Factory Automation Systems We Engineer
We integrate the full stack of factory automation technologies — from control and drives to vision and MES — for cohesive, scalable production systems.
PLC & Control Systems
Programmable Logic Controllers from Siemens (S7-1200/1500), Allen-Bradley (CompactLogix/ControlLogix), and Delta (DVP/AS) forming the core of automated production control.
HMI & Operator Interface
Touch-screen HMIs for operator control, machine status display, alarm management, and production data entry — Siemens, Rockwell, Weintek, and Delta panels.
Variable Frequency Drives
VFDs and servo drives for precise motor speed, torque, and position control across conveyors, pumps, fans, and positioning axes — Siemens, Delta, and Rockwell drives.
Industrial Robotics
Robotic work cells for material handling, palletising, welding, assembly, and packaging integrated with vision systems and safety-rated perimeter guarding.
Vision & Quality Inspection
Camera-based inspection systems for dimensional measurement, surface defect detection, barcode reading, and colour verification integrated into production line control.
MES & Production Reporting
Manufacturing Execution Systems (MES) for real-time production tracking, OEE dashboards, traceability, downtime tracking, and integration with ERP (SAP, Syspro) systems.
Automation Engineering Services
Complete factory automation services from concept design through electrical build, software development, commissioning, and production support.
Production Line Automation
End-to-end automation of production lines including conveyor control, robotic integration, vision inspection, and SCADA monitoring with full electrical design and panel building.
Brownfield Retrofit & Upgrades
Modernisation of existing production equipment with new PLCs, HMIs, drives, and networking — minimising downtime through phased implementation and pre-commissioning at our facility.
Control Panel Design & Build
Electrical design, panel layout, wiring, and commissioning of MCCs, PLC cabinets, VFD panels, and junction boxes — complying with SANS 10142 and client specifications.
Safety System Integration
Safety PLCs, light curtains, safety relays, emergency stops, and safety-rated drive interlocking per ISO 13849 and IEC 62061 standards for machine safeguarding.
OEE & Production Monitoring
Real-time OEE dashboards, downtime tracking, production counting, and shift reporting using SCADA, MES, or standalone data collection systems with SQL historians.
Robotic Work Cell Integration
Programming, commissioning, and integration of industrial robots (Fanuc, ABB, Kuka) with PLCs, vision systems, end-of-arm tooling, and safety perimeter systems.
Automation Results — Recent Projects
FMCG Packaging Line Automation
42% throughput increase, 60% reduction in changeover time
Food & Beverage, Gauteng
Automotive Assembly Retrofit
37% reduction in downtime, zero-defect quality achieved
Automotive, Tshwane
Chemical Process Plant Upgrade
28% energy savings, fully automated batch processing
Chemicals, Mpumalanga
Why Cretek for Factory Automation in South Africa?
Cretek is a South African factory automation company with multi-platform expertise across Siemens TIA Portal, Allen-Bradley Logix, and Delta automation. We design and implement automated production systems that increase throughput, improve quality, and reduce operating costs for manufacturers across Gauteng, Tshwane, and nationwide.
Our production line automation projects span the full engineering lifecycle: mechanical and electrical concept design, control panel building, PLC and HMI programming, robotic integration, vision system setup, MES connectivity, and commissioning. We also specialise in brownfield retrofits — upgrading older machines with modern controls, drives, and data collection without replacing entire production lines.
We serve the food and beverage, automotive, chemical, packaging, and logistics sectors with automation solutions that deliver measurable ROI. All our automation systems are designed for maintainability, with documented code (IEC 61131-3), standardised hardware, and remote support capability.
Factory Automation — Frequently Asked Questions
How long does a factory automation project take?▼
A typical single production line automation with PLC, HMI, drives, and SCADA integration takes 8-16 weeks from concept to commissioning. Larger multi-line projects with robotics and MES can take 4-9 months. We always provide a detailed project schedule with milestones upfront.
Do you work with my preferred automation brand?▼
We are platform-agnostic and work with Siemens (TIA Portal), Allen-Bradley (Studio 5000), Delta (ISPSoft/AS), and other platforms. We recommend the best platform for your application, budget, and in-house skills. We also support mixed-platform environments.
Can you automate my existing production line without stopping production?▼
Yes. We use a phased approach — building and pre-commissioning new control systems off-line, then executing changeovers during planned shutdowns or over weekends. For critical lines, we can implement parallel control systems with changeover switches for zero-downtime cutover.
What is OEE and how do you implement it?▼
OEE (Overall Equipment Effectiveness) = Availability × Performance × Quality. We implement OEE tracking via SCADA or MES systems — automatically collecting cycle times, downtime events, and quality counts from PLCs to generate real-time OEE dashboards without manual data entry.
How much does a factory automation system cost?▼
Costs depend on scope. A single machine PLC/HMI retrofit: R60,000-R150,000. A production line with conveyors, drives, and SCADA: R250,000-R800,000. A full factory with robotics, vision, MES, and networking: R1,000,000-R5,000,000+. We provide a detailed cost-benefit analysis and ROI projection with every proposal.
Do you provide ongoing support after commissioning?▼
Yes. We offer annual support contracts including remote assistance, software updates, spares management, and scheduled site visits. All our systems are designed for remote diagnostics — we can connect securely to your controls to troubleshoot issues without sending an engineer on site.
Start Your Automation Journey
Tell us about your production goals. Our automation engineers will conduct a site assessment and provide a detailed proposal with ROI projections within one week.