Manufacturers evaluating controls engineering services may start by comparing hourly rates against employee salaries, but that doesn’t tell the full story. An outside controls engineering team may appear more expensive on a rate basis, but the better comparison is the total project cost. 

It comes down to whether a manufacturer needs a full-time controls resource year-round or specialized engineering support for specific projects. The answer depends on project volume, technical requirements, staffing availability, and the financial impact of delays. In many situations, outsourced controls engineering services reduce overall costs by providing expertise and capacity as needed, without adding permanent overhead. 

When Automation Projects Are Infrequent 

Many manufacturers do not have enough controls work to keep an engineer fully occupied throughout the year. A plant may complete a PLC migration, production line expansion, control panel upgrade, SCADA implementation, or commissioning effort and then go months before the next major project. In that environment, hiring a full-time controls engineer means paying salary, benefits, training costs, software licenses, and overhead regardless of workload. During slower periods, the individual may be assigned tasks that do not require expertise in specialized controls. 

Project demand can also spike during commissioning and startup. A new production line may need multiple engineers onsite to support testing, troubleshoot issues, modify code, validate communications, and assist operators. Outsourced controls engineering services allow manufacturers to add capacity during those compressed project phases without maintaining excess staffing after commissioning is complete. 

When Projects Require More Than PLC Programming 

Automation projects frequently involve multiple disciplines. For example, a single production line upgrade may require electrical design, PLC programming, HMI development, industrial networking, motion control, safety systems, startup support, and troubleshooting across existing systems. A manufacturer hiring one internal controls engineer gains the experience of one person. Building an internal team capable of handling every discipline requires a much larger investment. 

Some projects also require specialized skills that manufacturers only need occasionally, such as safety validation, coordinated motion, drive integration, legacy system updates, or startup troubleshooting. These projects can carry substantial operational and financial risk. An incorrectly executed migration, a safety issue, or a delayed startup may cost far more than the project’s engineering fees. Outsourced controls engineering services provide access to specialists throughout the project lifecycle, as needed. Instead of building every capability internally, manufacturers can bring in the resources required for the work at hand. 

When Software and Tooling Costs Are Hard to Justify 

Controls engineering work requires more than engineering labor. Depending on the project, manufacturers may need access to a variety of different technologies and software. For organizations that complete only occasional automation projects, maintaining software subscriptions and training programs for internal staff can become a significant expense. 

Outsourced controls engineering services spread those costs across many projects and customers. The manufacturer pays for project execution rather than maintaining a complete controls engineering infrastructure internally. 

When Faster Project Completion Has Financial Value 

When looking at total cost, project delays should be treated as a financial cost, not just a scheduling issue. A delayed startup can postpone new production capacity, labor savings, quality improvements, or customer delivery commitments. Opportunity cost can also show up when internal engineers are pulled away from daily production support or process improvement work to manage a capital project. In those situations, the financial consequences of missing a deadline may exceed the engineering budget. 

An outsourced team can often assign multiple engineers to critical phases of a project while an internal engineer continues supporting daily operations. The ability to accelerate implementation can improve project economics even when hourly engineering rates are higher. 

When Hiring In-House May Be the Better Investment 

Outsourced controls engineering services are not always the lowest-cost option. Manufacturers with a steady stream of automation projects often benefit from maintaining internal controls engineering teams. Facilities that regularly develop machinery, modify production lines, support multiple shifts, and execute ongoing process improvements can keep engineers fully utilized throughout the year. Internal engineers also gain detailed knowledge of plant standards, equipment configurations, operational constraints, and maintenance practices. When engineering demand remains consistently high, that familiarity can improve responsiveness and reduce long-term costs. 

For many manufacturers, the most effective model combines both approaches. Internal engineers maintain ownership of automation systems while outsourced controls engineering services provide specialized expertise, additional project capacity, or support for major capital projects. 

Kasa’s Controls Engineering Services for Turnkey Industrial Automation 

Manufacturers often need automation expertise for projects that exceed the capacity of internal engineering and maintenance teams. Kasa provides controls engineering services that help organizations execute automation initiatives without diverting resources from day-to-day operations. Many customers engage Kasa for a specific project, while others rely on us as an extension of their engineering department. 

Our capabilities include control system design; PLC, HMI, and SCADA programming; system integration; control panel design and fabrication; commissioning; startup support; and automation consulting. From new installations to controls modernization projects, we help manufacturers design, integrate, and support industrial automation systems that improve reliability, streamline operations, and reduce startup risk. 

With more than 50 years of experience and over 10,000 completed projects, we bring the engineering resources, technical expertise, and project execution capabilities needed to move automation projects from concept through startup. Whether supporting a single phase of a project or providing broader automation engineering expertise, our team helps manufacturers implement control systems that operate safely, reliably, and at scale. 

Have an upcoming project? Contact us to learn how we can help you.