Controls engineered for production lines
that don't tolerate mistakes.
Automotive manufacturing runs on precision, speed, and repeatability. A weld cell that's off by a millimeter produces scrap. A paint booth with the wrong air balance creates defects. A conveyor system that hesitates for two seconds during a shift throws the entire line off schedule. The control systems running these operations need to perform at the same level of precision as the products they produce.
We design and deploy control systems for automotive and transportation manufacturers as an automotive manufacturing system integrator — body shops, paint systems, assembly lines, powertrain machining, EV battery production, and Tier 1/Tier 2 supplier operations. Systems engineered for takt time discipline, quality standards, and throughput demands of automotive production.
Systems that almost hit takt time and rely on manual intervention to keep up with the line.
- —Manual stations throttling line throughput
- —Safety circuits patched in over years
- —Mixed-vintage equipment with no unified data
Robot cells at takt, zoned safety that doesn't slow you down, and OEE from every machine on the line.
- Cycle times that meet the line requirement
- ISO 13849 / IEC 62061 safety, fully documented
- Unified OEE across mixed-vintage equipment
Eight capabilities,
built for takt time.
Structured PLC logic on Allen-Bradley and Siemens platforms for automotive production lines. Welding cell sequencing, conveyor tracking and accumulation logic, part presence detection, automated assembly station control, and quality gate interlocks. Multi-station line control with fault recovery logic that allows individual stations to resume without resetting the entire line. Code designed for automotive cycle times where every second of downtime is measured and accountable.
View serviceReal projects,
measurable results.
A weld cell that keeps up.
An automotive Tier 1 supplier was running a manual weld station that had become the bottleneck on their production line — the only non-automated station in a sequence of 12. Cycle time at the manual station was inconsistent, quality varied between operators, and throughput was capped at 60% of what the automated stations could handle. We designed and deployed a robotic weld cell with a FANUC arc welding robot, servo-driven positioner, and integrated fixture with part presence sensing. The cell was integrated into the existing line PLC and achieved consistent 45-second cycle times with automated weld quality inspection. Line throughput increased by 35%.
Safety that doesn't slow you down.
A body shop operation had expanded incrementally over several years, and the safety systems hadn't kept pace. Guard fencing had been modified, safety circuits were a patchwork of different technologies, and the maintenance team wasn't confident in the documentation. A risk assessment revealed multiple gaps. We redesigned the safety system for the entire cell — new safety PLCs, properly zoned safety circuits, area scanners that allow personnel access to non-hazardous zones without stopping the entire cell, and guard locking interlocks that coordinate with the robot program. The result: a safety system that meets current standards, comprehensive documentation, and cell utilization that actually improved because the safety zones were designed for how operators interact with the cell rather than how they were forced to work around the old system.
Data from equipment that wasn't designed for it.
A Tier 2 automotive supplier needed production data from 30+ CNC machines and presses for a customer-mandated OEE reporting requirement — but the equipment ranged from 2 years old to 25 years old, with different controllers, different communication protocols, and some machines with no network connectivity at all. We deployed a standardized data collection architecture using a combination of direct PLC communication for newer equipment, I/O monitoring modules for legacy machines, and edge gateways that normalize the data into a consistent format. All machine data flows into an Ignition SCADA platform that calculates OEE automatically and generates the reports the customer requires.
The stack we deploy
on automotive lines.
Allen-Bradley ControlLogix & CompactLogix, Siemens S7-1500 & S7-1200, Beckhoff TwinCAT
FANUC, ABB, KUKA — arc welding, spot welding, material handling, assembly
Allen-Bradley GuardLogix, Siemens F-PLCs, Pilz, SICK safety systems — ISO 13849, IEC 62061
Cognex, Keyence, SICK — 2D/3D inspection, vision-guided robotics
Ignition, FactoryTalk, Siemens WinCC
EtherNet/IP, PROFINET, EtherCAT, IO-Link
Allen-Bradley Kinetix & PowerFlex, Siemens Sinamics, Beckhoff servo systems
Built for the launch,
not adapted to it.
We design for takt time.
Automotive production is measured in seconds. We design control systems that meet the cycle time requirement — not systems that almost meet it and require manual intervention to keep up with the line.
We understand the launch.
Automotive programs launch on a date. The tooling arrives, the equipment installs, the control system commissions, and production starts — on schedule. We plan and execute to automotive launch timelines because that's what the industry demands.
Our team has been here before.
Our engineering team includes backgrounds from Tesla and other demanding production environments. We've built systems where the standard is zero defects and the schedule doesn't move.
Straight answers.
Yes. Automotive programs launch on a date — the tooling arrives, the equipment installs, the control system commissions, and production starts on schedule. We plan and execute to automotive launch timelines because that's what the industry demands.
FANUC, ABB, and KUKA for arc welding, spot welding, material handling, machine tending, dispensing, and assembly. We program and integrate the robot cell into the line control architecture — coordinated with conveyors, fixtures, vision systems, and safety circuits. Multi-robot cell choreography and offline programming with simulation to validate cycle times before installation.
Yes. Safety-rated PLC logic on Allen-Bradley GuardLogix and Siemens F-PLCs. Light curtain, safety scanner, and e-stop circuit integration. Safeguarding assessments for robot cells and automated machinery per RIA/ANSI standards. Safety system validation and documentation that meets automotive audit requirements.
Yes. We deploy standardized data collection that combines direct PLC communication for newer equipment, I/O monitoring modules for legacy machines, and edge gateways that normalize data into a consistent format. Equipment from 2 years old to 25 years old reports into one Ignition SCADA platform that calculates OEE automatically.
Yes. Legacy control system upgrades, HMI replacements, and safety system retrofits are executed during model changeover windows, summer shutdowns, and weekend maintenance periods — with commissioning planned to have the line back at takt time before production restarts.
Our engineering team includes backgrounds from Tesla and other demanding production environments. We've built systems where the standard is zero defects and the schedule doesn't move.
Ready to talk about your line?
Whether it's a robot cell, a line controls upgrade, or a full production system — tell us about the project.