From relay logic to a documented Siemens PLC path on a legacy cutting press.
A production cutting press was running on aging relay-based control. The owner wanted a modernization path that would not halt production and would leave documentation the next technician could actually use.
Starting condition
Relay-logic panel with no schematic, intermittent operator-station faults, and no practical way to add interlocks or diagnostics. Downtime events were diagnosed by tracing wires by hand.
What was scoped
Mithril mapped the existing I/O, defined a conversion architecture around a practical Siemens PLC platform, and specified remote-support hardware options so future faults could be diagnosed without an immediate site visit. The package included an I/O map, control narrative, and a staged changeover plan designed to keep the press running between steps.
Outcome
The owner received a buildable conversion path with a fixed budget range, vendor shortlist, and documentation set. Budget band for this class of work: roughly $12,000–$18,000 depending on panel hardware and staging preferences. Duration: about four weeks of scope work.
Why it matters to your machine
Old relay panels fail in ways that are expensive to diagnose twice. A documented PLC conversion path turns that risk into a planned, staged change with schematics the next tech can trust.
Related services
Case notes are anonymized where customers asked. Numbers are ballparks from project records, not offers. PE-stamped or code-regulated portions are handled through Utah licensed firms when required.