Special Purpose Machinery
DESIGN & BUILD FOR SPECIAL PURPOSE MACHINERY
Build Custom Machines Safely.
Special Purpose Machinery (SPM) solves problems that standard equipment cannot. Design & Build for Special Purpose Machinery (SPM) equips your engineering teams to turn that requirement into a custom automation cell, assembly station, robotic workcell, or complete production line, engineered specifically for your process, not adapted from someone else’s.
Design & Build for SPM brings together machine architecture, fixture tooling, mechatronic systems and robotic cells, the elements that turn a requirement into a buildable machine. Machine architecture defines the technical concept: station sequences, motion philosophy, tooling strategy and safety envelope. Fixture tooling, mechatronic systems and robotic cells translate that concept into a machine that is operable, serviceable and installable by design.
The result: a machine built right for your process from day one, that commissions reliably and stays serviceable across its lifecycle.
Machine Architecture
Define technical concepts for production readiness
Machine Architecture captures customer requirements and turns them into a practical, buildable technical concept before detailed design begins. We develop machine layouts, station sequences, motion concepts, tooling strategies, automation approaches, safety envelopes, operator workflows and utility architectures so the solution is operable, serviceable and installable.
Early architectural work exposes integration risks and trade‑offs between manual, semi‑automatic and fully automated options. By validating flow, access, safety and cycle‑time implications up front, we prevent machines that are mechanically complete but difficult to run, unsafe to maintain or unable to meet production targets.
What We Deliver
Requirement
Capture
Quantify targets for speed, cycle time, payload, uptime, part variation and operator interaction.
Station Breakdown
Define each station’s role: loading, clamping, processing, inspection, rejection, unloading, rework.
Flow Mapping
Map product, part, operator, robot and maintenance flows to prevent conflicts and bottlenecks.
Concept Layouts
Produce layout options for standalone machines, cells, multi‑station systems, indexers and transfer lines.
Utility Planning
Specify power, air, hydraulics, pneumatics, vacuum, coolant, lubrication, extraction and network interfaces.
Safety Zone Planning
Set preliminary guarding, access, interlock, light‑curtain, scanner and safe‑maintenance arrangements.
Trade-off Studies
Compare manual, semi‑auto, full‑auto, robotic, servo, pneumatic, hydraulic and cam solutions.
Where we Deploy
Assembly Machines | Automation Cells | Special-purpose Production Lines | Rotary Indexing Machines | Robotic Cells | Test Rigs | Material Handling Systems | Custom Production Equipment
DESIGN & BUILD FOR SPECIAL PURPOSE MACHINERY
Build Custom Machines Safely.
Special Purpose Machinery (SPM) solves problems that standard equipment cannot. Design & Build for Special Purpose Machinery (SPM) equips your engineering teams to turn that requirement into a custom automation cell, assembly station, robotic workcell, or complete production line, engineered specifically for your process, not adapted from someone else’s.
Design & Build for SPM brings together machine architecture, fixture tooling, mechatronic systems and robotic cells, the elements that turn a requirement into a buildable machine. Machine architecture defines the technical concept: station sequences, motion philosophy, tooling strategy and safety envelope. Fixture tooling, mechatronic systems and robotic cells translate that concept into a machine that is operable, serviceable and installable by design.
The result: a machine built right for your process from day one, that commissions reliably and stays serviceable across its lifecycle.
Fixture Tooling
Design fixtures that guarantee accuracy and repeatability
Fixture Tooling defines the jigs, nests, clamps, locators, datums, grippers, EOAT, pallets, gauges and mandrels that position, support and release parts with repeatable precision. We design fixtures so parts are presented correctly every cycle, removing a primary source of variation and ensuring the automation can deliver consistent quality.
Because the fixture is often the process‑critical element, we focus on datum strategy, serviceable clamping, ergonomic access and changeover simplicity. Our fixture designs are validated for inspection alignment, GD&T compliance and manufacturability so your machine achieves the intended accuracy, yield and maintainability in production.
What We Deliver
Datum Strategy
Define reference datums and part‑location schemes for consistent positioning.
Fixture Design
Develop jigs, nests, clamps, pallets, gauges and tooling for reliable handling.
Clamping Concepts
Specify pneumatic, hydraulic, servo, magnetic, vacuum and mechanical clamps.
Poka‑Yoke
Incorporate error‑proofing for orientation, wrong‑part prevention and missing‑part detection.
EOAT & Grippers
Design EOAT and grippers for robotic handling, tending and pick‑and‑place.
Access & Changeover
Plan tool, service and changeover access for safe, fast operator tasks.
GD&T & Repeatability
Drive fixture design from GD&T to secure inspection alignment and repeatability.
Where we Deploy
Automotive Fixtures | Ev Battery Module Tooling | Press-fit Fixtures | Welding Fixtures | Inspection Nests | Robotic Grippers | Leak-Test Fixtures | Machining Fixtures | Assembly Pallets.
DESIGN & BUILD FOR SPECIAL PURPOSE MACHINERY
Build Custom Machines Safely.
Special Purpose Machinery (SPM) solves problems that standard equipment cannot. Design & Build for Special Purpose Machinery (SPM) equips your engineering teams to turn that requirement into a custom automation cell, assembly station, robotic workcell, or complete production line, engineered specifically for your process, not adapted from someone else’s.
Design & Build for SPM brings together machine architecture, fixture tooling, mechatronic systems and robotic cells, the elements that turn a requirement into a buildable machine. Machine architecture defines the technical concept: station sequences, motion philosophy, tooling strategy and safety envelope. Fixture tooling, mechatronic systems and robotic cells translate that concept into a machine that is operable, serviceable and installable by design.
The result: a machine built right for your process from day one, that commissions reliably and stays serviceable across its lifecycle.
Mechatronic Systems
Align mechanics, controls & software from day one
Mechatronics Design integrates mechanical, electrical, controls and software into a single coordinated engineering solution that ensures motion, sensing, control logic and safety are specified before hardware is produced. We define interfaces, select sensors and actuators, size power and drive architectures, and produce I/O maps and control‑sequence definitions so the control and hardware teams work from the same, validated intent.
This integrated approach prevents late-stage rework, reduces commissioning risk and delivers predictable machine behaviour at target throughput, repeatability and maintainability.
What We Deliver
Interfaces
Mechanical | Electrical | Controls
Sensor & Actuator Selection
Fit for purpose
Power & Drive Architecture
Pneumatic | Hydraulic | Servo | Motor
I/O & Sequence Definition
I/O mapping and control-sequence definition
Safety
Safety function definition and circuit inputs
Control Philosophy
HMI | Alarms | Interlocks | Fault-state logic
Motion Profiles
Speed | Acceleration | Stroke | Dwell | Repeatability
Where we Deploy
Servo Assembly Machines | Press-Fit Stations | Robotic Handling Cells | Automated Inspection Machines | Leak-test Systems | Material Handling Cells | Dispensing Systems | End-Of-Line Test Equipment
DESIGN & BUILD FOR SPECIAL PURPOSE MACHINERY
Build Custom Machines Safely.
Special Purpose Machinery (SPM) solves problems that standard equipment cannot. Design & Build for Special Purpose Machinery (SPM) equips your engineering teams to turn that requirement into a custom automation cell, assembly station, robotic workcell, or complete production line, engineered specifically for your process, not adapted from someone else’s.
Design & Build for SPM brings together machine architecture, fixture tooling, mechatronic systems and robotic cells, the elements that turn a requirement into a buildable machine. Machine architecture defines the technical concept: station sequences, motion philosophy, tooling strategy and safety envelope. Fixture tooling, mechatronic systems and robotic cells translate that concept into a machine that is operable, serviceable and installable by design.
The result: a machine built right for your process from day one, that commissions reliably and stays serviceable across its lifecycle.
Robotic Cells
Design robot cells for safe, flexible automation
Robotic Cell Design creates custom automation cells using industrial robots, cobots, gantries, AMRs/AGVs, feeders, conveyors, vision systems, EOAT and safety devices. We size robots, define reach and tooling envelopes, and design cell layouts so that handling, inspection, welding, dispensing, or assembly work can be performed reliably and repeatably within the required footprint and cycle time.
With safety and integration as core principles, we specify guarding, access, sensor logic, and machine‑to‑robot handshakes, and validate cell behaviour through simulation and control sequencing. Our approach delivers cells that are safe to operate, simple to maintain and ready for certification against applicable standards such as ISO 10218 and ISO 3691‑4.
What We Deliver
Robot Selection
Choose robots by payload, reach, speed, repeatability and mounting needs.
Cell Layout
Define reach, tooling and maintenance envelopes and cell geometry.
EOAT & Tooling
Design EOAT, grippers, tool changers, compliance devices and utility routing.
Vision & Inspection
Integrate machine vision, barcode scanning, force sensing and inspection tools.
Guarding & Safe Zones
Plan guards, doors, scanners, light curtains and enabling devices for safe access.
Robot‑Machine Interfaces
Specify PLC, safety PLC, HMI, conveyor and fixture handshakes.
AMR/AGV Integration
Plan interfaces and safety for mobile robots and driverless trucks.
Where we Deploy
Robot Loading | Unloading | Welding Cells | Dispensing Cells | Vision Inspection Cells | Machine Tending | Palletizing/ De-Palletizing | Assembly Automation | AGV-fed Workstations | Flexible Manufacturing Cells.
DESIGN & BUILD FOR SPECIAL PURPOSE MACHINERY
Build Custom Machines Safely.
Special Purpose Machinery (SPM) solves problems that standard equipment cannot. Design & Build for Special Purpose Machinery (SPM) equips your engineering teams to turn that requirement into a custom automation cell, assembly station, robotic workcell, or complete production line, engineered specifically for your process, not adapted from someone else’s.
Design & Build for SPM brings together machine architecture, fixture tooling, mechatronic systems and robotic cells, the elements that turn a requirement into a buildable machine. Machine architecture defines the technical concept: station sequences, motion philosophy, tooling strategy and safety envelope. Fixture tooling, mechatronic systems and robotic cells translate that concept into a machine that is operable, serviceable and installable by design.
The result: a machine built right for your process from day one, that commissions reliably and stays serviceable across its lifecycle.
Safety Engineering
Embed safety from concept to operation.
Safety Engineering integrates hazard identification and risk reduction into the design from day one, not as an afterthought. We assess hazards, define safety functions and shape guarding, access and maintenance strategies so the machine protects operators while remaining serviceable and operable.
Our approach aligns functional safety, electrical safety and operating modes with applicable standards (ISO 12100, ISO 13849/IEC 62061, IEC 60204‑1, NFPA 79, UL 508A) and prepares CE technical‑file inputs for EU‑bound machines. The result is machines that meet certification expectations and deliver safer, more predictable production and maintenance outcomes.
What We Deliver
Hazard Identification
Identify hazards and plan risk‑reduction measures across the machine.
Guarding & Access
Design fences, interlocks, doors, removable guards and maintenance access.
Safety Functions
Specify E‑stop, guard locking, safe torque off, light curtains and scanners.
PL/ SIL Inputs
Define Performance Level or SIL requirements where applicable.
Safe Operating Modes
Specify automatic, manual, teach, maintenance, recovery and fault modes.
CE Technical File Support
Prepare safety documentation and CE file inputs for EU compliance.
Electrical Safety Coordination
Align electrical design with IEC 60204‑1, NFPA 79 and UL 508A where relevant.
Where we Deploy
All Special Purpose Machines | Especially Robotic Cells | High-force Machines | Press Systems | Welding Cells | Cutting Systems | Rotating Equipment | Conveyors | Automated Handling Cells | Operator-Loaded Stations
Simulate & Validate for Special Purpose Machinery
Prove Machine Performance Before You Build
A custom machine cannot simply be built and hoped to work. Simulate & Validate for Special Purpose Machinery (SPM) equips your engineering teams to prove structure, motion, cycle time, controls and safety before a single part is fabricated.
Simulate & Validate for SPM brings together structural validation, motion validation, cycle simulation, virtual commissioning and safety validation, the checks that confirm a machine will perform as intended under real operating conditions. Structural validation confirms frames, fixtures and moving assemblies withstand real loads and duty cycles. Motion validation, cycle simulation and virtual commissioning together prove that movement, throughput and control logic behave as required, while safety validation confirms that guarding and control logic protect operators under real fault conditions.
The result: a machine validated end to end, with fewer surprises during commissioning and a defensible record of proof for every stakeholder who needs it.
Structural Validation
Ensure structural integrity before fabrication
Structural Analysis confirms that components, assemblies, frames, supports, and fixtures will withstand the loads and conditions they might face in service. We apply finite element, modal and fatigue analyses across defined load cases – normal, peak, impact, emergency and abnormal to surface stress concentrations, deflection risks, resonance and endurance concerns, so design choices are proven against real operating demands.
This engineering-first validation also identifies opportunities for weight reduction and material optimization while establishing safety margins and factor-of-safety evidence. The result is reduced physical prototyping, fewer surprises during commissioning, and a traceable structural record that links analysis, design changes and verification through to handover.
What We Deliver
Finite Element Analysis
Stress | Deformation | Stiffness
Structural Studies
Static | Dynamic | Fatigue | Modal | Vibration
Load‑case Definition
Normal | Peak | Impact | Emergency | Abnormal
Weight & Material Optimization
Reduced mass & lower costs without compromising strength
Safety Margins
Factor‑of‑safety & design‑margin review
Support Structure Validation
Weldments | Frames | Brackets | Fixtures | Tooling
Simulation Reports
Actionable findings & recommendations
Where we Deploy
Press-Fit Machines | Welding Fixtures | Robotic Cells | Inspection Machines | Gantry Systems | Heavy-Duty Assembly Stations | Leak-Test Fixtures | Material Handling Systems.
Simulate & Validate for Special Purpose Machinery
Prove Machine Performance Before You Build
A custom machine cannot simply be built and hoped to work. Simulate & Validate for Special Purpose Machinery (SPM) equips your engineering teams to prove structure, motion, cycle time, controls and safety before a single part is fabricated.
Simulate & Validate for SPM brings together structural validation, motion validation, cycle simulation, virtual commissioning and safety validation, the checks that confirm a machine will perform as intended under real operating conditions. Structural validation confirms frames, fixtures and moving assemblies withstand real loads and duty cycles. Motion validation, cycle simulation and virtual commissioning together prove that movement, throughput and control logic behave as required, while safety validation confirms that guarding and control logic protect operators under real fault conditions.
The result: a machine validated end to end, with fewer surprises during commissioning and a defensible record of proof for every stakeholder who needs it.
Motion Validation
Validate motion for safe, repeatable performance
Motion Validation proves mechanisms, robots, gantries, conveyors and transfer systems will move as intended under real operating sequences. We run kinematic and dynamic analyses and cycle‑time studies to confirm reach, timing, clearance and synchronization so motions are safe, collision‑free and capable of the target throughput.
By validating motion before building, we prevent misses, undue accelerations, actuator undersizing and unstable transfers. The result is smoother operation, lower vibration and wear, and a validated motion specification that reduces commissioning time and secures first‑time functional performance.
What We Deliver
Kinematic & Dynamic Validation
Validate mechanism and system motion under real sequence loads.
Cycle‑Time Studies
Model automatic, manual, setup, recovery and fault‑mode timings.
Cycle‑Time Studies
Model automatic, manual, setup, recovery and fault‑mode timings.
Actuator Sizing Inputs
Provide sizing guidance for servos, motors, cylinders, gearboxes and drives.
Motion Profile Review
Confirm acceleration, jerk, dwell, torque, stroke, speed and sync values.
Robot Path Validation
Check robot reach, paths, singularities and interference risks.
Motion Optimisation
Recommend profile tuning to reduce vibration, wear and improve throughput.
Where we Deploy
Rotary Indexers | High-Speed Transfer Systems | Servo Presses | Robotic Handling | Conveyors | Machine Tending | Pick-and-Place Stations | Dispensing Systems | Multi-Axis Gantries.
Simulate & Validate for Special Purpose Machinery
Prove Machine Performance Before You Build
A custom machine cannot simply be built and hoped to work. Simulate & Validate for Special Purpose Machinery (SPM) equips your engineering teams to prove structure, motion, cycle time, controls and safety before a single part is fabricated.
Simulate & Validate for SPM brings together structural validation, motion validation, cycle simulation, virtual commissioning and safety validation, the checks that confirm a machine will perform as intended under real operating conditions. Structural validation confirms frames, fixtures and moving assemblies withstand real loads and duty cycles. Motion validation, cycle simulation and virtual commissioning together prove that movement, throughput and control logic behave as required, while safety validation confirms that guarding and control logic protect operators under real fault conditions.
The result: a machine validated end to end, with fewer surprises during commissioning and a defensible record of proof for every stakeholder who needs it.
Cycle Simulation
Validate the full cycle to secure real throughput
Cycle Simulation proves a machine can meet the required throughput under realistic operating conditions by simulating the entire sequence of operation. We model loading, inspection, clamp/unclamp, robot handoffs, rejects, sensor delays, recovery and operator tasks so quoted cycle times are verified against actual production behaviour.
This service reveals hidden bottlenecks, clarifies true takt and station times, and quantifies the impact of manual interactions and changeovers. The result is an accurate production capability forecast, fewer commissioning surprises and prioritized improvements to reach target throughput reliably.
What We Deliver
Sequence Simulation
Simulate the complete machine cycle and sequence of operation.
Takt & Bottleneck Analysis
Calculate takt, station times and identify throughput constraints.
Flow & Buffer Studies
Model part flow and buffer behaviour for multi‑station systems.
Operator & Manual Interaction
Assess loading, rework, reject and changeover impact on cycle time.
Scenario Testing
Test part variation, sensor delays, inspection time and downstream blocking.
Concept Comparison
Compare cycle times across design options for realistic selection.
Optimization Recommendations
Recommend station balancing, parallel ops and timing improvements.
Where we Deploy
Automated Assembly Lines | End-of-Line Test Systems | Inspection Lines | EV Battery | Assembly | Material Handling | Transfer Lines | Machine Tending Cells | Semi-Automated Operator-Loaded Equipment
Simulate & Validate for Special Purpose Machinery
Prove Machine Performance Before You Build
A custom machine cannot simply be built and hoped to work. Simulate & Validate for Special Purpose Machinery (SPM) equips your engineering teams to prove structure, motion, cycle time, controls and safety before a single part is fabricated.
Simulate & Validate for SPM brings together structural validation, motion validation, cycle simulation, virtual commissioning and safety validation, the checks that confirm a machine will perform as intended under real operating conditions. Structural validation confirms frames, fixtures and moving assemblies withstand real loads and duty cycles. Motion validation, cycle simulation and virtual commissioning together prove that movement, throughput and control logic behave as required, while safety validation confirms that guarding and control logic protect operators under real fault conditions.
The result: a machine validated end to end, with fewer surprises during commissioning and a defensible record of proof for every stakeholder who needs it.
Virtual Commissioning
Prove controls and sequences before site commissioning
Virtual Commissioning validates PLC code, robot programs, HMI workflows and I/O behaviour against a digital machine model, so control logic is proven before hardware arrives. By running sequences, safety interlocks and fault scenarios in the twin, we find logic errors, timing mismatches and interlock gaps early, saving costly on‑site debugging and schedule risk.
This approach ensures safety functions, robot handshakes and recovery paths work as intended and produces FAT‑ready issue logs and corrective actions, so commissioning becomes verification rather than troubleshooting.
What We Deliver
Digital Twin Integration
Connect digital machine model to PLC, robot, motion and HMI logic.
I/O Validation
Test sensors, cylinders, drives, robots, fixtures, safety and inspection I/O.
Sequence Testing
Exercise automatic, manual, setup, maintenance, reset and recovery modes.
Fault Scenario Testing
Simulate blocked parts, clamp or sensor failures, low air and E‑stop recovery.
Safety Validation
Verify interlocks, safe‑state transitions and fault‑response behaviour.
Robot‑Machine Handshakes
Confirm robot paths, timing and machine handshake reliability.
FAT‑Ready Outputs
Deliver issue logs, corrective actions and commissioning checklists.
Where we Deploy
Robotic Cells | Assembly Machines | Leak-Test Systems | Automated Inspection Machines | Press-fit Machines | Material Handling Systems | Machine Tending Cells | Custom Production Lines
Simulate & Validate for Special Purpose Machinery
Prove Machine Performance Before You Build
A custom machine cannot simply be built and hoped to work. Simulate & Validate for Special Purpose Machinery (SPM) equips your engineering teams to prove structure, motion, cycle time, controls and safety before a single part is fabricated.
Simulate & Validate for SPM brings together structural validation, motion validation, cycle simulation, virtual commissioning and safety validation, the checks that confirm a machine will perform as intended under real operating conditions. Structural validation confirms frames, fixtures and moving assemblies withstand real loads and duty cycles. Motion validation, cycle simulation and virtual commissioning together prove that movement, throughput and control logic behave as required, while safety validation confirms that guarding and control logic protect operators under real fault conditions.
The result: a machine validated end to end, with fewer surprises during commissioning and a defensible record of proof for every stakeholder who needs it.
Safety Validation
Prove controls and sequences before site commissioning
Safety Validation confirms identified hazards are effectively mitigated through guarding, safety functions, control logic and verification evidence. Custom machines combine many risks—moving axes, robots, clamps, stored energy, pneumatics/hydraulics, sharp tools, thermal and laser processes—so we verify protections behave under real operating and fault conditions.
We test safety functions, safe‑state transitions and mode behaviours, and produce documentation required for certification and customer review. The result is defensible safety evidence, fewer field incidents and smoother acceptance for operators, maintenance teams and compliance stakeholders.
What We Deliver
Risk‑Assessment Review
Evaluate hazards and risk reduction per ISO 12100 principles.
Hazard‑Zone & Distance Review
Assess safe distances, reach‑through/over risks and access prevention.
PL / SIL Inputs
Define Performance Level or SIL requirements under ISO 13849‑1 / IEC 62061.
Safety Function Verification
Test E‑stop, interlocks, light curtains, scanners, guard locking and safe‑torque‑off.
Mode Validation
Validate manual, setup, maintenance, recovery and teaching modes.
Electrical Safety Inputs
Provide electrical safety documentation aligned to IEC 60204‑1.
CE & Compliance Pack
Prepare CE technical file inputs and safety review packages for EU‑bound machines.
Where we Deploy
High-Force Stations | Robotic Cells | Welding Cells | Cutting Systems | Conveyors | Automated Handling | Operator-loaded Stations | Transfer Lines | Machine-Tending Systems
Plan & Execute for Special Purpose Machinery
Execute Builds That Run First Time
A validated design still has to become a working machine on your floor. Plan & Execute for Special Purpose Machinery (SPM) equips your engineering teams to move from released design to installed, accepted equipment.
Plan & Execute for SPM brings together build planning, assembly sequencing, controls readiness, FAT/SAT execution and installation ramp-up, the work that turns engineering release into a machine running on site. Build planning and assembly sequencing align procurement, fabrication and build order, while controls readiness and FAT/SAT execution confirm the machine performs to specification before handover. Installation ramp-up then stabilises performance once the machine reaches your floor.
The result: a machine that installs smoothly, commissions predictably and reaches stable production faster.
Build Planning
Plan the build for predictable delivery
Build Planning turns released engineering data into a practical, executable manufacturing and assembly plan so procurement, fabrication, controls and quality work from the same baseline. For SPM, where machines include custom frames, machined parts, control panels, pneumatics and specialised tooling, we define make‑vs‑buy decisions, long‑lead items and supplier packages to prevent late surprises and schedule slips.
We prepare revision‑controlled release packs, work orders and build sequences by subassembly and station, and run manufacturing‑readiness reviews for tolerance‑critical and outsourced items. The result: fewer assembly issues, clearer supplier handoffs and a controlled path to site acceptance.
What We Deliver
Manufacturing & Assembly Planning
Convert CAD, drawings, BoMs and specs into executable plans.
Make‑Buy Planning
Decide which parts to fabricate or purchase for cost and risk control.
Long‑Lead Identification
Spot long‑lead items and prepare procurement packages early.
Supplier Packages
Deliver drawings, quality notes, inspection points and controlled releases.
Work‑Order Sequencing
Plan build sequences by subassembly, station and final integration.
Readiness Reviews
Validate high‑risk parts, tolerance‑critical components and outsourced builds.
Build‑Risk Tracking
Monitor late changes, supplier constraints and integration dependencies.
Where we Deploy
Custom Machines | Multi-station Automation Systems | Robotic Cells | Fixtures | Test Rigs | Assembly Lines | Transfer Systems | Retrofit Projects
Plan & Execute for Special Purpose Machinery
Execute Builds That Run First Time
A validated design still has to become a working machine on your floor. Plan & Execute for Special Purpose Machinery (SPM) equips your engineering teams to move from released design to installed, accepted equipment.
Plan & Execute for SPM brings together build planning, assembly sequencing, controls readiness, FAT/SAT execution and installation ramp-up, the work that turns engineering release into a machine running on site. Build planning and assembly sequencing align procurement, fabrication and build order, while controls readiness and FAT/SAT execution confirm the machine performs to specification before handover. Installation ramp-up then stabilises performance once the machine reaches your floor.
The result: a machine that installs smoothly, commissions predictably and reaches stable production faster.
Assembly Sequencing
Sequence assembly for fast, first‑time correctness.
Assembly Sequencing defines the step‑by‑step build, alignment and verification process so the machine is assembled right the first time. We plan subassembly flows, lifting and rigging, torque and fit‑up steps, wiring and pneumatic routing, and inspection gates so teams execute predictable, safe assembly and handover.
By specifying datum checks, alignment procedures and tooling needs up front, we eliminate fit‑up issues, reduce rework and shorten commissioning. The result is a controlled build process with clear responsibilities, fewer surprises on site and faster progression to FAT/SAT.
What We Deliver
Subassembly & Final Sequence
Develop detailed build sequences from subassemblies to final integration.
Visual Work Instructions
Provide exploded views, torque specs, fit‑up steps and alignment procedures.
Datum & Calibration Checks
Specify level, square, parallelism, concentricity and calibration checkpoints.
Tooling & Rigging Plan
Plan fixtures, lifting, rigging and temporary supports for safe assembly.
Installation Sequencing
Coordinate pneumatic, hydraulic, electrical and sensor installation order.
Inspection Gates
Define mechanical, motion, guarding, wiring and pneumatic checkpoints.
Issue Tracking & Feedback
Capture assembly issues and feedback for design improvement and reuse.
Where we Deploy
Precision Assembly Stations | Robotic Cells | Gantry Systems | Fixtures | Material Handling Systems | Test Benches | Inspection Machines | Operator-Loaded Custom Machines.
Plan & Execute for Special Purpose Machinery
Execute Builds That Run First Time
A validated design still has to become a working machine on your floor. Plan & Execute for Special Purpose Machinery (SPM) equips your engineering teams to move from released design to installed, accepted equipment.
Plan & Execute for SPM brings together build planning, assembly sequencing, controls readiness, FAT/SAT execution and installation ramp-up, the work that turns engineering release into a machine running on site. Build planning and assembly sequencing align procurement, fabrication and build order, while controls readiness and FAT/SAT execution confirm the machine performs to specification before handover. Installation ramp-up then stabilises performance once the machine reaches your floor.
The result: a machine that installs smoothly, commissions predictably and reaches stable production faster.
Controls Readiness
Prepare controls for smooth FAT and commissioning
Controls Readiness readies electrical, PLC, HMI, robot, vision, safety, drive and network systems so controls work reliably at FAT and on site. We verify I/O mapping, safety logic, HMI workflows, robot handshakes and inspection triggers early to remove late‑stage surprises that cause commissioning delays and costly rework.
By validating panels, wiring, interfaces and diagnostic flows before shipment, we reduce on‑site debugging and accelerate acceptance. Deliverables include readiness checklists, I/O checkout sheets and FAT‑ready controls documentation so electrical and controls teams hand over a tested, auditable controls baseline.
What We Deliver
Panel & Wiring Review
Verify electrical panel, wiring, I/O, drives, network and safety devices.
Interface Planning
Define PLC, HMI, robot, vision, drive and safety‑PLC interfaces.
I/O Checkout
Provide I/O checkout sheets and sensor‑actuator validation lists.
Mode Definitions
Specify manual, automatic, setup, maintenance and recovery modes.
Alarm & Diagnostics
Review alarms, interlocks, resets, fault recovery and diagnostic flows.
Standards Alignment
Align documentation to IEC 60204‑1, NFPA 79 and UL 508A where applicable.
FAT‑Ready Packs
Deliver controls checklists, punch‑list tracking and commissioning aids.
Where we Deploy
Plc-controlled Machines | Robotic Cells | Safety Plc Systems | Machine Vision Stations | Servo Systems | Process Stations | Test Rigs | Automated Handling | Integrated Production Cells
Plan & Execute for Special Purpose Machinery
Execute Builds That Run First Time
A validated design still has to become a working machine on your floor. Plan & Execute for Special Purpose Machinery (SPM) equips your engineering teams to move from released design to installed, accepted equipment.
Plan & Execute for SPM brings together build planning, assembly sequencing, controls readiness, FAT/SAT execution and installation ramp-up, the work that turns engineering release into a machine running on site. Build planning and assembly sequencing align procurement, fabrication and build order, while controls readiness and FAT/SAT execution confirm the machine performs to specification before handover. Installation ramp-up then stabilises performance once the machine reaches your floor.
The result: a machine that installs smoothly, commissions predictably and reaches stable production faster.
FAT/ SAT Execution
Certify machine performance and safety
FAT/SAT Execution structures acceptance so the machine is verified against agreed technical, safety, performance and documentation criteria before handover. We build test protocols that go beyond “machine runs” to prove cycle time, part quality, safety functions, inspection logic, fault recovery and operator workflows under real production conditions.
By running variant, recipe and fixture‑aware test cases and capturing FAT/SAT evidence, punch lists and corrective actions, we turn commissioning into objective verification. The outcome is defensible customer acceptance, complete handover records and a validated machine ready for reliable production.
What We Deliver
Protocol Development
Develop FAT and SAT procedures defining pass/fail criteria and test sequences.
Variant Test Cases
Execute format, product, fixture, recipe and variant‑based tests as applicable.
Performance Tests
Verify cycle time, throughput, repeatability, accuracy, force, torque and leakage.
Fault & Recovery Tests
Exercise blocked‑part, sensor faults, low air, robot faults and reject handling.
Safety Function Tests
Validate guards, interlocks, E‑stop, scanners, light curtains and reset behavior.
Punch‑list Management
Track issues, close corrective actions and capture customer acceptance records.
Inspection & Vision Tests
Run vision, inspection and quality verification checks under production conditions.
Where we Deploy
Automated Assembly Machines | Leak-Test Rigs | Inspection Machines | Robotic Cells | Welding/ Fastening Machines | Press-fit Systems | Dispensing Machines | Machine-tending Cells | Custom Production Lines.
Plan & Execute for Special Purpose Machinery
Execute Builds That Run First Time
A validated design still has to become a working machine on your floor. Plan & Execute for Special Purpose Machinery (SPM) equips your engineering teams to move from released design to installed, accepted equipment.
Plan & Execute for SPM brings together build planning, assembly sequencing, controls readiness, FAT/SAT execution and installation ramp-up, the work that turns engineering release into a machine running on site. Build planning and assembly sequencing align procurement, fabrication and build order, while controls readiness and FAT/SAT execution confirm the machine performs to specification before handover. Installation ramp-up then stabilises performance once the machine reaches your floor.
The result: a machine that installs smoothly, commissions predictably and reaches stable production faster.
Installation Ramp-up
Stabilize Performance on Site
Installation Ramp‑Up supports the machine after shipment, installation, SAT and early production trials to convert acceptance into stable production. We validate utilities, site layout, anchoring and guarding, then tune cycle time, robot paths, sensors and fixtures so the machine suits real product, operator practice and downstream interfaces.
We capture early‑life issues, perform root‑cause analysis, implement corrective actions and train operators and maintenance teams. Final deliverables include as‑built documentation, recommended spares, training records and lessons‑learned so your operations sustain performance and reduce repeat interventions.
What We Deliver
Site Installation Support
Provide on‑site installation checks and readiness verification
Utility Verification
Confirm power, air, vacuum, cooling, extraction, network and safety interfaces.
Leveling & Layout Checks
Verify leveling, anchoring, guarding, access and site geometry.
Parameter Tuning
Tune cycle time, robot paths, sensors, fixtures and process variables.
Issue Tracking & RCA
Log early faults, run root‑cause analysis and close corrective actions.
Training & Handover
Deliver operator, maintenance and service training and materials.
As‑Built & Spares
Supply as‑built documentation, recommended spares and lessons learned.
Where we Deploy
Customer-Installed Machines | Integrated Production Lines | Robotic Cells | Transfer Systems | EV/ Battery Assembly Lines | Test Rigs | Inspection Systems | Retrofit Projects |High-utilization Automation Cells
Govern & Trace for Special Purpose Machinery
Trace Every Machine, Concept to Service
A custom machine’s story does not end at commissioning. Govern & Trace for Special Purpose Machinery (SPM) equips your engineering teams to prove, throughout the machine’s life, that every requirement was met, every configuration is known, and every compliance record can be produced on demand.
Govern & Trace for SPM brings together requirement traceability, configuration control, BoM governance, safety file management and service intelligence, the record-keeping that connects design intent to what was actually built, shipped and maintained. Requirement traceability and configuration control keep design, build and service data consistent for every machine, even when customer options create many similar but non-identical builds. BoM governance keeps parts and revisions synchronised across engineering, procurement and service, while safety file management structures the CE technical files and declaration inputs that EU-bound machines require under Machinery Regulation (EU) 2023/1230. Service intelligence then closes the loop, feeding field data back into design and maintenance decisions.
The result: a defensible, auditable record for every machine you build, ready for customer review, regulatory audit or field service, whenever it’s needed.
Requirement Traceability
Trace every requirement from design to delivery
Requirement Traceability links customer requirements, technical specifications, design decisions, validation evidence and acceptance records so every design choice is provably tied to an outcome. For custom SPM, where each machine begins with unique constraints, this traceability prevents ambiguity about why a decision was made and whether acceptance criteria have been met.
We create structured URS/FRS frameworks, map requirements to design artefacts and validation outputs, and maintain change histories so engineering, project teams and customers share a single, auditable view of requirement status through to handover.
What We Deliver
URS & FRS Framework
Structure user and functional requirements with clear acceptance criteria.
Requirement to Design Mapping
Link requirements to mechanisms, fixtures, motion, safety and controls.
Requirement to Validation Linkage
Associate requirements with simulation, FAT, SAT and commissioning results.
Change Impact Tracking
Track effects when customer requirements change and record decisions.
Requirement Status Dashboards
Provide visibility for engineering, project managers and customers.
Deviation & Concession Traceability
Record deviations, concessions, assumptions and open items for review.
Handover‑Ready Evidence Pack
Produce compliance matrices and validation packs for final handover.
Where we Deploy
Customer-Specific Automation | Regulated Equipment | Test Benches | Inspection Machines | Automotive/ EV Lines | Medical Device Equipment | Machines With Strict Customer Acceptance Requirements
Govern & Trace for Special Purpose Machinery
Trace Every Machine, Concept to Service
A custom machine’s story does not end at commissioning. Govern & Trace for Special Purpose Machinery (SPM) equips your engineering teams to prove, throughout the machine’s life, that every requirement was met, every configuration is known, and every compliance record can be produced on demand.
Govern & Trace for SPM brings together requirement traceability, configuration control, BoM governance, safety file management and service intelligence, the record-keeping that connects design intent to what was actually built, shipped and maintained. Requirement traceability and configuration control keep design, build and service data consistent for every machine, even when customer options create many similar but non-identical builds. BoM governance keeps parts and revisions synchronised across engineering, procurement and service, while safety file management structures the CE technical files and declaration inputs that EU-bound machines require under Machinery Regulation (EU) 2023/1230. Service intelligence then closes the loop, feeding field data back into design and maintenance decisions.
The result: a defensible, auditable record for every machine you build, ready for customer review, regulatory audit or field service, whenever it’s needed.
Configuration Control
Control configuration across design, build and service
Configuration Control captures exactly what was designed, built, shipped, installed and serviced so every machine’s state is discoverable and defensible. For SPM, where customer options, tooling, software and recipes create many similar but non‑identical machines, configuration control prevents costly mix‑ups and supports fast, correct service responses.
We maintain as‑designed, as‑built, as‑installed and as‑maintained records, track serials, revisions and option effectivity, and store field modification history so engineering, operations and service teams always know the true configuration and can act with confidence.
What We Deliver
Version Control
Manage mechanical, electrical, pneumatic, software, robot, vision and HMI versions.
Asset & Version Tracking
Track serial numbers, project IDs, customer options and revision history.
Configuration Baselines
Define baselines for FAT, shipment, SAT and handover releases.
Tooling & Spare Traceability
Link tooling, fixtures, spare parts and change parts to each configuration.
Systems Integration
Provide PLM/PDM/ERP/service integration inputs for downstream systems.
Field Modification History
Record retrofits, field changes and update rationale for service teams.
As‑State Records
Maintain as‑designed, as‑built, as‑installed and as‑maintained configuration views.
Where we Deploy
Custom Automation Lines | Multi-Machine Programs | Repeat Machines with Customer Variants | Retrofit Programs | Robotic Cells | Test Rigs | Machine Families
Govern & Trace for Special Purpose Machinery
Trace Every Machine, Concept to Service
A custom machine’s story does not end at commissioning. Govern & Trace for Special Purpose Machinery (SPM) equips your engineering teams to prove, throughout the machine’s life, that every requirement was met, every configuration is known, and every compliance record can be produced on demand.
Govern & Trace for SPM brings together requirement traceability, configuration control, BoM governance, safety file management and service intelligence, the record-keeping that connects design intent to what was actually built, shipped and maintained. Requirement traceability and configuration control keep design, build and service data consistent for every machine, even when customer options create many similar but non-identical builds. BoM governance keeps parts and revisions synchronised across engineering, procurement and service, while safety file management structures the CE technical files and declaration inputs that EU-bound machines require under Machinery Regulation (EU) 2023/1230. Service intelligence then closes the loop, feeding field data back into design and maintenance decisions.
The result: a defensible, auditable record for every machine you build, ready for customer review, regulatory audit or field service, whenever it’s needed.
BoM Governance
Synchronise parts, suppliers and service records
BoM Governance aligns engineering, manufacturing, service and spare‑parts structures so everyone references the correct parts, quantities and revisions. For SPM, where customer options, fabricated assemblies and control components vary by machine, robust BoM control prevents wrong orders, incomplete builds and costly rework.
We reconcile EBOM, MBOM and service BoMs, enforce part classification and make‑buy rules, and maintain revision‑accurate BoM comparisons through release, shipment and as‑built states. The outcome is reliable procurement, clear assembly packages and faster, accurate service support across the equipment lifecycle.
What We Deliver
BoM Structures
Create EBOM, MBOM, SBOM and spare‑parts structures with recommended spares.
BoM Comparison
Compare EBOM→MBOM→FAT→shipment→as‑built states to catch mismatches.
Component Classification
Standardise purchased, fabricated, electrical, pneumatic, hydraulic and controls parts.
Effectivity & Options
Manage effectivity and customer‑specific options within BoMs.
Governance Checks
Validate revision, quantity, unit, material, supplier and lead‑time data.
ERP/MRP Integration
Provide BoM integration inputs for procurement, MRP and production planning.
Make‑Buy & Supplier Links
Classify parts, define make‑vs‑buy rules and link supplier packages.
Where we Deploy
Large Custom Machines | Multi-Station Assembly Systems | Repeat Equipment Platforms | Robotic Cells | Fixtures/ Tooling | Material Handling Systems | Service-Intensive Machines
Govern & Trace for Special Purpose Machinery
Trace Every Machine, Concept to Service
A custom machine’s story does not end at commissioning. Govern & Trace for Special Purpose Machinery (SPM) equips your engineering teams to prove, throughout the machine’s life, that every requirement was met, every configuration is known, and every compliance record can be produced on demand.
Govern & Trace for SPM brings together requirement traceability, configuration control, BoM governance, safety file management and service intelligence, the record-keeping that connects design intent to what was actually built, shipped and maintained. Requirement traceability and configuration control keep design, build and service data consistent for every machine, even when customer options create many similar but non-identical builds. BoM governance keeps parts and revisions synchronised across engineering, procurement and service, while safety file management structures the CE technical files and declaration inputs that EU-bound machines require under Machinery Regulation (EU) 2023/1230. Service intelligence then closes the loop, feeding field data back into design and maintenance decisions.
The result: a defensible, auditable record for every machine you build, ready for customer review, regulatory audit or field service, whenever it’s needed.
Safety File
Prepare safety files for assurance and market access
Safety File Management organises the risk assessments, safety requirements, validation records and technical evidence that customers and regulators expect. We compile hazard analyses, safety‑function specifications, electrical documentation and operational manuals into a coherent package so acceptance and certification decisions are straightforward.
For EU‑bound machines, we structure CE technical files in line with Machinery Regulation (EU) 2023/1230; for other markets, we provide the declaration inputs and validation records required for customer FAT/SAT review. The result is defensible conformity evidence, faster customer acceptance and reduced regulatory risk.
What We Deliver
Risk Documentation
Capture risk assessments and risk‑reduction evidence for the machine.
Safety Requirements
Define safety function lists and requirement specifications.
PL / SIL Evidence
Provide Performance Level or SIL justification where needed.
Validation Records
Record guarding, interlock, scanner, light‑curtain and E‑stop validation.
Electrical Documentation
Deliver wiring diagrams, panel docs and IEC 60204‑1 alignment inputs.
User & Maintenance Docs
Provide operation, maintenance and residual‑risk information for users.
CE Technical File
Assemble CE file structure, declaration inputs and customer safety packs.
Where we Deploy
EU-bound Machines | Robotic Cells | High-force Systems | Operator-loaded Machines | Automated Lines | Welding/ Cutting Equipment | Machine-tending Cells | Integrated Production Systems
Govern & Trace for Special Purpose Machinery
Trace Every Machine, Concept to Service
A custom machine’s story does not end at commissioning. Govern & Trace for Special Purpose Machinery (SPM) equips your engineering teams to prove, throughout the machine’s life, that every requirement was met, every configuration is known, and every compliance record can be produced on demand.
Govern & Trace for SPM brings together requirement traceability, configuration control, BoM governance, safety file management and service intelligence, the record-keeping that connects design intent to what was actually built, shipped and maintained. Requirement traceability and configuration control keep design, build and service data consistent for every machine, even when customer options create many similar but non-identical builds. BoM governance keeps parts and revisions synchronised across engineering, procurement and service, while safety file management structures the CE technical files and declaration inputs that EU-bound machines require under Machinery Regulation (EU) 2023/1230. Service intelligence then closes the loop, feeding field data back into design and maintenance decisions.
The result: a defensible, auditable record for every machine you build, ready for customer review, regulatory audit or field service, whenever it’s needed.
Service Intelligence
Turn field data into faster, smarter service
Service Intelligence links installed‑machine telemetry, service history and configuration records so builders and service teams resolve faults faster and plan maintenance proactively. We capture serial‑level data, alarms, cycle counts, energy and condition signals to give a clear, live view of asset health across customer sites.
With that visibility, we enable predictive maintenance, spare‑parts readiness and a feedback loop from field failures into design and BoM updates. The outcome is reduced downtime, faster mean‑time‑to‑repair and stronger long‑term customer relationships.
What We Deliver
Installed‑base Database
Track machine serials, customer sites, configurations and software versions.
Service History
Link maintenance actions, field modifications and warranty records.
Spareparts Linkage
Connect spare‑parts and service BoMs to installed configurations.
Predictive Maintenance Inputs
Generate PM logic for bearings, drives, cylinders, grippers, pumps and valves.
Feedback Loop
Feed field failures back into design, BoM updates and module improvements.
Remote Diagnostics
Specify dashboards and remote‑diagnostic requirements for field teams.
Performance Mapping
Map alarms, downtime, cycle counts, energy, vibration, temperature and motor current.
Where we Deploy
Service-heavy Custom Machines | Automated Production Lines | Machine-tending Cells | Test Systems | Robotic Cells | High-utilization Assembly Machines | Long-Life Industrial Equipment
CASE STUDIES
Stories of Transformation
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