Success Stories & Case Studies

Gearset Matching Data Collection System Problem Statement: A Tier-1 automotive manufacturer in Pluak Daeng, Rayong, faced a traceability challenge with their Oerlikon T60 (Bevel Gear Testing) machines. The machine performs critical matching tests for Ring and Pinion gears, but the test results were stored locally in proprietary text files. The Challenge: Closed System: The machine runs on legacy software. Modifying the internal code to send data to a database was deemed too risky and would void the manufacturer’s warranty. Data Silo: Quality engineers had to manually check files, leading to data gaps and lack of real-time traceability in the central ERP/MES. Our Solution: The “Sidecar” Integration Pattern We implemented a Non-Intrusive Data Collection System. Instead of hacking the machine’s software, we treated the machine as a “Black Box” and monitored its outputs externally. ...

CSIAPipeBender: High-Precision Tube Bending Controller Problem Statement: In traditional tube bending, operators often struggle with complex geometry calculations. converting a 3D drawing (XYZ coordinates) into machine actions (Length, Rotation, Angle) requires advanced mathematics. Additionally, physical factors like Spring Back (metal elasticity) and Elongation (stretching) often lead to inaccurate bends, requiring significant trial and error. The Challenge: Complex Math: Manual calculation of bend sequences is prone to human error. Material Behavior: Different tube materials react differently; a standard fixed program cannot account for spring back variance without a smart compensation algorithm. Our Solution: PC-Based CNC Architecture We developed CSIAPipeBender, a Windows-based HMI/Controller that acts as the “Brain” for the machine, while the Mitsubishi PLC acts as the “Muscle.” ...

Real-time Crepper Motor Monitoring System Problem Statement: In a large-scale rubber processing plant, the “Crepper Machines” are the heart of production. The client, Sri Trang Agro-Industry PCL, needed to monitor the electrical current (Amps) of 3 critical motors in real-time. Previously, operators had to manually check readings from local panel meters, making it impossible to analyze historical trends or detect anomalies (like motor overload) instantly. The Challenge: Legacy Connectivity: The existing meters were standard Digital Meters (Primus TCM-94N-AB) communicating via Modbus RTU over RS-485, requiring a reliable bridge to the IT network. Data Integrity: The system needed to handle potential connection drops and ensure data continuity for accurate reporting. User Accessibility: The dashboard had to be accessible via a web browser on the local network without complex software installation on client machines. Our Solution: Hybrid IoT Gateway WP Solution architected a Web-based Monitoring System that bridges the gap between the factory floor and the control room. We utilized Node-RED as a robust middleware to poll data from the meters and Vue.js for a high-performance frontend dashboard. ...

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. ...