Project Experience & Technical Implementations

Industry
Automotive Manufacturing.
Technologies
Allen-Bradley PLC + Ignition SCADA.
Location
California, USA.
Scope
Upgrade and migration of existing Manufacturing Execution Systems (MES) to a newer and optimized MOS platform across multiple production plants.

Technical Focus
• Integration between PLCs and centralized SCADA systems across stations
• Communication restructuring and validation
• Offline functional verification
• Commissioning during planned downtime without production interruption

Architectural Contribution

While operating under existing plant standards, structured communication mapping and validation processes were implemented to ensure system stability during migration.

Outcome

• Faster and clearer operator interfaces
• Successful migration without production disruption
• Improved system responsiveness and reliability

MES Migration & MOS Upgrade Across Multiple Manufacturing Plants

Industry
Automotive Manufacturing
Location
Michigan, USA
Technologies
Siemens Step7 (Simatic Manager), Fanuc Robots, PowerFlex VFDs

Scope

Programming and deployment of 8+ gantry-type production lines for new automotive models.

Technical Focus

• PLC implementation under client programming standards
• Development of ISA-101 compliant HMI screens
• Alarm standardization under ISA-18.2
• Integration with robotic systems and VFD controls

Architectural Contribution

Although based on the client’s existing framework, improvements were introduced in alarm structure consistency and interface alignment to improve long-term maintainability.

Outcome

• Standardized production lines across multiple systems
• Improved clarity for operators
• Simplified future code modifications for new vehicle models

Multi-Line Gantry Production System – Powertrain Manufacturing

Industry
Automotive Manufacturing
Location
Monterrey, Mexico
Technologies
Siemens TIA Portal, KUKA Robot

Scope

Urgent programming and restructuring of an End-of-Line testing cell consisting of:

• Infeed conveyor
• Outfeed conveyor
• Reject conveyor
• Four electrical test stations
• Central robotic handling system

Project deadline: 2 weeks before customer acceptance testing.

Technical Focus

• Complete redesign of PLC and robot control logic
• Transition from sequential logic to state-machine-based architecture
• Redefinition of safe robot positions
• Optimization of motion flow to reduce cycle time

Architectural Contribution

A structured state-machine architecture was implemented to replace the existing sequential control model.

This architectural change enabled:

• Clear state ownership
• Reduced interdependency between test stations
• Future scalability
• Improved debugging efficiency

Outcome

• Project completed on time under critical schedule
• Reduced programming complexity compared to original design
• Prepared system for integration of two additional future test stations with minimal code modification
• Full compliance with customer technical requirements

EOL Robotic Cell – Architectural Redesign Under Critical Deadline

Industry
Automotive Manufacturing
Location
Torreón, Mexico
Technologies
Siemens TIA Portal v20, Festo Servo Systems

Scope

Urgent programming of a fully automated airbag folding station with a 4-nest rotary index table.

Technical Focus

• Implementation under client programming standards
• Coordination of 69+ servo axes
• Control of 200+ pneumatic cylinders
• Development of diagnostic-focused HMI due to system complexity

Architectural Contribution

Structured modular logic separation was applied to manage high device density and complex motion coordination, enabling maintainable control of multiple subsystems.

Outcome

• Fully automated and consistent machine operation
• Clear operator interface with structured diagnostics
• Stable control despite high mechanical complexity

Automated Airbag Folding Station – Rotary Index System