The project's client is a Russian automobile manufacturer in the Kaluga region. Until 2022, the plant was part of the international PSA Peugeot Citroën / Mitsubishi Motors alliance and produced vehicles under these brands.
Following a change in ownership structure due to geopolitical changes, the company transitioned to domestic management, retained its production capacity, and launched an active digital modernization program.After 2022, the foreign vendor ceased support for the auto plant's core production systems, including the platform that managed the assembly line. This created the risk of halting the launch of new production lines.
The customer needed to quickly restore and replace the outdated system without loss of functionality or interruption of the production cycle.Key Challenges
- Restore the conveyor control system to the domestic environment.
- Reduce dependence on foreign software and suppliers.
- Maintain the interface and logic of the previous system to minimize staff training.
- Develop a new version of the system with an exact replication of the functionality and interface.
- Configure integration with MES (1C), a QoS quality control system, and industrial PLC controllers.
- Ensure compatibility with existing equipment and communication protocols.
The project was set in November 2024 and was implemented in stages:
1. Prototyping – testing hypotheses and integration with controllers.
2. Development of a conveyor line control system for the paint shop – system launch in the first section.
3. Expansion to the assembly shop and finished goods warehouse.
4. Acceptance testing and pilot operation.
The ICL Services development team created a new version of the system, preserving the logic and visual interface of the previous platform, so that plant operators did not require additional training.
The work was performed remotely, with regular on-site visits during the setup and testing stages.
A key feature of the project was integration with a unique protocol—its documentation was either partially missing or at odds with the actual operating logic of the equipment. The ICL Services team manually adapted the data exchange and achieved stable operation.
The new system was launched in July 2025. The transition occurred with minimal downtime.
All production areas migrated to the new software on schedule, and the ICL Services team continues to provide support and participate in the design of the next stages of the plant's digitalization.
The client plans to further develop the system and integrate it with the company's other production solutions. Interface refinements and the migration of related applications to domestic platforms are being considered.
Products and technologies
- PMM (Pilotage Multi-Métier) — a production process management system
- Integration with the MES (1C: MES) production management system
- Integration with the QoS quality control system
- Integration with PLC (industrial controllers)
- Proprietary communication protocol with French-made equipment
- Java, Angular, Docker, GitLab, YouTrack
Results
- The domestic assembly line management system was operational in the existing environment without the involvement of foreign vendors.
- Production resumed on schedule—the system enabled the transition to a full vehicle assembly cycle.
- Downtime and the risk of assembly line shutdowns were minimized.
- The interface was maintained, and no personnel training was required.
- ICL Services developed internal expertise in the development and support of SCADA/MES systems.
- A support service was established: daily customer communication, prompt response (6:00–24:00, SLA 15 minutes).
