Project B

Machine Upgrade 1 – From Four Panels to One Integrated System 

Project Overview  

The customer’s production line originally consisted of four separate machine sections, each running with its own control panel and individual HMI. The machine formed, folded, and packaged a product, but because every section operated independently, small faults caused major interruptions. 

When a fault occurred, the operator had to stop the machine and reset all four sections individually before restarting. This resulted in unnecessary downtime and operational frustration. 

The Challenge 

• Four isolated machine sections
• Four control panels and HMIs
• Complicated reset procedures  
• Excessive downtime during faults 
• Outdated hardware and electrical design

The customer wanted the entire line upgraded to function as one unified system operated from a single HMI. 

Our Solution 

We carried out a full system upgrade—mechanical, electrical, and software—designed to modernize the machine and streamline operation. 

1. Consultation & System Assessment 

We inspected the machine in detail and discussed with the customer exactly how they wanted the updated system to work.

2. New Electrical Design 

We took the original drawings and redesigned them from the ground up, incorporating: 

• New PLCs 
• Updated input/output cards 
• New gearboxes and shafts 
• Modern, job-appropriate actuators 

3. Panel Rebuilds & Hardware Replacement 

All outdated components were removed.

We installed new hardware and rewired each panel according to the new design.

4. Complete Software Rewrite

We reprogrammed the machine so all four sections operated as one coordinated system with integrated control and modern safety functions. 

5. One Central HMI 

A brand new HMI was installed, providing: 

• Unified machine control 
• Clear fault diagnostics 
• Guided problem-solving 
• Simple, one-touch reset and restart 

The Result 

The machine now operates as one modern, streamlined system: 

• All resets performed from one central HMI
• Faster operator response and reduced downtime 
• Simplified operation and training 
• Improved reliability with updated hardware
• A safer, more efficient production line