Automation systems

Three layers of automation

• Workflow automation: removing repetitive office steps such as re-keying data, chasing approvals, generating documents and reconciling records between systems.
• Machine and process automation: controllers, sensors and actuators that monitor or run equipment, with the software to configure, log and alert.
• Data automation: collecting readings from machines, meters and devices into a database and turning them into dashboards, reports and alarms.

Most projects touch two of these. A monitoring system is only useful if its alarms reach a person and its data reaches the business system.

How we approach it

We start by mapping the current process, including the informal steps people do to keep it working. Then we automate the parts that are stable and measurable, keep humans in the loop where judgement is needed, and make every automated action visible in logs so that when something looks wrong, you can see exactly what happened.

For physical systems we design with fail-safe defaults, manual overrides and clear operator feedback. Automation that people cannot understand or bypass in an emergency gets switched off, and then the investment is wasted.

Typical building blocks

Microcontroller or single-board-computer based controllers, industrial sensors and relays, wired and wireless field networks, a server-side application for storage and rules, and web dashboards for operators and managers. We select components for availability and longevity, and we document the bill of materials so the system can be repaired and extended.