Controls engineered for the line, not adapted to it.
PLC and robotics integration, motion control, and predictive analytics for body shops, paint systems, assembly lines, powertrain, and Tier 1 / Tier 2 supplier operations. Built for takt time discipline and automotive launch schedules.
Three things keeping automotive lines from hitting takt.
Lines that miss takt
Automotive production is measured in seconds. One slow station throttles the entire line, and most plants find out after the shift report instead of in the moment. Manual stations and undertuned cells cap throughput well below what the equipment can do.
Robot cells off-cycle
Pick rates drift, motion paths inherit years of patches, and fault recovery takes minutes instead of seconds. Cells that should run lights-out spend the shift waiting on operator intervention because the integration was never tuned for the cycle.
Equipment that fails on the line
Spindles, drives, and weld guns degrade on a schedule the maintenance system can't see. Reactive repairs eat launch margin. Fixed-interval PMs replace healthy parts. The data to predict failure already exists on the equipment — it just isn't used.
Three systems we build for automotive production.
Numbers from the line,
where bottlenecks show up fast.
Aggregate impact across recent automotive controls, robotics, and predictive analytics deployments. Specific projects scoped on request.
Got a line that should be running faster than it is?
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.