15-Station Automotive Assembly Line Upgrade
Frequent safety halts and poor line diagnostics led to 4 hours of daily unscheduled downtime.
Programmed modular sequence blocks with integrated safety zone controls. Developed custom HMI overlays showing exactly which guard switch tripped.
Reduced daily line reset downtime by 35%. Plant uptime increased to 99.1%.
High-Performance HMI Upgrade for Process Plant
No central recipe storage or operator visualization for critical chemical reactions.
Designed and configured custom HMI screens communicating over PROFINET with 8 local PLCs. Integrated local recipe storage and advanced alarm logging layouts.
Batch cycle time decreased by 14%. Operators now have complete process visibility with role-based security.
Wastewater Treatment Plant Telemetry Migration
Legacy dial-up telemetry failed daily, requiring operator visits to remote lift stations.
Installed 4G LTE cellular telemetry modules. Programmed local PLC control backup files so stations continue automatic operation during signal loss.
Complete elimination of daily check trips. Central telemetry alarm warnings received instantly.
Cleanroom HVAC Control System Validation
System required strict 21 CFR Part 11 electronic records and room pressure calibration.
Programmed high-precision PID loops for room differential pressure. Configured username security groups and event audit logs on the HMI panel.
Passed regulatory validation inspection first time with zero issues. High accuracy pressure logs.
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