Industrial automationengineered.

A Bosch FRK 6180 C rotary piston filler for sterile pharmaceutical liquids, documented in 1993/94. The mechanics were intact, but the machine had stood still for four to five years: the original Bosch control had been removed, a Delta PLC had been fitted by others, sensors were missing and interlocks were bypassed.

Nobody knew what the machine still had or what it needed. The only reference was the original paper documentation, and every sensor, valve and interlock had to be found again before a new control program could be written.

With the team, traced the machine sensor by sensor and interlock by interlock against the original schematics, found what was missing and bench-tested suspect components out of circuit. Rebuilt the I/O map by hand from the machine documentation, calibrated photoelectric and proximity sensors, and recorded every test and replacement. The original Moeller contactors and TM-54/30 transmitters were kept where they still worked.

Component-level isolation rather than wholesale replacement. Each suspect part was verified out of circuit before condemning it, which saved the client unnecessary spares spend and made the eventual root cause defensible.