Step 1 – Understanding Your Needs
Many plants have been running reliably for 10, 20 or even 30 years – but with technology that is no longer up to today’s standards. Spare parts are difficult to obtain, specialists for old software are retiring, and the “patchwork” of solutions that has grown over decades makes failures more frequent and unpredictable.
Typical reasons for an upgrade
- Increasing capacity
- Improving product quality and process stability
- Reducing waste and ensuring higher predictability
- More automation, less manual effort and reduced risk of human error
Our role
We show you the most technically and economically sensible path:
- Retrofit – targeted replacement of outdated components (PLCs, panels, drives).
- Modernization – a combination of retrofit and functional/process improvements, such as energy optimization or new automation technology.
- New system – when retrofit or modernization are no longer viable, we develop a tailored complete system.
Your benefit
An honest, professional recommendation – without sales pressure, focused on getting the maximum out of your existing technology.
Step 2 – Technical Analysis & Feasibility Assessment
For a solution to truly fit, we need to understand your system in detail. In an analysis meeting, we capture the current state, processes, and operating conditions – making opportunities and risks visible at an early stage.
Our role
- Recording the control technology (PLCs, operator panels, networks)
- Reviewing existing schematics, software, and material flowsheets
- Assessing the spatial layout
- Documenting process interfaces with other systems
- Initial identification of bottlenecks, weaknesses, and safety risks
Result
A clear feasibility assessment:
- Feasible → we move on to the engineering phase
- Feasible with limitations → we outline possible compromises
- Not viable → we explain openly why and show alternative options
Your benefit
You only invest in detailed planning once technical feasibility is assured – providing a sound decision-making basis without unnecessary costs.
Step 3 – Engineering & Concept Development
In this phase, we establish the technical foundation of your project. We analyze existing documentation or, if necessary, apply reverse engineering – always with the goal of fully understanding the current state.
Our role:
- Analysis of existing documents: schematics, software, parts lists, operating manuals
- Reverse engineering if documentation is missing – e.g. wire-by-wire analysis or software analysis
- Recording of sensors, actuators, and communication interfaces
- Documentation of the current state as a basis for further planning
- Preparation of a solution concept with rough time and cost estimates
Result
A technically sound concept showing which parts can be reused, which components need replacement or adjustment, and which improvements are advisable.
Your benefit
Clear facts on how a retrofit, modernization, or new system would look in your specific case.
Important: Reverse engineering is often required but will only be carried out in detail once the project has been commissioned.
Step 4 – Technical Specification & Proposal
Based on the concept, we create a binding and transparent foundation for your project.
Our role
- Specification of the system architecture, including controller type, I/O scope, safety and communication concepts
- Description of functional areas and interfaces
- Overview of main components and assemblies (including a parts list summary)
- Preliminary schedule and timeline
- Commercial proposal, either as a fixed price or effort-based calculation
Result
A binding proposal with a clear scope of supply, defined costs, and a realistic delivery schedule.
Your benefit
Technical clarity, full transparency, and a reliable decision-making basis – without unnecessary upfront costs.
Step 5 – Implementation & Commissioning
With the order placed, implementation begins. TM BCS takes full responsibility for coordination – from manufacturing to commissioning.
Our role
- Manufacturing or modification of control cabinets
- Delivery and installation of new components
- Development and testing of PLC and HMI software
- Execution of FAT, SAT, and safety tests
- On-site commissioning – with a strong focus on minimizing downtime
- Shift work if necessary to further reduce production outages
- Training of operating and maintenance personnel
- Handover of all technical documentation
- Optional: support during the initial weeks of operation (“babysitting”, hotline)
Result
A tested, documented, and turnkey system with modern technology and secured spare parts availability.
Your benefit
One central point of contact, smooth coordination, and reliable commissioning – efficient, safe, and from a single source.