The Challenge
A line builder based in the Midlands was developing a gantry assembly system for the internal rings of medical devices, destined for the healthcare industry. The system required precise, well-tested PLC control to manage the gantry through its assembly sequence, and the project was working to a fixed customer Factory Acceptance Test (FAT) date that left little room for delay.
As the deadline approached, the line builder needed additional engineering capacity to keep the programme on track. Rather than working a standard single-shift pattern, the project required coverage across multiple shifts, including weekends, to compress the remaining timeline and give the team the best possible chance of being ready for FAT.
The brief: Provide flexible PLC engineering resource, working in Siemens TIA Portal V19, to support offline programming and commissioning of a gantry assembly system for medical device internal rings, including full safety commissioning, across an extended shift pattern ahead of a fixed customer FAT date.
What Duke Did
Flexible Engineering Capacity
Duke Control Systems is supplying flexible engineering resource directly to the line builder's project team, acting as an extra pair of hands during a critical phase of the build. Rather than running a separate workstream, Duke's engineers are integrated into the existing project, working alongside the line builder's own team to share the workload and keep the programme moving.
PLC Offline Programming in TIA Portal V19
The gantry system is controlled using Siemens TIA Portal V19. Duke's engineers are developing and refining PLC logic offline, working through the control sequences required to manage the gantry's movement and assembly operations accurately and reliably ahead of the system being proven on the physical build.
Commissioning
As the physical gantry system comes together, Duke's engineers are supporting commissioning directly, working through the control logic against the real equipment, resolving issues as they arise, and progressively proving out the system's behaviour ahead of FAT.
Safety Commissioning
Given the precision and scale of equipment involved in assembling medical device components, safety commissioning is a critical part of the scope. Duke's engineers are working through the safety system commissioning required to ensure the gantry operates correctly and safely throughout its full range of movement.
Extended Shift Coverage
To compress the remaining schedule ahead of FAT, the work is being carried out across multiple shifts, including weekends. This extended coverage allows the combined team to make faster progress against the programme than a standard single-shift pattern would allow, directly supporting the line builder's ability to meet its FAT date.
When a FAT date is fixed and the build is behind where everyone would like it to be, the most useful thing we can offer is genuinely flexible capacity, engineers who can slot straight into someone else's project, work the shifts the programme needs, and get on with it without needing weeks of onboarding first.
Need extra PLC capacity against a tight deadline?
Whether it is offline programming, commissioning, or safety work, we can provide flexible engineering resource that integrates directly with your existing team.
Start a Conversation →Current Status
This project is in progress. Duke's engineers continue to support the line builder's team with PLC offline programming, commissioning, and safety commissioning across an extended shift pattern, working towards the customer FAT date for the medical device gantry assembly system.
At a Glance
- Sector: Life Sciences, Healthcare Equipment, Midlands
- Scope: PLC offline programming, commissioning, safety commissioning
- Platform: Siemens TIA Portal V19
- Application: Gantry system assembling medical device internal rings
- Role: Flexible engineering resource supporting a line builder's team
- Working Pattern: Multiple shifts including weekends
- Driver: Compressing the schedule ahead of customer FAT
- Status: In progress