Case Studies

Anonymized examples of real automation problems and how they were resolved. Specific outcomes vary — these represent the type of work and approach applied.

Robotics

FANUC Cell Cycle Time Reduction via Path Optimization

Situation

A high-volume production cell was running consistently over its designed cycle time. The robot motions had not been reviewed since initial commissioning, and the maintenance team had no clear baseline for what the correct path and motion parameters should be.

Approach

Performed a systematic review of all motion segments using teach pendant diagnostics and cycle time logging. Identified several moves using conservative CNT values and unnecessary intermediate waypoints added during fault recovery. Adjusted motion parameters, removed redundant positions, and verified collision clearance throughout.

Outcome

Cycle time improved to within specification. The revised program was documented with motion parameter notes and backed up with version labeling. A recovery procedure was written for common fault states that previously required ad-hoc path edits.

Outcomes represent example results from this type of engagement. Specific results vary by facility and equipment condition.

PLC & Controls

Production Recovery After Critical PLC Fault + Backup Restoration

Situation

A manufacturing cell lost production after a ControlLogix fault that left the program in an unknown state. The most recent backup was over six months old and not verified. The maintenance team could not determine what had changed between the backup and the current state.

Approach

Performed a structured diagnostic of the fault state, compared the current controller program against the available backup, and identified the discrepancies introduced since the backup date. Restored the known-good elements, addressed the active fault causes, and brought the system back online with verified functionality.

Outcome

Production restored. A backup verification procedure was implemented along with a scheduled backup cadence. The fault history and root-cause analysis were documented for the maintenance team.

Outcomes represent example results from this type of engagement. Specific results vary by facility and equipment condition.

Vision Systems

Vision Inspection Accuracy Improvement via Lighting & Calibration

Situation

An in-line vision inspection system was generating false rejects during certain production shifts, attributed by operations to lighting conditions. The reject rate variability had not been systematically traced to a specific cause.

Approach

Conducted a lighting audit across production shifts — identified ambient light variability and a degraded strobe controller. Recalibrated the iRVision job, adjusted exposure and threshold parameters for robustness, and replaced the faulty strobe controller. Verified inspection accuracy across multiple production runs.

Outcome

False reject rate reduced to within acceptable limits. Calibration and lighting configuration documented. Strobe replacement schedule added to PM checklist.

Outcomes represent example results from this type of engagement. Specific results vary by facility and equipment condition.

Robotics / Electrical

Weld Cell Stabilization — EOAT & Changeover Logic Improvements

Situation

An automated welding cell was experiencing intermittent faults during product changeovers. The EOAT changeover logic had grown through multiple maintenance modifications without documentation, and the failure mode was not reproducible on demand.

Approach

Reviewed EOAT I/O mapping and changeover sequence in detail. Found a timing conflict introduced by a previous modification that only manifested under specific tooling combinations. Corrected the changeover logic, verified EOAT detection signals, and stress-tested across all product variants in the cell.

Outcome

Changeover faults eliminated. Revised changeover logic documented and a controlled change process recommended to prevent undocumented modifications going forward.

Outcomes represent example results from this type of engagement. Specific results vary by facility and equipment condition.

PLC & Controls

EtherNet/IP Troubleshooting & CIP Safety Validation Support

Situation

A newly integrated cell was experiencing intermittent EtherNet/IP communication faults between the safety PLC and a remote I/O chassis. CIP Safety devices were also not validating consistently after program downloads.

Approach

Performed network diagnostics using Studio 5000 RSLinx and physical layer checks. Identified incorrect module revision settings and a misconfigured network switch port causing packet collisions. Corrected the EtherNet/IP configuration and completed the CIP Safety functional validation sequence per Rockwell procedures.

Outcome

Communication faults resolved. CIP Safety validation completed and documented. Network configuration notes provided for future maintenance reference.

Outcomes represent example results from this type of engagement. Specific results vary by facility and equipment condition.

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