Factories are more complicated and linked together than ever before. AI, IIoT, and smart manufacturing projects promise to make things more efficient and provide more information. However, when something goes wrong, the stakes are higher. Choosing a plant system integrator is a big deal in this situation because it can change performance and downtime.
It takes more than looking at a list of skills to find the right match. Leaders need to carefully consider the provider and be sure they will work with a team as systems change. We’ve partnered with Malisko to bring this detailed guide on best practices for hiring a plant system integrator.
Define the Facility’s Needs
The first step is to look internally. Before hiring a plant system integrator, facility managers should carefully examine their present processes and make note of any persistent problems, data gaps or maintenance issues.
Leading research shows that it is important to write down processes and end goals for automation. Fully integrated production systems can increase throughput by an average of 37% and cut quality-related deviations by a significant amount. That kind of change in outcomes can only happen when the foundation is clear.
Next, make clear goals. A project to make it easier to see what’s going on with controls on the plant floor is majorly different from one that aims to connect old programmable logic controllers (PLCs) to new IIoT platforms or to make data consistent across various lines.
Setting clear goals, measurements of success, and limits from the start gives possible partners something real to look at. It also makes side-by-side comparisons easier when trying to find the best provider.
The Hallmarks of a Top-Rated System Integrator
It’s not only about technical skills when choosing a system integrator. Before a contract is ever signed, there are some traits companies with regularly good results tend to possess.
Certifications That Show They Know What They’re Doing
There is a reason why official certifications matter. An integrator that gets credentials from groups like Rockwell Automation, Cisco or the Control System Integrators Association (CSIA) shows they have met certain commercial and technical criteria.
For CSIA-certified companies, this means going through tough third-party audits that look at things like project management, the life cycle of system development and technical execution. These badges are not just for show. They exhibit that there are organized processes and responsibilities, both of which lower the owner’s risk.
Certifications also demonstrate their seriousness. Technology platforms change frequently, and partners who keep their credentials up to date usually spend money on training, compliance and continuing development.
A Mindset of Partnership
The right system integrator doesn’t see automation as a one-time project with a set endpoint. They know the data architecture and plant floor control systems will keep changing. A company that wants to grow from the start thinks about how its current solutions will help it expand in the future.
This kind of thinking affects everything, from how systems are built to how they are documented and supported. Manufacturers gain from having a partner who knows what their operating goals are and stays involved after the initial commissioning.
Red Flags During the Selection Process
Integrators can work at different levels. Vague plans, poorly defined scopes, or a lack of readiness to explain roles might lead to confusion later. A top-rated integrator should be able to write down what they will offer, what they can’t do, and what they assume.
How an Ideal Partner Operates
How they work is often the best way to tell the difference between a good provider and a real long-term partner. Values are also important because they help producers use technology to move forward.
An Approach Based on Partnerships
To see how these ideas work in practice, think about how Malisko handles integration. Malisko is an integrator of process automation and plant floor control that works on making tailored solutions for manufacturers across industries.
Its main goal is to build long-lasting relationships based on clear communication and common goals. Putting much of the weight on core values changes how projects are planned, recorded, and supported over time.
Putting the needs of the partnership first means taking the time to learn how the building works. It also means making control systems for the plant floor that can be expanded and fixed, not just working at the start.
How Important It Is to Guarantee Quality
How confident they are in the work of an expert says a lot about their own standards. Malisko offers a lifetime guarantee, which is valid as long as the customer’s team hasn’t changed the method they were given. When introduced carefully, this kind of promise signifies a long-term commitment instead of the end of a short-term project.
For manufacturers, that guarantee can make things less uncertain. It shows that engineers are dedicated and trust that the work will be done well.
Uses Technology and Data to Gain Insight
These days, more companies are investing heavily in smart technologies. On average,39% of factory budgets around the world are now spent on smart manufacturing projects, showing that an increasing number of factories are moving toward connected systems and data-driven processes.
With that much money being invested, hopes are raised. Facilities need integration partners who can show that the money they spend improves performance in a way that is measurable.
A good partner does more than set up PLCs and install gear. It helps places use data to make improvements that can be seen and measured. IoT and IIoT technologies, as well as IT/OT convergence strategies, are used by Malisko to link systems on the factory floor with data at the business level.
Manufacturers can see performance trends, downtime patterns and process differences more clearly when they turn operational information into usable data. The business as a whole makes better decisions because of it.
Best Practices for a Successful Integration Project
The process is important even if a facility has the right partner. For integration projects to go well, the building team and the integrator need to plan clearly and work together from the start.
Set up a Single Person to Talk To
Integrated projects move quickly. Every day, new questions come up, and choices often need to be made right away. Putting together a specialized project manager makes it easy to talk to the integrator’s lead. It clears things up, stops conversations from happening twice and keeps accountability strong.
Scope can also be better managed with a single point of contact. When people ask for changes or come up with new ideas, they can be reviewed consistently instead of being added on the spot.
Structured Communication Should Come First
Informal reports are rarely enough for strong projects. At an official kickoff meeting, everyone should agree on the project’s goals, timelines, success metrics, and who is responsible for what. That early clarity sets the tone for what to expect before the technical work starts.
From there, it’s important to check in often. The project stays on track with regular reviews of progress, tracking of issues, and open talks about risks. Dealing with small worries early on is much easier than dealing with shocks at the last minute.
Get End Users Involved Early
Every day, operators and repair workers will work with the system. Their feedback during design reviews can bring up practical issues that engineers might not see right away. Including them early on in the process makes them more likely to agree and less likely to fight against the mission.
This participation also improves long-term performance. Giving feedback on how to create an interface, handle alarms and integrate workflows can make things safer and more efficient.
Make a Plan for Testing Acceptance
Customers shouldn’t think of acceptance testing as a routine. Factory acceptance testing (FAT) is done at the integrator’s office to make sure the system works as planned before it is sent out. Site acceptance testing (SAT) makes sure that the system works well in real-world settings.
Both steps keep the building safe. They give structured chances to check standards and deal with problems before the final sign-off.
Ask for Thorough Training and Paperwork
Integration that works well goes beyond ordering. Along with high-level system overviews, teams need in-depth training. When it comes to maintenance, staff should know about design and code structure.
Documentation is just as important. Electrical diagrams, network layouts support long-term dependability, commented code and user guides. Detailed records allow for continuation even when systems change or people move on.
Choosing a Partner That Strengthens the Facility
One of the most important choices a manufacturing site can make is which plant system integrator to hire. The right partner has deep knowledge, follows strict procedures, and wants to work together for a long time.
When goals are clear and best practices are used, merging can lead to improvements that are measurable. Smart manufacturing and higher standards have changed the world, so choosing the right partners is a smart move.