Most control panels are designed to meet a spec.
But meeting the spec isn’t the same as solving the real problem.
In fast-moving manufacturing environments, panel design is often driven by individual project requirements: a sensor here, a VFD there, a mix of suppliers, and logic that works on that machine for now.
But what’s missing from this approach is harmonisation. Without standardisation across your control systems, you’re introducing cost, complexity, and long-term risk you might not feel until it’s too late.
At ECS, we build control panels for maintainability and lifecycle cost, not just for tick-box functionality. In this blog, we aim to explore why standardising your panel design might be the best investment you make this year.
Let’s make your control panels work in perfect harmony
Meeting Needs vs Harmonising Systems
There’s a big difference between building something that works and building something that works better, longer, and cheaper.
Meeting the spec looks like:
- Panels designed around a single machine or process
- Mix-and-match components based on supplier preference
- Control logic is written from scratch every time
- Part numbers are unique to each asset
- Schematics that only make sense to one engineer
It’s functional. It gets the job done. But it creates:
- Slowdowns during breakdowns
- Dependency on a few “in-the-know” staff
- Growing part diversity and storage requirements
- A spiderweb of documentation and support needs
Harmonisation looks like:
- Shared control architectures across lines and plants
- Common components with approved alternates
- Standard logic blocks reused across builds
- Consistent HMI layouts and diagnostics
- Fewer surprises when things go wrong
- One supports the business. The other barely supports itself.
The Business Case for Standardisation
Let’s break it down into five key benefits, each one tied to your operational performance and bottom line.
1. Faster Repairs and Less Downtime
When systems follow a common structure, same layout, same drive types, and same logic patterns, your engineers can diagnose and fix faults faster.
“Standard panels reduce troubleshooting time by up to 40% across multi-line facilities” — Internal ECS Benchmark
A line stoppage becomes a familiar scenario instead of a head-scratcher. The right tools and parts are already in stores. The engineer has seen the fault before. The fix happens faster. Production recovers sooner.
2. Parts Rationalisation = Supply Chain Resilience
Every variation in component choice adds pressure on your spares strategy.
With standardisation:
- You reduce the number of SKUs you need to stock
- You can buy in larger quantities and negotiate better pricing
- You build resilience into your supply chain by reducing dependency on obscure or one-off parts
When global component shortages strike (like they did in 2020–2023), standardised systems are easier to support and keep running. You don’t scramble to find a one-off obsolete relay buried in a bespoke machine; it’s already on your shelf, because it’s used everywhere.
3. Economies of Scale
It’s not just the parts themselves; it’s your whole operational overhead:
- Installation time drops when your team is familiar with the layout and spec
- Design time drops when logic blocks and schematics are templated
- Training time drops when operators only need to learn one interface style
This scales across sites, too. If you’re a multi-site operation, the benefits of standardisation don’t just add up; they multiply.
4. Proactive Obsolescence Management
Here’s a scenario we see far too often:
A machine fails. The drive is dead. Turns out it hasn’t been manufactured since 2015. The supplier is long gone. The entire control scheme needs rewriting. Downtime: three days and counting.
Standardisation helps avoid this because:
- Approved part lists are reviewed more often
- It’s easier to build and maintain obsolescence reports
- You can proactively migrate systems before support ends
And if you’re using ECS Vault, you’ll already have a live digital record of what’s installed where, with age, version control, and replacement plans ready to go.
5. Easier Maintenance, Better Staff Retention
Maintenance engineers don’t just want tools; they want the right tools. And they want to use their time solving real problems, not relearning obscure code or figuring out how to remove a relay from behind a compressor pipe.
With harmonised panels:
- Fault finding is familiar
- Training new staff is easier
- Confidence and autonomy go up
- Frustration goes down
That means you don’t just reduce downtime, you reduce turnover too. Engineers stay longer when they feel competent and supported.
The Cost of Getting It Wrong
Let’s flip it. Here’s what happens when you don’t harmonise your panel strategy:
- Engineers waste time figuring out unfamiliar layouts
- Different systems require different spares, tools, and training
- Documentation becomes scattered and hard to manage
- Risk of obsolescence grows unnoticed until a fault happens
- Your support team becomes reactive instead of proactive
These costs don’t hit the CAPEX budget, but they absolutely hammer OPEX.
Standardisation Is Not About One-Size-Fits-All
It’s worth saying, standardisation doesn’t mean forcing every machine to use identical components or logic regardless of function. That’s poor engineering.
What we’re talking about is structured flexibility:
- Shared frameworks
- Modular designs
- Clear rules for when and why you can deviate
- Built-in paths for future upgrades
Think of it like a LEGO kit: diverse outcomes, but always built on a common language.
Where ECS Adds Value
At ECS, we don’t push standardisation because it makes our job easier. We do it because it makes your systems stronger, cheaper, and easier to manage over time.
With ECS Projects:
- We design standard panel layouts that can be rolled out across multiple lines or sites
- We use templated, version-controlled logic blocks that can be modified without reinventing the wheel
- We document every system with future maintenance in mind
With ECS Vault:
- You get a single source of truth for all your digital assets
- We help you maintain part lists, update logs, wiring schematics, and software backups
- Our obsolescence reports let you plan years ahead, not panic days behind
With ECS Connect:
- Our engineers can remotely support your systems using familiar architecture
- Faults are diagnosed faster because we know what we’re looking at
- Updates and support can be templated and repeatable
Whether you’re building your first automated line or managing ten sites, we help you harmonise without compromise.
ECS Standardisation Snapshot
| Area | ECS Approach | Result |
| Panel Layout | Standardised footprint and wiring zones | Faster build and repair |
| Components | Approved part lists with alternates | Better pricing and spares control |
| Software | Reusable, version-controlled logic blocks | Lower dev time and easier troubleshooting |
| Documentation | Vault-based asset tracking and backups | Compliance-ready and accessible |
| Support | Remote diagnostics via Connect | Less downtime and faster resolution |
Getting Started: What You Can Do Today
You don’t need to rip and replace your entire system to get the benefits of standardisation. Start with:
- A review of your most common breakdowns – Are they tied to complex or unique systems?
- Create a preferred parts list – Limit variations unless justified
- Update your panel design spec – Include layout rules, spacing, and HMI conventions
- Centralise documentation – Even a shared folder is better than five engineers’ desktops
- Talk to ECS – We’ll help audit and identify quick wins that won’t disrupt your ops
FAQs
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What if our machinery varies a lot across lines?
That’s fine. Standardisation isn’t about sameness, it’s about structure. You can still standardise logic blocks, panel layout, or naming conventions across different machinery types.
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Will this lock me into one supplier or vendor?
No. It gives you more flexibility because your systems are easier to support across multiple suppliers and engineers.
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We already have a standard. Isn’t that enough?
Not always. We often see outdated or unused “standards” that live in a PDF but not in practice. The real value comes when standards are actively applied, maintained, and improved.
Final Thoughts: The Power of Intentional Design
Every control panel you install becomes part of your long-term ecosystem. It will be opened, cleaned, repaired, updated, and fault-found by people who didn’t install it, possibly years after the project team has moved on.
Harmonising your panel design isn’t just a design choice. It’s an operational strategy.
One that saves time. Saves money. And keep your plant moving.
Let’s Build Panels That Last
Whether you’re starting a new project or want to review your existing setup, ECS can help you put standardisation into practice. No jargon, no BS, just real engineering, done well.
🔍 Request an audit of your current control panels
💡 Ask about ECS Vault and Connect for long-term support