Industrial Automation & Electrical Engineer · 35 Years

The PLC Guy

North West Leicestershire · Nationwide Travel · Remote Support Available

Expert PLC programming, HMI/SCADA, control panel design and electrical fault finding.
When your plant stops — I get it running again. Fast, methodical, and experienced.

⚡ Get a Quote 🔴 Emergency Support
35+
Years electrical & automation engineering
3
Core industry sectors served
PLC
Siemens · Mitsubishi · Allen Bradley · Telemecanique · Modicon
Fast
Rapid response for breakdowns & faults
Emergency Services

Electrical Breakdown
& Fault Finding

Production downtime costs real money. Whether you have an intermittent fault nobody can pin down, a failed drive, a PLC error stopping the line, or a complete electrical failure — I provide fast, methodical diagnosis and repair.

Small and medium-sized companies without in-house automation expertise rely on me for exactly this. I'm used to coming in cold on unfamiliar systems, reading the installation, and finding the problem quickly.

Request Emergency Support
🔴
PLC Fault DiagnosisAlarm investigation, programme faults, I/O failures, comms errors — Siemens, Allen Bradley, Mitsubishi
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Electrical TroubleshootingPanel faults, motor drives, sensors, wiring faults — traced and resolved systematically
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HMI / SCADA FaultsScreen faults, comms loss, database issues, display errors — diagnosed and fixed on site
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Intermittent ProblemsThe tricky faults others have given up on — systematic root cause analysis finds the answer
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Remote Diagnostics AvailableInitial remote assessment where feasible to evaluate the fault before travelling to site
What I Do

Core Services

🔧

PLC Software

New project development, system modifications, and upgrades. From small standalone systems to complex multi-processor installations — new builds or working on your existing code.

Schneider ElectricOmronAllen BradleySiemens S7/TIAMitsubishiTelemecanique TSX (Legacy)Modicon (Legacy)Twido (Legacy)New ProjectsModifications
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HMI & SCADA

Design and implementation of operator interfaces and supervisory control systems. Practical, intuitive screens that your operators will actually use and understand.

Ecostructure Machine Scada ExpertMagelis XBTTrend DataAlarms
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Control Panel Design

Full design, build, and installation of industrial control panels. CE-marked, properly documented, built to last, and fully tested before delivery.

SchematicsPanel BuildInstallationCommissioning
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Remote Monitoring & Data

Modern IoT solutions for remote access, real-time datalogging, and OEE measurement. Know what your plant is doing from anywhere, at any time.

ESP32LoRa WirelessOEECloud DataPWA Apps
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System Integration

Connecting disparate systems — PLCs, SCADA, ERP, databases, and third-party equipment. Making everything communicate properly and reliably.

Modbus RTUModbus TCPProfibusOPC
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Project Management

End-to-end project delivery from specification through commissioning. Clear communication, on-time delivery, and minimal disruption to your production schedule.

SpecificationDesignDeliveryDocumentation
Rare Expertise

Legacy PLC & HMI
Support

I started as an apprentice electrician at 16 and have been in electrical and automation engineering for over 35 years. Much of that career was spent working with the Telemecanique, Modicon and Schneider Electric PLC and HMI ranges that were dominant in UK industry through the 1990s and 2000s.

These systems are now classified as legacy or end-of-life — but thousands of them are still running in factories across the UK. Finding an engineer who still has the knowledge, the programming software, and the diagnostic tools to support them is increasingly difficult.

If you have one of these systems and need support — modifications, fault finding, backups, or advice on upgrade paths — I can help where others can't.

Telemecanique
Modicon
Schneider Electric
Enquire About Legacy Support
TSX Premium & Micro
TSXPremium
TSX57
TSX37
TSX17
TSXMicro
TSX Series 7
TSX7
TSX47
TSX67
TSX87
TSX107
Nano & Compact
TSXNano
TSXNeza
TSXTwido
TwidoSuite
Modicon & HMI
Modicon984
ModiconM340
MagelisXBT
MagelisG

The programming software, adapters, and cables for these platforms are no longer freely available. I have retained the tools and software licences to work on these systems. If you need programme backups taken before a machine is decommissioned, or fault-finding on a system others have walked away from — get in touch.

Industry Experience

Sectors I Work In

🌾

Agricultural & Grain

Extensive experience in grain drying, storage management, routing and conveying systems. Automated fan and heater control, moisture monitoring, batch management, and full-site SCADA. I understand the seasonal pressures and what harvest downtime actually costs.

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Precast Concrete

Automation of precast concrete manufacturing — batching plants, curing systems, product handling, and production data collection. Familiar with the demands of continuous-shift heavy production environments.

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Clayware & Ceramics

Kiln and drier control, forming machinery automation, conveying and handling systems. Experienced with the specific temperature profiling and process control requirements of the ceramics and clayware industry.

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Woodworking

CNC routers, edge banders, panel saws, and automated handling lines. Experience with multi-axis motion control, tooling sequences, and the integration of safety systems in high-speed woodworking environments. Comfortable working on both standalone machines and production-line setups.

💊

Healthcare & Pharmaceuticals

Tablet pressing, granulation, grinding, coating, and packaging line automation. Experience with vitamins and mineral supplement processing — precise dosing, batch traceability, and the strict process control requirements that regulated production demands.

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Injection Moulding

Automation of injection moulding cells — machine integration, robot and conveyor interfacing, cycle monitoring, and reject handling. Experienced with the fast cycle times and the production data requirements of high-volume thermoplastic moulding operations.

Recent Work

Projects

A selection of completed projects across the sectors I work in. Every job is different — these give a flavour of the range of work I take on.

Grain routing SCADA upgrade — Leicestershire
Agricultural & Grain

Grain Routing SCADA Upgrade

Full replacement of an ageing grain routing control system — converted from a trafolyte mimic and a lot of buttons and switches to a new Schneider M251 PLC and Ecostructure Scada Expert SCADA system. Giving the ability to monitor and control the whole plant across two, side be side, 32 inch monitors and has the ability to run seven parallel routes simultaneously.

Control Panel Design & Build — Leeds Control Panel Design & Build — LeedsControl Panel Design & Build — Leeds
Precast Concrete

Control Panel Design, Build & Install

Full design and build of a motor control centre for a concrete slab extruding machine — schematic design, panel manufacture, PLC & HMI software, machine installation, wiring and commissioning. I have built this panel several times for this customer. Always delivered on time and within budget.

Panel requiring upgrading Panel requiring upgradingPanel requiring upgrading
Controls Panel

Controls Panel requiring upgrading

Have you got electrical control panels that look like this? Maybe it time you thought about giving us a call and getting them replaced. Teetering on the edge of failure and leaving your production standing.

Machine build
Machine build

Bespoke HDPE plastic sheet former

Fully automated, bespoke HDPE sheet heating/bending machine designed and built on our premises. This customer has had me build this three times over the last ten years, must have done something right.

Control Panel Design & Build — Leeds Control Panel Design & Build — Leeds
Controls Panels

Small Control Panel Builds

Regular small control panels built in quantities.

Control Panel Design & Build — Leeds
Precast Concrete

Prototype development

Prototype HMI & PLC control for precast concrete stressing unit.

Upgrade - Stockport Upgrade - Stockport
Controls Panel Upgrade

PLC & HMI Upgrade - Stockport

Legacy Schneider/Modicon TSX37 Micro upgraded to the Schneider M251. Converstion planned, coded, installed and commissioned.

All project details are anonymised or shared with the client's permission. Photographs are added as they become available.

✓ Authorised UK Distributor — HSK Kunststoff Schweißtechnik GmbH

Plastic Welding &
Fabrication Machines

I am the authorised UK distributor for HSK Kunststoff Schweißtechnik GmbH — a specialist German manufacturer based in Bad Honnef with decades of experience producing professional-grade plastic welding and fabrication equipment for industrial use worldwide.

From handheld welders for site work to stationary production machines, HSK machines are built for reliability in demanding environments. I provide full UK sales, commissioning, operator training, and ongoing technical support.

Authorised HSK distributor — direct factory relationship
Full UK sales, delivery and commissioning
Operator and maintenance training provided on-site
Spare parts and consumables supply
Suitable for PP, PE, PVC and all common thermoplastics
Rental machines available for short-term requirements
Enquire About Machines 🇩🇪 Visit HSK Website

Hot Air Welding

Manual and automatic hot air welding guns and systems for thermoplastic sheet joining — tanks, ducting, liners, and fabricated structures in PP, PE and PVC.

Extrusion Welding

Handheld and stand-mounted extruder welders for thick-section plastic work. Strong, consistent welds where speed and penetration matter.

Hot Wedge Welding

Automated hot wedge machines for continuous seam welding of geomembranes, roof membranes, and industrial plastic sheet — high output, repeatable quality.

Pipe & Socket Welding

Butt fusion and socket fusion equipment for thermoplastic pipe systems — clean, reliable joints for industrial pipework in PP and PE.

Sheet Bending

Precision line benders and table heating strips for accurate thermoplastic sheet forming — clean, stress-free bends in PVC, acrylic and similar materials.

Bespoke & Custom

Non-standard applications? HSK design and build custom welding and fabrication machines to specification. I liaise directly with the factory on your behalf.

🇩🇪 HSK Kunststoff Schweißtechnik GmbH · Bad Honnef, Germany

An internationally recognised manufacturer with distribution across Europe, North America, and Australasia. As the UK representative, I bring their full machine range to British industry with the added benefit of local engineering support, site visits, and first-hand technical knowledge.

Modern Technology

Beyond Traditional Automation

Traditional PLC expertise combined with modern microcontroller and IoT technology — more data, more visibility, and better decisions for your business.

📡

Wireless Sensors

LoRa-based wireless probe systems for temperature, humidity and process data across large sites without cabling runs

📊

OEE & Datalogging

Real-time Overall Equipment Effectiveness measurement and historical production data analysis and reporting

🌐

Remote Access

Secure remote monitoring and control via web apps — check and manage your plant from anywhere, any device

📱

Progressive Web Apps

Custom web-based operator interfaces that work on phones, tablets, and desktops with no app store required

Why Work With Me

One Engineer.
Full Accountability.

01
You speak directly to the engineer

No account managers, no handoffs. You describe the problem to the person fixing it — no information lost in translation.

02
35 years — apprentice electrician to automation engineer

Started on the tools at 16. Three and a half decades of hands-on experience across electrical maintenance, control systems, and industrial automation. I know what downtime costs and I work with urgency to end it.

03
Cost-effective for small and medium businesses

Senior engineer expertise without the overhead of a large systems integrator. Competitive rates, transparent costs.

04
Wide technical range — one contact

From legacy PLC systems to modern distributed cutting edge control systems — you don't need multiple specialists.

Ready to talk?

Whether you have a new automation project, need urgent fault finding, want to explore modern monitoring technology for your site, or are looking at plastic welding machines — get in touch. You'll get an honest assessment, not a sales pitch.

Start the Conversation

Leicestershire based · Nationwide travel · Remote support available

Get In Touch

Let's Discuss Your Project

Whether it's a new installation, an ongoing fault you can't trace, a question about remote monitoring, or an enquiry about plastic welding machines — don't hesitate to reach out. I respond promptly.

✉️
Emailinfo@theplcguy.co.uk
🌐
Websitewww.theplcguy.co.uk
📍
Based InNorth West Leicestershire · Nationwide travel · Remote support available

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