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Discrete Manufacturing Automation

Secondary Manufacturing

With a fully integrated range of services from machine level to ERP, you can count on iconsys to deliver your Discrete Automation package.

Integrating different types of machines and equipment from multiple manufacturers is essential. It ensures the progress of your product via conveyors or other transport mechanisms between storage locations, buffer storage and the required sequence of discrete manufacturing operations (de-palletising, machining, painting, sub-assembly, packaging, palletising, End-of-Line solutions etc). All while tracking its progress and monitoring machine status.

A platform-independent systems integrator with wide-ranging experience of PLCs, SCADA/HMI, AGVs, ASRS, robots, vision systems and machinery, we’re well-placed to assist you in selecting package units/machines and the vertical integration of superordinate systems. Our knowledge of acquisition, analysis and visualising operation and production data completes the profile.

We are experienced in engineering solutions which are compliant with functional safety standards (such as BS EN 13849, BS EN 62061), PUWER compatible and CE-marked.

Package Unit/Machine integration

Our expertise in PLC programming and HMI/SCADA application development makes iconsys an ideal partner for the integration of package units/machines.

  • Coordination of machine cross communication
  • Consistent reporting on machinery status
  • Consistent solutions for visualisation
  • Connection to SCADA system
  • Connection to Line Management System
  • Specification and integration of Data Acquisition technology
  • Commissioning coordination
  • Accomplishment of FAT/SAT
  • Procurement and implementation
  • Operational assistance and support
  • Project Management

Data Acquisition

Business and Machine Data Capture are all-important when evaluating a production plant.

  • Provide connectivity to control systems (DCS/PCS) or process controls (PLC)
  • Process data acquisition and data archiving
  • Acquisition and processing of manual operating data
  • Equipping workstations with tools for data analysis
  • Establishing user specific calculations and reporting
  • Procurement and implementation
  • Support in operation and supervision
  • User-oriented training

Production Security and Traceability

In many industries, trademark protection and production security are becoming increasingly important.

  • IT connection from production to ERP (vertical integration)
  • IT solutions for data security
  • Support for product and process traceability (track & trace)
  • Support for evaluation of proprietary systems and suppliers
  • Operational assistance and support
  • Training

Realisation of SCADA Systems

Centralised, integrated SCADA systems enable machine-by-machine monitoring and interrogation, as well as line-to-line and entire plant throughput tracking.

iconsys’ knowledge of the various HMI/SCADA solutions in the market helps clients select a suitable system.

  • Integration of machines and package units
  • Supervisory control and visualisation
  • Acquisition and archiving of production data
  • Acquisition and converting of manual process data
  • Assembly of user-specific calculations and analysis
  • Preparation of reports
  • Procurement and implementation
  • Operational assistance and support
  • Training

Line Management Systems

These systems are an integral part of modern production plants, supporting the operator with efficiency analyses, optimisations and maintenance.

  • Coordination of package units/machines interfaces
  • Integration of the production layer to the ERP level
  • Accomplishment of vertical and horizontal integration
  • Usage of industry standards (such as OMAC PackML) together with modern portal technology as an appropriate middleware
  • Implementation of dashboards for visualisation and correlation between ERP and production – e.g. KPI, OEE, SPC, scheduling of production, maintenance, etc.
  • Load/flow balancing
  • Production throughput management
  • Planning and consulting
  • Procurement and implementation
  • Operational assistance and support
  • Training

KPI – OEE – SPC Analysis

iconsys offers the following services:

  • Aggregation of data into production information for example by integrating from machines, information management systems, data acquisition etc.
  • Preparation of analyses and reporting
  • Implementation of dashboards for visualisation and correlation between ERP and production
  • Acquisition of production information in order to manage and rate the production process based on benchmarks and operating figures (OEE/KPI/SPC)

Barcode and RFID

Traceability and the archiving of production data are achieved using techniques such as barcodes or RFID tagging. iconsys has experience in all aspects of providing this important functionality.

  • Consulting concerning different logistic solutions
  • Conception and specification
  • Integration into existing systems
  • Procurement and implementation
  • Training

Ongoing Maintenance Support

To develop and strengthen partnerships, iconsys supports clients after the project is complete.

  • Transitional phase from commissioning to operating
  • Planned maintenance
  • Standby service
  • System training / advanced training
  • System monitoring
  • Optimisation
  • Extension / Alteration / Upgrading
  • Long term mentoring

The iconsys strategy

Business Process

Our operational consultants use iconsys business systems to analyse your processes and provide actionable insights for streamlining the flow of business information to realise measurable benefits. Combining people, processes and technology, we work with you to ensure that the requirements for your targeted automation technology implementation produce the desired results. We connect your enterprise from the plant floor to the boardroom, with the business and operational processes in place to support the implementation.

Data Management and Historian

Collecting, storing and distributing real-time production data as part of an automation system allows identification of the causes of operational problems and quality issues. iconsys works with customers to implement data management systems and historians as part of continuous improvement with initiatives, helping managers use these tools to analyse their production data and make smarter decisions for increased productivity, quality and compliance.

Preliminary Engineering Design

This second phase follows the feasibility study and often happens prior to final process automation project approval. It can be used to generate Requests for Quotation (RFQ), which can then be sent to potential suppliers and contractors in order to develop an investment-quality cost estimate. Preliminary equipment layouts and schematics may be generated during the phase for automation projects that involve the instrumentation and control system — for example, in greenfield projects, major equipment updates and control system upgrades. iconsys engineers have been responsible for preliminary engineering design on many automation projects within different industries, ensuring they stay within the approved scope and budget.

Control System Design/Engineering

A facility’s process control systems are critical to every automation project. iconsys provides design, engineering and troubleshooting services for these systems to ensure the quality and proper integration of the system components, drives, motor control circuits, power supplies, PLCs and SCADA systems.

Process Analysis

To develop a sound automation system design with improved operation and productivity, a clear understanding of processes is critical. Process analysis includes reviewing the electrical and mechanical drawings, together with operating data, and gathering input from operations personnel through key interviews. This uncovers the key operating goals and targets and important product quality variables, as well as the constraints, limitations and bottlenecks that challenge operators. The best automation system designs create the tools that empower operators to overcome the challenges and meet key goals and targets. Our process control engineers apply sound process analysis on all automation projects.

Programming and Configuration

Bringing to life the detailed design of the instrumentation and control system, our control engineers have extensive experience working with every major DCS, PLC and SCADA system. They apply this process automation knowledge in using the latest engineering tools to convert logic diagrams into PLC ladder and functional block logic, to write generic and custom code and to build I/O and control applications using standard system function blocks and other features. With the features available in modern control systems, even the most complex advanced control strategies can be configured and programmed.

Project Management

Project management is one of the most important factors in a successful automation project. iconsys employs a proven structured approach to project management at every stage, eliminating many of the problems that can keep an automation project from meeting its scheduled requirements.


iconsys understands that in today’s business world of enterprise-wide facility integration, many companies are concerned about the risk of exposing process control systems to networks that have connectivity beyond the facility’s boundaries. We work closely with automation customers, ensuring that every network is protected sufficiently to maintain its integrity and confidentiality, and minimise the risk of unwanted intrusion.

Systems Design

Throughout each automation project, iconsys provides top-to-bottom design of integrated control, manufacturing and business systems. Our design expertise spans the spectrum, including electrical, DCS, PLC, HMI and SCADA implementations; I/O point configuration; advanced process control; and control and business networks.

Systems Development

Our systems development service offering is based on a robust project methodology. This ensures that we follow best engineering practices during all phases, including system configuration and setup; control, HMI and SCADA programming and configuration; historian configuration and database programming; business interface development; and documented testing. All phases of software development are subject to revision control and documentation.

System Implementation

The comprehensive implementation of our engineered solutions includes technical services at all stages of the project, installation, system commissioning and start-up, as well as ongoing support.

Consultative Services

Expert manufacturing consultation from iconsys can provide immediate, effective automation solutions. Our team can help you identify and eliminate the specific operational constraints that impact your profitability. Everything from distribution inefficiencies, outdated, underutilised or inappropriate technologies and capacity bottlenecks, to organisational resource levelling, manufacturing, scheduling and planning issues, and inadequate strategic vision.

iconsys enhance performance through integration of automation technologies.
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