Providing Outsourced Engineering to Build Lasting Relationships
At Pigler Automation, we are dedicated to building lasting relationships by creatively addressing our customers’ needs. This dedication to excellence inspired us to develop EXPERTFUSION™, a solution that provides engineering staff augmentation to support project execution.
Customer Challenge
This year, we were approached by a long-standing customer facing significant challenges at their semiconductor fabrication facility in Pennsylvania. They needed to update several Siemens TIA Portal projects from WinCC Comfort to WinCC Professional. However, years of inconsistent standards and incorrect programming from previous personnel had left their systems in disarray, making it challenging to complete the migration on time. Systemic issues with the programs created a substantial roadblock to their progress.
Engineering Staff Augmentation
The customer’s team was stretched thin, and hiring additional personnel was not an option. They needed more hands on deck, but the budget and time required to hire and train new employees was prohibitive. This is where EXPERTFUSION™ came into play.
We recommended an engineering staff augmentation solution to bridge the gap. Our team quickly identified significant programming inconsistencies within the TIA Portal projects. The immediate objective was to make all programs operational and standardize functions within the existing framework, a daunting task given the state of the systems.
Project Execution
Our engineer took ownership of the project, moving older versions of TIA Portal and WinCC to newer versions and consolidating them into one project. This involved many PLCs and HMI Comfort Panels used both in the plant and at various field locations.
As the project progressed, we discovered incomplete and incorrect work done by previous integrators. These issues needed to be addressed before moving forward, requiring our engineer to sift through volumes of data and code. They had to delete non-functional programs and repair those that could be salvaged, ensuring all systems were updated and functioning correctly.
Adapting to Changing Needs
Partway through the project, the customer urgently needed a new life safety system at their facility. Thanks to the flexibility of EXPERTFUSION™, our engineer immediately shifted focus to designing and commissioning the safety system. Within five weeks, the new system was operational, meeting all safety requirements and avoiding any shutdowns or extended non-compliance periods.
Once the life safety system was operational, our engineer returned to the original project scope. The flexibility and responsiveness of EXPERTFUSION™ prevented significant delays and maintained project momentum.
Evolving Project Scopes
Projects often reveal new challenges as they progress. In this case, the programming inconsistencies within the TIA Portal and WinCC systems required continual adjustments. Our engineer worked closely with the customer to navigate these evolving requirements, ensuring the project stayed on track and aligned with their goals.
EXPERTFUSION™ provided the flexibility to make necessary changes without bureaucratic delays, allowing the project to progress smoothly despite the challenges. This adaptability was crucial in maintaining project momentum and ensuring the customer’s needs were met.
Long-Term Support and Transition
EXPERTFUSION™ goes beyond addressing immediate project needs and provides long-term support. During the project, the customer’s plant manager decided to retire earlier than expected. This unexpected change raised concerns about operational continuity and the potential impact on future projects.
Our engineer’s deep understanding of the customer’s control systems and project work enabled us to offer crucial support during this transition. We extended the EXPERTFUSION™ contract to maintain the appropriate level of operational support, ensuring the plant continued to run smoothly without interruption.
To facilitate a seamless transition, our engineer worked closely with the retiring plant manager, strategizing the best course of action and preparing for the arrival of a new manager. When the new plant manager is hired, our engineer can provide comprehensive training and support, ensuring they are set up for success from day one.
Looking Back: The Impact of EXPERTFUSION™
Reflecting on the journey with our customer, it’s clear that EXPERTFUSION™ made a significant impact. The initial task of updating the Siemens TIA Portal projects was complex and fraught with challenges. However, our engineer’s dedicated support and expertise helped us effectively navigate these difficulties.
The urgent need for a new life safety system could have derailed the project. Yet, the flexibility and responsiveness of EXPERTFUSION™ allowed us to address this critical need without compromising the original project scope. The customer’s ability to quickly adapt to changing priorities and meet safety requirements without shutting down operations was a testament to the effectiveness of our approach.
A Personal Touch
Our engineer’s role extended beyond technical expertise. They became integral to the customer’s team, understanding their unique challenges and working collaboratively to find the best solutions. This personal touch ensured that the customer’s needs were always at the forefront, and the project evolved in a way that best suited their goals.
When the plant manager announced their early retirement, the potential for disruption was high. However, our engineer’s familiarity with the customer’s systems and ongoing projects provided a safety net. The extended support during the transition period ensures that operations will continue smoothly and the new plant manager will be well-prepared to take over.
Conclusion
At Pigler Automation, our commitment to building lasting customer relationships is at the heart of everything we do. EXPERTFUSION™ exemplifies this commitment by offering tailored solutions that address immediate and long-term needs. Whether navigating complex automation system updates, implementing critical safety measures, or ensuring seamless transitions during personnel changes, EXPERTFUSION™ provides our customers the flexibility and expertise to succeed.
With EXPERTFUSION™, you gain a trusted partner dedicated to your success. We work closely with you to understand your unique challenges and deliver solutions that meet your requirements. Working with Pigler Automation, you can be confident that your projects will be completed efficiently, effectively, and with the highest quality standards.
Contact Pigler Automation today to learn more about how EXPERTFUSION™ can support your engineering needs and help you achieve your goals. Together, we can build a future of innovation, excellence, and lasting success.
