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.
Our Approach to Shop Floor Control Systems
At Malisko, we understand that all plants operate differently. Each operation requires an individualized strategy tailored to its unique business objectives. Whether starting from scratch with an entirely new automation system or upgrading an existing one, we can help you develop a solution to streamline your manufacturing processes.
Our strategy begins with a site assessment to learn more about your shop’s operations and systems. We’ll pinpoint your existing automation controls and identify opportunities for improvement. Our specialists will stand by your side throughout each project phase, from engineering and design to validation and post-project support.
Site Assessment
Before we can design your new system and implement automation solutions that save you money and improve efficiency, we have to understand your challenges. To achieve this, we can engage with you to perform a site assessment. We listen to your operators, maintenance staff, engineers and operations personnel to fully understand your process, how your business operates, the problems you want to solve and what success means to you. Most important, we take the time to understand the best ways to collaborate with your in-house engineers throughout the automation process as we become familiar with your facility and the systems that make it run.
Our site assessment follows a tried and true process and is the first step in implementing an automation solution. During each site assessment, we will:
- Identify Existing Automation Controls
- Identify Potential Cost-Saving Solutions
- Identify Opportunities
- Business Justification
- Presenting Automation Solutions
Front-End Engineering Design (FEED)
Successful engineering has to align everyday production with the big picture. Each processing unit and work cell must come together with your automation system to form not only an efficient production process but also one that matches your business goals and realities. When we present an automation solution to you, we make sure it matches your budget, your timeline, your current production realities and your goals, all while minimizing risk.
Our Front End Engineering Design (FEED) sets the foundation for a successful project accomplished on time, on budget and in a way that fits your in-house team.
If the needs of your business, plant and production line change over time, our systems come ready to change along with them. And if you need, we’ll even tweak the system design to fit the skill sets of your support team. We believe the best systems change for you. It shouldn’t be the other way around.
Once the FEED is completed, you will receive:
- Outlined Business Objectives
- Project Timeline & Budget
Detailed Engineering and Design
In our detailed engineering and design service, we transform the conceptual into the final design. We use all the knowledge we gain from the automation solutions site assessment and Front End Engineering Design (FEED) to minimize your risk, get you running quickly, and align our work with your business realities. Here we will also flush out project risks, planning for them by nailing down a realistic project budget, execution plan and timeline.
Malisko both designs your automation system and implements it. Our detailed engineering and design service picks up right after our FEED services leave off, and our system integration execution picks up right after our detailed engineering and design. We can handle the complete package: specification, design, procurement, development, on-site execution, troubleshooting and support of the control, network, security and MES layers.
During this phase, we can provide you with:
- Drawing Packages
- Documentation
- Hardware & Software Specification
- Industrial IT Infrastructure Design
Project Execution
After we’ve completed our thorough automation solutions site assessment, Front End Engineering Design and Detailed Engineering Design, we have the information we need to document, code and integrate your automated system. We keep in mind your business goals. We factor in the strengths and limitations of your team, and we prioritize your most important objectives.
We design your system on a foundation of understanding so that we can rapidly implement it with absolute precision. We program each function in your system and set up an intuitive Human Machine Interface (HMI) and reporting that allows your team to adopt your system efficiently. We outfit your system with the reporting you need to stay on top of your production. Prior to installation, we run your system through several rounds of intensive testing in a simulated environment to make sure it works. Once we have programmed your machines, set up your HMI, created a useful reporting program and tested the functionality and performance of your system, it is time to install your system in your facility. When on-site system installation is complete, our team again extensively tests the operation, performance and functionality of the new system holistically from the field devices through to reporting.
During this phase, we can provide you with:
- Programming & Logic Development
- Human Machine Interface (HMI) Development
- Reporting
- System Integration Testing & Simulation
- On-Site Process Commissioning
Validation
Computer System Validation (CSV) is a must in FDA-regulated industries. We design and implement your system to deliver consistent, efficient production that also meets CSV for FDA. And we prove it too. If you operate in a regulated industry, we take care of the paperwork related to CSV and reduce your Regulatory risk. We can provide a Validation Master Plan (VMP) and use it to guide our work. We document requirement specs, design specs, functional specs, test plans, installation and operational protocols, trace matrices and summary reports. We execute the protocols as well. We assist with keeping your records up-to-date via change control and help keep your system in compliance. Minimizing risk is ingrained in our company because we are committed to delivering you ROI.
During this phase, we can provide you with:
- Computer System Validation Documentation
- Executed Validation Protocols
- Electronic Records
Post Project Support
If any troubles emerge with your system, we have you covered, whether it is warranty or support under a formal service contract. When you work with Malisko Engineering, you don’t just get a system, you get a whole team to support it. If you have a full maintenance and system support staff on hand, we will provide assistance to fill the cracks. As much as practical, we can help your team be properly equipped to maintain and troubleshoot your process and automation system. If you need full support services, we are available 24/7 to make sure your system works.
During this phase, we can provide you with:
- Post-Commissioning Technical Support
- Remote Support
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.
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