Manufacturing Control Systems & Industrial Automation
SCADAware designs, programs, and integrates industrial control systems that help manufacturers improve equipment reliability, streamline operations, and support production. From upgrading obsolete PLCs to engineering controls for new machinery and complete production lines, our team delivers automation solutions built around your manufacturing process.
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Industrial Controls Engineering for Every Stage of Manufacturing
Whether you’re upgrading a single machine or integrating equipment across an entire production facility, SCADAware provides the engineering expertise needed to develop reliable, maintainable control systems.
PLC Programming & Control Systems
Design, programming, troubleshooting, and integration of industrial PLC systems for manufacturing equipment, automated machinery, production cells, and process operations.
Legacy Controls Modernization
Upgrade obsolete PLCs, outdated operator interfaces, aging control panels, unsupported drives, and industrial communication networks while retaining suitable existing machinery.
New Equipment Controls
Complete electrical and software controls engineering for new machinery, including PLC programming, HMI development, motion control, equipment interfaces, and commissioning.
HMI & SCADA Development
Operator interfaces, centralized process visualization, alarms, equipment monitoring, historical trending, data collection, and production reporting.
Electrical Engineering & Control Panels
Custom electrical design, PLC control panels, remote I/O panels, motor and drive controls, industrial networking, fabrication, and testing.
Equipment Integration & Technical Support
Integration of new equipment with existing production systems, troubleshooting, control system modifications, machine startup, and ongoing engineering support.
Complex Manufacturing Systems. Proven Engineering Experience.
Manufacturing SCADA Integration
SCADAware developed a large-scale supervisory control and reporting system for an automobile manufacturing facility.
The system incorporated four SCADA servers, 20 operator display clients, and communications with approximately 370 Mitsubishi PLCs.
Industrial Energy Monitoring
SCADAware developed a monitoring system for a tire manufacturing facility to collect information about electricity, natural gas, compressed air, and steam consumption.
The system provided detailed operating information that supported significant customer-reported energy cost reductions.
Weld Cell Controls Upgrade
SCADAware provided controls engineering and system integration services for a weld line at a closet organization products manufacturing facility.
The project involved developing an updated control system that incorporated PLC-based automation, servo motion control, machine safety, and automated inspection.
COMPLETE CONTROLS ENGINEERING
SCADAware brings together electrical engineering, PLC programming, industrial networking, software development, control panel fabrication, and commissioning expertise to deliver complete manufacturing automation solutions.
Control System Design
System architecture, functional specifications, equipment interfaces, and automation strategies.
PLC Programming
Equipment sequences, interlocks, diagnostics, coordinated operations, and process control.
Electrical Engineering
Schematics, hardware selection, control panels, motor controls, and system documentation.
HMI & SCADA Development
Operator interfaces, alarms, machine status, historical information, and reporting.
Industrial Integration
Communication between machines, PLC platforms, OEM equipment, and plant systems.
Testing & Commissioning
Factory testing, onsite startup, troubleshooting, operator training, and support.
From Production Challenge to Working System
Step 1
Define the Application
We review your parts, cycle targets, equipment, floor space, and operator needs to establish practical requirements for automation.
Step 2
Engineer, Build & Test
Our team designs the cell, builds and integrates its mechanical and electrical systems, programs the controls, and tests operation before shipment.
Step 3
Commission & Support
We install and commission the system on site, train operators and maintenance teams, and remain available for ongoing technical support.
Robotic Machine Tending, Built Around the Process
Manufacturing Challenge
Client
Date
My Role
Kawasaki, Mitsubishi & More: Platforms Selected for Your Process
Answers to Common Automation Questions
Explore how a custom robotic system moves from application evaluation to production and ongoing support.
How do we know whether our process is a good fit for robotics?
We evaluate the part, cycle time, production volume, handling requirements, available space, and current workflow. That assessment helps determine whether a robotic cell is practical and what equipment the complete solution would require.
Can a new robotic cell work with our existing equipment?
Yes. We can design interfaces to existing machines, conveyors, PLCs, and production systems. The integration plan accounts for equipment signals, material flow, physical constraints, and operator access.
How is operator safety addressed?
Safety is considered during cell design, not added at the end. We engineer guarding, access points, safety controls, and operating sequences around the application and its applicable requirements.
Will the system be tested before it reaches our facility?
We plan factory testing to verify the assembled equipment, controls, robot programs, and key operating sequences before shipment. Testing also provides an opportunity to identify adjustments ahead of on-site installation.
What happens during installation and commissioning?
Our team installs and integrates the cell with the surrounding process, checks interfaces and safety functions, then tunes operation using production conditions. We work with your team to transition the system into service.
Do you provide operator training and support after startup?
Yes. We train operators and maintenance personnel on system operation and routine troubleshooting, provide documentation, and remain available for technical support as production needs evolve.
Let’s Evaluate Your Production Challenge
Tell us what you need to automate. Share your current process, parts or materials, target cycle time, existing equipment, and any space or safety constraints. We’ll use those details to start evaluating a custom robotic system built around your operation.