Technical portfolio

Design and development of a modular, reusable PLC library for an automated intralogistics system: conveyors, diverters, sorters and sequencers handling material flow between the warehouse and the production lines.

The library is object-oriented (OOP in SCL), with standard function blocks for each actuator type: motor control, valve control, conveyor, sorter, pick-and-place. Every block implements start, stop, fault handling and interlocking logic the same way, which keeps maintenance and future plant expansion straightforward.

Commissioning covered full plant start-up with FAT and SAT acceptance testing, safety interlocking and production cycle optimisation.

Design, programming and commissioning of distributed control systems (DCS) on the Siemens PCS7 platform for the chemical industry. The project covered the full control system lifecycle: from basic engineering through commissioning and plant qualification.

The PCS7 configuration handles batch reactors, with automatic sequences for reagent charging, reaction, discharge and cleaning (CIP). APL (Advanced Process Library) modules were configured and parameterised for control valves, flow meters, pressure and temperature transmitters, and agitation systems.

Particular attention went to safety & compliance: implementation of SIS (Safety Instrumented System) functions and full documentation for ATEX certification and IQ/OQ plant qualification.

Full management of the engineering and maintenance department of an automated intralogistics factory, responsible for a multidisciplinary team of technicians, engineers and maintenance staff. The role covered planning preventive and corrective maintenance, managing the department budget and coordinating with production and quality.

The department was set up quantitatively: maintenance KPIs (OEE, MTBF, MTTR, failure rate), a structured work order system and a maintenance plan driven by asset criticality (RCM — Reliability Centered Maintenance).

The engineering side handled modifications and improvements to existing plant, management of change (MOC) requests, keeping technical documentation current, and coordinating automation vendors and external maintenance contractors.

Project management of the entire build of a new automated intralogistics factory, from initial planning to production start-up. The project covered plant design, installation of the automation systems, qualification and testing, through to training the operating staff.

The project was run on Earned Value Management (EVM) for budget and progress control, with continuous forecasting of estimate at completion (EAC) and cost performance index (CPI). The risk register was kept current with active response plans.

Coordination spanned international automation vendors, civil construction firms, systems integrators and the end client. Project documentation ran through a structured document control system with formal revisions and approvals.

AILET is a web platform built with Django and Python that links intralogistics plant design, PLC programming and electrical design in a single workflow. The plant is modelled once, with zones, assets and process connections, and the technical deliverables are produced from that model.

The code generation module starts from function block templates and parameter rules, defined once as automation know-how. It produces Siemens SCL sources, the asset DB configuration, function block instances and the IO tag table in Excel, with parameter generation for Rockwell as well. Generation can cover the whole plant, single zones or single assets.

For the electrical side, each asset can be enriched with EPLAN metadata and electrical connections: AILET exports a JSON payload that a dedicated .NET orchestrator uses to build the EPLAN project. REST APIs, JSON and Excel import/export and Docker deployment complete the integration with existing tools and cut manual work and consistency errors between disciplines.

Ordo is a warehouse management system (WMS) built in-house with Django and Python for industrial environments. It handles the full cycle of warehouse movements: goods receipt, issues, internal transfers and stocktaking, with full barcode traceability.

The system includes a production order module that links assembly requests to available stock, generating picking lists automatically and updating quantities in real time. Production progress reports are built in and available from a responsive web interface.

The REST API architecture allows integration with existing ERP systems and barcode data capture devices. The audit trail module keeps a complete history of every transaction, essential wherever regulatory traceability applies.

PTecSIL is a web application built with Django, Bootstrap and HTMX for managing the Safety Integrity Level (SIL) lifecycle to IEC 61508 and IEC 61511. It grew out of the need for a structured, documentable tool for functional safety on process plants.

The risk analysis module walks the user through the LOPA (Layer of Protection Analysis) procedure, calculating the SIL target for each Safety Instrumented Function (SIF). The SIF matrix records every safety loop in the plant together with component reliability parameters (PFDavg, λDU, β).

The SIL verification module calculates loop PFDavg automatically and compares it against the required target, producing the technical documentation the standards call for. The HTMX interface keeps the experience fluid without page reloads, which matters during long working sessions.

Design, installation and commissioning of a machine vision system for in-line quality control on a chemical process. The system inspects every single product at line speed, identifying surface defects, shape anomalies and foreign contaminants without stopping production.

The architecture uses high-resolution industrial cameras with structured lighting, an acquisition system synchronised to the line encoder, and image processing software combining deep learning classification with classical morphological analysis.

Integration with the line PLC runs over Profinet: the vision system reports each inspection result in real time, triggering automatic rejection of non-conforming product through a pneumatic actuator. The reject log is available from SCADA, with process statistics and analysis of the most frequent causes of non-conformity.

Full retrofit of the packaging, palletising and wrapping line for industrial powder bags: electrical and control work on a multi-machine in-line system. The aim was to modernise the control architecture, improve reliability and add production monitoring.

The project included complete replacement of the machine control panels, rewiring of the field cabling with new trunking, and migration from an ageing proprietary system to a Siemens S7-1500 PLC on Profinet. Communication between the machines on the line (bagger, weighing conveyor, palletiser, wrapper) now runs on a standardised protocol, which removed the synchronisation problems of the old system.

The new main panel carries a 15" touch HMI for centralised line control, with recipes for the different bag formats, fault diagnostics and production counters. The safety system was redesigned to EN ISO 13849-1, with PL d certified safety functions.