ONES SYSTEM provides professional automation engineering services designed to improve the efficiency, reliability, and performance of industrial operations. Our expertise includes machine automation, control system integration, monitoring solutions, and machine retrofitting. By combining engineering experience with modern automation technologies, ONES SYSTEM delivers practical and cost-effective solutions that reduce downtime, improve productivity, enhance safety, and support the long-term growth of manufacturing operations.
Case Application:
Retrofitting Extrusion Machine in Bangi
Retrofitting factory machines provides a cost-effective way to improve the performance, reliability, and functionality of existing equipment without the need to replace the entire machine. By upgrading outdated control systems, sensors, drives, or automation components, manufacturers can improve machine efficiency, reduce downtime, and enhance production accuracy. Retrofitting can also enable modern monitoring and data collection capabilities, allowing machine performance, energy consumption, alarms, and maintenance conditions to be tracked more effectively.
Retrofitting factory machines provides a cost-effective way to improve the performance, reliability, and functionality of existing equipment without the need to replace the entire machine. By upgrading outdated control systems, sensors, drives, or automation components, manufacturers can improve machine efficiency, reduce downtime, and enhance production accuracy. Retrofitting can also enable modern monitoring and data collection capabilities, allowing machine performance, energy consumption, alarms, and maintenance conditions to be tracked more effectively.
Compared with purchasing new equipment, a retrofit can significantly reduce investment costs while extending the useful life of existing machinery. Ultimately, machine retrofitting helps factories modernize their production systems, improve operational efficiency, enhance safety, and remain competitive while minimizing disruption to ongoing production.
At a manufacturing facility in Bangi, the existing extrusion machine’s PC-based control system was experiencing frequent breakdowns, resulting in machine downtime, production losses, and material wastage. The HMI display was also damaged and difficult to read, while the control panel’s internal wiring had deteriorated over time, causing intermittent power and signal interruptions.
Compared with purchasing new equipment, a retrofit can significantly reduce investment costs while extending the useful life of existing machinery. Ultimately, machine retrofitting helps factories modernize their production systems, improve operational efficiency, enhance safety, and remain competitive while minimizing disruption to ongoing production.
At a manufacturing facility in Bangi, the existing extrusion machine’s PC-based control system was experiencing frequent breakdowns, resulting in machine downtime, production losses, and material wastage. The HMI display was also damaged and difficult to read, while the control panel’s internal wiring had deteriorated over time, causing intermittent power and signal interruptions.
ONES SYSTEM replaced the outdated PC-based control system with a modern PLC-based control system, re-engineering the machine controls to match the existing operation while improving reliability and performance. A new HMI was installed with a clearer, more user-friendly interface, making machine operation and monitoring easier for operators.
The control panel was also refurbished, with the internal wiring cleaned up, reorganised, and properly relabelled. With the upgraded PLC control system, new HMI, and improved panel wiring, the extrusion machine now operates more reliably with significantly reduced intermittent faults, helping minimise downtime, production losses, and material wastage.
ONES SYSTEM replaced the outdated PC-based control system with a modern PLC-based control system, re-engineering the machine controls to match the existing operation while improving reliability and performance. A new HMI was installed with a clearer, more user-friendly interface, making machine operation and monitoring easier for operators.
The control panel was also refurbished, with the internal wiring cleaned up, reorganised, and properly relabelled. With the upgraded PLC control system, new HMI, and improved panel wiring, the extrusion machine now operates more reliably with significantly reduced intermittent faults, helping minimise downtime, production losses, and material wastage.
