Full Circuit
Automation
Controls, robotics, and reliability serving central NC manufactures.
Our Services
Manufacturing solutions by those who have spent the last 15 years on manufacturing floors. We did the day to day programming, maintenance and repairs to keep the facility running. Yes, even fixing the botched integrator jobs.
OEE & downtime baselineMachine & panel health
Maintenance practices & PM/TPM programs
Controls obsolescence
Spare parts risk
Machine safety & guarding gaps
Automation readiness
Assessments
PM program developmentCMMS selection and implementation
Critical spares & storeroom optimization
Maintenance team training
Reliability Support
PLC migrations & controls restrofits
HMI & operator interface upgrades
VFD & motor control conversions
Control panel builds
Machine networking & data collection
Controls & Integration
Robotic work cells - machine tending, palletizing, pick-and-placeCollaborative robot deployment
Custom automation & assembly cells
End-of-arm tooling & fixturing
Vision inspection & error-proofing for quality control
Robotics & Automation
Machine guarding upgradesSafety circuits & safety PLC integration
Light curtains, interlocks, e-stop systems
Lockout/tagout improvements
Safety & Compliance
Maintenance mechanical and electrical troubleshooting and repairModify and optimize existing PLC programs
Assist new equipment setup/commissioning
In house training
Documentation of repair process SOP/SWI
On Site Active Support
Start with an assessment
Tier 1 and Tier 2 assessment can be applied as credit to the next tier or towards a follow up project within 90 days of the assessment.
Starting at $1,500 <60 Employees (1-3 lines)
Tier 1 - Plant Walk
4 Hour guided floor walk with your team or manager
Visual survey of equipment condition up to 3 lines/stations/cells
Quick look at controls systems
Rough downtime and constraint discussion with operations
Observe processes and procedures
Deliverables: 3-5 page findings brief with top 5 observations ranked by opportunity and first next step roadmap.
Tier 2 - Reliability & Automation
3-5 Days on site in (4 Hours daily)
Everything in Tier 1
Asset criticality ranking across the assessed area
30 Day downtime logged by plant personnel and then we analyze the data
Overall Equipment Efficiency (OEE) Calculations and gaps
Machine safety gap identification
Panel condition survey with thermal scan
Critical spares audit and min/max recommendations
Controls obsolescence inventory with part parts risk
Deliverables: Full findings and roadmap document with baseline metrics. Findings sorted into safety/reliability/spares/automation, each priced with payback math sequenced into a 12 month plan.
Starting at $5,000 <60 Employees (1-3 lines)
Tier 3- Baseline & 90 Day Program
Starting at $40,000 <60 Employees (1-3 lines)
Full tier 2 assessment as a starting point
CMMS Selection and startup, or optimization of existing system
Asset registry and PM schedule build out
TPM autonomous maintenance checklists for operators
Spare parts min/max implementation with storeroom
Training sessions for maintenance team
Deliverables: Everything from tier 2 plus a working CMMS with populated assets and PM schedules, printed operator checklists, and spare parts lists.