Replaced a flat, unmanaged network with a segmented, redundant ring topology across six production lines, cutting unplanned network-related downtime to zero over 14 months.
Managed switches · VLAN segmentation · Redundant ring topology
Migrated a 20-year-old SCADA system to a modern historian and HMI suite across 14 remote lift stations, with cellular failover for radio dead zones.
SCADA migration · Cellular telemetry · Historian and reporting
Consolidated production data from nine sites into a single cloud platform, replacing a weekly spreadsheet process with dashboards that update continuously.
Edge gateways · Cloud data pipeline · Operations dashboards
Rebuilt controls on three legacy case packers with modern servo drives and a unified HMI, increasing line speed by 22% without a mechanical overhaul.
Servo motion control · HMI redesign · Legacy PLC migration
Deployed hazardous-location rated RTUs and remote monitoring across 40 unmanned wellsites, cutting site visit frequency by half.
Class I Div 2 hardware · RTU integration · Remote monitoring
Redesigned a 1.2M sq ft distribution center's industrial Wi-Fi to eliminate scanner dead zones and support a new voice-picking rollout.
Industrial Wi-Fi survey and design · RF planning · WMS integration
Moved a decade of process history off an unsupported on-premise server into a managed time-series database, with edge buffering so no data was lost during cutover.
Time-series database · Edge buffering · Zero-downtime cutover
Replaced obsolete PLC-5 controllers on a rotary kiln with a redundant ControlLogix platform, with zero unplanned kiln downtime during cutover.
PLC-5 migration · Redundant controllers · Hot cutover planning
Integrated cooling and power distribution PLCs with an existing building management system, unifying alarms into a single operations dashboard.
BMS integration · Alarm rationalization · Custom dashboarding
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