Industrial Automation (I&C) System Design: Why Saving on Documentation Costs Millions On-Site

Major challenge for the client:

Creating documentation just for “box-ticking” or with a “we’ll figure it out on site” approach. The result: incorrect equipment is purchased, cables do not fit in the trays/raceways, and control cabinets must be reworked directly on the production floor.

• Hidden costs of erroneous P&ID schematics: If the technological schematic (P&ID) is disconnected from reality, the PLC programmer will write logic for a non-existent process. Correcting such errors during the commissioning phase costs 10 times more.
• 3D control cabinet design: A modern approach requires precise 3D modeling before ordering enclosures. This eliminates clashes/collisions (e.g., when terminals block wiring ducts) as well as heat dissipation issues from inverters (VFDs).
• Forward-looking architecture selection: Why reserving 15-20% spare capacity for Inputs/Outputs (I/O) and selecting scalable controllers (e.g., redundant fieldbuses) is not overpaying, but an insurance policy against future plant expansion.

Invest in a comprehensive detailed design (e.g., EPLAN) with a 3D cabinet model before purchasing any equipment. A 10-15% higher engineering cost at the start guarantees zero downtime, costly rework, and delays in the assembly phase, ultimately saving up to 30% of the total project budget.