Packaging Plant
Faridabad
Packaging Line Commissioning Under Tight Startup Timeline
Problem: A newly installed packaging line could not achieve stable production because multiple machine sections were not sequencing correctly, and alarm conditions were confusing operators during startup.
Solution Provided: Our onsite team handled PLC commissioning, HMI validation, drive checks, sensor verification, and startup sequence stabilization. We corrected the interlock flow, aligned machine permissives, and trained the operator team during live trials.
Technologies Used: PLC, HMI, VFD
Result: The client achieved a smoother startup process, reduced repeated trial stoppages, and moved into dependable production faster with clearer operator-side diagnostics.
Textile Unit
Gurugram
Breakdown Maintenance for Repeated Control Panel Faults
Problem: A textile processing machine was facing repeated breakdowns caused by intermittent control panel faults, drive alarms, and unclear feedback signals that maintenance staff could not isolate quickly.
Solution Provided: We performed onsite troubleshooting, panel inspection, signal tracing, and VFD fault diagnosis. The team cleaned up critical panel-side issues, corrected the affected control points, and validated stable operating conditions before handover.
Technologies Used: PLC, VFD, Control Panel Diagnostics
Result: The client saw a noticeable drop in repeat stoppages, faster maintenance response, and more dependable machine behavior during regular production shifts.
Food Processing Unit
Noida
Preventive Maintenance Program for Critical Automation Equipment
Problem: A food processing client wanted to reduce unexpected automation-side failures that were interrupting production planning and forcing emergency service calls.
Solution Provided: We carried out preventive maintenance for PLC-connected panels, HMI screens, field signals, and critical drive sections. The work included inspection, health checks, parameter review, alarm observation, and maintenance recommendations for the plant team.
Technologies Used: PLC, HMI, Electrical Panel Inspection
Result: The plant improved maintenance visibility, reduced avoidable emergency calls, and gained a more structured approach to control-system upkeep.
Automotive Component Plant
Manesar
Emergency Servo and PLC Fault Recovery During Production Run
Problem: A production-critical station stopped during an active run because of servo-related alarms and coordination issues between the PLC logic and motion section.
Solution Provided: Our engineers supported emergency onsite fault diagnosis, servo parameter review, PLC sequence checks, and recovery testing. We stabilized the motion behavior, validated fault handling, and monitored the station through restart.
Technologies Used: PLC, Servo Drive, HMI
Result: The station was returned to controlled production faster, and the client gained better insight into the root cause of the motion-control stoppage.
Printing Industry
Delhi NCR
SCADA-Linked Commissioning Support for Multi-Stage Production Monitoring
Problem: A printing operation needed help bringing an upgraded machine online while also ensuring that status, alarms, and production values were visible correctly in the supervisory layer.
Solution Provided: We supported onsite commissioning across the PLC, HMI, and SCADA layers, verified tag communication, checked alarm visibility, and validated production status flow between machine and monitoring screens.
Technologies Used: PLC, HMI, SCADA
Result: The client achieved a more reliable startup, better operator visibility, and smoother reporting continuity from the machine layer to supervisory monitoring.
