Real-World Case Studies and Customer Success Stories with FactoryTalk

Arena Simulation Software helped a package delivery company plan routing and delivery from terminal to plane. The company used the TAPS model to simulate unloading, sorting, and loading packages, as ...well as aircraft maintenance. This improved scheduling and equipment allocation. The company eliminated large material handling purchases and reduced production costs. The solution led to cost savings in the millions of dollars.
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Arena Simulation Software helped Rockwell Automation’s CEDC improve order batching and reduce training time. The supply chain simulation model let planners test different batching strategies and use ...real-time order data. This reduced errors in order processing and made it easier to find better ways to batch orders. Training time for new planners dropped from six months to one week. The model covered 90-95% of orders and improved efficiency.
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Arena Simulation Software helped Rockwell Automation’s CEDC improve order batching and reduce training time. The supply chain simulation model let planners test different batching strategies and use ...real-time order data. This reduced errors in order processing and made it easier to find better ways to batch orders. Training time for new planners dropped from six months to one week. The model covered 90-95% of orders, making the process faster and more accurate.
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Rockwell Automation and Brock Solutions helped The Region of Waterloo modernize its SCADA and PLC systems across 157 water facilities. The challenge was to upgrade critical infrastructure without dis...rupting water service. The solution used ControlLogix, CompactLogix, Stratix switches, and distributed I/O for a phased, standardized approach. The project minimized downtime, improved operational efficiency, and increased system resilience. The five-year transformation enhanced monitoring, security, and reliability for over 600,000 residents.
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Rockwell Automation helped Axtel Industries automate their chocolate molding and spice blending lines. Axtel needed more accuracy, efficiency, and safety in production. They used Kinetix 5700 servo d...rives, ControlLogix processor, PlantPAx, and GuardLink 2.0. The new system made Axtel's chocolate molding line a top choice in the global market. Automation improved precision, efficiency, and safety, and made remote troubleshooting possible.
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DST needed high accuracy in microdosing for their plant-protein processing solution. They installed a Rockwell Automation solution with Allen-Bradley Kinetix servo motors and other components. This s...etup achieved dosing accuracy within 1% and faster installation. The SHEARTEX process uses less energy and produces high-quality plant-based meat alternatives. It allows for realistic textures and flavors, making plant-based products more competitive with animal meats.
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Garvey used Emulate3D software to show the benefits of its bottle accumulation systems. The software helped demonstrate efficiency to beverage customers. It improved sales by showing real-time scenar...ios. Garvey's systems reduce bottlenecks in production lines.
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PFi created a titanium cross flow membrane for wastewater. It reduces downtime and increases yield. Rockwell Automation provided CompactLogix and PanelView Plus for integration. The solution is used ...by a leading beverages company. It offers high flow rates and is recyclable.
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Maple Leaf Foods uses AR and digital twins to improve efficiency. They work with Rockwell Automation and others. At the Guelph plant, operator efficiency improved. The London plant achieved over 99% ...accuracy. The Brampton plant reduced downtime.
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Rockwell Automation helped DST improve its plant-based meat production with Allen-Bradley Kinetix servo motors and PowerMonitor 5000. DST needed very accurate microdosing for quality and repeatabilit...y. The solution gave DST dosing accuracy within 1% and precise energy monitoring. DST can now produce 1,000 kg per hour of high-quality protein products using less energy. The new process also speeds up installation and time to market.
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OWS Foods faced challenges with manual scheduling and multiple data sources. They implemented Plex ERP and Supply Chain Planning with Control+M Solutions' help. This led to a 25% increase in demand f...orecasting accuracy and a 33% reduction in customer lead times. The automation allowed employees to focus on more meaningful tasks and improved recruitment and retention.
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Plex ERP helped Leaf Infusions, a cannabis manufacturer, automate inventory tracking and compliance in just 73 days. The company faced rapid growth and struggled with manual processes and regulatory ...reporting. Control+M Solutions implemented Plex ERP, meeting a tight deadline and tailoring the system for Health Canada compliance. Leaf Infusions now saves six days per month on compliance reporting and has improved production planning and cost efficiency. The new system increased user adoption and set a new standard for fast ERP deployment in the cannabis industry.
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Leaf Infusions, a cannabis manufacturer, needed a scalable ERP solution due to rapid growth. Their manual processes were inefficient and compliance reporting was time-consuming. They implemented Plex... ERP with the help of Control+M Solutions in just 73 days. This provided real-time inventory tracking and automated compliance reporting, saving six days per month. The new system improved production planning and user adoption, setting a new standard for ERP deployments.
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Emulate3D by Rockwell Automation helped Garvey show the benefits of its bottle accumulation systems. Garvey needed a solution that worked on standard hardware and could change scenarios in real time ...for live demos. Glenvern Group used Emulate3D to create 3D models of Garvey’s bottling lines. The sales team used these visual demos to show production line improvements to beverage customers. This helped Garvey communicate key data and support customer acquisition.
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Rockwell Automation helped Axtel Industries automate their chocolate molding and spice blending lines. Axtel needed more accuracy, efficiency, and safety in production. They used Kinetix 5700 servo d...rives, ControlLogix processor, PlantPAx, and GuardLink 2.0. The new system made Axtel's chocolate molding line a top choice in the global market. In spice processing, they now manage over 100 ingredients with better precision and efficiency. The automation improved product quality, safety, and allowed for remote troubleshooting.
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Rockwell Automation helped Maple Leaf Foods use AR, digital twins, and smart manufacturing to improve efficiency. At the Guelph plant, Vuforia AR and Harpak-ULMA solutions boosted operator training a...nd OEE. In London, FactoryTalk and ControlLogix systems enhanced product flow and cut costs, achieving over 99% accuracy. At Brampton, Plex Production Monitoring and FactoryTalk reduced downtime and improved throughput. Maple Leaf Foods gained a competitive edge in the food industry with these digital transformation tools.
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Drillmec used Allen-Bradley PowerFlex 755TL AC drives from Rockwell Automation to improve its carbon-capture drilling operations. The company needed to make drilling faster, safer, and more cost effe...ctive. The new drives increased drilling precision and reduced the number of staff needed on site. This helped lower costs, improve safety, and boost energy efficiency. Drillmec expects less downtime and longer equipment life with this solution.
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PowerFlex 755TR drives helped a global energy company modernize its well pad infrastructure. The company faced aging assets and wasted energy with old VFDs. DSI and Rockwell Automation installed new ...regenerative drives that recycle energy. Over 130 drives have been deployed so far. The project is expected to save $3 million per month in energy costs. The new system achieved 17% regeneration, with 95% of that power reused.
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BCPGroup uses technology to save energy and cut costs. They use AI and magnet motors in oil and gas. They save 20% to 30% energy in pumping. Maintenance costs drop by 40%. Well productivity goes up b...y 30%.
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Arena simulation software helped MTS Medical Technologies test many variables in their medical packaging line. MTS used the software to find bottlenecks and improve machine design. The simulation let... them analyze different scenarios and pick the best solution. As a result, MTS cut design time by half and reduced risk. The software also helped them gain customer buy-in for their new packaging system.
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Rockwell Automation's Asia Pacific manufacturing facility in Singapore faced challenges with legacy systems that lacked scalability for energy management. They implemented AI-driven FactoryTalk Energ...y Manager for real-time monitoring and predictive analytics for energy optimization. As a result, they achieved 15%–30% projected annual energy savings and a 20%–40% projected reduction in Scope 1 & 2 emissions. The facility also received the BCA Green Mark Platinum certification and increased workforce efficiency.
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FactoryTalk Energy Manager helped Rockwell Automation Asia Pacific Business Center in Singapore cut energy use and emissions. The team replaced manual tracking with real-time monitoring and predictiv...e analytics. They saw 15%–30% projected annual energy savings and a 20%–40% projected drop in Scope 1 & 2 emissions. The plant earned BCA Green Mark Platinum certification. Employees now use dashboards for better decisions and efficiency.
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Strand Products faced challenges with their existing ERP system, which relied on eight different programs, leading to inefficiencies and delays. They implemented Plex ERP to automate and digitize the...ir operations. As a result, they achieved a 40% revenue growth and a 7% improvement in gross margin. The new system also improved compliance processes and provided real-time visibility into production, enhancing decision-making and operational efficiency.
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Plex Enterprise Resource Planning (ERP) helped Pax Machine Works move from paper to digital processes. The company improved data visibility and accountability. Quoting became faster and easier. Emplo...yees adapted quickly to the new system. Plex made audits simpler and increased customer response speed. Pax now plans to expand automation and data visibility with Plex.
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Fluorsid S.p.A. faced challenges with process stability and raw material variations in their Cagliari plant. They implemented FactoryTalk® Analytics™ Pavilion8® MPC from Rockwell Automation to optimi...ze their processes. The solution reduced raw material waste by over 50%, improved product quality, and decreased energy consumption and CO2 emissions. The improved control also enhanced the quality of their gypsum byproduct, leading to increased demand.
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Plex ERP and Plex MES A&O helped Jay Industries fix unreliable data and poor inventory control. The company gained real-time production visibility and tighter inventory management. After switching, J...ay Industries cut yearly costs by $152,000. Inventory variance dropped by 86%. Overall equipment effectiveness went up by 6%. Machine availability increased by 8%. Employees now trust the data and make better decisions.
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Rockwell Automation and CaseiZ help manufacturers save energy. They use a system called AirView Cloud. It finds hidden inefficiencies in compressors. This can save 25-50% in energy costs. The system ...improves visibility and support.
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Rockwell Automation's Asia Pacific facility in Singapore reduced energy use by 15%–30% and emissions by 20%–40%. They used AI-driven tools for real-time monitoring and predictive analytics. The facil...ity earned the BCA Green Mark Platinum certification. The model is scalable to other facilities.
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PlantPAx distributed control system helped Corteva Agriscience migrate 15 legacy DCS systems. The project included new redundant Industrial Data Center servers and over 30 Stratix switches. The team ...integrated about 4000 I/O and IT/OT components for better connectivity. High-performance HMI graphics improved operator control and alarm response. State-based control automated tasks and reduced project risk. The migration improved reliability, efficiency, and remote monitoring for Corteva's operations.
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Fiix CMMS helped Pro-Vac manage a large fleet across 13 sites. The company struggled with manual processes and poor visibility as it grew. Fiix CMMS automated data entry, improved work order tracking..., and made compliance easier. Pro-Vac cut fleet downtime by 27%. Route planning got 17% more efficient. Fuel tracking accuracy improved by 12%. The team now has better inventory control and faster repairs.
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Plex software from Rockwell Automation helped Bayrak Technik GmbH unify ERP, MES, and QMS modules. The company needed better quality, planning, and inventory control. The solution created a single so...urce of truth for manufacturing data. Bayrak Technik saw tighter inventory control, more accurate production planning, and better asset integration. Employees now have real-time insights and improved analytics. The company improved quality and sustainability with machine monitoring.
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EtherNet/IP In-cabinet Solution helped Volga cut control panel wiring time by 66%. Manual wiring was slow and error-prone, making it hard to meet tight deadlines. The new solution made wiring faster ...and easier. Panel size dropped by 36% and weight by 32%. Volga used less wire and copper, saving materials. The team found the technology simple and strong, boosting productivity.
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ParkOhio faced challenges with outdated ERP systems and needed real-time data for better decision-making. They implemented Plex ERP and MES solutions to automate processes and integrate new plants qu...ickly. This led to improved quality control, reduced costs, and increased profitability. The company can now access real-time data, enhancing their ability to monitor and improve operations.
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FactoryTalk Optix and Studio 5000 helped Samson Machinery boost production efficiency and safety. Samson faced high competition, labor shortages, and demand for machine data insights. They used Rockw...ell Automation's digital tools for real-time data, seamless integration, and a dual-core control system. Samson reduced downtime by 20%. The solution improved machine safety and made integration easier for customers.
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Bayrak Technik GmbH needed a unified approach to quality, planning, and inventory control. They installed a Rockwell Automation solution, including Plex Software's ERP, QMS, and MES modules. This led... to tighter inventory control, more accurate production planning, and better asset integration. The solution also improved operational-data analytics and empowered employees with real-time insights. Bayrak Technik's digital transformation supports integration into customers' digital chains.
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Pro-Vac faced challenges with fleet management due to rapid growth and reliance on manual processes. They adopted Fiix CMMS to streamline operations and integrate with their existing tools. This led ...to a 27% reduction in fleet downtime and a 17% improvement in route planning efficiency. The solution also improved fuel consumption tracking by 12% and simplified compliance with DOT audits.
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Ionetic used Rockwell Automation to build Arc Fab, a flexible system for making custom EV battery packs. They used Emulate3D digital twin technology to cut setup time by up to two-thirds. The Plex Sm...art Manufacturing Platform improved production tracking and workflow. iTRAK systems made it easy to switch between battery designs. FactoryTalk DataMosaix gave real-time data to boost energy efficiency. Ionetic sped up time to market by 25% and cut capital costs by 5x per GWh.
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Ionetic and Rockwell Automation made custom EV battery packs. They reduced setup time by two-thirds. Time to market was faster by 25%. Capital expenditure was 5 times lower per GWh. They improved ene...rgy efficiency and production flexibility.
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EtherNet/IP In-cabinet Solution helped Volga cut control panel wiring time by 66%. Manual wiring was slow and error-prone, making it hard to meet tight deadlines. The new solution made wiring faster ...and easier, reducing panel size by 36% and weight by 32%. Volga used less wire and copper, saving materials. The team found the technology simple and strong, boosting productivity and supporting sustainability.
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The Shyft Group used Plex ERP to speed up making electric delivery trucks. They went from idea to working vehicle in nine months. Plex helped them set up in two weeks. The new trucks can go over 220 ...miles and are lighter. A big delivery company ordered 150 trucks.
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Dong-A ST opened a new plant in Songdo, Korea, to meet excess production capacity and support global expansion. They faced challenges in meeting GMP regulations and managing data. They implemented Ro...ckwell Automation's MES, SCADA, and other systems to automate processes and improve compliance. This led to easier regulatory reporting and allowed Dong-A ST to enter global markets. The new systems also improved operational efficiency and quality management.
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FactoryTalk Optix helped NKP Pharma meet 21 CFR Part 11 compliance. The company needed a cost-effective way to manage data and give customers more access. FactoryTalk Optix replaced expensive IPC-SCA...DA systems. NKP Pharma reduced costs and improved compliance. Customers now have better data access and are more satisfied. NKP Pharma plans to expand the solution to more machines and products.
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Rockwell Automation helped Pharbaco automate its pharmaceutical manufacturing. Pharbaco needed to meet GMP-EU compliance, control cleanroom conditions, and improve energy efficiency. The solution inc...luded ISA-95-compliant automation, smart HVAC, and real-time data analytics. Pharbaco reduced energy use by 45%. The facility now has better compliance, data integrity, and process control.
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FactoryTalk PharmaSuite and other Rockwell Automation solutions helped Dong-A ST build a cGMP-compliant smart factory in Songdo, Korea. The company needed to meet excess production capacity and globa...l GMP regulations. They used MES, SCADA, ThingWorx IIoT, and FactoryTalk Analytics DataView to automate systems and manage data. The new system made regulatory reporting easier and improved quality management. Workers now use tablets for all tasks, reducing errors and downtime.
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FactoryTalk InnovationSuite helped Probiotical S.p.A. scale its manufacturing to meet rising demand. The company used ThingWorx IIoT to collect real-time and historic data, improving visibility and c...ontrol. Machine availability increased by 15-20%. Operational equipment effectiveness is now near optimum. Energy use and packaging waste dropped. Operators now make better decisions with improved data access.
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Everyday Technologies faced challenges with an outdated ERP system that lacked forecasting and real-time data capabilities. They implemented Plex ERP, a cloud-based solution, to modernize operations ...and create a live inventory. This led to a 20% reduction in on-hand inventory within the first three months and improved forecasting capabilities up to 6 months in advance. The new system also enhanced real-time decision-making and operational efficiency.
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Precision Coating faced challenges with disparate systems and manual processes that hindered growth. They implemented Plex ERP, MES, and QMS to create a single source of truth and improve communicati...on. As a result, they achieved company-wide standardization, 100% inventory accuracy, and enhanced collaboration across locations.
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BETA Technologies is using Plex Systems software to improve air transportation. They are developing electric aircraft and a charging network. They focus on data collection for manufacturing. They aim... for a fully integrated plant. They use Plex's automation module for quality data.
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Green Hydraulic Power, Inc. uses variable frequency drives to save energy. Their systems cut energy use by up to 80%. Noise is reduced by 20 decibels. This makes workplaces safer and more productive.

FactoryTalk DataMosaix helps Minetek add real-time data monitoring to mining equipment. Minetek wanted to give customers better visibility and enable proactive maintenance. JH Tester integrated Facto...ryTalk DataMosaix, a SaaS platform, into Minetek’s water evaporation systems. The solution provides secure, real-time data from remote assets. Customers can now optimize maintenance and reduce downtime. The platform is easy to scale and lowers upfront costs.
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McGregor Metal, a metal stamping company in Springfield, OH, wanted to transition from the legacy Plex Classic interface to Plex UX. They aimed to automate more plant floor processes and align growth... with modern technology. They used Plex ERP and MES to digitize operations and optimize processes. The transition to Plex UX will enhance automation and modernize their ERP/MES solutions, sustaining their competitive edge.
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Pax Machine Works faced challenges with error-prone paper processes and a slow quoting process. They adopted Plex Enterprise Resource Planning (ERP) to improve data visibility and digitize operations.... The implementation led to increased accountability and faster customer response times. The company also streamlined its quoting process and improved audit preparation. With Plex, Pax Machine Works is enhancing operational efficiency and planning for future growth.
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PowerFlex 755TS VFDs and EtherNet/IP products helped Hexcel modernize its manufacturing lines. Hexcel faced frequent encoder failures, causing $70,000 loss per downtime incident and high unplanned ma...intenance. EOSYS guided a step-by-step upgrade, starting with a small line and expanding to more complex systems. The solution reduced unplanned downtime from 2% to 0.4%. Hexcel set a new standard for modernization, now used globally.
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Falcon Group faced challenges with low machine utilization and considered buying new machines. They used the ThingWorx IIoT platform to get real-time data insights. This helped them improve machine u...tilization from 8% to 57% on one machine. They avoided $2 million in new machine costs and kept work in-house.
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Plex ERP helped Tech Met Inc. get real-time insight into revenue and inventory. The company moved from paper-based systems to a cloud platform. Production and quality documents are now accessible fro...m anywhere. Invoicing that once took over a month now takes only a few days. Employees trust the data and use inventory more efficiently. Tech Met plans to expand automation with Plex MES and QMS.
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NKP Pharma used FactoryTalk Optix to meet compliance and cut costs. They improved data access for customers. The solution reduced expenses compared to IPC-SCADA systems. It also enhanced customer sat...isfaction and market presence.
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FactoryTalk DataMosaix helps Minetek add real-time data monitoring to mining equipment. Minetek wanted to give customers better visibility and support for remote assets. JH Tester integrated FactoryT...alk DataMosaix, a SaaS platform, into Minetek’s water evaporation systems. The solution provides secure, real-time data from sensors and alarms, viewable on dashboards. Customers can now schedule predictive maintenance and reduce downtime. The platform is easy to scale and lowers upfront costs.
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Greatech Technology Berhad needed a flexible system design to serve various industries like solar, semiconductor, and life sciences. They used Rockwell Automation's Independent Cart Technology, inclu...ding MagneMover LITE and QuickStick systems, to meet these needs. This solution allowed for flexible configurations, system scalability, and increased workforce productivity. A key life sciences customer reduced their footprint by 25% using the MagneMover LITE. The unified platform also reduced engineering hours and improved system mastery.
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The Royal Mint faced a challenge in developing a new precious metals recovery solution to commercial volumes. They partnered with Rockwell Automation to install a PlantPAx Distributed Control System,... which included operator and engineer workstations and broader infrastructure works. As a result, gold was successfully extracted in the first run, and 500 metric tons of e-waste were processed, surpassing the FY24/25 target of 400 metric tons. The plant has proven its commercial potential and is set for wider deployment.
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Hexcel faced frequent equipment failures, causing significant downtime and financial loss. They needed to modernize their aging technology without disrupting existing processes. Hexcel partnered with... EOSYS to implement a step-by-step modernization approach. They used PowerFlex 755TS VFDs and EtherNet/IP products to reduce encoder failures and improve system reliability. As a result, Hexcel reduced unplanned maintenance downtime from 2% to 0.4%, saving costs and increasing efficiency. The successful model is now being expanded globally.
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