Control panel projects don’t typically fail because of bad engineering. They fail because critical information is missing or unclear from the start.
A weak intake process creates confusion, delays, and costly rework. But what are the specific mistakes companies make? Let’s break them down—and more importantly, discuss how to avoid them.
Mistake #1: Not Clearly Defining the Project Scope
The Problem:
Some projects begin with only a vague description—like “Design a new control panel for Machine A.” That’s not enough. Without clarity on what’s required, teams will make assumptions, leading to scope creep, redesigns, and extra costs.
How to Avoid It:
- Be specific about the purpose of the panel—Is it replacing an existing system? Expanding functionality? Controlling multiple processes?
- List required features and components—Will it need remote monitoring, safety interlocks, or integration with a PLC?
- Document what is NOT included—Clearly state if certain elements (e.g., field wiring or installation) are out of scope.
Mistake #2: Overlooking Environmental and Compliance Requirements
The Problem:
Many projects ignore critical environmental conditions until it’s too late. A control panel designed for a clean, indoor space might fail completely if installed in a high-heat, dusty, or wash-down environment. Similarly, missing compliance requirements (UL 508A, NFPA 70) can lead to major rework before final approval.
How to Avoid It:
- Specify the environment upfront—Will the panel be exposed to moisture, dust, vibrations, or chemicals? Define ambient temperature ranges as well.
- Select the right enclosure rating—Use UL Type 12 for indoor industrial spaces, UL Type 4X for washdown areas, and so on.
- Confirm compliance requirements early—If UL 508A or CE certification is needed, design for it from the start rather than modifying later.
Mistake #3: Not Capturing Power and Integration Details
The Problem:
A panel design can’t move forward without knowing what power is available and how the panel will interface with other systems. Yet, many projects start without this info—leading to incompatible components, last-minute redesigns, and even unsafe installations.
How to Avoid It:
- Document the available supply voltage—Is it 120V, 480V, single-phase, three-phase? Don’t assume—verify!
- Confirm network and control integration—What communication protocol is required (Ethernet/IP, Modbus, Profibus)? What IP ranges or existing system connections must be considered?
- Account for SCCR (Short Circuit Current Rating)—Ensure the panel’s protection devices are rated for the available fault current at the installation site.
Mistake #4: Not Establishing Clear Timelines and Milestones
The Problem:
Projects without clear deadlines tend to drag on indefinitely or hit last-minute bottlenecks. Teams often forget to consider long lead times for critical components, delaying the entire project.
How to Avoid It:
- Set firm milestones—Define design completion, review dates, and final delivery deadlines upfront.
- Plan around lead times—If a key component takes 12 weeks to arrive, account for that before finalizing the schedule.
- Align with installation needs—If the panel needs to be installed during a planned shutdown, the design must be completed well ahead of that window.
Mistake #5: Lack of Standardization in Documentation
The Problem:
If each project follows a different documentation structure, miscommunication is inevitable. Inconsistent schematics, part numbers, and wire labels create confusion for panel builders, technicians, and end-users.
How to Avoid It:
- Use standard templates and naming conventions—Ensure every project follows the same format for drawings, wire labels, and BOMs.
- Define part preferences and approved manufacturers—Standardizing components makes purchasing and maintenance easier.
- Make documentation part of the intake process—Require that CAD templates, customer standards, and panel shop instructions are established before design begins.
Final Thoughts: Why Intake Matters
All of these mistakes stem from the same core issue: not gathering the right information before starting the design.
A structured control panel intake form ensures:
- No assumptions—just clear, verified project details
- Fewer surprises, delays, and costly redesigns
- A smoother, more efficient design-build process
Next Up: The Must-Have Sections of a Control Panel Intake Form
Now that we’ve covered the biggest mistakes companies make, our next post will break down exactly what your intake process should include.