Engine assembly · six-station cell with SIL 3 robotic safety.
Tier-1 supplier to a Japanese OEM. Six-station engine block assembly with a Festo gantry, two Schmersal-guarded robot cells and a Redlion SCADA layer pushing OEE to a plant-head dashboard. Cycle floor: 22 seconds.
Biscuit packaging upgrade.
Retrofitted three lines from a legacy Siemens setup to a Redlion + Festo stack. Twelve-recipe HMI; changeover time cut from 22 min to 6 min.
Blister pack with 21 CFR audit.
New blister-pack line with electronic batch records, signed-and-sealed change control, and an audit-trail HMI that passed a US FDA pre-inspection.
Module string-test farm · 512-channel I/O.
End-of-line PV module test rig running 1200V DC, 512-channel measurement, and cloud telemetry over MQTT. Throughput: 220 modules/hr at 99.6% PASS rate.
Curing press PLC retrofit · 14 cabinets.
Replaced 14 legacy curing-press PLCs without stopping production. Phased cutover, weekend by weekend. Cycle accuracy improved to ±0.1°C on cure temperature.
Dairy aseptic filler.
IP69K-rated stainless cabinet, hygienic Schmersal interlocks, CIP loop with closed-loop temperature control to ±0.3°C.
Seat assembly with vision QC.
Eight-station seat-frame assembly with Carlo Gavazzi vision check and Wachendorff servo feedback. End-of-line load test integrated.
Storage tank ESD system · Zone 1.
SIL 3 emergency shutdown for a coastal storage terminal. ATEX cabinets, Carlo Gavazzi IS barriers, fibre ring back-haul to the main control room.