Food & Beverages Case Studies and Customer Success Stories with ProposalWorks Proposal Builder
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 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.
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.
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.
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.
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.
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.
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.
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.
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 i...mproved 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.
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 th...em 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.
Arena simulation software helped The Maschhoffs, a leading U.S. pork producer, improve their supply chain in 2014. The company faced challenges in optimizing regional business structure and automatin...g logistics. Arena provided flowchart modeling, scenario analysis, and dashboards. This led to better space utilization, faster business decisions, and extended forecasting from one to five years. The solution reduced costs and improved flexibility in their logistics operations.
Rockwell Automation helped Tate & Lyle modernize its new Matão plant. The challenge was to optimize production, digitize the plant, and integrate equipment. Rockwell Automation provided automation pa...nels, software, and technical support. The solution included transformers, switchgear, MCCs, and PlantPAx. The project enabled 100% integration with plant equipment. Operators now have better control and monitoring of all processes.
Rockwell Automation's smart machine solutions helped Yichao Packaging boost global growth. The company faced export challenges with old automation systems. Rockwell provided Micro850 controllers, Kin...etix 5100 servo drives, and TLP servo motors. Packaging speed rose by 33%, from 150 to 200 packs per minute. Cutting accuracy improved to ±1mm, and machines ran 24/7 without faults. Flexible, real-time speed adjustments and fast installation helped Yichao win overseas orders and expand their business.
Rockwell Automation and Tri Tech Automation helped a large cheese manufacturer automate a new plant. The challenge was a tight schedule, supply chain issues, and complex documentation. Tri Tech Autom...ation used Rockwell's CENTERLINE 2100 MCCs, PowerFlex drives, and ControlLogix controllers. They unified process and power controls on one network. Operators now get real-time data and improved plant performance. The new system also reduces water and energy use.
Automotive Case Studies and Customer Success Stories with ProposalWorks Proposal Builder
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 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.
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.
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.
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.
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.
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.
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.
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 mee...t 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.
The Shyft Group needed to develop commercial-grade electric vehicles quickly. They faced challenges with expedited timelines and the need for a real-time manufacturing platform. They used Plex Enterp...rise Resource Planning to accelerate innovation, going from concept to vehicle in nine months. The Plex system was implemented in two weeks, aiding in the transition from prototype to manufacturing. The new EV trucks, with a range of over 220 miles, are set to launch in late 2024, with an initial order of 150 vehicles from a delivery company.
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 and dual-core control system to cut downtime by 20%. Real-time data collection improved decision-making and integration. The solution made their machines safer and easier to connect with other systems.
Arena Simulation Software helped a major tire manufacturer test a modernization plan for its final finish process. The simulation found bottlenecks in the conveyor system that would have cut system c...apacity by 25%. The model showed where the design would fail and let the team fix it before building. The new design saved the company over $4 million by keeping equipment efficient. The project used real system logic to make sure the results matched real-world operations.
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.
Manufacturing Case Studies and Customer Success Stories with ProposalWorks Proposal Builder
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 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.
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.
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.
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.
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.
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.
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. They cut yearly co...sts by $152,000 and reduced inventory variance by 86%. Overall equipment effectiveness (OEE) went up by 6%. Machine availability increased by 8%. Employees now trust the data and make better decisions.
CUBIC, a Rockwell Automation company, and RLAY supplied control panels for Fenagy’s sustainable CO2 heat pumps. Fenagy needed a supplier who could keep up with rapid growth and changing requirements.... RLAY delivered a standardized control panel solution using CUBIC tools and Galaxy software. This enabled fast, flexible series production and quick adaptation to customer needs. Fenagy accelerated electrical development and is now ready for future market growth.
Arena Simulation Software helped COSIPA model their ore conveyor system. The challenge was to represent both continuous and discrete material flows. Arena allowed the team to model the entire process..., from material arrival to storage and transportation. The simulation showed the system was viable for their needs. The results confirmed the approach worked for systems with both discrete and continuous behaviors.
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.
Pharmaceuticals Case Studies and Customer Success Stories with ProposalWorks Proposal Builder
Dong-A ST
- Pharmaceuticals
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.
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.
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.
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.
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.
FactoryTalk InnovationSuite helped Probiotical S.p.A. scale its manufacturing as demand grew. The company used the ThingWorx IIoT solution to connect and monitor production data. Machine availability... increased by 15-20%. Operational equipment effectiveness is now near optimum. Probiotical also reduced energy use and packaging waste. Operators now make better real-time decisions with improved data visibility.
Rockwell Automation helped Pharbaco automate its pharmaceutical manufacturing. Pharbaco needed to meet strict GMP-EU compliance and improve cleanroom controls. They used Rockwell’s FactoryTalk, Logix... PLC, and PowerFlex VFD for smart automation and energy management. The solution integrated IT and OT systems and optimized HVAC for cleanroom efficiency. Pharbaco cut energy use by 45%, improved compliance, and made its facility scalable for the future.
Biopharmax used Rockwell Automation's ControlLogix PLC solution to build a stem cell therapy facility for Pluristem. The system integrated HVAC, plant utilities, and critical systems for better contr...ol and efficiency. The solution reduced energy use, optimized CAPEX and OPEX, and protected sensitive product batches. The facility meets strict regulatory standards and supports future expansion. The result is a highly efficient, cost-effective plant for commercial-scale stem cell production.
PlantPAx modern DCS from Rockwell Automation replaced old control systems for a large biopharmaceutical producer. The company faced risks from aging equipment, frequent critical alarms, and lack of s...ystem visibility. The new solution upgraded PLCs and VFDs, improved network communications, and enabled remote access. Critical alarms dropped from five or six per week to zero in the first two months. The upgrade also cut validation costs in half and sped up troubleshooting, saving significant time and reducing downtime risk.
Utilities Case Studies and Customer Success Stories with ProposalWorks Proposal Builder
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 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.
Rockwell Automation helped The Region of Waterloo modernize its water systems. The challenge was to upgrade SCADA and PLC systems across 157 facilities without disrupting water service. Brock Solutio...ns used ControlLogix, CompactLogix, Stratix switches, and distributed I/O for a phased upgrade. The project minimized downtime, improved operational efficiency, and increased system resilience. The five-year transformation is now in its final phase, delivering reliable and secure water management.
Verve Security Center by Rockwell Automation helped an integrated energy company improve its OT cybersecurity. The company used the NIST Cybersecurity Framework to measure and benchmark its security ...maturity. Verve provided real-time visibility, asset management, and automated compliance reporting. In 18 months, the company doubled its NIST CSF maturity scores across all categories. The solution also reduced operational overhead by automating key security tasks.
Verve by Rockwell Automation helped a major US-based energy company reach CIS Controls maturity in just 8 months. The company faced inconsistent security across thousands of IT and OT assets and need...ed to unify under a single cybersecurity framework. Verve provided automated asset inventory, endpoint management, and a structured remediation roadmap. The company gained full asset visibility, improved security, and built a sustainable compliance program. They reduced long-term cyber risk and avoided operational disruptions.
Verve Security Center by Rockwell Automation helped a major power company achieve NERC CIP v5 compliance in just three weeks. The company faced tight deadlines and managed many different cybersecurit...y tools across its plants. The unified platform replaced siloed tools, improved visibility, and made compliance reporting faster. The company cut costs by removing redundant tools and simplified security management. They expanded the solution to more sites for enterprise-wide cybersecurity.
A leading North American power company
- Utilities
Verve by Rockwell Automation helped a leading North American power company cut threat response time from weeks to hours. The company faced security gaps, lack of OT asset visibility, and fragmented r...emediation processes. Verve's platform provided real-time risk assessment, unified asset visibility, and a "Think Global, Act Local" strategy. The solution reduced labor costs by 70% and improved threat detection. The company now responds to cyber risks faster and more efficiently across all generation assets.
Oil & Energy Case Studies and Customer Success Stories with ProposalWorks Proposal Builder
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.
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%.
Verve Security Center by Rockwell Automation helped a top 10 oil and gas producer improve OT/ICS cybersecurity. The company faced complex, remote operations and needed a vendor-agnostic security plat...form. They deployed Verve Security Center across thousands of endpoints and used VIP services for fast rollout. The solution gave full asset visibility, risk assessment, and integrated backup and malware protection. Within 6 months, the company became a model site for cybersecurity best practices.
PowerFlex 755TR drives helped a global energy company modernize its well pad infrastructure. The company faced aging assets and wasted energy with old drives. DSI and Rockwell Automation installed ne...w regenerative drives that recycle energy. Over 130 drives have been deployed so far. The project is expected to save $3M per month in energy costs. The new system achieved 17% regeneration, with 95% of that power reused.
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.
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.
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.
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 effi...cient. The new drives increased drilling precision and reduced the number of staff needed on site. This helped lower costs, improved safety, and made the system more energy efficient. Drillmec expects less downtime and longer equipment life with this solution.
Wholesale Case Studies and Customer Success Stories with ProposalWorks Proposal Builder
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.
PlantPAx distributed control system helped Corteva Agriscience migrate 15 legacy DCS systems. The project included new redundant Industrial Data Center servers and over four miles of new fiber and co...pper connections. Operators gained better control and alarm response with high-performance HMI graphics. The migration improved plant reliability, enabled remote monitoring, and reduced lifecycle costs. State-based control automation increased efficiency and asset utilization across the site.
Media Production Case Studies and Customer Success Stories with ProposalWorks Proposal Builder
A leading U.S. power transmission provider
- Power Generation
Verve by Rockwell Automation helped a leading U.S. power transmission provider gain remote OT visibility. The company needed to monitor OS-based and embedded OT devices in remote substations for NERC... CIP compliance. Verve's agent-agentless solution collected and transmitted configuration data over low-speed serial connections. The provider achieved compliance, reduced labor and travel, and lowered costs by avoiding new hardware. Continuous monitoring improved cybersecurity and integrated with existing corporate tools.
Consumer Goods Case Studies and Customer Success Stories with ProposalWorks Proposal Builder
Encore Tissue
- Consumer Goods
PlantPAx DCS helped Encore Tissue upgrade its Victorian plant. The old DCS was outdated and no longer supported. PlantPAx gave Encore Tissue a unified system and a user-friendly interface. The upgrad...e simplified integration and made future upgrades easier. The new system reduced the number of controllers from four to two and took up less space. The migration was completed in just four days, with only 72 hours of machine downtime.
Medical Devices Case Studies and Customer Success Stories with ProposalWorks Proposal Builder
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
PFi needed an advanced automation solution for their new titanium cross flow membrane wastewater treatment. They required hardware that was streamlined, repeatable, and easy to integrate, with a codi...ng style of PAC-ML. Rockwell Automation provided the CompactLogix Control System and PanelView Plus Graphic Terminal, which met these needs. The solution increased performance, capacity, and productivity, while reducing downtime and environmental impact. PFi's innovation is now used by a leading beverages company in Australia.
Plex ERP gave Tech Met real-time access to inventory and revenue data. The company moved from paper-based processes to a cloud system. Production and quality documents are now accessible anywhere. In...voicing 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 with more Plex solutions.
Emulate3D digital twin software and Independent Cart Technology helped Cartesian Kinetics automate existing warehouses. The challenge was to boost speed and accuracy in old facilities with manual rac...king and uneven floors. The solution let them simulate operations and use magnetic levitation carts for precise movement. Worker productivity increased 5x. Error rates dropped 10x. Warehouses now meet higher demand without big infrastructure changes.
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 manufacturi...ng execution, enhancing compliance and operational efficiency in regulated environments.
Volga Reduces Control Panel Wiring Time by 66% with Rockwell Automation's EtherNet/IP In-cabinet Solution - PR Newswire
Volga achieved a 66% reduction in control panel wiring time by deploying Rockwell Automation's EtherNet/IP in-cabinet solution. This implementation highlights the efficiency gains possible with Rockw...ell Automation's industrial networking technology in manufacturing automation.
