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Manufacturing Case Studies and Customer Success Stories with Fiix

 

Cartesian Kinetics - Manufacturing - Small

USA

Cartesian Kinetics used Rockwell Automation's Emulate3DTM digital twin software and Independent Cart Technology to automate existing warehouses. The solution let... them simulate warehouse operations and test changes before making investments. Workers saw a 5x increase in productivity and a 10x drop in error rates. The system helped warehouses meet rising order demands without major infrastructure changes. This approach improved order fulfillment and reduced costs.

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COSIPA (Companhia Siderúrgica Paulista) - Manufacturing - Large

Santos, Brazil

Arena Simulation Software helped COSIPA model its ore conveyor system. The challenge was to represent both continuous and discrete material... flows in a complex steelmaking plant. Arena enabled COSIPA to simulate all raw material movements, from arrival to storage and processing. The model showed that discrete simulation could accurately reflect continuous behaviors. This approach proved viable for systems with mixed flow types.

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Foshan Yichao Packaging Machinery Technology Co., Ltd. - Manufacturing - Medium

Foshan, China

Rockwell Automation helped Yichao Packaging boost packaging speed by 33%, from 150 to 200 packs per minute. The smart machine... solution improved cutting accuracy to ±1mm and enabled 24/7 fault-free operation. Yichao Packaging gained real-time speed adjustment and seamless integration with weighing systems. Virtual commissioning cut installation and delivery times. These upgrades helped Yichao Packaging win overseas orders and expand globally.

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Fenagy - Manufacturing - Small

Copenhagen, Denmark

Fenagy used CUBIC’s modular control panels, supplied by RLAY, to scale production of sustainable CO2 heat pumps. Rapid growth created... a need for flexible, high-volume electrical control solutions. RLAY’s expertise and CUBIC’s Galaxy software enabled fast, adaptable series production. Fenagy accelerated electrical development and innovation. The new system supports quick changes and short lead times, preparing Fenagy for future market growth.

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Tech Met - Manufacturing - Small

Pittsburgh, USA

Plex ERP helped Tech Met move from paper-based processes to a cloud-based system. The company gained real-time access to production... and quality documents. Invoicing that once took over a month now closes in just a few days. Employees now trust inventory data and can bill customers instantly after shipping. Tech Met plans to expand automation and plant-floor visibility with further Plex integrations.

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Samson Machinery - Manufacturing - Medium

Taiwan

Samson Machinery used FactoryTalk Optix and Studio 5000 from Rockwell Automation to boost production efficiency. They faced high competition, labor... shortages, and a need for better machine data insights. By integrating digital tools and a dual-core control system, they reduced downtime by 20%. Real-time data visualization improved safety and made integration easier for customers. Samson Machinery now competes globally with enhanced automation and data-driven operations.

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Jay Industries - Manufacturing - Medium

Mansfield, USA

Jay Industries used Plex ERP and Plex MES A&O to fix unreliable production data and poor inventory control. They gained real-time... visibility into their operations. Inventory variance dropped by 86%. Machine availability increased by 8%. Overall equipment effectiveness (OEE) improved by 6%. The company saved $152,000 each year after the upgrade.

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Minetek - Manufacturing - Medium

Sydney, Australia

FactoryTalk DataMosaix gives Minetek real-time visibility into mining equipment. The platform enables remote monitoring and predictive maintenance for water evaporators.... Minetek’s customers can now reduce downtime and save costs by scheduling maintenance based on live data. The SaaS solution supports secure data capture and analysis across multiple sites. No complex infrastructure is needed, making scaling easy and cost-effective. Minetek benefits from improved asset performance and operational efficiency.

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Hexcel - Manufacturing - Large

Stamford, USA

Hexcel used Rockwell Automation solutions to cut unplanned downtime by 80%. Frequent encoder failures caused $70,000 losses per incident. EOSYS... and Hexcel modernized legacy lines with PowerFlex 755TS VFDs and EtherNet/IP products. They reduced downtime from 2% to 0.4%. The new system became a global standard for Hexcel, improving reliability and enabling future analytics.

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Jay Industries - Manufacturing

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, Jay 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 Asia Pacific Business Center (APBC) - Manufacturing

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 predictive 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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Pax Machine Works, Inc. - Manufacturing

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. Employees 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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Greatech Technology Berhad - Manufacturing - Medium

Penang, Malaysia

Rockwell Automation's Independent Cart Technology helped Greatech Technology Berhad design flexible production systems for multiple industries. Greatech used MagneMover LITE... for lightweight needs and QuickStick for heavy-duty applications. The solution enabled scalable, space-saving configurations and reduced engineering time. One life sciences customer cut their production footprint by 25%. Greatech's team improved productivity by working with a single platform.

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Falcon Group - Manufacturing - Medium

Dubai, UAE

ThingWorx IIoT platform helped Falcon Group boost CNC machine utilization from 8% to 57%. Real-time data replaced manual tracking, revealing... hidden inefficiencies. Falcon avoided $2 million in new equipment costs by optimizing existing assets. The company kept more machining work in house, reducing subcontracting. Autonomous mobile robots further improved workforce productivity on the plant floor.

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McGregor Metal - Manufacturing - Small

Springfield, USA

McGregor Metal used Plex ERP and Plex MES to digitize all manufacturing operations. The company automated plant floor processes and... improved workforce connectivity. They are now moving to the Plex UX interface for a more modern user experience. Their plan includes robotics integration and self-printing solutions. This transition supports long-term growth and efficiency in a complex market.

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Strand Products, Inc. - Manufacturing - Small

Ventura, USA

Plex ERP helped Strand Products, Inc. automate operations and eliminate manual work. Before, they used eight programs and paper-based processes,... causing delays and errors. After a six-month implementation, they gained real-time data and full production visibility. Revenue grew by 40% and gross margin improved by 7% year-over-year. Compliance packet preparation became faster and more accurate, supporting growth in aerospace, MedTech, and defense sectors.

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Fluorsid S.p.A. - Manufacturing - Medium

Cagliari, Italy

FactoryTalk Analytics PavilionX MPC helped Fluorsid S. p.A. cut waste by over 50%. The software stabilized complex chemical processes at...their Cagliari plant. Raw material use and energy consumption dropped. Product quality improved, and CO2 emissions fell. The cement industry now uses more of Fluorsid’s synthetic anhydrite byproduct. Fluorsid plans to expand the solution to more lines and sites.

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The Royal Mint - Manufacturing - Large

London, UK

PlantPAx DCS from Rockwell Automation helped The Royal Mint recover 99% of gold from e-waste. The system enabled the plant... to process 500 metric tons, beating its 400-ton target for 2024/25. The solution replaced multiple control systems with one integrated platform. Engineers extracted gold on the first run, showing the technology works at scale. The Royal Mint now plans to expand this process globally.

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Everyday Technologies - Manufacturing - Small

Sidney, USA

Everyday Technologies used Plex ERP to modernize its operations. The company replaced an outdated ERP system that lacked real-time data... and forecasting. With Plex ERP, they automated inventory control and improved production workflows. They reduced on-hand inventory by 20% in three months. Now, they can forecast inventory needs up to six months ahead and make faster decisions.

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CaseiZ - Manufacturing - Small

CaseiZ used a Rockwell Automation platform to modernize and integrate old compressed air systems. They developed AirView Cloud, which connects... devices and data for better monitoring. This solution helps manufacturers find hidden energy savings in compressors. Many users have seen potential energy savings of 25-50%. The system also improves visibility and speeds up customer support.

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Green Hydraulic Power - Manufacturing - Small

USA

Green Hydraulic Power used Rockwell Automation's Allen-Bradley PowerFlex 755 variable frequency drives to upgrade hydraulic systems. The new solution provides... on-demand hydraulic pressure and flow, cutting energy use by up to 80%. Noise emissions dropped by 20 decibels, improving workplace safety. The system also reduced the need for cooling, helping lower the carbon footprint. Operators now work in a quieter, more productive environment.

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Unidentified - Manufacturing

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 Energy 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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Food & Beverages Case Studies and Customer Success Stories with Fiix

 

The Maschhoffs - Food & Beverages - Medium

Carlyle, USA

Arena simulation software helped The Maschhoffs, a leading pork producer, optimize their supply chain. The company used Arena to model... logistics, automate flow, and improve space utilization. Weekly updates now capture the lowest yardage costs and available space, cutting costs and boosting flexibility. Scenario analysis enables fast, accurate business decisions. Forecasting improved from one to five years, helping The Maschhoffs plan for future demand.

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A large cheese manufacturer - Food & Beverages - Large

Rockwell Automation helped a large cheese manufacturer automate a new greenfield plant. The project faced tight deadlines, supply chain issues,... and complex documentation. Tri Tech Automation used Rockwell's integrated architecture, including motor control centers and controllers, to unify process and power systems. Operators gained real-time data insights and improved sustainability by reducing water and energy use. The plant started on time and now produces cheese at full capacity.

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Tate & Lyle - Food & Beverages - Large

London, UK

Rockwell Automation helped Tate & Lyle modernize its new plant in Matão. The project automated production and integrated all equipment.... Operators now monitor and control the plant from a central room. The system provides real-time data on alarms, temperature, and energy use. The plant is ready for Industry 4.0 upgrades. This boosts reliability, safety, and efficiency for Tate & Lyle.

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Axtel Industries - Food & Beverages - Medium

Vadodara, India

Axtel Industries used Rockwell Automation solutions to automate their chocolate molding and spice blending lines. They needed higher accuracy, efficiency,... and safety in production. Rockwell Automation’s Kinetix servo drives and PlantPAx system enabled full automation and improved precision. The chocolate molding line became a global market leader. In spice processing, Axtel now manages over 100 ingredients with better quality and consistency. Automation also improved safety and remote troubleshooting.

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Garvey - Food & Beverages

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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Leaf Infusions - Food & Beverages

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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Maple Leaf Foods - Food & Beverages

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 and 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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DST - Food & Beverages

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 repeatability. 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 - Food & Beverages - Small

USA

OWS Foods used Plex ERP and Supply Chain Planning to automate scheduling and improve demand forecasting. With Control+M Solutions, they... increased forecasting accuracy by 25% and cut customer lead times by 33%. The new system gave them a single view of procurement and scheduling. Employees now spend less time on manual tasks and more on value-added work. The automation also helped OWS Foods attract and retain talent.

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Dutch Structuring Technology (DST) - Food & Beverages

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 setup 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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Leaf Infusions - Food & Beverages

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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a leading beverages company - Food & Beverages - Very Large

Rockwell Automation's CompactLogix and PanelView Plus helped a leading beverages company adopt PFi's titanium cross flow membrane for wastewater treatment. The solution reduced... downtime and increased yield by enabling longer times between cleaning cycles. The automation system provided easy integration and met strict coding standards. The new membrane also lowered the plant's environmental footprint and energy use. The recyclable titanium design supports sustainability goals.

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Maple Leaf Foods - Food & Beverages

Maple Leaf Foods wanted to improve efficiency and worker training across three locations. They used advanced automation and digital technologies... like AR and digital twins. At the Guelph plant, they improved operator efficiency and OEE. The London plant enhanced product flow and reduced costs with over 99% accuracy. The Brampton plant gained better throughput understanding and reduced downtime. These efforts helped Maple Leaf Foods stay competitive in the food industry.

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Garvey - Food & Beverages

Garvey needed a solution to demonstrate the benefits of its bottle accumulation systems to potential customers. They used Emulate3D by... Rockwell Automation to create dynamic 3D models. This allowed them to show real-time changes and scenarios during live demonstrations. As a result, Garvey improved its ability to communicate production line insights and support customer acquisition efforts.

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Automotive Case Studies and Customer Success Stories with Fiix

 

A major tire manufacturer - Automotive - Large

USA

Arena Simulation Software helped a major tire manufacturer find bottlenecks in its new plant design. The simulation showed that conveyor... issues could cut system capacity by 25%. The team used these insights to redesign the system. This change preserved equipment efficiency. The client estimates savings of over $4 million from the improved design.

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Bayrak Technik GmbH - Automotive - Medium

Germany

Plex Software from Rockwell Automation helped Bayrak Technik unify its ERP, MES, and QMS systems. The company gained tighter inventory... control and more accurate production planning. Bayrak Technik improved asset integration and operational data analytics. Employees now have real-time insights for better decisions. The solution supports quality and sustainability goals through machine monitoring. Bayrak Technik can now share accurate data with its automotive customers.

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Samson Machinery - Automotive

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 Rockwell 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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Volga - Automotive

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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Ionetic - Automotive

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 Smart 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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Pro-Vac - Automotive

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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ParkOhio Assembly Components Group - Automotive - Large

Cleveland, USA

ParkOhio Assembly Components Group used Plex ERP and Plex MES to replace outdated ERP systems. They automated manual processes and... gained real-time access to production data. This helped them reduce unnecessary costs and improve product quality. They integrated new plants quickly and improved decision-making. Real-time monitoring also prevented production errors and improved profitability.

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Bayrak Technik GmbH - Automotive

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 - Automotive

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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The Shyft Group - Automotive - Medium

Novi, USA

Plex Enterprise Resource Planning helped The Shyft Group launch its Blue Arc electric delivery trucks. The company needed to speed... up development and production for commercial-grade EVs. Plex enabled a record-setting two-week ERP implementation. This allowed The Shyft Group to move from concept to working vehicle in just nine months. The new EV trucks offer over 220 miles of range and support last-mile delivery companies. The first order includes 150 vehicles for a major delivery firm.

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Ionetic - Automotive

Ionetic, a battery pack developer, faced challenges in providing custom battery solutions for niche and low-volume OEMs. These manufacturers struggled... with off-the-shelf battery packs that didn't meet their needs and costly custom solutions from Tier 1 suppliers. Ionetic partnered with Rockwell Automation to create Arc Fab, a flexible manufacturing system. This system uses digital twin technology and smart manufacturing platforms to reduce setup time by two-thirds and accelerate time to market by 25%. The partnership also reduced capital expenditure by 5x per GWh and improved production flexibility and energy efficiency.

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Pharmaceuticals Case Studies and Customer Success Stories with Fiix

 

Pharbaco - Pharmaceuticals - Medium

Hanoi, Vietnam

Pharbaco used Rockwell Automation solutions to meet strict GMP-EU standards. They automated their cleanroom and HVAC systems for better control... and compliance. The new system cut energy use by 45%. Pharbaco improved process control and data integrity. Their facility is now ready for future growth and meets global pharmaceutical regulations.

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Biopharmaceuticals producer - Pharmaceuticals - Very Large

Rockwell Automation's PlantPAx modern DCS helped a major biopharmaceutical producer upgrade aging skid control systems. The old systems caused up... to six critical alarms per week and risked $10 million in downtime. The new solution cut alarms to zero in the first two months and improved visibility into VFDs and other components. The upgrade also halved validation costs by enabling shared code across skids. Remote access and faster troubleshooting now boost uptime and operational efficiency.

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Biopharmax - Pharmaceuticals - Small

Tel Aviv, Israel

Biopharmax used Rockwell Automation's ControlLogix PLC to build a stem cell therapy facility for Pluristem. The system integrated HVAC, utilities,... and production controls, ensuring strict regulatory compliance. The solution reduced energy use and operating costs while protecting sensitive cell therapy batches. Remote I/O and EtherNet/IP enabled fast response to plant changes and easy future expansion. The facility is described as highly efficient and cost effective for commercial-scale cell therapy production.

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Probiotical S.p.A. - Pharmaceuticals - Medium

Novara, Italy

FactoryTalk InnovationSuite helped Probiotical S. p.A. scale production to meet rising demand. The company used ThingWorx IIoT to connect and...monitor manufacturing data. Machine availability increased by 15-20%. Operational equipment effectiveness reached near optimum. Energy use and packaging waste dropped. Operators now make faster, better decisions with real-time insights.

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Dong-A ST - Pharmaceuticals - Large

Seoul, South Korea

Dong-A ST used Rockwell Automation solutions to build a cGMP-compliant smart factory in Songdo, Korea. The company needed to meet... excess production capacity and global regulatory standards. They implemented MES, SCADA, and IIoT platforms to automate processes and manage data for compliance. System automation made regulatory reporting easier and improved quality management. The new plant helped Dong-A ST expand into global markets.

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NKP Pharma - Pharmaceutical Machinery Manufacturing

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-SCADA 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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Pharbaco - Pharmaceuticals

Rockwell Automation helped Pharbaco automate its pharmaceutical manufacturing. Pharbaco needed to meet GMP-EU compliance, control cleanroom conditions, and improve energy... efficiency. The solution included 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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Probiotical S.p.A. - Pharmaceuticals

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 control. 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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Dong-A ST - Pharmaceuticals

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 Rockwell 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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Utilities Case Studies and Customer Success Stories with Fiix

 

A leading North American power company - Utilities - Very Large

SecureOT Platform gave a leading North American power company real-time risk visibility across coal, gas, wind, solar, and hydro assets. The company cut... labor costs by 70% using a centralized, vendor-neutral solution. Threat response time dropped from weeks to hours. The platform unified OT and IT data for better detection and faster mitigation. The company improved compliance and reduced false positives with less manual work.

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A leading power transmission provider - Utilities - Large

USA

SecureOT Platform helped a leading U. S. power transmission provider achieve NERC CIP compliance. The company needed remote OT visibility...for substations with low-speed connections. SecureOT Platform enabled agentless configuration management and real-time monitoring. The solution reduced labor and travel costs by automating data collection. It improved cybersecurity and integrated with existing corporate tools. The provider avoided costly hardware and gained full asset visibility.

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An integrated energy company - Utilities - Large

SecureOT Platform helped an integrated energy company double its NIST CSF maturity scores in 18 months. The company faced low... cybersecurity maturity and lacked visibility into OT assets. By deploying SecureOT Platform, they gained real-time insight and automated asset management. The solution enabled centralized control and compliance reporting. Executive leaders could now measure cybersecurity ROI with clear metrics.

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A major power company - Utilities - Large

SecureOT Platform helped a major power company achieve NERC CIP v5 compliance at one plant in just three weeks. The company unified... cybersecurity operations across diverse industrial systems using a vendor-neutral platform. They eliminated redundant tools, cut costs, and improved compliance reporting accuracy. Centralized dashboards enabled faster audits and simplified security management. The solution scaled to more sites, giving the company an enterprise-wide cybersecurity view.

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The Region of Waterloo - Utilities

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 disrupting 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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Oil & Energy Case Studies and Customer Success Stories with Fiix

 

One of the world’s top 10 oil and gas producers - Oil & Energy - Very Large

SecureOT Platform was deployed by a top 10 oil and gas producer to improve OT cybersecurity. The company needed measurable... results in 6 months across complex, segmented refining operations. SecureOT enabled full asset visibility and risk assessment for thousands of endpoints. The platform integrated Dell backup and Carbon Black malware protection for centralized security management. Within 6 months, the site became a model for OT cybersecurity, with major risks remediated and unified monitoring in place.

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a global energy company - Oil & Energy - Very Large

Rockwell Automation's PowerFlex 755TR drives helped a global energy company modernize its well pad infrastructure. The company replaced aging motor... control assets that wasted energy as heat. With the new drives, over 130 units were deployed, achieving 17% energy regeneration and reusing 95% of that power. The project is projected to save $3 million per month in energy costs once fully rolled out. The solution also supports the company's sustainability and carbon reduction goals.

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A major US-based energy company - Oil & Energy - Very Large

USA

Rockwell Automation helped a major US-based energy company reach CIS Controls maturity in just 8 months. The company unified IT... and OT security across tens of thousands of assets. Automated asset inventory and compliance monitoring improved visibility and threat detection. The solution reduced long-term cyber risk and avoided operational disruptions. The company now maintains a sustainable cybersecurity program integrated with corporate operations.

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A well-known global energy company - Oil & Energy

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 - Oil & Energy - Medium

Monterrey, Mexico

BCPGroup used Rockwell Automation's PowerFlex drives and MAGNETA AI solutions to help oil and gas companies cut energy use and costs. The company aimed... to reduce energy consumption, carbon footprint, and maintenance expenses. By deploying permanent magnet motor technology and AI-enabled controllers, BCPGroup achieved 20%–30% energy savings and 40% lower maintenance costs. Well productivity increased by 30%. These solutions support sustainability and compliance in the oil and gas sector.

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Transportation/Trucking/Railroad Case Studies and Customer Success Stories with Fiix

Rockwell Automation Central European Distribution Centre (CEDC) - Transportation/trucking/railroad

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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Package Delivery Company - Transportation/trucking/railroad

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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Mechanical or Industrial Engineering Case Studies and Customer Success Stories with Fiix

 

Drillmec - Mechanical Or Industrial Engineering - Medium

Piacenza, Italy

Drillmec used Rockwell Automation's PowerFlex 755TL AC drives to improve precision in carbon-capture drilling. The solution helped Drillmec drill faster... and with fewer staff on site, reducing health and safety risks. The drives kept harmonic distortion within 5%, optimizing pump speed and performance. This upgrade reduced maintenance costs and downtime, while increasing energy efficiency. Drillmec now creates safer, more cost-effective carbon-capture sites.

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Drillmec - Mechanical Or Industrial Engineering

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 effective. 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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Medical Devices Case Studies and Customer Success Stories with Fiix

MTS Medical Technologies - Medical Devices

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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Precision Coating - Medical Devices - Medium

Hudson, USA

Plex ERP, MES, and QMS helped Precision Coating align operations across all locations. The company replaced six disparate systems and... manual records with a single digital platform. Employees now access real-time data and reporting, improving collaboration and decision-making. Precision Coating achieved 100% inventory accuracy and reduced manual errors. The cloud-based solution supports growth and quality compliance for medical device manufacturing.

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Wholesale Case Studies and Customer Success Stories with Fiix

 

Corteva Agriscience - Chemicals - Large

Indianapolis, USA

Corteva Agriscience migrated 15 legacy distributed control systems to the PlantPAx modern DCS with Rockwell Automation. The project included integrating... 4000 I/O and IT/OT components and installing over four miles of new fiber and copper connections. The team improved operator control and alarm response with high-performance HMI graphics. State-based control automation helped optimize efficiency and reduce project risk. Remote monitoring and new redundant servers increased reliability and reduced lifecycle costs.

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Corteva Agriscience - Chemical

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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Government Administration Case Studies and Customer Success Stories with Fiix

 

Region of Waterloo - Government Administration - Large

Waterloo, Canada

Rockwell Automation technology helped the Region of Waterloo modernize water systems across 157 facilities. Brock Solutions led a five-year upgrade... of SCADA and PLC infrastructure, using phased implementation to avoid service disruption. Operators now resolve issues faster and downtime is reduced. The project improved network security and built a strong IT/OT partnership. The region now has a resilient, future-ready water management system.

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Consumer Goods Case Studies and Customer Success Stories with Fiix

 

Encore Tissue - Consumer Goods - Medium

Melbourne, Australia

Encore Tissue upgraded its Victorian plant with Rockwell Automation’s PlantPAx DCS. The new system unified control, improved reliability, and made... integration with PowerFlex drives easier. Staff adapted quickly due to the familiar software platform. The migration reduced the number of controllers from four to two, saving space. Commissioning was completed in just four days, with only 72 hours of machine downtime.

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Other Industry Case Studies and Success Stories with Fiix

Tech Met Inc. - Aerospace

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 from 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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Pax Machine Works, Inc. - Metals

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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Hexcel - Aerospace

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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BETA Technologies - Aerospace - Medium

Burlington, USA

BETA Technologies uses Plex Systems Manufacturing Execution Software to support safe, sustainable air transportation. The company is developing electric vertical... take-off and landing aircraft and a charging network. Plex helps BETA collect data for production and traceability, especially for batteries. Integration with CAD software and automation improves workflow visibility. BETA uses MES Automation and Orchestration to capture quality data and reduce operator error.

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NKP Pharma - Pharmaceutical Machinery Manufacturing

NKP Pharma needed a cost-effective solution to maintain 21 CFR Part 11 compliance and provide customers with more data access. They partnered with... Rockwell Automation to implement FactoryTalk® Optix™. This solution reduced costs compared to IPC-SCADA systems and improved compliance. It also enhanced data management and customer satisfaction. The success led to increased orders and plans for further integration into their machinery.

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Customer Success Stories of Fiix

 

Rockwell Automation and Actemium Deploy AI to Reduce Refrigeration ...

Rockwell Automation and Actemium have implemented an AI-powered refrigeration optimization application, RtCOP, using Rockwell's PlantPAx DCS. This solution enhances energy... efficiency by 17% in frozen food manufacturing, saving $130,000 annually per site. It autonomously optimizes refrigeration operations, addressing energy consumption and operational efficiency challenges in the food industry.

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Rockwell Automation, Actemium Deploy AI to Cut Refrigeration Energy Use ...

Rockwell Automation and Actemium have deployed an AI-powered application, RtCOP, to enhance energy efficiency in industrial refrigeration systems. Utilizing Rockwell's PlantPAx... DCS, the solution improves energy efficiency by 17% for a frozen french fry producer, saving $130,000 annually per site. This autonomous system optimizes compressor, condenser, and evaporator configurations, addressing energy consumption challenges in food manufacturing.

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Rockwell Automation advances ice-cream production with Plex

Rockwell Automation has partnered with Chocolate Shoppe Ice Cream Company to implement its Plex Smart Manufacturing Platform, enhancing production and inventory management. The platform improved... inventory accuracy by 27%, reduced raw material inventory by 18%, and streamlined operations. This collaboration demonstrates how Rockwell's technology supports growth and efficiency in the ice cream industry.

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Rockwell Automation Advances Chocolate Shoppe Ice Cream Production ...

Rockwell Automation's Plex Smart Manufacturing Platform has been adopted by Chocolate Shoppe Ice Cream to enhance production and inventory management. The platform improved... inventory accuracy by 27% and reduced raw material inventory by 18%. It replaced manual systems, providing real-time data access and improving quality management. This adoption supports Chocolate Shoppe's growth and future automation plans.

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Pharmaceutical Digitalization: Rovi chooses MES from Rockwell Automation

Rovi, a Spanish pharmaceutical manufacturer, has chosen Rockwell Automation's FactoryTalk PharmaSuite 11 MES for its digital transformation. This implementation replaces... paper-based workflows, enhances traceability, and standardizes processes, setting a foundation for scalable digitalization across Rovi's facilities. Rockwell Automation, alongside Adasoft, supported the project, aligning with Rovi's vision for competitive and sustainable manufacturing.

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Rockwell Automation Spain

Rockwell Automation collaborated with Rovi to implement a Manufacturing Execution System (MES) in Spain, enhancing digital transformation. The project improved... traceability, reduced review times, and increased competitiveness. Rockwell Automation provided comprehensive support, and Adasoft ensured seamless integration. This successful partnership sets a foundation for further digital advancements across Rovi's operations.

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Rockwell Automation Announces the Advance of Rovi Pharmaceutical Manufacturing Digitalization

Rockwell Automation, in collaboration with Adasoft, has successfully implemented a digital batch execution system for Laboratorios Farmacuticos Rovi. This integration, using... Rockwell's FactoryTalk PharmaSuite MES, enhances Rovi's manufacturing processes by eliminating paper records and improving traceability. The project marks a significant step in Rovi's digital transformation, with plans for further rollouts.

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Rockwell Automation Announces the Advance of Rovi Pharmaceutical ...

Rockwell Automation and Adasoft have successfully implemented a digital batch execution system for Laboratorios Farmacuticos Rovi, integrating Rockwell's FactoryTalk PharmaSuite with Rovi's ERP and LIMS. This digital transformation... enhances traceability and competitiveness, marking a significant milestone in Rovi's operations. The collaboration will continue to advance Rovi's digital and process automation efforts.

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Rockwell Automation Announces Ronal Group modernize remote access with ...

Rockwell Automation has enabled Ronal Group to modernize its remote access by implementing a secure, centralized system. This system enhances... security, productivity, and regulatory compliance by supporting encrypted communication and role-based authorization. The solution aligns with regulatory requirements, including NIS2, and facilitates structured management of external access, enhancing operational resilience and transparency.

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Rockwell Automation gibt bekannt: Ronal Group ...

Rockwell Automation announced that the Ronal Group, a leading wheel manufacturer, has adopted Rockwell's secure remote access technology to enhance global connectivity. This solution ensures... encrypted communication, role-based access management, and comprehensive monitoring, helping Ronal Group meet regulatory requirements like the NIS2 directive. The implementation supports operational resilience and compliance goals.

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Rockwell Automation Announces Ronal Group Will Modernize Remote Access ...

Ronal Group is enhancing its global remote access by implementing Rockwell Automation's secure remote access technology. This centralized system supports... encrypted communication, role-based authorization, and comprehensive monitoring, aligning with regulatory requirements like NIS2. The solution standardizes remote access management across Ronal Group's operations, ensuring consistent governance and operational efficiency.

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Rockwell Automation Opens Bologna Customer Experience Center to Accelerate Industrial Innovation Across Europe, Middle East and Africa

Rockwell Automation has opened a new Customer Experience Center in Bologna, aimed at helping machine builders and manufacturers across EMEA tackle technology, workforce, and supply chain challenges. The center offers... hands-on experiences with advanced technologies like AI and digital twins, and provides strategic planning, training, and innovation support to accelerate digital transformation.

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Rockwell Automation : Reducing Energy Consumed by Hydraulic Power Systems by up to 80%

Rockwell Automation's model predictive control solution has enabled a leading cement producer to reduce energy consumption by 6% and increase production rates by 8. 5%. This initiative...is part of a broader sustainability program aimed at reducing CO2 emissions by 2030.

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Rockwell Automation Cuts Maintenance Costs, Finds Savings for Canadian Supplier, Perth County Ingredients, with Fiix CMMS

Rockwell Automation's Fiix CMMS helped Perth County Ingredients reduce maintenance costs by 54% and after-hours calls by 47%. The integration with... Majik Systems enabled real-time monitoring, reducing equipment failures and saving over $40,000 annually. This success led to a rollout across seven more facilities, enhancing multi-site management and proactive maintenance.

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Rockwell Automation Digital Twin Technology Accelerates Project ...

Rockwell Automation's digital twin technology, Emulate3DTM, has significantly enhanced project delivery and reduced costs for Falcare Industrial Equipment in Brazil. By simulating mechanical... behavior before construction, Falcare achieved 60% faster project execution, improved precision, and reduced waste. This innovative approach set a new standard in intralogistics engineering, enhancing sustainability and operational predictability.

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Rockwell Automation to Power Lucids EV Manufacturing Facility in Saudi Arabia with Advanced Software Solutions - Process and Control Today

Rockwell Automation will supply its FactoryTalk MES software to Lucid's new EV manufacturing facility in Saudi Arabia, enhancing production efficiency and workforce development. This collaboration supports... Saudi Arabia's Vision 2030 by integrating advanced manufacturing technologies and training local talent.

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Rockwell Automation to Power Lucid's EV Manufacturing Facility in Saudi Arabia with Advanced Software Solutions - PR Newswire

Rockwell Automation is partnering with Lucid to enhance its EV manufacturing facility in Saudi Arabia using FactoryTalk MES software. This collaboration aims... to optimize production, improve operational efficiency, and support Saudi Arabia's Vision 2030. Rockwell will also provide training to develop local expertise in EV manufacturing.

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Rockwell Automation to Power Lucid EV Manufacturing Facility in Saudi Arabia with Advanced Software Solutions

Rockwell Automation is partnering with Lucid to enhance its electric vehicle manufacturing facility in Saudi Arabia. Lucid will implement Rockwell's... FactoryTalk MES software to optimize production across various operations, supporting Saudi Arabia's Vision 2030. This collaboration includes local training programs to develop a skilled workforce in EV manufacturing.

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Rockwell Automation supports Tate & Lyles new Brazil plant - Engineering.com

Rockwell Automation partnered with Tate & Lyle to automate a new facility in Matao, Brazil, producing NUTRAVA Citrus Fiber. The plant uses... Industry 4.0-ready systems, enhancing operational efficiency and sustainability. Rockwell Automation provided electrical panels, automation software, and technical support, integrating advanced automation for digital transformation and energy management.

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Quality, traceability and time to market improved with Sintetica's deployment of PharmaSuite MES - PR Newswire

Sintetica has improved quality, traceability, and time to market by deploying Rockwell Automation's PharmaSuite MES. The pharmaceutical manufacturer leverages PharmaSuite... MES for advanced manufacturing execution, enhancing compliance and operational efficiency in regulated environments.

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