to achieve these goals. We’ll work with you to learn about your existing processes and develop a strategy tailored to your operation’s unique goals and objectives.
Our vast experience in developing shop floor control solutions enables us to offer services for the most critical elements of your operation, including:
- Electrical power distribution with monitoring, including main and sub switchgear.
- Electrical and control panel design, including lighting and utility.
- Instrumentation specifications.
- Controllers, such as programmable logic controllers (PLCs) and distributed control systems (DCSs), for processes, utilities and building services.
- Motor control centers (MCCs) and variable frequency drives (VFDs).
- Inline analytical equipment.
- Machine controllers.
- Human-machine interfaces (HMIs), including standalone and distributed.
- Communication networks for controllers, I/O and special-purpose devices.
- Wiring and cabling, including secure remote telemetry (wireless).
- Process and operational data collection, storage and reporting.
- Web-based SCADA (Supervisory Control and Data Acquisition).
- Secure remote system monitoring for troubleshooting and technical support.
As part of our shop floor control offerings, Malisko offers integration services for hardware, software and other equipment to deliver an efficient and cost-effective solution.
Benefits of Shop Floor Control Software
An effective production and shop floor control software solution is one of the most critical aspects of improving your shop’s efficiency. This software lets you connect all your automated equipment and components from your plant’s operations to streamline production and enable successful manufacturing. Implementing high-quality software allows you to control all your most critical manufacturing elements in real-time.
Integrating a software solution tailored to your company’s unique operation enables you to enjoy benefits like:
- Reducing manufacturing costs.
- Improving product quality.
- Ensuring production consistency and minimizing errors.
- Integrating with existing production software.
Frequently Asked Questions About Smart Manufacturing
Still have questions about smart manufacturing? We can answer them.
What is manufacturing intelligence and how is it different from regular reporting?
Smart manufacturing applies the Industrial Internet of Things (IIoT) to the production process. Manufacturing intelligence goes beyond static reports. It involves continuously collecting, contextualizing, and presenting operational data in ways that support real-time decisions. Where traditional reporting tells you what happened after the fact, a well-designed manufacturing intelligence system tells you what is happening now — and often why — so your team can act before a problem becomes a loss.
Do we need to replace our existing control systems to get started?
Not necessarily. Malisko specializes in integrating manufacturing intelligence solutions with existing infrastructure — including legacy historians, PLCs, DCS systems, and ERP platforms. In many cases, the data you need is already being collected; the gap is in how it is structured, presented, and made available to the people who need it.
How long does a manufacturing intelligence project typically take?
Project timelines vary based on scope, the number of data sources being integrated, and the complexity of the reporting requirements. A focused dashboard or reporting project for a single line or facility can often be completed in weeks. Enterprise-scale deployments across multiple sites are phased over several months. Malisko works with you during the front-end design phase to define scope and set realistic project timelines. The easiest way to start with smart manufacturing is to partner with a company that offers a full suite of automation and IoT services, such as Malisko.
Can manufacturing intelligence solutions be accessed remotely or on mobile devices?
Yes. Modern manufacturing intelligence platforms support web-based and mobile access, allowing managers and executives to view production KPIs, alerts, and reports from anywhere. Malisko designs solutions with your access requirements in mind, whether that means plant-floor displays, office dashboards, or remote mobile access.
What is the difference between a DCS and a PLC-based control system?
A Distributed Control System (DCS) is designed for complex, continuous process applications — think chemical plants, pharmaceutical manufacturing, or large food and beverage facilities with many interdependent control loops. DCS platforms excel at managing hundreds or thousands of I/O points with tight integration between control, alarming, and historian functions. PLC-based systems (often combined with SCADA) are more common in discrete and hybrid manufacturing environments where the emphasis is on machine-level control and sequencing. Malisko has expertise in both architectures and can help you determine which approach best fits your process requirements.
How disruptive is a DCS migration? Can we do it without shutting down production?
Migration complexity depends on the size of your system, the criticality of the process, and the gap between your existing platform and the target architecture. Malisko uses a structured migration methodology that prioritizes production continuity — including parallel operation strategies, phased cutover plans, and thorough simulation and testing before any live changes. Many migrations can be executed during planned maintenance windows, minimizing impact on production schedules.
Can Malisko help us make the business case for a process automation investment?
Yes. We regularly support clients in building the justification for automation projects, including ROI modeling, energy savings projections, downtime cost analysis, and compliance risk assessments. A front-end engineering design (FEED) engagement is often the right first step — it gives you the engineering detail needed to develop an accurate capital estimate and a clear picture of the expected return.
Learn More About Shop Floor Control With Malisko
Malisko aims to solve your company’s manufacturing challenges by connecting each critical component in your operational process. Our specialists have decades of combined experience developing solutions for companies across a comprehensive industry range, from small fabrication shops to large-scale manufacturing companies. Connect with us today to learn more about how our services can benefit your operation.
Why Hire a Systems Integrator?
Can’t decide between a systems integrator and a general contractor for plant automation? Learn how systems integrators save you money, add value and ensure quality. Download our White Paper to learn more.
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