Project Portfolio

The Challenge

Large distribution center needed to automate manual palletizing operations for both inbound receiving and outbound shipping. Goals included reducing labor dependency, increasing throughput, and improving consistency.

Our Solution

Designed and programmed complete robotic palletizing cells for case handling:

• Inbound palletizing: Automated case stacking from receiving conveyors
• Outbound palletizing: Order fulfillment case palletizing for shipping
• Allen-Bradley ControlLogix PLC programming for complete cell control
• GuardLogix safety system integration for safe human-robot collaboration
• HMI development: Operator interface for pattern selection, diagnostics, and production monitoring
• Conveyor integration: Seamless integration with existing material handling systems

The Challenge

Complex warehouse conveyor system requiring sophisticated control logic for material flow, accumulation zones, and sortation. System needed to handle high-volume package flow with minimal downtime.

Our Solution

• ControlLogix PLC programming for multi-zone conveyor control
• Accumulation logic: Zero-pressure accumulation for product protection
• Zone control: Precise timing and coordination across dozens of zones
• Sortation integration: Diverter control and destination routing
• Photo eye and sensor network for package tracking
• HMI development: System monitoring, diagnostics, and operator control
• Network architecture: EtherNet/IP communication between multiple PLCs

The Challenge

Injection molding operation running obsolete Allen-Bradley SLC 500 PLCs for cooling tower control. Parts availability becoming critical, system reliability declining, and maintenance becoming difficult.

Our Solution

Complete control system retrofit and modernization:

• PLC migration: Upgraded obsolete SLC 500 to modern CompactLogix platform
• Control panel redesign: New panel layout with improved maintainability
• Cooling tower automation: Temperature control, pump sequencing, alarm management
• Program conversion: Migrated and optimized existing logic to new platform
• AutoCAD Electrical drawings: Complete electrical documentation
• HMI upgrade: Modern PanelView replacing old operator interface
• Testing & commissioning: Validated performance matches original system

The Challenge

Injection molding facility needed comprehensive Energy Control Power Lockout (ECPL) documentation for safe maintenance and troubleshooting procedures. Existing documentation was incomplete or outdated.

Our Solution

• ECPL graphics design: Clear visual identification of energy isolation points
• Lockout/tagout procedures: Step-by-step safety procedures for each machine
• Energy source identification: Electrical, pneumatic, hydraulic isolation points
• Equipment-specific procedures: Customized ECPL for each injection molding machine
• Visual documentation: Color-coded graphics for quick reference
• Compliance ready: Meets OSHA and Ontario MOL requirements