Manufacturing Consulting services have provided the following solutions:

City Water Treatment facility

Challenge:

• Power outage caused loss of control program.
• System was not capable of starting, immediate need.

Solution:

• Reinstall control program
• Modified program to accommodate recent electrical modifications.
• Restart and debug.

Challenge: 

• System was not generating clean water, immediate need.

Solution:

• Troubleshoot root cause through access to controller
• Discovered system had pressure, but no water flow. 
• Discovered vapor lock causing no flow situation, problem solved quickly after.

Reactive Balance Systems used in rehabilitation and performance enhancement. 

Challenge:

• Servo driven components going obsolete and prices were increasing by over 115%
• Source cost effective replacement parts.
• System redesign to accommodate new components.
• Facing major 10% product cost increases or shut down of product sales.

Solution: 

• Found cost effective replacement actuator, with only minor engineering change to structure.
• Upgraded controls to eliminate obsolescence challenges in future.
• We manufacture the control panel for reactive balance system.

Consumer Packaging Industry – Major manufacturer of paper cups/containers, as well as plastic lids.

Challenge: 

• Supervisory control system outages due to antiquated control hardware
• Old PC’s and servers with no back-up systems in place.
• Massive loss of data, due to lack of disaster recovery protocol.
• Critical equipment was experiencing large amounts of downtime.

Solution:

• Designed robust industrial network to facilitate human to machine interfacing.
• Integrated system analytics and machine reporting.
• Design leverages redundancy to minimize risk to data loss.
• System wide upgrade the current application versions.

Results:               

• Increased system uptime and vast reduction of machine downtime.
• Increased process visibility.
• Highly expandable for rollout to multiple locations and company growth.

Challenge: 

• Customer requirements dictate updating of barcoding process for improved traceability.\
• Automation update required, due to customer barcode and date/time stamp requirements.
• Minimize manual label applications.

Solution:

• Integrate solution to existing ERP system.
• Add print and apply barcoding stations to automate labeling process.
• Redesign conveyor system to accommodate material flow and barcode station throughput.
• Highly expandable for rollout to multiple locations and company growth.

Agriculture Industry - Hog ferruling industry requires positive pressure buildings to prevent contamination from negatively impacting the health of livestock.

Challenge: 

• Reduce overall system cost to end customer through energy conservation.
• Design user friendly system for monitoring and maintaining building temperature and pressure.
• Develop system maintaining balance between static and variable speed fans.
• Capability needed to remotely diagnose and troubleshoot systems.

Solution:

• Develop program to operate static and variable speed fans according to user parameters.
• Developed user interfaces and secure remote access control.
• Designed and manufacture system UL control panels.
• Maintain program version control remotely as a disaster recovery safeguard.

 

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