How Agile System Development Creates Scalable Automation Solutions

In modern industrial automation, companies face the challenge of developing control systems that are both powerful and cost-effective. This case study demonstrates how ootb automation GmbH enabled a machine manufacturer to build their automation system incrementally through agile development methods, while maintaining complete cost control.

The Initial Situation

A mid-sized manufacturer of specialized machinery faced a typical challenge: the company needed a modern control system for a newly developed production machine. The particular difficulty was that system requirements would grow over time. Initially, the machine should be launched with basic functionality to generate first sales. As demand increased and customer feedback accumulated, additional features would be added successively.

The classical approach would have required specifying and developing the complete system from the start – an approach associated with high upfront investments and the risk of developing features that ultimately wouldn’t be needed. The customer therefore sought a more flexible path that would allow the system to grow organically.

The Agile Solution Approach

ootb automation proposed a consistently agile development approach. Instead of comprehensive upfront planning, the project was divided into clearly defined development phases, with each phase creating immediate value for the customer. This iterative approach enabled prioritizing features based on actual needs and aligning investments directly with business success.

The development team consistently focused on the question: “Which feature brings the greatest benefit to the customer in this phase?” This created a development roadmap closely oriented to real market requirements.

Phased Implementation

Phase 1: Building the Foundation The first step implemented solid control logic representing the machine’s core functionality. The Human Machine Interface (HMI) was deliberately kept simple and connected via the established Modbus/TCP protocol. This solution was technically mature and enabled rapid market entry.

Phase 2: Transparency Through Data Acquisition Once the first machines were in operation, the need for better production process traceability became evident. The system was extended with web server-based data recording that automatically generated Excel reports. This enabled customers to perform detailed production analyses for the first time.

Phase 3: Modernizing Communication As system complexity grew, the Modbus/TCP protocol reached its limits. Visualization was migrated to the more modern MQTT protocol, enabling significantly more flexible and performant data communication. The modular software architecture allowed this migration without reimplementing core functions.

Phase 4: Optimizing Production Planning The machine’s success led to increasing production volumes. In this phase, intelligent planning and control systems were integrated, enabling optimal utilization and higher throughput. This investment paid for itself immediately through increased sales figures.

Phase 5: Location-Independent Access Increasing connectivity in industry enabled another evolutionary step: the development of a modern web interface accessible from both the shop floor and the office. This significantly improved usability and enabled new use cases.

Phase 6: Predictive Maintenance As the culmination, the system was extended with intelligent sensor data analysis. By analyzing wear indicators, predictive maintenance could be implemented, minimizing unplanned downtime and significantly increasing Overall Equipment Effectiveness (OEE).

Measurable Success

The agile approach proved to be a complete success. The customer maintained full control over budget and functionality throughout the entire development process. Each development phase was only pursued when justified by concrete market requirements. The modular software architecture enabled cost-effective adaptation of interfaces and protocols without affecting existing functionality.

The financial aspect was particularly remarkable: instead of a large initial investment, the customer could distribute development costs over several years. Each new expansion stage paid for itself through the additional sales or efficiency gains it enabled. The risk of bad investment in unneeded features was completely eliminated.

Conclusion: Agile Development as a Success Factor

This case study impressively demonstrates how agile methods can play to their strengths even in industrial automation. The ability to grow systems organically while always keeping maximum customer benefit in focus creates a decisive competitive advantage.

ootb automation GmbH has comprehensive expertise in simplifying complex automation projects. Our range of services includes risk-free simulations for concept validation, real-time monitoring of critical processes, remote maintenance for rapid problem-solving, and development of reusable software components that sustainably reduce your development costs.

Through our consistently agile approach, we create solutions perfectly tailored to your requirements that grow with your company. Contact us to learn how we can make your automation project a success.