Building a custom machine is full of challenges, cooperation, and transformation. From the start of a plan to a fully commissioned system, the process requires engineering, craftsmanship, software, and human ingenuity. Keep reading to learn more about each phase of a custom machine build with AHE Automation.
Ideation and Conceptual Design
Every great machine begins with a problem (or opportunity). In this initial phase, teams brainstorm design goals, functionality, and performance targets. This is when early involvement of PLC programming services specialists can clarify system requirements; like the number and type of I/Os, HMI interfaces, safety interlocks, and communication protocols.
This ensures your concept is grounded in achievable automation goals, setting expectations early. Including software capabilities from the outset helps prevent redesigns later, saving time and money.
Detailed Engineering and Prototyping
Once the concept has been approved, designers can produce detailed schematics, 3D models, and electrical layouts. At the same time, software engineers can begin architecting ladder logic or function-block programs for your PLC, embedding modularity, flexibility, and safety.
Ask our engineering team how we structure the PLC code. You’d be surprised how much this affects long-term reliability!
Software Integration and FAT (Factory Acceptance Test)
Next in line is FAT, where the machine is tested in a controlled environment. PLC code is downloaded, HMIs are configured, and safety protocols are tested with emergency stops, light curtains, alarms, and failure modes. Experts providing PLC programming services also verify communication with upstream systems like SCADA or MES. FAT ensures everything works as intended before shipping, saving time and travel costs.
Invite your team to watch the FAT process and see how the machine runs, so you can spot quirks in the interface or software flow.
Installation and Commissioning
On the big day where your machine is delivered, it will be installed, leveled, wired, and powered up onsite. Commissioning teams align software and hardware by tweaking timings, sensor thresholds, and flow rates. PLC specialists finalize runtime code and conduct Site Acceptance Tests (SAT), training operators and documenting procedures. With strong PLC programming services, every change is version controlled, documented, and handed off with SOPs and change logs.
Make the process of commissioning a team effort by including operators, maintenance staff, and software to capture a comprehensive view of performance.
Training, Handover, and Support
Your machine may be running, but training and documentation will determine its operational resilience. Modern PLC programming services providers offer code walkthroughs, maintenance manuals, logic flow diagrams, and operator guides.
In this scenario, your team isn’t just handed a new system. Instead, they are supported with deeper insight. And because your software is modular and documented, future tweaks and expansions become smoother.
Maintenance, Optimization, and Lifecycle Evolution
A commissioned machine is just the beginning. Ongoing maintenance, both preventative and predictive, keeps downtime low. Analytics from PLCs can be used to identify wear patterns, inefficiencies, bottlenecks, or safety risks. AHE’s PLC programming services include analytics-ready build packages that log events, performance, and alarms, empowering continuous improvement and operational excellence.
Activate performance logging on your machine, as these insights are gold for spotting small issues before they become big ones.
AHE Automation: Your Partner in PLC Programming Services
From concept to completion, the lifecycle of a custom build is full of technical complexity and human decision-making. Here’s how AHE Automation stands out:
- Over 50 years of industrial automation experience
- Expertise in PLC programming services, custom control systems, system integration, and safety compliance.
- Proven processes, from FAT to St to thorough documentation and analytics
Want to build something that’s more than just hardware? One that grows, adapts, and serves your team? Consider speaking with us at AHE Automation – we can map out your vision so you can step confidently from concept to commissioning.
Contact us at AHE Automation to discuss your next custom machine project, and experience automation built the right way!