When you build for speed, you get it fast. When you build for life, you get it right.
Across UK manufacturing, we see the same story again and again: automation projects designed around headline output figures but with almost no thought given to how those systems will actually be maintained. On paper, it looks great: maximum throughput, clean commissioning, everything on spec. But six months in? The doors are sticking, the drives are failing, no one can fault-find the logic, and cleaning the panel without flooding the floor takes three engineers and a mop.
At Enhanced Control Solutions (ECS), we think differently because we are engineers. And we’ve been on the sharp end of it.
This blog explores what happens when you take a maintenance-first approach to automation and control panels, why it matters, and how to build systems that last.
The Industry’s Obsession with Output Per Hour
The world of automation loves a metric, and there’s one that dominates procurement briefs: units per hour.
That’s not surprising; high throughput is a clear commercial goal. But when output is the only consideration, you create a blind spot that leads to much bigger problems down the line:
- Panels that are too cramped to fault-find live
- Drives positioned in heat zones with no active cooling
- HMIs placed where the operator can’t see the machine
- No integration with Clean-in-Place (CIP) or Washdown protocols
- Labelling systems that make no sense unless you’re the original installer
We’ve walked into facilities where 12-month-old panels already look ten years old. Because once the project team packs up, it’s the maintenance team who inherit the mess.
And that’s the real measure: Products per Lifetime, not Products per Hour.
The Cost of Ignoring Maintenance
When maintenance isn’t baked into the design, your systems will cost you more in the long run. Here’s how:
1. Increased Downtime
Poor layout and inaccessible components delay fault resolution. What should be a five-minute fix can become an hour-long outage.
2. More Callouts, More Cost
You’ll rely more heavily on OEM engineers or third-party support, racking up service charges for basic interventions.
3. Compliance Risks
In food, pharma, and chemical sectors, hygiene isn’t optional. Lack of CIP or improper sealing leads to audit failures or even product recalls.
4. Higher Staff Turnover
Frustrated maintenance teams are more likely to leave. Retaining skilled engineers becomes harder when they’re firefighting avoidable issues daily.
5. Premature Asset Failure
Overheating, water ingress, and vibration fatigue, all more likely in a system not designed with long-term wear and real-world usage in mind.
The Health & Safety Price Tag
Poorly designed control systems don’t just slow production; they can actively create unsafe working conditions. Tight panel layouts may force engineers to work live in cramped spaces, components mounted at awkward heights increase manual handling risks, and lack of safe isolation points can lead to lockout/tagout violations.
In regulated sectors, these aren’t minor oversights; they’re compliance failures. Health & Safety fines in UK manufacturing have doubled in recent years, with the average breach costing £115,440, and the cost of non-compliance running 65% higher than simply doing it right in the first place. Building for safe access and operation from day one isn’t just a moral obligation; it’s a financial one.
Case in Point: A Real-Life Scenario
We once supported a client whose automated filling line had fantastic throughput, but required a full system shutdown just to replace a single flow sensor.
Over two years, what started as a flagship install became a weekly maintenance bottleneck. Engineers regularly worked overtime to maintain output, and the company eventually lost a major contract due to consistent late deliveries.
All avoidable. All down to design.
Hygiene: The Overlooked Compliance Killer
Hygiene-critical environments like food and beverage production have to meet strict regulations, not just during commissioning, but every single day.
And yet, control systems are still being installed with:
- Flat surfaces that trap debris
- Unsealed cable entry points
- Components that corrode under washdown
- No integration with CIP systems
These are the kinds of details that can fail a BRC audit or trigger product withdrawal. When you build with hygiene in mind, you build resilience, not just compliance.
Project-Led vs Lifecycle-Led: A Quick Comparison
| Factor | Project-Led Focus | Lifecycle-Led Focus |
| Output | Units per hour | Units per asset lifespan |
| Budget | Upfront CAPEX | Total cost of ownership |
| Design input | OEMs + Project Managers | Maintenance + Operations teams |
| Cleaning & hygiene | Often overlooked | Integrated from the start |
| Spares & support | Optional | Strategically planned |
| Engineering change risk | High | Low (built with future in mind) |
What Good Looks Like: A Maintainability-First Build
Maintainable control systems share common traits:
- Clear labelling with logical hierarchy
- Accessible layout: nothing buried or blocked
- Remote diagnostics via secure PLC connection
- Airflow and cooling designed for realistic conditions
- Standardised components for easier spares handling
- Version control and backups stored securely
- Operator interface that makes fault-finding simple
In short: they’re built for the people who use and maintain them, not just the people who spec them.
Maintainability Checklist (Downloadable Version Coming Soon)
Use this as a quick litmus test on your next panel or project:
- Can a fault be diagnosed remotely?
- Are all components labelled and documented?
- Can I replace key components without stopping production?
- Does the layout allow for airflow and thermal protection?
- Are hygiene-critical standards met for your industry?
- Is there a secure record of firmware, software, and backups?
- Can an engineer unfamiliar with the install safely fault-find?
If you’ve ticked fewer than five, let’s talk.
How ECS Does It Differently
We build control systems and automation solutions designed to make life easier after the project is complete. Why? Because we’re the ones who often get called in when it all goes wrong.
With ECS Projects:
- Panels built with accessibility, fault-finding and compliance in mind
- Collaborative scoping with your maintenance and ops teams
- Clear documentation and structured wiring
With ECS Connect:
- Secure remote access to PLCs and HMIs
- Fast-response support from actual automation engineers
- On-demand diagnosis to reduce downtime and engineer travel
With ECS Vault:
- A cloud-based digital asset management system
- Stores backups, contract details, obsolescence reports and software history
- Helps meet audit and compliance requirements without scrambling
This combination means we don’t just build once and walk away. We build systems that support themselves, through smart design, robust access, and intelligent data.
But Isn’t That Just Best Practice?
You’d think so. But in our experience, best practice often gets thrown out when:
- Budgets are tight
- Deadlines loom
- OEMs are driving specs
- Maintenance teams aren’t involved in planning
The result? Good people end up firefighting poor decisions they had no part in making.
We make it our business to change that, from the first conversation to the final panel screw.
Short-term cost-cutting is often the biggest enemy of maintainability. Opting for cheaper enclosures, skipping cooling fans, reducing panel size, or cramming layouts to shave a few thousand from the CAPEX might please the budget sheet today, but it sets you up for expensive breakdowns, safety breaches, and production losses tomorrow. True cost savings come from designing out risk and inefficiency, not designing them in to save on initial spend.
Let’s Build Something You’ll Be Proud to Maintain
We know that as an Engineering or Operations Manager, you’re juggling cost, compliance, people, and output every day. You don’t just need a flashy new install; you need one that works, every day, for the next 10 years.
Whether you’re planning a panel upgrade, a full automation build, or simply want to get better visibility of your current system health, we’re here to help.
Book a meeting with the team
From planning your next automation solution, protecting your existing intelligent devices, or making sure you have the right people when you need them. Why not speak to our sales team and book a meeting to see how we can transform your business:
ECS: Engineered for Maintainability. Built to Last.