Transforming Automation File Comparison into Validated Efficiency

Manual processes limiting scalability and compliance

As part of installing new production lines and upgrading existing ones, a multinational life sciences company needed to compare automation software project files across multiple systems, including PLCs, vision systems, and robot files.

Standard compare tools were either insufficient or unavailable. Where tools existed, they were generic and could not produce a validated history of changes, a key compliance requirement. Engineers were forced to take screenshots and manually document reasons for changes, a time-consuming process with significant scope for human error. For applications without built-in compare functionality, the process was even more laborious.

This approach placed pressure on automation engineering resources, increased compliance risk, and extended site acceptance testing (SAT) timelines.

A validated and automated compare solution

NNIT developed a customized compare solution tailored to the client’s environment, including different platform firmware versions used onsite.

The solution:

• Compared automation software project files across required platforms.

• Automatically generated time-stamped history reports and code review documentation without manual intervention.

• Enabled a validated compare approach aligned with compliance requirements.

• Was itself validated to ensure reliability and regulatory alignment.

Following implementation and validation on the first production line, the solution was used to verify that repeat installations matched the original, streamlining subsequent testing and validation activities.

Driving measurable impact across production lines

The customized compare solution delivered tangible operational and compliance benefits:

• 75% reduction in required automation engineering hours for accurate history generation and highlighting all code changes.

• Reduced SAT execution time and overall line downtime.

• Lower risk of human error through automated data recording and reporting.

• Improved compliance through validated documentation and structured code reviews.

By enabling validated, repeatable comparisons across installations, NNIT helped the manufacturer accelerate deployment, reduce testing effort, and implement reduced testing strategies for repeat lines.

The result was a scalable, compliant approach to automation software management – demonstrating how targeted custom solutions can generate significant ROI through improved efficiency, reduced risk, and enhanced quality performance.