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Efficient, Safe, Full-Service

Modernisation and obsolescence to deliver more efficient production operations

Malone Group provides legacy systems modernisation and obsolescence management services to ensure your mission-critical production processes remain fully operational with minimum downtime. This is one of the greatest challenges and concerns in manufacturing and process industries. We work collaboratively with your team to address the obsolescence management challenge in a way that delivers a smooth transition, modernises the production/ operating systems offering greater efficiency and data insights while solving some of the challenges of the past.

Obsolescence in legacy systems typically relates to PLC hardware, SCADA and HMI equipment, to control panel equipment, cabling and instrumentation and control devices. Obsolescence problems generally lead to excessive downtime, as parts are become unavailable. This can really impact the productivity, efficiency and lead times for your business. Malone Group manages this whole process for you to manage these risks by identifying potential issues, planning replacements and implementing changes.

Understanding Your Unique Needs

Complete Automation Solutions

Our focus is not on upgrading/migrating the legacy equipment and systems with new technology but to use this opportunity to look at the bigger picture and resolve the nagging unaddressed issues of the past and transform the overall operations. Our services begin with site wide control systems survey to document the installed base with obsolescence risk assessments supported by migration plans for key equipment.

This involves the replacement of legacy systems with detailed installation, migration and commissioning plans to minimise disruption. Our structured approach ensures that the critical equipment is identified and areas of greater risk are prioritised, and a plan is in place to mitigate that. This avoids downtime and manages legacy systems modernisation and obsolescence to deliver more efficient production operations.

Legacy Systems Modernisation

We specialise in modernising legacy systems and managing obsolescence to keep mission-critical production processes running smoothly with minimal downtime, addressing one of the major challenges in the manufacturing and process industries.

Collaborative Approach to Obsolescence Management

We work closely with your team to tackle obsolescence management challenges, ensuring a seamless transition to modernized production and operating systems that offer enhanced efficiency and deeper data insights, while resolving past issues.

Comprehensive Coverage of Legacy Components

Our services address obsolescence in critical areas including PLC hardware, SCADA and HMI equipment, control panel components, cabling, and instrumentation and control devices, thereby preventing excessive downtime due to unavailable parts.

Strategic Risk Management and Planning

Through identifying potential obsolescence issues, planning for replacements, and implementing necessary changes, Malone Group manages the entire process to mitigate risks and enhance productivity, efficiency, and lead times for your business.

Holistic Upgrade Strategy Beyond Mere Replacement

Beyond simply upgrading or migrating legacy equipment, we seize the opportunity to address long-standing issues, offering a comprehensive review and transformation of overall operations with a site-wide control systems survey and obsolescence risk assessments.

Minimized Disruption with Structured Migration Plans

Our approach includes detailed installation, migration, and commissioning plans for legacy system replacement, prioritising critical equipment and high-risk areas to mitigate downtime, ensuring a smooth transition to more efficient production operations.

Related Capabilities

Capabilities are the cornerstone of our expertise

Automation & Control services encompass a comprehensive suite tailored to modernize and optimize industrial processes. With deep expertise across both contemporary and legacy platforms such as B&R, Omron, Mitsubishi, GEM, Siemens, and Rockwell, we ensure seamless specification, installation, and networking integration right at the plant floor. Our approach integrates business systems for enhanced reporting and scheduling, backed by the expertise of our in-house process engineers to deliver efficient plant control and vital production information.

We manage complete automation solutions from design to commissioning, including skid systems like CIPs, providing end-to-end support for a ready-to-operate system. Our services extend to include FAT, SAT, and performance trials for commissioning support, real-time remote access support for immediate issue resolution, and a broad portfolio covering everything from SCADA systems and process control to system integration and legacy upgrades. This comprehensive offering is designed to streamline operations, reduce downtime, and ensure a rapid, secure transition into automated efficiencies.

By integrating cutting-edge technology, eco-friendly materials, and green spaces, we strive to enhance community well-being, reduce environmental impact, and build spaces that are safe, accessible, and geared towards the future.

Comprehensive support across the lifecycle of manufacturing projects, from initial design through to execution and maintenance, thereby driving operational improvements and fostering innovation within customer operations.

By closely examining and understanding every aspect of the production line, we identify opportunities for improvement, integrating advanced automation, data analytics, and process re-engineering to drive performance and reduce costs.

By implementing advanced data analytics, AI, and IoT solutions, our team enhances connectivity across processes, improving decision-making, productivity, and operational agility, ultimately delivering a more streamlined manufacturing or built environment.

Automation & Control Services

Frequently Asked Questions

If you have any further questions or require additional information, please don’t hesitate to contact us. We’re here to assist you.

Malone Group's automation and control services are designed to streamline and optimize industrial processes through the implementation of cutting-edge technologies. Our services range from designing and implementing bespoke automation solutions, PLC (Programmable Logic Controller) programming, SCADA (Supervisory Control and Data Acquisition) systems, to integrating advanced control systems that enhance efficiency, productivity, and safety. We focus on delivering solutions that are tailored to meet the unique needs of our clients' operations.

By leveraging our automation and control services, clients can expect significant improvements in their manufacturing processes, including increased operational efficiency, reduced production costs, enhanced product quality, and minimized downtime. Our solutions are designed to optimize resource use, automate repetitive tasks, and provide real-time data for better decision-making, leading to overall process improvement and competitive advantage.

Absolutely. We understand that each industry and client has unique requirements and challenges. Our team works closely with clients to understand their specific needs, designing and implementing automation solutions that are fully customized to align with their operational goals. Whether it's food and beverage, pharmaceutical, manufacturing, or any other sector, we tailor our solutions to fit the particular nuances of each industry.

Data is at the heart of our automation and control services. We implement systems that not only automate processes but also collect and analyze data to provide actionable insights. This enables continuous process improvement, predictive maintenance, and more informed decision-making. Our aim is to transform data into a strategic asset for our clients, driving efficiency and innovation.

Our team specializes in integrating new automation and control systems with existing infrastructure in a seamless manner. We conduct thorough analyses to understand the current setup and design solutions that complement and enhance the existing processes. Our expertise ensures that the transition is smooth, with minimal disruption to ongoing operations, maintaining continuity and maximizing the value of both new and existing systems.

What sets Malone Group apart is our comprehensive approach that combines technical excellence with a deep understanding of our clients' business goals. Our team of engineers and specialists is dedicated to delivering not just solutions but also strategic advantages that make our clients' operations more efficient, resilient, and competitive. We stay at the forefront of technological advancements to ensure our clients benefit from the latest innovations in automation and control, tailored to their specific operational needs.

Send us a message

At Malone Group, we eagerly anticipate connecting with you. Whether you’re seeking innovative design solutions or just wish to learn more about our community-centered approach, we’re here to assist. Reach out to us; let’s start a conversation that could lead to remarkable collaborations.

Design, build, and maintain properties, along with public infrastructure

Creating and managing spaces where people live, work, and interact daily, focusing on light building environments beyond heavy machinery or manufacturing. This includes designing, constructing, and maintaining residential and commercial buildings, public spaces, and infrastructure with an emphasis on sustainability, safety, and innovation.

Where engineering marvels meet practical application

We appreciate that each facility is a unique entity, a bespoke blend of technology, human skill, and process. This understanding is the bedrock upon which we offer our services, ensuring that each customer’s facility is not only built to last but also to evolve.

A committed journey towards the project's outcomes

We are committed to the outcomes and to the journey towards them. It’s about harnessing technology, human ingenuity, and process excellence to ensure that every step of the manufacturing process is optimized for quality, sustainability, and efficiency.

Simplified, practical,
cost effective solutions

As society moves towards increased digitalization, it is inevitable that manufacturing will also move in that direction. Many companies, out of necessity, have embraced this journey and created truly modern futuristic factories.

Maximizing waste management

Sustainability means meeting our own needs without compromising the ability of future generations to meet their own. Embedded in most definitions of sustainability, we also find concerns for social equity and economic development.

Interacting with complex systems and machinery in a virtual overlay

Explore the untapped potential of AR and 3D modeling, setting new standards for excellence and pushing the boundaries of what’s possible. Welcome to the future, where every challenge is an opportunity for innovation, and every vision is within reach.

Collaborative planning
and execution

Working hand-in-hand with your team, Malone Group assists in planning and executing your project from its conceptual stage to commissioning. Our goal is to ensure timely completion within budget, prioritizing safety compliance throughout the process.

Comprehensive range
of design services

Your capital project will benefit from our comprehensive range of engineering design services, including feasibility studies, outline designs, budget costing, detail designs/full specifications and tendering packages.

Delivering Zero Harm
in all environments

Our team provides world-class safety management services by combining a unique set of project skills and collective industry sector experience driven by the close integration between our safety and engineering departments.

Simplified, practical,
cost effective solutions

As society moves towards increased digitalization, it is inevitable that manufacturing will also move in that direction. Many companies, out of necessity, have embraced this journey and created truly modern futuristic factories.

Maximizing waste management

Sustainability means meeting our own needs without compromising the ability of future generations to meet their own. Embedded in most definitions of sustainability, we also find concerns for social equity and economic development.

Commissioning and
remote access

Automating production and process environments provides many benefits. Utilizing the experience and expertise of our teams, we manage the delivery of automation solutions; from system design, integration, build for skids such as CIPs, to commissioning.