control system upgrade project

Control System & PLC Upgrade

The Challenge

Lack of Uniformity in Product Finishes

A leading manufacturer of bathroom fixtures required improved pattern quality and uniformity in the brush finishes on their fixture sets. They needed a control panel manufacturer who could implement consistent repeatability from one set to another, throughout their varied product lines.

This client designed and built a small-footprint machine that would allow their operators to quickly change out tooling for each specific product line. This allowed them to make small runs for the custom fixtures being produced. During the finishing process, the variety of fixture sizing and orientation made it particularly difficult to achieve uniformity throughout each run.

The iAutomation Solution

Control System Upgrade + Innovative Programming

  • iAutomation engineers conducted on-site visits to our client’s manufacturing facility to better understand the mechanical process, human interaction, and environment for applying the finishes.
  • It was clear that automating as much of the process as possible would provide greater efficiency, higher output, less waste, improved quality, and greater operator safety.
  • In collaboration with our client, iAutomation designed and built electrical control panels and created the PLC and HMI software. We installed visual and proximity sensors on the machine to provide the needed input for programming. The sensors also allow for dynamic compensation in regards to tool wear.
  • As a full-service control panel manufacturer, our job doesn’t end after we’ve built the panels. To ensure flawless performance, the machine was brought to our facility for final assembly, programming, and testing. The customer openly visited the iAutomation facility to work with our engineers, conduct test runs, and ultimately the final testing.


Our customer was able to achieve their manufacturing goals for consistent high quality finishes, increased volume output, and ease of operation. After the successful control system & PLC upgrade, they built and implemented a second machine for a different process. They have plans for additional machines as they continue upgrading their manufacturing practices.

Does Your Manufacturing Process Need a Control System Upgrade?

Turn to iAutomation when you’re in need of a reliable outsource partner with proven experience in PLC control systems including conveyor control systems. We take a consultative approach, learn about your needs, and apply our experience to offer creative engineering solutions. We have quick turnaround on quotations and an open-door policy with our customers.

Contact iAutomation to request a quote or more information about control system upgrades.