Project Management
Industrial Automated Systems offers Project Management services to our customers in a variety of industries. We are available to help throughout the entire project lifecycle, from project feasibility and scope development, to commissioning, validation and production startup. Our team of experts can tailor the project management process to fit your needs utilizing their experience to meet the requirements of the industry. We are uniquely equipped to oversee projects from start to finish by working with our sister company, Triune Electric, for the installation. This allows for flawless communication of client needs and project goals that only Industrial Automated Systems can provide.
Our Project Managers can assist the day you start considering a project by helping develop the business case and benefits management framework. We are adept in helping you plan and realize the benefits of your project, and more importantly, helping to plan and sustain those benefits. We manage scope through an effective and established WBS (Work Breakdown Structure), change control process, and project deliverables. We manage cost and schedule through EVA (Earned Value Analysis), baseline analyses, gates, and milestones. Quality is managed through objectives, metrics, and standards. However, our greatest strength is communication, which is the foundation for every successful project.
Throughout the project lifecycle we can assist in oversight and execution of key stages of the process such as:
- Estimate Preparation and Evaluation
- Funding Request Preparation
- Budget Analysis
- Strategic Planning for Capital Improvements
- URS- User Requirements Specification
- Proposal and Purchase Order
- Internal Kick-off Meeting
- Customer Kick-off Meeting Onsite
- System Development
- System Checkout
- FAT- Factory Acceptance Test at IAS
- Start-up and Commissioning
- SAT- Site Acceptance Test
- Customer Training
- Final Documentation
- Customer Close-out Meeting
We tailor Project Management methodology to the project and customer requirements. We have found that a tailored approach, as well as implementing multiple methodologies is the most effective approach to project planning, execution, and management. Some of our Project Management Capabilities and Methodologies include:
- PMI PMBOK
- Waterfall
- Kanban
- Lean
- Critical Path
Upfront Design and Planning
Any success begins with the right plan, and every system we build begins with the solid foundation of our proven expertise in design and planning. That planning is a team effort, drawing upon expertise across every level of our organization to ensure a quality solution that is seamless from inception to completion.
Our comprehensive design capabilities include:
- Define and Develop a project scope
- Process & Instrumentation Development (P&ID)
- User Requirements Specification
- Develop System Architecture
- Provide Project Budgetary Estimates
- RFQ package development
- Develop Validation Master Plan
- Develop Project Implementation Master Plan
- Control System Design
- Electrical Design
- Functional Requirement Specification (FRS)
- Detailed Design Specification (DDS)
- Process Optimization
- Rockwell Automation NC
- Hazard and Operability Reviews (HAZOP)
In creating your custom solution, our dedicated design team draws upon its extensive knowledge and experience of creating successful systems to know what will work best for your specific individual needs. We utilize many standard components and design libraries to help reduce costs and work closely with Controls Technicians throughout the development process to ensure the best product.
Even during the installation process, our designers are on site as directors, working with our sister company Triune Electric, to ensure quality control and adherence to customer required safety ratings.
Controls Automation
Our controls automation services offer a diverse range of solutions to tackle whatever your needs may be. Those solutions are built on a unique combination of top-of-the-line products and an expertise built upon years of successful implementation for our clients.
Our controls automation services include:
PLC Programming
- Modular code development
- Scalability
- Process naming conversions
- Cohesive documentation throughout package
- Allen-Bradley Rockwell Automation NC
- GE Intelligent Platforms
- Modicon Quantum
- Siemens
- Omron
HMI/SCADA Development
- Graphical user interface screens
- Real time dashboards or heads up display
- Pop up faceplates
- Alarming
Control System Migration Strategies
- Hardware upgrades for obsolete PLC equipment
- I/O migration strategies to convert existing I/O
- Software conversions of old PLC programs
- Drive upgrades for old obsolete DC/AC VFD’s
- HMI conversions for outdated, no longer supported hardware
Drives Engineering
- Coordinated drive systems
- Tension control systems
- Extruders (heavy load)
- Non-woven drives system
Startup
- Loop Checking
- Downtime Coordination
- Commissioning
- Site Acceptance Testing (SAT)
- IQ, OQ, PQ Execution
Support
- Training
- Maintenance
- Emergency Response
- System Support
- Technician Services
- Safety Reviews
Completed Program Documentation
Simulation Development
Factory Acceptance Testing (FAT)
Our experience has given us the capability to create very complex and sophisticated programming along with a particular specialization in drives, coordinated drives and motion/servo controls. In fact, we recently designed and installed a machine featuring 13-axis motion.
We also partner with Rockwell Automation in NC, offering specialized data collection to optimize operations and improve production performance. Using a suite of reporting and analysis tools we can deliver contextual, localized, role-based information to easily monitor the key factors that impact performance, efficiency and quality. We have an extensive range of Rockwell Automation NC experience dealing with DeviceNet, RsLogix5, RsLogix500, RsLogix5000 and RsView32. We know and understand the role Rockwell Automation NC has as the market leader in Industrial Controls and we feel that IAS can help enhance that role in Eastern North Carolina.
Validation
Validation is critical to ensuring optimum integration, automation, and controls on an ongoing basis. That’s why we provide a combination of industry-leading hardware and testing software to ensure the proper installation, performance, accuracy, data collection and compliance.
Our validation services specialize in:
- User Requirements Specification (URS)
- Functional Requirement Specification (FRS)
- Detailed Design Specification (DDS)
User Requirements Specification (URS)
Before we even begin, we’ll work closely with you to create the URS that specifies the system requirements that you are seeking to scope out planning cost, timetables, milestones and testing.
Functional Requirement Specification (FRS)
We’ll then map out the FRS to define in further detail the functional specifications and properties for your automated system.
Detailed Design Specification (DDS)
Finally, we’ll create the DDS to set out the specific criteria and expectations for the capabilities of your unique custom system.
Installation
When it comes to installing a solution as complex as an integrated automated system, you don’t just want theory, you want the absolute expertise that only proven experience can provide. That is exactly what IAS delivers for our clients.
Panel Fabrication
Our partner, Triune Electric, is a UL 508A certified panel builder that can manufacture panels in-house or on-site to these standards, and install and terminate all of the various components required for your unique application. Triune technicians pride themselves on delivering panels that are correctly manufactured, accurately connected, labeled and with neatly routed cables and wiring.
Project Installation Management
With so many intricate details, experienced project management with hyper-attention to detail is the only way to ensure that a job will be completed on time and on budget.
Our team of experienced estimators and project managers work with customers to understand the project and map out the action plan to completion. Our project managers are the key to strong starts, effective flexibility and expected outcomes. Our skills are not limited to planning and estimating, we are dedicated to seeing the entire project through to completion and making sure it is a coordinated effort from all parties involved.
I/O Checkout
We don’t just install your system and pack up. Testing and verification of new and existing systems is essential for any integrated system. Our team of experienced technicians always includes this in our scope of work as a matter of quality assurance, but we also can be a resource when third-party validation or diagnostics are required.
Staging/Testing Calibration
Our experienced team works side-by-side with our sister company Triune Electric to deliver a flawless installation and seamless integration. Our extensive relationship ensures a synergy and communication between team members to get the job done right the first time, every time.
Through all phases of the process, we are dedicated to delivering the highest quality and reliability of installations with the expertise to deliver on time, and stand behind it with expert service for as long as you need it.
Legacy Equipment Migrations
Upgrading facilities doesn’t have to be a drastic rip and replace operation. IAS can help you reduce costs while increasing operational efficiency and productivity by migrating existing equipment and integrating it with newer systems.
Our legacy migration experts can help you:
- Verification of current system
- User requirements planning
- Migration strategy and planning
- Modern controls recommendations
- Functional specification
- Cutover planning for hot and cold switchovers and phased transitions
- Training
- Implementation and staging
- Demolition, installation and commissioning
- Documentation and support
Our experts will work with you closely to plan the best migration strategy based on your technical and budgetary needs in conjunction with an analysis of your legacy systems and future specifications.
Machine Vision
Machine vision is a critical component in automatic inspection, process control, and robot guidance, providing imaging-based automatic inspection and analysis.
Our solutions include:
- Test & Inspection Systems
- Inspection of pre-manufactured objects
- Pattern Recognition
- Barcode/Dot Matrix
- Keyence 3000, 5000, 7000 Series
- Visual Stock Control and Management Systems
- Error Proofing
- Shape, Size and Volume
- Cognex Insight, Checkpoint, Checker
- Banner Presence Plus Geo
- Microscan
From simple barcode reading for stock control and management to complex imaging for robotic accuracy, IAS provides a broad suite of solutions for machine vision based on our own vision of perfection and innovation.
UL Panel Fabrication
IAS can help with the fabrication of panels of your own design, or to develop a custom panel or system based upon your specifications or conceptual design.
Our Panel Fabrication Services Include:
- Engineering and Design
- Fabrication
- Certifications including UL 508A Certified
- Arc Flash NFPA 79E Design
- FAT- Factory Acceptance Test
- Field Installation
- CAD Drawings
- Build-to-Print
- Sub-Assembly
- MCC Modifications
- Custom Enclosure
Examples of Panels Fabricated:
- NFPA 79E Arc Flash Compliant Designs
- Junction Boxes
- Control Panels
- PLC/DCS Systems
- Drive Systems
- HMI Panels
- Single/Multi Loop Control Panels
- Custom Control Panels
- Burner Management Panels
- HVAC Fan and Pump Control Panels
- Special Fabrication
We leverage the extensive industry-leading experience of our sister company Triune Electric to design and install your panels
Triune Electric is a UL 508A certified panel builder who can manufacture panels in-house or on-site to these standards, and install and terminate all of the various components required for your unique application. Triune technicians pride themselves on delivering panels that are correctly manufactured, accurately connected, labeled and with neatly routed cables and wiring.
Support
Our level of personal dedication to responsive service and support is a distinguishing factor for IAS.
We don’t just install our products and close the door behind us. Our system experts are on hand 24/7 as your dedicated partner for the entire product lifecycle to reduce downtime and ensure quality maintenance for optimal operations of all systems.
Our experts are on-call to help with:
- System Support
- On-site Automation System Troubleshooting
- Maintenance services
- Emergency Response services
- Safety Audits