Case Study

Greenfield control system automation for automotive plant – paint process air houses

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The Client

Automotive Line Builder- automotive manufacturer end-customer

Capabilities Demonstrated

  • Factory Automation
  • New equipment automation
  • Electrical design
  • Panel Fabrication
  • PLC programming
  • HMI software development
  • VFD installation / integration / configuration
  • Construction management


An automotive manufacturer required a new paint line to increase production capacity and efficiency while improving absorption and removal of contaminants and environmental emissions. The new system required air houses (air houses provide filtered/conditioned air for work space and paint booths and also filter/remove fumes and gases for quality).


A&E was contracted by the line builder to provide the control system automation for the paint process air houses.

A&E delivered the process control system, handling the automation, design, control panel fabrication, construction management, installation, and commissioning of the entire system for motors, instrumentation, and controls.


  • Increased manufacturing capacity
  • Improved manufacturing efficiency
  • OEE / downtime-critical
  • More consistent product quality
  • Safety-focused implementation

Project Overview

Automotive manufacturing is extremely schedule-driven, requiring planning and flexibility. At times working around the clock, managing multiple electrical contractors and schedules.

Five (5) electrical shops were contracted by A&E to maintain project pace.

The line builder provided P&ID’s, functional specification, building/general arrangement layouts, and all mechanical installation.

A&E developed the associated design docs & required PLC code, leveraging customer-supplied modules as building blocks.

A&E designed and manufactured over 100 control panels.

A&E provided installation bid packages, secured, and managed the controls and electrical scopes for installation, commissioning, and startup.

Software Developed
HMI and PLC-based paint process air house control software
Hardware Utilized
Siemens S7 PLC
Siemens ET200SP Remote I/O
Danfoss VFDs
Endress and Hauser Instruments