Services · Brevard County, FL

PLC Programming and Controls — Local and On-Site

PLC programming, controls upgrades, and robotic cell integration for manufacturers in Brevard County and across Central Florida. One engineer handles the whole stack — mechanical design, controls, programming, safety, and commissioning — without integrator minimums or six-month lead times.

Sound familiar?

The controls guy retired

One person understood the machine. Now a fault code means production stops while you search for anyone who still knows the platform.

Integrators won't take small jobs

The big automation houses quote $100K minimums and book out two quarters. A single-cell upgrade or one stubborn machine isn't worth their sales process.

Manual stations limited by labor

Loading, inspection, and finishing stations that can't hire reliably are exactly the processes a small robotic cell or smarter controls can absorb.

How it works

Controls work spans from a one-day program fix to a full robotic cell. The shape is always the same:

  1. 1

    Assess and spec

    On-site review of the machine or process — electrical drawings, existing program, safety state — and a written fixed-price scope before any work starts.

  2. 2

    Design

    Mechanical design in SolidWorks (CSWP certified), electrical schematics, control panel layout, and component selection — with vendor quotes passed through at cost.

  3. 3

    Program and build

    PLC programming (Click, Allen-Bradley ecosystems, and others), HMI screens, servo and motion configuration, machine vision integration, and robot programming for cells.

  4. 4

    Commission, verify safety, train

    Installation, I/O checkout, safety circuit verification, operator training, and full documentation — code, drawings, and manuals are yours, not held hostage.

What a controls upgrade buys

A manual station absorbed by a small automation cell returns its labor every shift it runs — and the Factory Floor Pilot guarantee makes it concrete: we agree on one KPI before signing, and if it hasn't improved 15% within 60 days, I keep optimizing for 30 more days free.

When the machine is down, local is the spec

Controls problems don't schedule themselves. When the machine that anchors your whole flow faults out on a Tuesday morning, the difference between a controls engineer based in Cocoa and an integrator two states away is the difference between losing an afternoon and losing a week. I cover Brevard County and Central Florida on-site — Titusville, Rockledge, Melbourne, Palm Bay, and the I-95 corridor between — and a diagnostic visit is a drive, not a travel quote. Remote support has its place, but faults that involve intermittent sensors, mechanical binding, or program logic tied to physical layout almost always diagnose faster in person, and faster diagnosis means less production lost.

Local also changes how projects run. Robotic cell and controls work involves dozens of small decisions that go better standing at the machine: guarding clearances, operator reach, where the HMI actually belongs so people use it. Those conversations are cheap when the drive is short, so they happen early instead of after something is welded down. And after commissioning, the 30-day support window means in-person follow-ups with your operators — while every program, drawing, and manual lives on your server, not mine. If we never speak again, you still own a complete, documented system. That full-ownership model is intentional: the goal is a machine or cell that your people understand, can troubleshoot on their own, and can hand to the next engineer without starting over.

Factory Floor Pilot

$5,000 – $12,000

Most controls work fits the Factory Floor Pilot: one process, fixed price, hardware at documented pass-through cost. Bigger transformations step up to the Full-Stack Package.

  • ✓Single-process factory floor automation
  • ✓3D CAD design and engineering documentation
  • ✓PLC/controls programming and commissioning
  • ✓Safety verification and operator training
  • ✓30-day post-launch support

Timeline: 4-8 weeks · Hardware/materials quoted separately

Guarantee: We define the target KPI before signing. If it doesn't improve 15%+ within 60 days, I provide 30 days of additional optimization at no charge.

Every engagement starts with the free Automation Audit — on-site in Brevard County, written report in 48 hours, no cost and no obligation.

Common questions

Which PLC platforms do you work with?+
Click PLCs and the Allen-Bradley ecosystem are the daily drivers, and the engineering transfers across platforms — if your machine runs something else, the assessment visit confirms fit before you spend anything beyond the audit.
Do you build complete robotic cells?+
Yes — cell layout, fixture design, robot selection and programming (Fanuc), guarding and safety circuits, and commissioning. Pilot-scale cells are the sweet spot: one process, proven before you scale.
Can you support equipment after the project ends?+
Every project ships with documentation and a 30-day support window. After that, the monthly retainer covers ongoing support, optimization, and new features — or you call when something breaks. You own everything either way.
Can you take over a half-finished or undocumented system?+
Yes — rescue work is common. Undocumented programs get backed up first, then mapped I/O point by I/O point until there's a drawing set that matches reality. From there we fix the immediate fault and decide together whether the right move is targeted repair or a controls refresh. Either way, you end up with documentation that makes the next problem cheaper.

Related

Based in Cocoa. On-site across the Space Coast.

The free audit walks your floor, maps your processes, and prices the opportunities — 3+ actionable findings, no cost, no obligation.