Machine Software Limited

The Problem with Modern Control Systems

While modern control systems have evolved in terms of processing power and connectivity, many still suffer from poor usability and outdated interface design. They are often built with a strong focus on hardware capabilities or legacy integration, but not enough attention is paid to the operator experience.

This lack of user-centred design introduces several challenges. Systems may require extensive training for engineers and operators to use effectively, which delays onboarding and increases dependency on a small group of experienced personnel. The interface logic can be unintuitive, making routine diagnostics or configuration tasks time-consuming and error-prone. Furthermore, inconsistent or unclear feedback from the system can lead to misinterpretation of operational states, increasing the likelihood of human error—potentially resulting in unplanned downtime, process inefficiencies, or safety risks. In complex environments where speed, precision, and reliability are essential, a poorly designed control interface becomes a hidden cost that compounds over time.

These issues are especially problematic in industries where flexibility, scalability, and real-time decision-making are critical, yet the tools in place fail to support those demands in a user-friendly and reliable manner.

The solution

The Solution...

At Machine Software, we design control systems that prioritise both engineering precision and operational usability. Our approach combines modern software architecture with intuitive user interface design, ensuring that your systems are not only powerful but also easy to understand, operate, and maintain.

We leverage contemporary frameworks and UX principles to create operator interfaces that are clean, consistent, and purpose-driven — reducing cognitive load and minimizing the chance of error. Whether it's real-time diagnostics, dynamic visualisation of process states, or system overrides, every function is engineered for clarity and responsiveness.

Behind the interface, our systems are built on modular, scalable platforms that integrate seamlessly with existing PLCs, SCADA systems, and industrial protocols. This means you get advanced functionality without compromising compatibility or requiring complete infrastructure overhauls.

We also emphasise maintainability and flexibility. Engineers can easily update workflows, modify control logic, or deploy changes without introducing system instability. This translates to faster commissioning, reduced downtime, and lower total cost of ownership over the lifecycle of your equipment.

With Machine Software, your control systems become assets — not obstacles — to operational excellence.

Key Features

Design is key, and is the most important part of any project to achieve success

If the design doesn’t work or the user cannot use it efficiently then we’ve got it wrong, and it’ll be time consuming and costly to fix. Our number one golden rule is DESIGN — it must be finished and approved before any manufacturing can take place. We have invested in AutoCAD, Solid Works, ePlan, various offline robot and PLC programming tools, together with the normal Word, Excel, PowerPoint tools and they are used throughout all projects.

Project management can go horribly wrong if communication and relationships are not seen as key

Failure in these critical areas can mean that things can get out of control very quickly indeed. So, keeping a close eye on project management and keeping it friendly is very important, something we try very hard to maintain.

Data is such a small word that means such a lot, data is key to all things

We accumulate data as we travel through life to make informed decisions about our next moves. This is so true when we consider any project, so it is important that we collect and analyse the data as we design and develop a project. Key at the outset is to gather information (Data) about our customer’s requirements to the smallest detail possible. This is then analysed and its findings fed back into the design. If we do this correctly then the project will be a success.

It’s important to us and our customers that we all remain flexible when undertaking a project large or small

At the outset of a project, we try to consider everything so the journey is smooth and efficient, but when things change, or something is found to not work as expected, then rapid informed decision making based on the data and flexibility from all parties is extremely important to keep projects within budget and on time.

Manufacturing

We manufacture the various elements at our facilities, where possible we test as much as we can prior to delivering and installing on site. But the real work starts once the systems are in place at our customers' sites.

Installation

Installation is always hard work. There are a lot of different disciplines that have to come together, and they are all key to the success of any project large or small. If the installation has inferior equipment or is not understood by the installers, then you’re on a loser before you’ve got going. So, first class Design, Project management and Quality control are key elements, and we take great pride in controlling installations so they work first time.

Commissioning & Testing

This should be the easy part to any project if the key elements above are right. Historically software has been a problem on site during commissioning if the design element was not fulfilled, so once again design is key to the success of a project. We have developed MADOS Machine Automation Diagnostic Operating System as a standard piece of software that fits all forms of machine and systems, making commissioning and ultimately the using of the machine or system much easier for the end user. During the commissioning phase we also carry out a lot of testing. This phase of all projects is always exciting when everybody’s hard work starts to come to life, and is extremely important for the longevity of the installation. So, rigorous testing is carried out. If we can break it, so can the end user.

Training & Support

These elements are also key parts to any project. Users must understand the systems they're using for them to work at their full potential. Do you know how to use all of the functions on your phone? Probably not! So, we put a lot of effort into Training & Support. The support element can run much smoother if data management systems are employed, allowing us to support remotely and feedback information for both maintenance and management alike. Please ask about data monitoring and gathering systems — they are the way forward. Please read my paper on “BIG data & IoT”.

MADOS

MADOS Machine Automation Diagnostic Operating System. We have designed MADOS as our standard offering for controls software, the principal is a steps based PLC operating system which has all of the basic operating modes built in as standard, there’s just a little interlocking to be done to suit the system which its operating.

General Offerings

We supply all the above parts in varying degrees depending on the type of project.

For Industrial Control, we offer a full turn key solution for the each of the above elements. Please do not hesitate to contact us about any sized project or part project, we are more than happy to discuss your needs.