Solution 01
Automation & retrofit
Reuse the mechanical base when it still makes sense, and selectively replace controls, sensors, drives, HMIs and interfaces when they limit performance, safety or maintainability.
Describe the need →
SYNTAVER · Automation & retrofitWhen this solution makes sense
Signals we look for on site.
We favour maintainable architectures, components available in Europe and an automation level consistent with the client’s real ROI.
Repetitive or physically demanding manual tasks
Repetitive handling, loading or transfer that consumes operator time without adding value.
Insufficient or unstable throughput
Cycle variability, micro-stops or poor synchronisation between subassemblies.
Useful equipment with ageing controls
Mechanical base still usable but PLC, HMI, drives or components are becoming difficult to maintain.
Product or format changes
Long changeovers, manual settings or missing structured recipes.
Missing data or traceability
Production data, alarms or stop causes not available to operations.
Typical scope
What the project can include.
Functional scoping and on-site survey
Automation / motion / robotics architecture
Mechanical and electrical interface study
PLC / HMI programming and sequences
FAT, installation, SAT and ramp-up
Documentation and maintenance handover
Technical depth
Open the technical layer that matches your question
These items do not replace a site survey; they show the level of detail used to scope a pre-study.
01Data to collect+
- Actual and target cycle time
- Operating modes and shutdown windows
- Actuator / sensor / drive list
- Drawings, schematics and PLC backup if available
02Possible building blocks+
- PLC / HMI / motion
- Robot or cobot when justified by the task
- Conveying, indexing, gripping
- Safety, interlocks and degraded modes
03Useful deliverables+
- Functional note and operating sequence
- Architecture and interface list
- Migration / shutdown / restart plan
- FAT/SAT pack and maintenance handover
04Acceptance criteria+
- Throughput and cycle stability
- Changeover time
- Stop rate or stop causes visible
- Restart, backup and maintenance modes validated
Method
Three scoping steps before integration.
The objective is to reduce grey zones before placing orders or starting on-site work.
1. Survey the existing line
Mechanical base, interfaces, obsolescence, safety and current throughput.
2. Freeze the useful scope
Functions to automate, acceptable downtime, expected gains and acceptance criteria.
3. Prepare the integration
Modules, shutdown plan, testing and restart.
Related use case
Automating a repetitive manual workstation
See how this type of need can be scoped, structured and measured.
View the scoping →
Next step