Modernizing Control Systems for Scalable Performance, Growth, and Future-Ready Innovation
Overview
A leading aerospace manufacturer needed to replace aging control systems while preparing for future plant expansions. Kendall Electric collaborated with the manufacturer to deliver a scalable automation solution to improve production, reduce downtime, enhance security, and simplify operations.
The Challenge
The facility was operating with legacy SLC control systems and PanelView HMIs. Parts were becoming obsolete, and internal stock was running low.
The customer needed a solution that would:
Eliminate legacy risk and support long-term maintainability
Integrate with their existing PI Historian for advanced data collection
Meet evolving safety standards, including SIL2 compliance
Fit within tight capital budgets while supporting future plant expansions
The goal was to create a plant-wide automation standard that could be deployed across new and existing systems. By establishing a future-ready foundation, Kendall Electric ensured the solution would support ongoing growth, adaptability, and evolving operational needs.
Implementation Highlights
Architected a replacement of over 30 legacy SLC systems with a unified, modern control architecture
Integrated secure data collection and access control across the plant
Established a repeatable standard to support ongoing growth and safety upgrades
Enabled increased production by 15% and uptime by 20%
Designed for up to 60% cost savings per upgrade
The Solution
Kendall Electric designed a comprehensive solution tailored to the customer’s technical and operational needs by selecting scalable, future-ready platforms like CompactLogix 5380 and PanelView 5000 from Rockwell Automation. The solution addressed immediate risks while laying the groundwork for evolving demands and future growth.
A scalable automation standard
1
The team collaborated to define a plantwide control standard using Rockwell Automation’s CompactLogix 5380 platform and PanelView 5000 HMIs. This standard was designed to be scalable, maintainable, and easy to deploy across both retrofits and new expansions.
Built in security and data visibility
2
The solution included managed Stratix switches to support secure Ethernet/IP communication and advanced data collection. RFID badge access was integrated to enhance operator-level security and enable traceability. These features aligned with the customer’s existing infrastructure and goals.
Ongoing support through every stage
3
The project was shaped through continuous collaboration. Adjustments were made along the way to fit real-world constraints, and support remained active as the customer continued rolling out the standard across the plant.
Impact
The modernization effort delivered measurable improvements across performance, cost, and operational visibility. The reliability and consistency of the new control systems increased production and uptime. The customer reported strong gains in efficiency and reliability, supported by real-time data and a standardized control environment.
15% increase in production output
20%+ improvement in uptime
Estimated cost savings of up to 60% per upgrade
Real-time visibility into machine performance with Ethernet/IP hardware
Modernized operations with phased upgrades and minimal disruption
Your Possibility. Our Purpose.
At Kendall Electric, we’re your trusted ally for turning plans into progress. Whether you’re modernizing, maintaining, or moving to solve a new challenge, we’re ready to help you succeed with strategic expertise, premium products, and practical action.
Connecting power with possibility is not just our vision. It’s what we do every day.