Our projects
here you will find some examples of the projects we have previously worked on.
7 day turn around
One of our customers relied on a 25+ year-old machine from a manufacturer no longer in operation, equipped with an outdated Siemens S5 PLC. When the PLC failed one day, leaving the customer unable to recover, they turned to us for help. After a thorough assessment, we concluded that due to the machine's age and complexity, along with the irrecoverable program, a complete control system redesign was imperative. Understanding the critical importance of this machine to their manufacturing operations, we dedicated ourselves to round-the-clock work to execute the repair. Today, with a modernized control system in place, the machine is running smoothly and is easily maintainable. Moreover, our customer possesses a copy of the new program we developed, safeguarding them from similar predicaments in the future.
Modern industrial data extraction
While we've worked with various MES and SCADA packages, we realized that fulfilling our customers' needs could entail significant costs and technical challenges, especially with the limitations of OPC-UA approaches. As a solution, we developed our proprietary toolset, Unity. Offering a cost-effective and swift data capture solution on the factory floor, Unity has been successfully deployed at one of our customer's sites. Furthermore, we've secured an Innovate UK R&D grant to enhance its capabilities further.
Engineering log system
Our client faced challenges tracking engineering work progress and lacked an engineering warehouse management system, hindering expenditure tracking on critical items like sensors. Upon our recommendation, they adopted our Unity Engineering system. A few months post-implementation, the electrical department identified high failure rates in hardware. Consulting with the manufacturer, they switched to hardware better suited to the factory environment. This decision led to significant short-term savings and promises millions saved in the long run.
Rats nest
Our client operated a large, aging machine for raw material processing, plagued by frequent faults and downtime due to failing components and overheating drives. Both operators and electrical staff struggled with its poor condition, leading to operational challenges. Unable to afford major shutdowns for repairs, they sought our expertise.
We proposed a phased approach, systematically replacing outdated control system components with new ones, often digitizing hardware using the CODESYS development environment. After a month-long effort, we successfully installed a new control system, resolving all common faults reported by operators and the electrical department.
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