We stay
until it runs.
I/O checkout, FAT/SAT execution, loop tuning, startup support, operator training, and IQ/OQ/PQ validation — the system works when we leave because we didn't leave until it worked.
Engineering on paper
is one thing.
The PLC program compiles. The HMI screens look right. The panel passed its factory test. None of that matters until the system is installed, powered up, connected to real equipment, and running real product.
Commissioning is where everything gets tested against reality. Wiring mistakes get found. Sequence timing gets adjusted. Control loops get tuned on actual process conditions. Operators learn the system by running it — not by reading a manual.
The system works when we leave because we didn't leave until it worked.
Engineers leave before the system is stable. Operators learn by trial and error. Issues found in production.
- —Wiring errors found during production
- —Loops untuned on actual process
- —No formal handoff or training
Systematic verification, tuned loops, trained operators, and engineers who stay until it runs.
- Every I/O point verified before startup
- Loops tuned on actual process conditions
- Formal training and documentation handoff
From I/O checkout
to running production.
Point-by-point verification of every input and output in the system. Every discrete input toggled and confirmed in the PLC. Every discrete output forced and confirmed at the field device. Every analog input signal verified for correct scaling, engineering units, and display on the HMI. Every analog output verified from PLC command through to the final element. Wiring errors found during I/O checkout take minutes to fix. The same errors found during sequence testing take hours.
End-to-end verification of each instrument loop: field device calibration verification, signal path confirmation through marshalling panels and I/O modules, PLC/DCS tag verification, historian tag confirmation, and HMI display validation. For control loops: verification that the controller output drives the correct final element in the correct direction. Loop commissioning happens before process introduction.
Testing every automated sequence — startup, shutdown, normal operation, mode transitions, fault handling, and recovery — against the functional specification. Machine sequences stepped through manually first, then in automatic at reduced speed, then at full speed. For process systems: batch sequences tested with water or surrogate materials before introducing actual product. Every deviation documented, diagnosed, and resolved.
Factory Acceptance Test: testing the assembled system in the shop before it ships to site. Simulated I/O used to exercise the program through all operating modes and fault conditions. Site Acceptance Test: formal on-site testing of the installed and commissioned system against defined acceptance criteria. Test scripts, results, and deviations documented. SAT completion typically triggers warranty and the transition from project to production.
On-site engineering support during initial process introduction and first production runs. Control loops tuned on real product instead of water. Sequence timing adjusted for actual equipment behavior. Operator screens refined based on what the crew actually needs. Our engineers are on the floor, at the HMI, and on the radio with operators as the process comes up — adjusting, troubleshooting, and optimizing in real-time.
Hands-on training delivered during commissioning and startup — on the actual system, running the actual process. Different training for operators (how to run it) and maintenance technicians (how to troubleshoot it). For regulated environments: IQ/OQ/PQ validation protocols with documented test results, deviation management, and summary reporting per your quality system requirements.
Every system
that needs to run.
New installations, upgrades, migrations, and validated environments — we commission it all with the same engineering rigor.
New Equipment Installations
Commissioning new production lines, process systems, packaging lines, and utility systems. Full scope from I/O checkout through production startup.
System Upgrades and Migrations
Cutover commissioning for control system replacements. Verifying that the new system replicates and improves upon the behavior of the system it replaced.
Plant Expansions
Commissioning new areas that integrate with existing production infrastructure. Verifying integration points, communication, and coordinated operation with existing systems.
OEM Machine Installations
Startup support for equipment purchased from OEMs, where the site integration, utility connections, and control system tie-ins require on-site engineering support.
Validated Environments
Pharmaceutical, biotech, and food manufacturing facilities where commissioning must follow qualification protocols with documented evidence of compliance.
Remote and Challenging Sites
Oil and gas facilities, water treatment plants, mining operations, and other locations where commissioning requires travel, extended on-site presence, and self-sufficiency.
From planning
to production handoff.
Plan the commissioning.
Commissioning plan developed during the engineering phase — not the week before startup. The plan defines the sequence of activities, resource requirements, schedule, safety requirements, and coordination with other trades.
Verify readiness.
Pre-commissioning walkthrough to confirm installation completeness. Punch list development and tracking. Coordination with mechanical, electrical, and piping trades to resolve open items.
Check out the I/O.
Systematic, point-by-point I/O verification with documented results. Every sensor, every actuator, every communication link confirmed before sequence testing begins.
Test the sequences.
Functional testing of all automated sequences, interlocks, alarms, and control strategies. Issues documented, resolved, and retested. Logic adjustments made on-site to match actual equipment behavior.
Start the process.
Process introduction, loop tuning, sequence timing optimization, and initial production runs with engineering support on-site. System performance verified against the functional specification.
Train and hand off.
Operator and maintenance training on the live system. Documentation delivery — as-built drawings, program backups, operating procedures, and maintenance guides. Formal handoff to your operations team.
What we commission.
Every platform, every protocol, every validation requirement — commissioned by the engineers who designed the system.
We don't leave
until it runs.
The engineers who designed it commission it.
We don't hand off a design package to a separate commissioning crew seeing the system for the first time. The engineers who wrote the functional specification and programmed the PLC are the same engineers on your floor during commissioning. They know the design intent behind every sequence, every interlock, and every alarm.
We plan for things to go wrong.
Every commissioning plan includes contingency time, rollback procedures, and prioritized issue resolution. We don't build optimistic schedules that assume everything works perfectly on the first try. We build realistic schedules that account for the wiring errors, sequence timing adjustments, and design refinements that are a normal part of every commissioning.
We don't leave early.
Commissioning is complete when the system runs in production — not when the punch list is mostly done, not when the FAT passed, and not when the schedule says the engineers are supposed to leave. If the system needs another day of tuning or another shift of operator training, we stay.
Training that happens at the right time.
Hands-on training delivered during commissioning and startup — not weeks before when the system doesn't exist yet, and not months after when bad habits have already formed. Operators learn by running the system under supervision, building confidence on real equipment before they're expected to run it independently.
It depends entirely on the system scope and complexity. A standalone machine might take 3–5 days on-site. A multi-line production system with process control, batch management, and MES integration might require 4–8 weeks of on-site commissioning. We provide a realistic commissioning schedule during project planning that accounts for installation coordination, testing time, training, and a contingency buffer.
Yes. We regularly commission systems designed by other integrators, OEMs, or in-house engineering teams. We review the design documentation, familiarize ourselves with the logic, and execute the commissioning with the same rigor we apply to our own work. We'll flag design issues we find during commissioning and work with the responsible party to resolve them.
They will be. That's the purpose of commissioning — to find and fix issues before the system is in production. We maintain a commissioning punch list that tracks every issue: description, severity, assigned owner, and resolution status. Critical issues are resolved before startup. Non-critical items are tracked to completion after the system is in production.
For system upgrades and migrations, yes — that's often the only option. We plan cutover windows, test during scheduled downtime, and execute phased cutovers that minimize production impact. For new installations, commissioning typically happens before the system enters production, with startup support continuing into the first production runs.
Validated commissioning adds 30–50% to the commissioning scope, primarily in documentation — writing and approving protocols before testing, executing against defined test scripts with formal acceptance criteria, and managing deviations through your quality system. The testing itself is largely the same. The difference is the documentation rigor and the change control process.
Yes. Our engineers travel to project sites domestically and internationally. For international commissioning, we coordinate with local electrical contractors, manage time zone logistics for remote engineering support, and ensure compliance with local standards and site safety requirements.
Straight answers.
Need commissioning support?
Whether it's a new installation, a system upgrade, or a startup that needs engineering support on the floor — tell us about the project and the timeline.