Success Stories & Case Studies

Rubber Compounding & Precision Weighing Control System Problem Statement: In the Master Batch (MB) and Carbon Master Batch (CMB) production lines of a leading automotive rubber manufacturer, manual chemical weighing processes were prone to human error. Deviations from the specific rubber formula resulted in quality issues, waste, and a lack of digital traceability. The Challenge: Precision Requirement: The system must interface directly with high-precision scales to ensure chemical weights fall within strict tolerance levels. Network Instability: Production cannot stop even if the factory network/server goes down. Inventory Control: Need real-time stock deduction and validation to prevent incorrect material usage (wrong lot/wrong type). Our Solution: Smart Weighing & Interlock System We developed a robust Windows Forms Application (C# .NET) that acts as the “Process Controller” for the mixing line. The system integrates IT and OT layers to enforce strict process control. ...

Precision Agriculture for Commercial Hemp Problem Statement: Hemp (Cannabis sativa) is a highly sensitive crop. Successful cultivation requires precise control over the Vapor Pressure Deficit (VPD). Excessive humidity leads to mold (Bud Rot), while improper lighting schedules can disrupt the flowering cycle. Managing 8 large-scale greenhouses manually is inefficient and risky. The Challenge: The project required retrofitting and automating 4 out of 8 greenhouses. The system needed to integrate various actuators (Fans, Curtains, Pumps) and execute complex logic based on multiple sensor inputs (Light, Temp, Humidity) and Schedules. ...

Adaptive Visual Inspection for Stamped Parts Problem Statement: In automotive part manufacturing, “Stamped Characters” (serial numbers/codes) are critical for traceability. However, the physical stamping process is inconsistent. Factors like die wear, hydraulic pressure changes, or slight positioning shifts cause the characters to look different over time. The Challenge: A traditional Vision System uses a static “Master Image.” When the production line’s stamping tool degrades slightly, the characters no longer match the static Master perfectly. This leads to a high rate of False Rejects (Good parts being rejected), causing frequent machine downtime and requiring constant code adjustments by engineers. ...

Smart Fleet Management for 1.2 Ton Forklift AGVs Problem Statement: A leading tire manufacturer faced bottlenecks in transporting heavy rubber rolls (1.2 tons) between the Iron MC machine and the Liner/Stock rails. The manual process was slow, prone to accidents, and difficult to track in real-time. The Challenge: Heavy Load: Handling 1.2-ton payloads requires precise and safe navigation. Complex Traffic: Multiple AGVs operating in shared aisles with human workers. Legacy Integration: Need to communicate with existing machines via varied protocols. Our Solution: Intelligent Traffic Control WP Solution architected a comprehensive Fleet Management System that acts as the “Air Traffic Control” for the factory floor. The system manages job queues, calculates optimal routes, and prevents traffic jams using a dynamic node-based algorithm. ...

Ceramic Kiln HMI Modernization Problem Statement: A leading ceramic tile manufacturer faced critical risks with their tunnel kiln control systems. The existing operation relied on obsolete UniOP Touch Screens and proprietary “Designer 6” software, which were no longer supported. Spare parts were scarce, and the system suffered from limited memory, preventing the storage of new production recipes. Furthermore, the legacy system lacked data logging capabilities, making it impossible to analyze fuel consumption or track alarm history efficiently. ...