Controls & Automation Setup
Complex deployments where integration, safety, and operational handoff determine production success.
Inside this journey
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Customer Discovery
Align on production targets, commissioning milestones, safety/regulatory constraints, stakeholders, and maintenance handover requirements.
Discovery Questions
A Short Intro — Tell Us Which Line We're Talking About
- Which best describes this project?
- What product(s) will this line/cell produce and what is the target output (units/hour or shift)?
- What is your target production start / go-live date (or window)?
- Who are the primary decision-makers and influencers for controls and commissioning on your side?
- If timeline slips by a week or two, what operational or commercial consequences happen (e.g., missed launches, overtime, lost shipments)?
If Controls Were the Only Thing Standing Between You and Production, What Would Break First?
- In past projects, which part of the controls work has caused the longest delays (code bugs, I/O mapping, network issues, safety validation, HMI polishing, other)?
- Tell us about one recent commissioning problem that cost you significant time—what exactly happened and how long did it take to resolve?
- How often do control-related issues surface after 'handoff' and require integrator return visits?
- When a controls problem delays production, how does it feel inside your organization—what conversations and pressures follow?
Who Truly Owns Operations After We Leave?
- If the integrator handed over code and left tomorrow, how capable does your maintenance team feel at troubleshooting PLC/HMI issues?
- What type of documentation and deliverables do you insist on receiving at handover (pick all that apply)?
- What format of training feels most effective for your team—brief on-site workshop, full training course, recorded sessions, shadowing during commissioning, or other?
- How many people on your team will need access to modify or troubleshoot the application after handover, and what are their typical skill levels?
Where Safety and Compliance Actually Starts to Bite
- Which safety or regulatory standards will this project need to meet or be validated against?
- Have you experienced audits or safety-related hold-ups during commissioning before—what was the root cause?
- Who signs off on safety validation and what documentation is mandatory for your auditors?
- If there’s a conflict between a tight schedule and a safety activity, how is that normally resolved and how comfortable are you with delay for safety?
- What’s your expectation for the integrator’s role in safety validation—lead, support, or provide artifacts only?
Imagine Commissioning That Actually Runs Smoothly — What Changes?
- If commissioning went perfectly, how many days from site install to RTP (running to production) would that be for you?
- Describe the operator interactions and alarms you’d want to see on day one so operators feel in control—what’s most important?
- Which measurable acceptance criteria would convince you that commissioning succeeded (select up to three)?
- How should we demonstrate maintainability during acceptance—code walk-through, failure mode drills, documentation review, or live troubleshooting?
- If we could remove one logistical headache from past commissions, what would that be?
What Keeps You Up at Night After Handover?
- When a system goes sideways after handover, what’s the biggest recurring pain—response time, root cause clarity, cost of return visits, or something else?
- How many return visits or post-handover support incidents would you budget for in the first 12 months?
- Would you prefer a retainer/SLAs for guaranteed response or pay-per-incident support, and why?
- What’s acceptable remote troubleshooting capability for you (VPN access, secure remote desktop, historian/telemetry access) and what is off-limits?
- Share an example where post-commissioning support worked well—what did the integrator do right?
How We’ll All Agree It’s Done — Your True Success Signals
- What are the non-negotiable sign-off items you require before accepting the system (FAT report, SAT success, documentation, training, others)?
- Who needs to be present or approve SAT/FAT sign-off on your side and in what order do approvals happen?
- How do you prefer to capture acceptance—formal signed packet, digital checklist, or staged sign-offs tied to milestone payments?
- Which KPIs should we instrument and hand over so success can be measured over the first 90 days?
- If an acceptance condition temporarily fails during ramp-up, what remediation path do you expect (patch, rework, hold, partial acceptance)?
Let’s Map Who Does What — Avoid Surprise Gaps
- Which of these modules should be included in our scope (select all that apply)?
- For each selected module, who will own commissioning and who will provide hardware/electrical work—your team, us, or a third party?
- Are there specific deliverables you require as part of each module (e.g., editable source code, PLC comments, as-built schematics)? Give examples.
- What platform stacks or vendors must we support (PLC/HMI brand, drives, safety controllers, MES/ERP interfaces)?
- Is there any proprietary IP, existing codebase, or legacy constraints we must adapt to rather than replace?
Risk, Commercials, and the Things That Stop Deals Cold
- What commercial or contractual terms have stopped you from signing with integrators in the past (warranty length, liability caps, change order process, payment terms)?
- What level of warranty and response SLA would make you comfortable for the first 12 months post-commissioning?
- How do you prefer change orders to be handled when scope shifts during commissioning (fixed fee, time & materials, not-to-exceed)?
- What internal procurement or legal milestones must be met before we can start (PO issued, contract signed, insurance certificates, other)?
- How long is your typical procurement cycle from proposal to PO for projects like this?
What Would Make You Say ‘Yes’ Right Now — Let’s Make Next Steps Obvious
- What single deliverable or assurance would most accelerate your decision (detailed timeline, firm milestone L1 schedule, FAT demo, reference visit, cost certainty)?
- What would make you walk away from any proposal immediately (examples: unacceptable warranty terms, lack of platform experience, missing safety expertise)?
- Which next step feels most useful right now—intro workshop, scope validation call, site visit, or draft SOW and estimate?
- Realistically, when should we schedule the next touchpoint to keep momentum and who should attend from your side?
- Please list the primary contacts we should include going forward (name, role, email, phone) and who is the final approver.
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Solution Experience
Walk through how the controls solution delivers the required commissioning speed, maintainability, safety compliance, and operator workflows using the customer's scenarios and acceptance tests.
Experience Meetings
- Pre-Experience Alignment (Current State, Consequence, Future State)
- Scenario Mapping & Acceptance-Test Traceability
- Controls Proof — Simulation & FAT Walkthrough (Prove Future State)
- Failure Mode, Recovery & Operator Validation Exercises
- Validation Signoff & Next Steps (Decision & Milestones)
- Update troubleshooting and operator SOPs to reflect lessons from drills and distribute to maintenance.
- Confirm maintainability features (diagnostics, modular code, documentation) meet the customer's handover requirements.
- Show safety logic behavior and obtain confirmation that safety acceptance criteria are met.
- Get explicit customer validation for each proof point during the demo.
- Host to provide recorded simulation/FAT run and time-stamped logs proving commissioning steps and durations.
- Deliver a maintainability package (code map, runtime diagnostics guide, example debug session) to customer reviewers.
- Produce a safety traceability document linking safety acceptance tests to implemented safety functions and standards.
- Customer to provide validation notes and any objections within 48 hours for resolution.
- Safety Briefing & Scope
- Verify each failure mode yields expected safe behavior and provides diagnostics needed for repair.
- Confirm operator and maintenance recovery procedures achieve required time-to-recover targets.
- Identify and assign remediation for any gaps discovered during fault injection.
- Introductions & Objectives
- Host to implement code or HMI changes needed to improve diagnostics where gaps were found.
- Schedule a retest for any remediated failure modes and owners to confirm closure.
- Summary of Proofs & Outcomes
- Obtain explicit customer confirmation that the Solution Experience proves the defined future-state outcome.
- Agree and document FAT/SAT schedule, attendees, and acceptance signoff authority.
- Capture all remaining gaps, owners, and closure dates required before FAT/SAT.
- Confirm post-commissioning support commitments and the SLA terms relevant to the customer's concerns.
- Prepare and circulate a Solution Experience signoff document summarizing proofs, metrics, and agreed acceptance criteria for signature.
- Host to publish the finalized FAT/SAT schedule with named owners and required artifacts.
- Assign remediation owners for outstanding gaps with target completion dates and schedule retest if required.
- Customer and Host to confirm support SLA and return-visit terms to be appended to the mutual commit stage documentation.
- Produce and record one clear current-state sentence agreed by stakeholders.
- Quantify the business/consequence metrics tied to the current state.
- Agree on a single future-state outcome (operational metric) that the Solution Experience must prove.
- Create a complete inventory of scenarios and acceptance tests to be executed during the experience.
- Assign prework owners and deadlines so demo environments and data are available.
- Document the agreed one-line current-state, consequence figures, and future-state outcome and distribute to attendees.
- Customer to deliver scenario scripts, acceptance test steps, sample logs, and any network/panel access by agreed date.
- Host to confirm simulation/FAT environment readiness and provide checklist of required test equipment.
- Schedule the Scenario Mapping meeting with finalized attendee list and artifacts attached.
- Recap of Preconditions
- Produce a scenario-to-test traceability matrix draft covering all prioritized scenarios.
- Agree measurable pass/fail criteria for each acceptance-test step (times, counts, states).
- Identify and prioritize any gaps or ambiguities that would block a valid Solution Experience.
- Assign owners and deadlines for closing identified gaps before the demonstration/FAT.
- Host to deliver the initial traceability matrix (scenario → control logic → test criteria) within 48 hours.
- Customer to clarify ambiguous acceptance-test language and provide missing data/thresholds.
- Joint team to update or create any missing test procedures or simulated inputs required for FAT.
- Context & Success Criteria Reminder
- Demonstrate measurable reduction in commissioning steps/time for the prioritized scenario(s).
- Commissioning Flow Demonstration
- Current State Statement
- Execute Failure Mode Tests
- Prioritized Scenario Walkthrough
- Review Outstanding Gaps & Mitigations
- Consequence Quantification
- Maintainability Proofs
- Agree FAT/SAT Schedule & Owners
- Operator Recovery & Troubleshooting Drill
- Acceptance-Test Mapping
- Safety Integration & Compliance Mapping
- Future State Outcome
- Support & Return-Visit Commitments
- Identify Gaps & Risks
- Post-Test Log Review & Root Cause Mapping
- Operator Workflow Execution
- Validation Checkpoint
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Solution Scope
Define modules, responsibilities, deliverables (application code, documentation, electrical schematics, safety validation, FAT/SAT), milestones, and measurable acceptance criteria.
Scope Configuration
- Deliver PLC application code and documentation
- Develop HMI screens and navigation
- Configure servo drives and motion profiles
- Program VFDs and motor control logic
- Implement safety PLC logic and validation report
- Produce electrical schematics and wiring diagrams
- Fabricate and wire control panels
- Build and commission industrial network infrastructure
- Execute Factory Acceptance Test and deliver report
- Install and commission controls onsite
- Provide O&M manual and annotated code
- Deploy remote monitoring and secure support VPN
- Deliver archived project backup and version control
Scope Questions
Deliver PLC application code and documentation
- Which PLC platform(s) should the application target?
- What is the expected I/O count and types (digital, analog, high-speed)?
- Do you require adherence to specific coding standards or style guides?
- What level of code modularity and reuse is required (libraries, function blocks)?
- Which acceptance tests or scenarios must be implemented and automated in the PLC?
- How should code and documentation be delivered (repository, archived files, vendor tool export)?
Develop HMI screens and navigation
- Which HMI/SCADA platform(s) do you require?
- Approximately how many screens and roles (operator, supervisor, engineer) are anticipated?
- Do you require role-based access and user authentication integrated with corporate AD/LDAP?
- What alarm management and historian integration are required?
- Are there specific HMI response time or UX design requirements (e.g., touchscreen, mobile views)?
- Do you want operator training materials and quick reference guides included with the HMI deliverable?
Configure servo drives and motion profiles
- How many motion axes and what types (servo, stepper, linear motor) will be controlled?
- Which servo vendors/models are planned or preferred?
- What motion profile types are required (point-to-point, camming, electronic gearing, continuous path)?
- What feedback devices are used (encoder type, resolver, absolute)?
- Are safety-rated motion features required (Safe Torque Off, Safe Stop, Safe Limited Speed)?
- Do you require factory tuning and motion acceptance tests, or is onsite tuning acceptable?
Program VFDs and motor control logic
- How many VFDs and what motor sizes (HP/kW) are in scope?
- Which VFD manufacturers/models will be used or supported?
- Which control modes are required (V/Hz, sensorless vector, closed-loop vector, torque control)?
- Do you require advanced energy optimization, regen, or harmonic mitigation features?
- How should VFD faults and trip handling be integrated with PLC/HMI (automatic retries, lockout, notifications)?
- What communications method for VFD integration is preferred (digital I/O, analog, Modbus, EtherNet/IP, Profinet)?
Implement safety PLC logic and validation report
- Which safety standards and regulations apply to this project?
- What safety functions are in scope (e-stop, light curtain, safety mats, guard interlocks, safe motion)?
- What Performance Level (PL) or SIL target is required for safety functions?
- Which validation deliverables are required (risk assessment, safety plan, validation report, FMEA, functional safety file)?
- Is third-party or notified body certification/assessment required?
- Do you require on-site safety validation (SAT) and demonstration with safety fault injection?
Produce electrical schematics and wiring diagrams
- Which drawing standards should be followed (IEC, ANSI, company standard)?
- What deliverables are required (single-line, panel wiring, terminal lists, cable schedules)?
- What CAD tool or file format do you require (EPLAN, AutoCAD DWG, PDF, other)?
- Do schematics need to include PLC I/O mapping and cross-reference to field devices?
- Are there site-specific electrical constraints (voltage class, grounding scheme, hazardous area)?
- Will as-built updates be required after commissioning?
Fabricate and wire control panels
- What panel ingress rating and environmental rating are required (NEMA, IP)?
- Do panels require third-party listing (UL508A, CE) or local compliance labeling?
- Should panels be fully factory-wired and tested, or partially assembled for field wiring?
- Are special components required (cleanroom, washdown, explosion-proof)?
- Do you require labeling, wire numbering, and terminal identification to a specific template?
- Is Factory Acceptance Test (FAT) witnessing for panels required?
Build and commission industrial network infrastructure
- Which industrial network protocols must be supported (EtherNet/IP, Profinet, Modbus TCP, OPC UA)?
- Do you require managed switches, VLAN segmentation, and network QoS?
- Will plant IT be involved and is there an IP addressing scheme to follow?
- Are wireless links, fiber runs, or special cabling required for the network?
- Do you require cybersecurity hardening and monitoring (ACLs, NAC, Log collection)?
- What network acceptance tests are required (latency, jitter, packet loss, redundancy failover)?
Execute Factory Acceptance Test and deliver report
- Where should FAT be performed (supplier facility, customer site, third-party lab)?
- What is the scope of the FAT (full system, module-level, witness-only)?
- Who will witness the FAT and what groups must be present (engineering, maintenance, QA)?
- Are formal test scripts and acceptance criteria provided by the customer or to be created by the supplier?
- Which deliverables are required after FAT (test report, deviation log, signed acceptance certificate)?
- Are travel, accommodation, and scheduling constraints for FAT witnesses defined?
Install and commission controls onsite
- What are the preferred commissioning windows and site access restrictions?
- How many onsite engineering days and what crew composition do you anticipate?
- Are there site safety and induction requirements (LOTO, PPE, site orientation)?
- Do any third-party trades need coordination (mechanical, electrical contractor, integrator)?
- Are on-site acceptance tests and ramp-to-production support required after commissioning?
- Are there special logistics (cranes, confined spaces, hazardous area permits) the team should plan for?
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Mutual Commit
Finalize commercial terms, SLAs for post-commissioning support and return visits, risk allocation, and formal acceptance conditions.
Agreement Modules
- Statement of Work (SOW)
- Master Services Agreement (MSA)
- Pricing & Payment Schedule
- Service Level Agreement (SLA) — Post‑Commissioning Support
- Acceptance Criteria & Handover Certificate
- Change Order & Variation Process
- Risk Allocation & Liability Schedule
- Warranty & Defect Remediation
- Intellectual Property & Source Code Escrow
- Insurance, Indemnity & Safety Compliance
- Spare Parts, Training & Maintenance Plan
- Termination, Renewal & Extension Terms
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Deployment & Commissioning
Plan and execute panel build, factory acceptance testing, field installation, commissioning, and operator training with clear owners, schedule, and contingencies.
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Success
Confirm acceptance against success signals, transition O&M ownership, capture lessons, and maintain a shared channel for issues and enhancements.
Success Reviews
- Final Acceptance & Success Signal Review
- O&M Handoff & Knowledge Transfer Workshop
- Lessons Learned & Continuous Improvement Session
- Ongoing Support, SLAs & Communication Channel Setup
Issues & Enhancements
- Opening & Objectives
- Agree logistics for spares, return visits, and immediate support escalation process.
- Grant repository and remote access to named O&M accounts and confirm multi-factor setup.
- Deliver final code bundle, version tag, and MD5 checksum into agreed archive and notify the customer.
- Publish runbooks and SOPs to shared channel and schedule follow-up hands-on training if competency gaps were found.
- Confirm spare parts list and place any recommended critical spares orders or reservations.
- Project Recap vs Objectives and KPIs
- Produce a concise lessons-learned document capturing root causes and agreed improvements.
- Create a prioritized backlog of enhancements with owners and timelines.
- Agree metrics and cadence to measure effectiveness of implemented improvements.
- Publish the lessons-learned report to the shared project channel within 5 business days.
- Create enhancement tickets in the agreed tracker with owners, estimates, and due dates.
- Schedule the first backlog review and metrics checkpoint (30–60 days after handoff).
- Support Model Options & SLA Definitions
- Establish a live shared channel and ticketing flow with agreed rules and severity definitions.
- Agree and document SLA commitments, escalation paths, and monitoring responsibilities.
- Schedule the initial support cadences and assign the on-call roster.
- Create the shared support channel, add named participants, and post onboarding guide and document links.
- Configure monitoring alerts and route them to the agreed distribution list; run a test alert.
- Finalize and sign the support agreement or SLA amendment; enact billing as agreed.
- Publish the escalation matrix and contact list to the shared channel and to O&M posters on site.
- Obtain a clear acceptance decision (Accept, Conditional Accept with deadlines, or Reject) recorded in writing.
- Verify each success signal has objective evidence and customer validation.
- Agree owners, deadlines, and contingency plan for any remaining punch-list items.
- Trigger administrative steps (warranty start, final invoice, archive of deliverables) once acceptance is confirmed.
- Produce and circulate signed acceptance certificate or conditional acceptance record within 48 hours.
- Create and assign punch-list tickets with owners, due dates, and acceptance retest criteria.
- Start warranty/support clock and issue final invoice if full acceptance granted.
- Archive final deliverables (code, schematics, test logs) to agreed repository and notify O&M team.
- Roles, RACI & Ownership Confirmation
- Formally transfer O&M ownership and document RACI for operations and escalations.
- Ensure customer has received and can access all deliverables and the canonical code/build.
- Validate operator/maintenance competency through scenario exercises.
- Deliverables Review (Code, Schematics, Docs)
- Structured Lessons Capture (Start / Stop / Continue)
- Current State Summary
- Escalation Matrix & Contact List
- Runbooks & Troubleshooting Walkthrough
- Shared Channel & Ticketing Rules of Engagement
- Root Cause Analysis of Major Incidents
- Success Signals Walkthrough
- Prioritize Improvement Backlog by Impact & Effort
- Live Validation/Demo of Key Acceptance Tests
- Hands-on Operator/Maintenance Validation
- Monitoring, Alerts & Remote Access Configuration
- Recurring Cadence & Performance Reviews
- Punch List & Risk Review
- Agree Next Review & Metrics to Track
- Access, Backups & Version Control Handover
- Formal Acceptance Decision & Documentation
- Spare Parts, Return Visit Planning & Support Roster
- Agreement & Enrollment
- Next Steps & Close