INDUSTRIAL AUTOMATION · LEAN · SOFTWARE

Manufacturing that works smarter,
not harder

17+ years of experience in industrial automation, LEAN implementation, and software development for optimizing production processes in metal and process industries.

Schedule a call → Our services
17+
Years of experience
5
Countries delivered
7+
Industrial sectors
40+
Team members led
OUR SERVICES

From PLC code to management strategy

A rare combination of hands-on technical knowledge and management experience — because we understand both the machine and the person operating it.

// 01

Industrial Automation

Design, programming, and commissioning of automated systems. Specialization in Siemens platforms with years of experience in metal and process industries.

TIA PortalS7-1500WinCCSinamicsSafety
// 02

LEAN & TPM Implementation

Implementation of LEAN methodology, TPM systems, and 5S programs adapted to the reality of production floor — not textbook theory, but practice from the line.

OEE5STPMKaizenSFM
// 03

Manufacturing Software

Custom software development for production tracking, maintenance, and quality management — with direct PLC integration and real-time data.

ASP.NET CoreMESSCADAReal-time
// 04

Commissioning

Complete commissioning of industrial lines — from FAT testing to final production handover, including operator training and technical documentation.

FAT/SATStart-upHandover
// 05

Digital Transformation

Strategy and implementation of Industry 4.0 solutions: from paper reports to real-time dashboards, from reactive to predictive maintenance.

Industry 4.0IoTAnalytics
// 06

Training & Education

Practical team training for automated system operation, LEAN tool application, and manufacturing software usage.

PLCLEANOperators
TECHNICAL EXPERTISE

Deep technical knowledge, broad application

We cover the full spectrum of industrial automation — from the lowest level of PLC communication to business analytics and reporting.

Siemens S7 PLC Platforms

S7-300, S7-400, S7-1200, S7-1500 — TIA Portal V14–V20, STEP 7, WinCC SCADA, Safety Integrated

Drive Systems

Sinamics S/G series, Sinamics DC, configuration and commissioning of drive systems for industrial applications

Industrial Networks

Profibus DP, Profinet IO, Industrial Ethernet, OPC UA communication, Modbus TCP/RTU

Safety Systems

TIA Portal Safety, SIL2/SIL3, ET200SP Safety, functional safety per IEC 61508

Software Development

ASP.NET Core, C#, JavaScript, Entity Framework, SQL Server, REST API, real-time web applications

LEAN & Continuous Improvement

OEE, 5S, TPM, Kaizen, SFM, SMED, SPC — practical implementation on production lines

Quality Management

QMS systems, ISO 9001/14001, SPC process control, complaint management, root cause analysis (8D, Ishikawa)

Project Management

Leading complex industrial projects from design to commissioning, coordinating international teams

SIEMENS · Safety Technologies
SIEMENS · Motor & Regulation
SIEMENS · STARTER Software
SIEMENS · TIA-PRO 1
Danfoss · VLT FC300
Cambridge · BEC Preliminary
CASE STUDIES · REFERENCES

Projects where we built expertise

A selection of representative projects from various industrial sectors. Client details anonymized for confidentiality reasons.

CS-01
Metal industry
Serbia · 2025

Optimization of continuous production line

Problem: A continuous line for metal strip processing with over 200 AC motors and a complex multi-phase process had limited visibility into actual performance. Manually calculated OEE gave delayed signals, and production losses were not clearly attributed.

Solution: Direct PLC communication integration with a developed MES system for real-time tracking. Implementation of TPM methodology with autonomous maintenance, SPC control of key process parameters, and daily OEE reports. 5S audit program and structured PDCA cycles for the most significant losses.

Result: OEE increase of more than 10 percentage points within 12 months, with significant annual savings. Introduced structured complaint tracking and root cause analysis (8D, Ishikawa, 5-Why).
+10ppOEE improvement
40+Team members
12 moTime to results
CS-02
Wood industry
Serbia & Bosnia · 2016–2022

Complete automation of wood processing and pellet production facilities

Problem: Multi-year construction and automation of multiple production facilities for wood processing and pellet production, with diverse equipment from different manufacturers. Need for unified automation, drive system integration, and centralized supervision.

Solution: Design, programming, and commissioning of complete automated systems based on Siemens TIA Portal platform with integration of Yaskawa, Siemens, and Omron drive systems. Centralized SCADA supervision, control hierarchy from machine to plant level.

Result: Successfully executed greenfield projects in Serbia and Bosnia and Herzegovina. Built a multi-vendor integration methodology later used as a template for future projects.
2Countries delivered
6 yrsEngagement duration
Multi-vendorIntegration
CS-03
Energy · Hydroelectric
Philippines · 2021–2022

Remote commissioning of hydroelectric power plant

Problem: Client needed expert support during the commissioning phase of a hydroelectric power plant with Beckhoff TwinCAT control platform. Due to geographic distance and pandemic restrictions, on-site engagement was not feasible.

Solution: Remote commissioning methodology — system configuration of Beckhoff TwinCAT platform, parameter tuning, and real-time troubleshooting via VPN access. Coordination with local technical team with structured knowledge transfer.

Result: Successful plant start-up and stable long-term operation without the need for physical expert travel. Proven validity of the remote commissioning model for geographically distant projects.
100%Remote delivered
4 moCommissioning period
BeckhoffTwinCAT platform
CS-04
Water & Chemical
Serbia · 2017–2020

Automation of water treatment and chemical production plants

Problem: Automation and commissioning of water treatment plants, chemical production (aluminum sulfate), and industrial material handling systems. Diverse process logic, different PLC models, different HMI platforms.

Solution: Engineering of complete automation system with TIA Portal platform, integration with Siemens SCADA systems, and systematic documentation enabling client's autonomous maintenance after handover.

Result: Multi-sector expertise — from water treatment, through chemical production, to material transportation systems. All projects delivered on time and on budget.
3+Process sectors
TIA PortalPlatform
3 yrsEngagement period
ABOUT KONTROLER

An engineer who understands both machines and people

DŠ

Dušan Šaponjić

Founder · Lead Consultant

I'm not a typical consultant who arrives with textbook theory. I spent 17+ years on production lines — programming PLC systems, leading teams of 40 people, solving problems at 3 AM when a line stopped.

Automation engineer, production manager, software developer — all in one. Master of Engineering in Mechanical Engineering (University of Niš) and Bachelor of Science in Electrical Engineering (University of Belgrade, Automation).

I understand production because I ran it. I can program PLCs because I'm an automation engineer. I can build software because I'm a developer. All three together = unique value for the client.

in ✉ ⚙
INDUSTRIES · EXPERIENCE
🏭
Metal rolling mills
🎨
Coating lines
💧
Water treatment
🪵
Wood processing
⛏️
Mines · Quarries
🧪
Chemical industry
⚡
Energy
OUR SOFTWARE

Software that understands production

Developed from 17 years of shop floor experience — not laboratory theory.

CTRL · PRODUCTION INTELLIGENCE PLATFORM

30+ modules. One platform.

CTRL is an integrated MES / OEE platform that connects machines and PLC devices, tracks OEE, manages maintenance, and enforces LEAN methodology. Built from real production plant requirements.

OEE Analytics (real-time)
CMMS & TPM Maintenance
LEAN Tools (5S, Kaizen, A3)
Contract tracking
SPC Process Control
Automated PDF reports
PLC Integration (S7, OPC UA)
Production Planning
Learn more at kontroler.tech →
CONTACT

Start a conversation

Free 30-minute consultation — no obligation. Analysis of your specific challenge and recommended next steps.

Kontroler — Industrial Consulting

Email
dusan.saponjic@kontroler.rs
Phone
+381 60 07 18 018
Location
Jug Bogdanova 6, 31000 Užice
Serbia · Remote collaboration across Europe
LinkedIn
linkedin.com/in/dusan-saponjic-kontroler