General Advice on Automation Projects.

Essential Advice and Best Practices for Implementing a New Control System Project

Introduction

Implementing or retrofitting an industrial automation system is a major undertaking that can have a lasting impact on your facility’s efficiency, reliability, and scalability. Whether you’re upgrading legacy equipment or installing a brand-new control system, following proven best practices will help ensure a smooth process and a successful outcome. This guide provides actionable advice and key considerations for engineers and project managers embarking on a new automation project.

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1. Embrace Simplicity in Design and Programming

Keep it Simple:

• Avoid overcomplicating your system—focus on essential components and features.
• Simplicity in both hardware selection and programming makes the system easier to understand, maintain, and troubleshoot.
• Streamlined code and clear logic reduce the risk of errors and speed up commissioning.

Tip:
Adopt a minimalist approach: if a function or component isn’t necessary, leave it out.

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2. Plan Thoroughly: Proper Planning Prevents Poor Performance

The Power of Planning:

• Invest time in detailed upfront planning, including system requirements, hardware selection, and risk assessment.
• Create comprehensive documentation: electrical schematics, I/O lists, and functional descriptions.
• Involve all stakeholders early to clarify expectations and avoid costly changes later.

Tip:
Use project management tools and checklists to stay organized and on schedule.

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3. Choose Vendors and Brands Wisely

Support Matters:

• Not all vendors offer the same level of technical support or user resources.
• Select reputable brands known for reliability and responsive customer service.
• Evaluate the availability of documentation, training, and spare parts.

Tip:
Build relationships with vendors who provide accessible, knowledgeable support—this can be invaluable during troubleshooting or emergencies.

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4. Standardize and Simplify Your Platform

Stick to What You Know:

• Standardize on a small set of proven PLCs, drives, and HMIs to streamline training and spare parts management.
• Choose platforms with straightforward programming philosophies and good documentation.
• Avoid unnecessary features or “bells and whistles” that add complexity without value.

Tip:
Familiarity breeds efficiency—using trusted hardware and software reduces learning curves and project risks.

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5. Select the Right Motion Control Solution

Servos vs. Steppers vs. VFDs:

• Servos offer high speed and precise control—ideal for demanding motion applications.
• Steppers excel at small, accurate positioning tasks and can be more cost-effective for simple moves.
• Variable Frequency Drives (VFDs) have advanced significantly and can replace servos in some applications, but for high-speed, high-precision tasks, servos remain the top choice.

Tip:
Match the motion solution to your specific application needs—don’t overengineer.

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6. Standardize Components and Buy Quality

Standardization Benefits:

• Use widely available, off-the-shelf components from respected brands to ensure easy maintenance and quick replacement.
• Standardization simplifies training and reduces inventory costs.

Buy the Best You Can Afford:

• Investing in quality components pays off with fewer failures, less downtime, and longer service life.

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7. Documentation and Knowledge Sharing

Document Everything:

• Maintain clear records of hardware, software, and configuration changes.
• Good documentation speeds up troubleshooting and future upgrades.

Share Knowledge:

• Share your experiences and lessons learned with team members and the wider community to foster continuous improvement.

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Conclusion

Implementing a new control system project doesn’t have to be overwhelming. By focusing on simplicity, thorough planning, reliable vendors, standardization, and quality components, you’ll set your project up for long-term success. Remember, the best solutions are often the simplest and most reliable ones.

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Best wishes for your next automation project!