Standardised processes for efficient engineering

Traditionally, panel builders have struggled to recruit and retain skilled workers due to the complexity and expertise required for engineering tasks. These include schematic design, the generation of production-ready documentation and the preparation of bills of materials. The hand-off to shopfloor technicians for assembly often introduces inconsistencies that impact lean operations.

ADS faced this challenge from the outset. The company aimed to optimise its engineering and manufacturing processes to reduce complexity, lower dependency on specialist staff, and make it easier for new employees to integrate into production workflows.

As part of this strategy, ADS invested in automation technologies: a wire fabrication machine for cutting, stripping, terminating and marking, and a CNC machine for automated enclosure modifications. To generate the required manufacturing data for these systems, ADS sought a comprehensive engineering software solution capable of standardising electrical design and enabling direct data exchange with its production environment.

ADS deployed Pro Panel to support schematic generation and 3D layout design for control cabinets and power distribution systems. The software enables the creation of modular circuit macros and automates panel layout and wiring documentation. Engineering teams source standardised components from the Data Portal, a cloud-based repository of manufacturer-verified device data used for bills of materials and detailed project documentation.

To support cross-team collaboration and project review, ADS uses Project viewer – eView. This tool visualises the digital twin of the control cabinet in 3D, helping users validate the physical layout before assembly and gain an in-depth understanding of the system architecture.

The digital twin functions as a virtual replica of the cabinet design, enabling error detection, design validation, and improved communication between engineering and operations teams.

The Project viewer also includes a feedback feature that allows technicians, engineers and service providers to add notes and comments that are routed back to the design team. These changes are tracked, ensuring that documentation remains up to date.

By leveraging the augmented reality (AR) functionality, ADS technicians can project a 3D model into the real-world environment, inspect the cabinet layout interactively, and navigate from individual components to their representations within the electrical schematic.

To further enhance collaboration across departments and external partners, ADS utilises Data management. This tool enables project versioning, file sharing and centralised access across locations.

On the shopfloor, ADS uses the wiring module of Eplan Smart Production to guide technicians through the wiring process. This digital assistant standardises physical wiring, reducing errors and lowering the need for highly trained staff.

ADS employs a cell-based manufacturing system, where tasks are distributed across dedicated workstations. For instance, a technician wires cabinet doors using the AR-enhanced wiring module, while another tests the finished panel in a separate cell.

Any changes noted during the review process in Project viewer are automatically synchronised with the wiring module, ensuring consistency across the production cycle and maintaining a digital record for future maintenance.

By implementing the modular Eplan software suite, ADS reduced total project time—including engineering and panel assembly—by 59%. Change tracking and documentation control have significantly improved over previous methods.

Importantly, the company successfully scaled from five to 18 employees in under three years. This growth would not have been possible without the streamlined processes enabled by digital engineering and smart production tools. New team members without prior industry experience can become productive within just two weeks.

Automated reporting tools enable one-click generation of accurate bills of materials, directly supporting ERP integration. The company has also increased the number of wire terminations completed per hour, boosting overall productivity.

With improved process reliability, scalability, and customer responsiveness, ADS has successfully transformed its operations using an integrated engineering and production platform.