Quick snapshot: the line you want running

• Tell me briefly about the production line or automation cell you are preparing, including product families and shift cadence.
• Which of these best describes your project? Options: New production line, Retrofit of existing equipment, Control platform migration, Incremental upgrade to controls or HMI, Other
• How many PLCs, I/O racks, or controllers will be in the control boundary at go-live?
• Who on your staff will be the daily point person for controls and commissioning? Options: Plant electrical lead, Controls engineer, Maintenance manager, Project engineer, No single owner assigned yet
• When do you need the line to pass production acceptance, is that date fixed or flexible? Options: Fixed date with penalties, Preferred date but flexible ±2 weeks, Target month only, No firm date yet

Where the timeline gets tight

• If controls-related delays cost you a week of production, estimate the lost revenue or throughput impact.
• Walk me through your current target go-live milestone and any immovable freeze dates that affect controls work.
• Which internal approvals are tied directly to the go-live decision? Options: Operations / plant manager, Quality / QA, Safety / EHS, Engineering leadership, Procurement / Finance
• Who must be available during commissioning windows to unblock technical, safety, and production issues? Options: Controls engineer, Maintenance lead, Operations supervisor, EHS representative, IT / OT network admin
• What single schedule constraint would force you to pause or cancel the controls scope?

Where the current controls or process lets you down

• What's the most common controls failure you see today, and how does that failure affect production throughput or quality?
• Describe a recent incident where controls caused unplanned downtime, include duration and the known or suspected root cause.
• How often does your team need outside vendor support to recover from controls faults? Options: Multiple times per week, Weekly, Monthly, Quarterly, Rarely
• List the safety validations, lockout procedures, or audit requirements the solution must satisfy at handoff. Options: Emergency stop validation, Safety interlock testing, Functional safety / proof testing, Lockout/tagout compliance, Third party safety audit
• If a control failure during commissioning would risk worker safety or regulatory noncompliance, would you stop the project until it is fully mitigated? Options: Yes, stop until resolved, Continue limited work with mitigation, Proceed and document risk, Undecided

Hidden scope and handoff expectations

• Imagine your maintenance team running the line a week after handoff, what would need to exist in the code and documentation for them to troubleshoot without integrator help?
• Provide the exact artifacts you require at handoff, for example code comments, wiring diagrams, HMI guides, tag lists, and test scripts. Options: Executable PLC code with comments, Annotated I/O lists and wiring diagrams, HMI screen guide and alarm descriptions, Tag list and mapping document, Commissioning test scripts and FAT report
• Name the roles that should be listed for on-call return support for the first 90 days after handoff. Options: Integration project lead, Controls programmer, Field service technician, Remote support engineer, No return support required
• How many hours of training and shadowing does your team expect during commissioning? Options: Less than 8 hours, 8–24 hours, 24–40 hours, More than 40 hours
• What single missing artifact or capability at handoff would cause you to withhold final acceptance?

Who else is in the mix and why they matter

• Name the other options you are actively considering, including internal teams, incumbents, and alternative delivery models. Options: Internal engineering team, Existing incumbent integrator, New external integrator, OEM-provided controls, Hybrid approach
• For each option on your shortlist, state the primary advantage and the biggest risk compared with using an external specialist for controls and commissioning.
• Estimate how long each alternative would take to meet the same acceptance criteria we are proposing. Options: Less than 2 weeks, 2–4 weeks, 1–2 months, More than 2 months
• Has anyone on your team proposed delivering the control software internally instead of using an external partner? Options: Yes, internal team proposed, No, always planned externally, Discussion ongoing
• What conditions would have to be true for you to stay with your current approach and not engage an external integrator?

Operational readiness: access, network, and staffing

• Many projects fail to kick off when a single dependency is missing, which access, permit, or resource gap would block the field team from starting work on your site? Options: On-site safety permits, Network/VLAN access, Spare parts or hardware, Dedicated site electrician, None of the above
• Identify the external systems that the controls must integrate with and the technical owner for each (MES, ERP, vision, motion controllers, etc.).
• Are API specifications, PLC tag lists, network diagrams, or other integration documents available today, or will they need to be created? Options: All available, Partial documentation available, None available, must be created, Unknown
• Do you have scheduled on-site access windows and any required EHS escorts booked for the commissioning phase? Options: Yes, windows and escorts scheduled, Windows scheduled, escorts TBD, No windows scheduled yet, Not required
• Estimate the number of internal engineering hours per week you can commit to support commissioning and validation. Options: Less than 10 hours, 10–20 hours, 20–40 hours, More than 40 hours
• Would you accept a timeline delay if remote debugging proved impossible and all commissioning required an on-site presence? Options: Yes, acceptable with revised timeline, No, must keep current timeline, Depends on length of delay

Acceptance, tests, and sign-off that actually matter

• Define the top three measurable acceptance criteria that will prove the controls are production-ready.
• For each acceptance criterion, describe the test procedure, pass threshold, and the sample size or run time you will accept.
• List the approvers who must sign acceptance for safety, performance, and operator competence. Options: Operations lead, Maintenance manager, Quality lead, Safety officer, Engineering manager
• Describe the FAT scenarios and any pass/fail criteria that must be completed before shipment to your site.
• Clarify which role or committee has authority to require remediation or stop production sign-off if key acceptance tests fail on site. Options: Plant manager, Safety committee, Engineering director, Quality committee, Procurement / Legal

Communication, escalation, and realistic next steps

• How quickly should we expect decisions on critical issues during commissioning, measured in hours? Options: Within 2 hours, Within 8 hours, Same business day, Within 48 hours
• Select the communication channels you prefer for daily commissioning updates. Options: Email with daily summary, Daily stand-up call, Shared ticketing system, SMS for critical alerts, Platform-based updates
• Provide a three entry escalation list including role, preferred contact method, and backup for 24 hour failures.
• Will budget approval for emergency onsite support be centralized or delegated to site management? Options: Centralized (corporate), Delegated to site, Pre-approved contingency exists, Case-by-case
• What outcome would make you expect the integrator to return at their cost if a repeatable fault halts production within a week of handoff?

Decision clarity and immediate next steps

• Assuming the pilot meets your acceptance criteria, how quickly could you sign and issue a purchase order? Options: Immediately upon pilot sign-off, Within one week, Within 2–4 weeks, Longer than a month
• Identify any procurement, legal, or insurance milestones that must be completed before work can begin.
• Please enter the role or title that holds final budget authority for this controls scope.
• Outline expected procurement lead times for major items like PLC hardware, panels, and critical spares. Options: Less than 2 weeks, 2–4 weeks, 1–2 months, More than 2 months
• What's the fastest action you can take internally that would allow us to start work within your target window?

• Controls Solution Experience

• Confirm the current state and its cost
• You confirm the proposed commissioning flow reduces unplanned on-site debugging and fits your go-live window.
• Provide the definitive go-live date, list of stakeholders required for acceptance, and the specific acceptance criteria for controls and safety.
• You confirm the code structure and documentation are sufficient for your maintenance team to troubleshoot after handoff.
• Walk the commissioning flow mapped to your timeline
• Deliver a controls solution overview that maps each commissioning step to expected onsite hours and first-pass acceptance criteria.
• Produce and share a sample annotated code module and the proposed documentation checklist for handover review.
• You confirm the safety validation approach and acceptance milestones meet your compliance and sign-off needs.
• Show code structure and handover artifacts
• Demonstrate safety validation and acceptance milestones
• Agreement on the remaining evidence required to reach a decision and an estimated schedule for delivery.
• Define the proposed return-support options and associated SLA for post-handoff support and onsite return visits.
• Validate that this matches your requirements
• Agree remaining evidence and next decision steps

• Controls Solution Experience
• Controls Solution Experience Deck
• Controls Solution Brief

• meeting
• slides
• document

• Develop PLC Application Code
• Design and Deploy HMI/SCADA Screens
• Safety System Engineering and Validation
• Configure and Tune Servos and VFDs
• Design and Configure Industrial Network
• Design and Fabricate Control Panel
• Execute Factory Acceptance Testing (FAT)
• Perform Field Installation and Wiring
• Commissioning and Start-up Support
• Operator and Maintenance Training Sessions
• Application Code Documentation and Handoff
• Remote Monitoring and Troubleshooting Service
• Migrate and Modernize Legacy PLC Code
• Backup and Version Control for Control Software

Develop PLC Application Code

• Do you have an existing PLC I/O list or single-line I/O spreadsheet for this line? Options: Yes, No
• Which PLC programming language standard should we use for the application (refer to your control strategy artifact)? Options: IEC 61131-3 Ladder/Function Block, Structured Text (ST), Function Block Diagram (FBD), Other / Hybrid
• How many discrete and analog I/O points (including safety inputs) must be supported by the PLC application? Options: Less than 200, 200-1000, More than 1,000
• List any upstream/downstream integration endpoints the PLC must expose or consume (for example OPC UA server nodes, Modbus registers, or a machine-to-MES handoff tag list).
• Provide the expected error handling and watchdog behavior for device failure scenarios (for example, safe stop on encoder loss, forced output off on comms loss).

Design and Deploy HMI/SCADA Screens

• Which HMI screens or operator workflows must be present at minimum (for example start/stop, batch recipe select, fault diagnostics, and motor status screens)? Options: Standard run/stop and alarms, Recipe selection and logging, Fault diagnostics and historical trends, Custom operator workflows
• How many unique HMI screens or templates do you estimate are required for operator and supervisor roles? Options: 1-10, 11-25, 26-50, 50+
• Identify any color, iconography, or safety-tagging conventions we must follow on screens to match your plant standards (for example alarm priority colors, LOTO indicators).
• Describe the data logging and historian requirements from HMI/SCADA (for example cycle time trends, batch traceability CSV export, or tag sampling rate).
• When should HMI access levels and user authentication tie into your plant identity source or onsite operator badge system? Options: At handoff, During commissioning, Not required / local HMI accounts

Safety System Engineering and Validation

• Specify the applicable machine safety standards and targets for this project (for example ISO 13849-1 performance level, IEC 62061 SIL target, or NFPA 79 compliance). Options: ISO 13849-1 (PL), IEC 62061 (SIL), NFPA 79 / electrical safety, Other / multiple
• Do you have an existing safety risk assessment or safety requirements specification (SRS) we should use as the validation baseline? Options: Yes - SRS available, Yes - preliminary risk assessment, No - need us to perform
• Identify the safety inputs and outputs to be integrated (for example safety light curtains, safety-rated E-stops, safety PLC I/O count) and provide required response time thresholds.
• Describe required safety validation deliverables (for example safety validation report, wiring SLD annotated for safety circuits, and functional test scripts).
• Confirm if a third-party functional safety assessor or your internal safety engineer must sign the validation report as part of acceptance. Options: Yes - third party required, Yes - internal engineer sign-off, No additional sign-off required

Configure and Tune Servos and VFDs

• Which motion axes and drive types need configuration (for example position servos for pick-and-place, VFDs for conveyors, indexed rotary tables)?
• How many axes require closed-loop tuning and multi-axis coordination (provide axis count and whether cam profiling or electronic gearing is required)? Options: Single axis only, 2-8 axes, More than 8 axes
• Provide servo/VFD commissioning constraints such as maximum allowable settle time, overshoot percentage, and torque limits per axis.
• Do you require encoder health monitoring, drive alarm forwarding into PLC alarm tables, or remote drive diagnostics integrated into HMI? Options: Yes - all, Partial - select items, No
• Indicate whether motion tuning must be completed during FAT or postponed to on-site commissioning windows. Options: Complete at FAT, Complete at site during commissioning, Hybrid approach

Design and Configure Industrial Network

• Do you have an existing network topology diagram or single-line diagram for the cell or line (for example VLAN allocation, fiber run endpoints, and switch locations)? Options: Yes - diagram provided, No - need network design
• Which industrial protocols must be supported on the network backbone and edge devices (for example EtherNet/IP, PROFINET, OPC UA, Modbus TCP)? Options: EtherNet/IP, PROFINET, OPC UA, Modbus TCP, Other
• How many managed switches, VLANs, and subnets will the line require according to your plant networking standards?
• Identify required cybersecurity controls for OT network equipment (for example port lockdown, managed switch ACLs, or jump-host procedures).
• Specify whether remote access for support will be provisioned via your VPN, a plant jump-host, or not permitted. Options: Plant VPN, Jump-host (jump box), No remote access allowed

Design and Fabricate Control Panel

• Provide your control panel power and environmental constraints (for example 480 V / 400 V incoming, NEMA or IP enclosure rating, and ambient temperature range).
• How many terminal strips, PLC racks, and drive footprints must the panel design accommodate (attach individual counts or a point list)?
• List required panel deliverables you expect at handoff (for example as-built electrical schematics, wiring harness diagrams, BOM, and component C-IDs). Options: As-built schematic, Wiring harness diagram, BOM with vendor part numbers, Nameplate and label schedule
• Describe any site-specific labeling, grounding, or conduit routing standards we must follow when fabricating and installing panels.
• Specify whether panel factory wiring harnesses should be pre-tested and cable-identified to a certificate before shipping. Options: Yes - pre-tested with certificate, No - test at site, Partial testing only

Execute Factory Acceptance Testing (FAT)

• Do you require a witnessed FAT at our shop, remote FAT by live video, or a document-only FAT package? Options: Witnessed on-site FAT, Remote live-video FAT, Document-only FAT package
• Which FAT scripts or scenarios must be included (for example full recipe run, safety stop recovery, network failover, and encoder fault injection)?
• How many full production cycles or lot samples should be executed at FAT to validate performance against process cycle-time targets? Options: No cycles - functional tests only, 1-3 production cycles, More than 3 cycles
• What evidence will validate FAT acceptance (for example signed FAT test log, video capture of failure modes, or completed punch-list below a threshold)? Options: Signed FAT test log, Recorded video of scripts, Punch-list with zero Priority 1 items
• Indicate needed attendees or stakeholder roles for FAT sign-off (for example operations lead, maintenance engineer, and safety officer).

Perform Field Installation and Wiring

• Do you provide site cable trays, conduit, and power rough-in, or should the scope include field cabling and conduit work? Options: Buyer provides rough-in, We perform field cabling, Hybrid - specify
• How many line-side connection points and field junction boxes must our installation team wire (supply an approximate count or attach a panel-to-field map)?
• Identify any site access constraints and required permits or lockout/tagout (LOTO) procedures before field wiring and hot-work.
• Describe required field inspection artifacts at completion (for example torque records, insulation resistance test results, and wire ID verification checklist).
• When must field wiring be completed relative to mechanical install and FAT to meet your production schedule? Options: Before site FAT, Between FAT and commissioning, At commissioning window

Commissioning and Start-up Support

• Who from your team will act as the owner for commissioning milestones (for example operations commissioning lead or maintenance supervisor)?
• Describe the commissioning milestones and their target dates (for example network bring-up, I/O checkout, dry-run production, and live product start).
• Specify the on-site resource requirements we should schedule (for example crane, lift, or dedicated electrician and hours per day).
• What acceptance criteria will confirm successful site commissioning and handoff (for example signed checklists, production run quality metrics, or zero critical safety findings)? Options: Signed commissioning checklist, Production run meeting quality KPIs, Zero critical safety items
• Estimate required return-support availability after handoff (for example 8-hour SLA for remote support, 24-hour on-site response during first week). Options: 8-hour remote SLA, 24-hour on-site response, Business hours only

Operator and Maintenance Training Sessions

• Do you require separate operator and maintenance training sessions, and how many attendees per session? Options: Separate sessions required, Single combined session, Only documentation required
• Which training artifacts should be delivered (for example step-by-step runbooks, troubleshooting flowcharts, and hands-on lab exercises)? Options: Runbooks and SOPs, Troubleshooting flowcharts, Hands-on lab exercises, Video recordings
• Provide target competency outcomes for trainee groups (for example ability to perform changeover in X minutes, perform safe restart, and replace a drive).
• When should training be scheduled relative to commissioning to ensure trained operators are available for first production runs? Options: Before commissioning, During commissioning, After commissioning
• Specify if certification or attendance sign-off is required for operators and maintenance staff as part of acceptance. Options: Yes - signed certificates, No - attendance only, Electronic sign-off ok

Application Code Documentation and Handoff

• What code documentation standards must be met at handoff (for example tag naming convention, module-level header comments, and function block diagrams)?
• Which deliverables do you require in the handoff package (for example compiled source, editable project files, tag list CSV, and change log)? Options: Compiled runtime only, Compiled + editable source, Tag list CSV, Full change log
• Describe the expected documentation evidence for maintainability (for example inline code comments, navigation map, and a troubleshooting guide mapping faults to root causes).
• Confirm the allowed formats for handoff artifacts (for example project archive, PDF schematics, and CSV tag exports). Options: Project archive, PDF schematics, CSV exports, Other
• What acceptance criteria will define completed documentation handoff (for example review sign-off by maintenance lead or successful execution of a documented recovery procedure)? Options: Maintenance lead sign-off, Successful recovery test per doc, Document completeness checklist

Remote Monitoring and Troubleshooting Service

• Do you want continuous remote monitoring of PLC/HMI logs and alarms or on-demand troubleshooting only? Options: Continuous monitoring, On-demand troubleshooting, Hybrid schedule
• Which telemetry and diagnostic feeds should be included (for example real-time tag streaming, drive alarms, and energy consumption metrics)?
• Specify your acceptable remote response time SLA for high, medium, and low priority incidents. Options: 4 hours / 8 hours / 24 hours, 8 hours / 24 hours / 72 hours, Custom SLA required
• Identify any network or security constraints that limit remote access (for example no direct inbound, only site jump-host, or specific port restrictions).
• Indicate whether remote sessions must be recorded and retained for audits and for how long. Options: Yes - retain 90 days, Yes - retain 1 year, No recording required

• Master Services Agreement (MSA)
• Statement of Work (SOW)
• Payment Terms & Order Summary
• Warranty & Support Agreement
• Service Level Agreement (SLA) & Return Support Availability
• Acceptance Criteria & Final Sign-Off
• Change Order Agreement
• Intellectual Property & Source Code Escrow Agreement
• Data Processing & Security Addendum (conditional)

• Go-Live Health Check (weeks 1-4)
• First Performance Measurement (weeks 4-10)
• Acceptance Gate Review (around day 90)
• Quarterly Success Review (ongoing quarterly)

• Update incident resolution playbooks and the escalation contact list as needed.
• Produce a documented pass or fail result for each acceptance criterion recorded in the Solution Scope.
• Capture a formal acceptance decision and the named signatory, or document conditional acceptance with remediation milestones.
• Create a timeboxed remediation plan for any failed criteria with verification steps and dates.
• Publish the formal acceptance record showing pass/fail per criterion and the named signatory.
• Open remediation tasks for any failed items with resolution deadlines and verification requirements.
• Update handoff and O&M documentation to reflect the acceptance outcome and any outstanding actions.
• Performance trend summary
• Confirm whether mean time to resolve critical control incidents and on-site return visit counts are within the tolerance set in the Solution Scope.
• Agree a prioritized list of persistent issues and enhancement requests to address in the next quarter.
• Reaffirm the ongoing support cadence and escalation path for post-handoff troubleshooting.
• Create a prioritized backlog of enhancements and recurring issues with target quarters for delivery.
• Schedule any required on-site stabilization visits or remote detailed review sessions with target dates.
• Reconfirm success criteria and owners
• All success criteria from the Solution Scope have a confirmed owner and a next validation date.
• A prioritized list of open issues and immediate remediation actions is documented with due dates.
• Schedule for the First Performance Measurement meeting is confirmed.
• Publish the go-live health report listing confirmed owners, open issues, and remediation dates.
• Log all defects and safety observations in the shared tracker and assign target resolution dates.
• Circulate operator training completion records and any quick reference updates for on-floor staff.
• Present first-period metrics and logs
• Determine whether commissioning time to production and safety validation first-run pass rate are progressing toward the targets recorded in the Solution Scope.
• Document root causes for any shortfalls and agree a remediation plan with specific tasks and completion dates.
• Confirm the evidence package required for the Acceptance Gate meeting.
• Produce a remediation plan that lists technical fixes, test-script updates, and procedural changes with target completion dates.
• Update safety validation test scripts and capture re-test schedule.
• Collect and freeze the evidence set for the Acceptance Gate meeting, including run logs and training records.
• Restate acceptance criteria and numeric targets
• Deployment and system validation
• Present outcome data against each criterion
• Incident and ticket burn-down review
• Root-cause analysis for gaps
• Enhancement and persistent issue triage
• Agree corrective actions and timelines
• Early adoption and operator readiness signals
• Document pass/fail per criterion and acceptance decision
• Confirm readiness timeline to acceptance gate
• Agree remediation items and resolution timelines for any failed criteria
• Support cadence and escalation confirmation
• Open issues and blockers
• Agree immediate remediation actions