Case Studies
Real Problems, Engineered Solutions
Each project follows our approach: understand the physics, model the system, implement the fix, and confirm it on the floor. Client names are withheld.
Cold Mill Start-Up Strip Breaks
Cold RollingThe Challenge
After a main drive upgrade, a tandem cold mill saw repeated strip breaks on start-up when rolling light and ultra-light gauges.
Our Approach
Field data showed that when the mill stopped, a short length of strip rolled back through a stand and was over-reduced, then broke on restart. We built a stand and drive model in MATLAB/Simulink and simulated alternative drive stop methods.
Results
- Root cause identified from measured mill data
- Model reproduced the measured start-up and predicted the break
- Recommended drive stop setting now in plant trials
Reheat Furnace Engineering Support
Hot Strip MillThe Challenge
A hot strip mill needed ongoing engineering help to get more from its walking beam reheat furnaces and their Level 2 control.
Our Approach
Our engineers work on-site each month: analyzing furnace pacing and mill logic, estimating achievable tonnage improvements, reviewing radiation and convection heat transfer, and studying air-fuel ratio, NOx, and scale formation. We also designed a digital shadow for testing model and PLC changes offline.
Results
- Monthly on-site support with signed service reports
- Throughput and pacing analysis to guide furnace changes
- Offline test environment design for safer control changes
Naval Vessel Propulsion Trips
Marine & DefenseThe Challenge
A government marine vessel was experiencing propulsion trips.
Our Approach
We traveled to the vessel and traced the trips to a loss of power in its supply chain — motor-generator set, no-break UPS, and automatic bus transfer — including a failed UPS battery in a motor control center. We also tested the thrusters.
Results
- Propulsion trips traced to a specific power-supply failure
- Thrusters tested
- Written findings and recommendations delivered
Batch SCADA Upgrade
Food ProductionThe Challenge
A snack-food manufacturer was running batch production on an aging iFix SCADA system.
Our Approach
We rebuilt the batch SCADA in Ignition and tested it at our Crown Point office before installation at the plant.
Results
- Batch control moved to a current, supported platform
- Factory acceptance tested before go-live
- Follow-on HMI and drive work for the same client
Emergency Drive Response
Manufacturing SupportThe Challenge
Drive failures stopped production — a servo drive at a bakery and shear drives at a metals service center.
Our Approach
Our engineers responded on-site, replaced the failed drives, updated network settings where needed, and brought the equipment back online.
Results
- Bakery servo faults cleared in a single visit
- Service-center shear drives replaced on an emergency basis
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