Control Systems Success Stories

Case #1
A world-class manufacturer of hardwood flooring hired us to work as part of their engineering team on a very large and complex manufacturing line upgrade.  The general requirements of the line’s existing operation were known, but the details of the new operation modes weren’t completely known until startup.  The control programs were written with this in mind, permitting flexibility and simplicity.  The entire startup was completed ahead of schedule, and the system offered more features and functionality than originally anticipated.  The design also accommodated future enhancements and manufacturing line modifications.

Case #2
With ever increasing costs and tight profit margins in raw hardwood, Genesys Controls was sought to assist a lumber processing company increase the measurement accuracy of purchasing and selling their products.  A new real-time measuring system was designed and installed, which removed the human element of visually judging the board dimensions, and a radical increase in accuracy was obtained by measuring the lumber’s width and length on the fly.  Width measurements of 1/40^th of an inch were realized, and the boards were paint-marked on the fly with their grade.  All lumber grades and measurement data are tracked and reported to an upper-level IBM Manufacturing Resource Reporting and Management system. 

Case #3
We were hired by a world-class candy manufacture to partner with them on a variety of projects. Over the past few years the industry has shown a trend towards down-sizing, especially with on-staff engineering.  In this case, the relocation and upgrade of a production line meant the company had a short-term need for experienced control engineering expertise. Acting as an extension of their engineering team, we took ownership of the project. In the process, we gathered the requirements, created and executed the specification, designed and developed the electrical layouts and programs, and lastly oversaw the installation and startup.