04 / INDUSTRY 3.0 AUTOMATION
Industry 3.0 Automation
The electrical and controls work that makes everything else possible. We rewire panels, map SCADA tags, and add sensors to machines built decades before anyone said Industry 4.0 — so they report what they are doing and refuse to do the wrong thing.
What it actually does
Retrofitting Legacy Machines — PLC/SCADA Monitoring
A 1998 press with a Siemens S5 can still tell you its cycle count — it just needs the right interface. We map existing PLC tags where comms exist, and add sensors and compact PLCs where they do not. The machine keeps running exactly as before; it just stops being silent.
Stack Siemens S7 / Delta / Mitsubishi PLCs · SCADA tag mapping · retrofit sensor kits
Barcode & QR Integration
Scanners at stations tie every part and batch to the machine and moment it was processed. Wrong part at the wrong station? The fixture will not clamp. Scan data flows into the same traceability records the IoT layer uses, so one scan serves quality, dispatch, and audit at once.
Stack Station-level barcode/QR scanners · PLC interlock logic · traceability DB writes
Panel & Control Updates
Ageing relay panels rebuilt with modern PLCs, drives, and HMIs — documented, labelled, and photographed, with drawings you keep. Safety circuits brought up to current practice while we are in the panel. The upgrade that usually happens only after a panel fire, done before one.
Stack Panel rewiring · HMI upgrades · VFD integration · as-built electrical drawings
Poka-yoke Fixtures
Sensor-interlocked fixtures that make the wrong assembly physically impossible: part-presence checks before clamp, torque confirmation before release, sequence enforcement across stations. Defect prevention at the point of work, which beats inspection at the end of the line every time.
Stack Proximity/vision sensors · pneumatic interlocks · compact PLC logic · andon signalling
Architecture
Deployment requirements
The plant provides
- Machine access
- Agreed downtime windows for panel work
- Drawings
- Existing electrical drawings if available (we redraw if not)
- Power isolation
- LOTO procedure and an authorised electrician contact
- Spares budget
- Approval path for parts found failing during work
We install
- Control hardware
- PLCs, HMIs, drives, sensors as scoped
- Fixtures
- Poka-yoke fixtures built to your part drawings
- Documentation
- As-built drawings, tag lists, panel photos
- Commissioning
- Supervised first-production runs per machine
Timeline Per machine: 2–5 days of panel work in planned windows. Fixtures: 3–6 weeks from drawing approval.
The questions plant heads ask.
Panel work is scheduled into your planned maintenance windows and weekends; a typical monitoring retrofit needs the machine off for hours, not days. Full panel rebuilds are staged so the line runs on remaining machines while one is in work.
Pairs well with
Ask us about industry 3.0 automation.
A short note about your plant is enough — we reply within one working day, or call +91 95990 94602.