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.