Manufacturing Execution Dashboard
OPC UA + Modbus bridges to tiered dashboards; OEE lifted 61% to 74% inside two quarters.
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Capability
Industrial Automation in Australia
For plants that cannot stop. We integrate PLCs, SCADA and modern OT/IT bridges into production lines that are already running - retrofit paths for machines older than the engineers running them, without breaking the ones that still are.
Scope
What industrial automation covers - and what it doesn't.
Industrial automation is control that keeps a plant producing safely and predictably. We treat it as a brownfield discipline: most of what we do is adding sensing, control and visibility to lines that were commissioned before the operators’ laptops were made.
In scope
- PLC integration: Siemens S7, Allen-Bradley ControlLogix, Beckhoff, Omron
- SCADA and HMI: Ignition, WinCC, FactoryTalk, custom web HMIs
- OT/IT bridge: OPC UA, Modbus TCP/RTU, MQTT Sparkplug, historian integration
- Retrofit sensing and edge inference cells on existing lines
- Motion control, servo drives, and line synchronisation
- Safety-adjacent design: interlocks, emergency stops, guarded zones
- OEE, MES and downtime-classification systems
Honestly out of scope
- Turnkey mechanical machine builds (we integrate; you or your OEM builds)
- Certified functional-safety design (we design with FSE partners, not as one)
- Full-time on-site maintenance operations
- Reselling PLC or drive hardware as a distributor
Outcomes
What you get out of it.
A retrofit that works is one that goes in during a scheduled window and comes out with the line running faster the next morning. What our automation programs consistently deliver:
Visibility into lines that had none
OPC UA and Modbus bridges into PLCs that were previously islands, feeding dashboards operations teams actually open. One recent build lifted OEE from 61% to 74% inside two quarters just by making the downtime causes visible.
Retrofits that install in a scheduled window
We commission during planned outages, with backout plans documented before install day. The line comes back online before the shift starts.
Automation that survives operator turnover
HMIs written for the operator who arrives at 6 am, not the engineer who wrote them at 2 am. Alarm hierarchies designed to be actionable, not noise.
An architecture that scales beyond one line
Choices made on the first line - historian, tag naming, dashboard patterns - are the choices that carry to the whole plant. We build with the fleet-of-lines view even when only one is in scope today.
Process
How a industrial automation program runs here.
Four phases with a real deliverable at each gate - you always know what you paid for and what ships next.
PHASE 01
Discover (paid week)
We start from the constraint that binds - power, latency, thermal, certification - and design backwards from it. You leave with a written architecture, a budget range and the risks named, whether or not we build it.
PHASE 02
Design
Schematics, mechanical and firmware architecture proceed in parallel. High-risk blocks get simulated or breadboarded before the full layout commits.
PHASE 03
Build
Iterative revisions against real bench and field testing. You see every revision, not just the last one. Integration is continuous, not a phase.
PHASE 04
Deploy
Pilot in the field, closure with the contract manufacturer, production test procedures, and a commissioning-grade handover pack.
Technologies
What we build on - chosen per constraint, not per preference.
The platforms we reach for most. If a project needs something not on this list, we say so - the tool is chosen for the constraint, never to fit our habits.
Siemens S7Allen-Bradley ControlLogixBeckhoff TwinCATOmronIgnition (Inductive Automation)WinCCFactoryTalkCustom web HMIsOPC UAModbus TCP/RTUMQTT Sparkplug BProfinetEtherCATHistorian: InfluxDB, TimescaleDB, GE Historian integration
Industries
Where industrial automation we ship runs today.
Deliverables & IP
What ships to you at handover.
Every automation program hands over: PLC source (native project files), HMI source or Ignition project export, tag database with naming conventions documented, OPC UA namespace map, network diagrams with VLAN plans, wiring documentation, factory acceptance test records, site acceptance test records, and a written commissioning report. All foreground IP transfers on payment.
Case studies
Programs we shipped in this space.
Every entry links to the full case study - constraints, what we built, and what it measured afterwards.
Inline Weld Seam Inspection
Retrofit inspection cell integrated into a live production line with 45 ms cycle constraints.
Read case study
Building Energy & Utility Monitoring
Retrofit metering across mixed-vintage switchboards feeding a unified energy dashboard.
Read case study
Compliance
Safety-adjacent by design.
Australian workplaces run under AS/NZS 4024 machine-safety standards; our designs sit inside those requirements by default - guarded zones, emergency-stop hierarchies, redundant safety monitors where risk assessment demands them. Where the risk assessment calls for a formally certified functional-safety solution (SIL-rated), we design the architecture and work with a Functional Safety Engineer (FSE) partner for the certification path.
OT-side cyber-security aligns to IEC 62443 principles: segmented networks (control plane isolated from IT), least-privilege service accounts, audited remote access, and firmware signing on the devices we build ourselves. When the plant needs to expose data to corporate IT, we do it through a documented DMZ pattern - not by flat-networking everything and hoping.
FAQ
Industrial Automation in Australia - straight answers.
Small retrofit sensing + dashboard: AUD $15,000-$40,000. Line-level PLC/HMI integration: AUD $40,000-$150,000. Multi-line plant-wide OEE and MES: AUD $100,000-$500,000+. All programs start with a plant walk-through and a paid scoping engagement.
Yes - most of our automation work is brownfield. We integrate with S7, ControlLogix, Beckhoff, Omron and older Siemens/Mitsubishi hardware. Where the PLC itself is at end-of-life, we quote migration options honestly.
Yes, during scheduled outages, with backout plans documented up front. We do not surprise a plant with a change - the commissioning plan is signed off by production before install day.
Yes, via OPC UA or MQTT Sparkplug bridges into a DMZ, with the security posture documented. Historian data, real-time telemetry and MES data flows are all supported.
We design to align with IEC 61508 / AS/NZS 4024 expectations, but formal SIL certification is executed with an accredited Functional Safety Engineer. We are honest about that boundary and manage the FSE relationship end-to-end when needed.
Documented backout in the commissioning plan; on-call for the first shift after commissioning; and a warranty period during which we own defect fixes at no extra cost. This is in the contract.
Why Incendio
One team, no seam between vendors.
Automation is one of the domains where the difference between a system integrator and a systems engineer is visible in month three: whether the alarms are actionable, whether the dashboards get opened, whether the retrofit needs a rework in six months. We build with the plant's operational reality in view - not the SI catalogue - and the outcomes are measurable.
Related practices: IoT development, robotics, edge AI, cloud software development.
Start
Tell us the constraint that worries you most.
A latency budget, a power budget, a certification date. We reply within one business day - and we’ll say so if we’re not the right team.