Controls & Digital Services

Challenge

A global seed producer operating roughly 40 processing sites across North America needed a single, trustworthy count of sellable units for every SKU — in real time, throughout the compressed harvest window. Counts were stitched together after the fact from disconnected systems, and every site ran a little differently, making it impossible to know unified, up-to-date sellable inventory levels.

Solution

CONVERGIX used Inductive Automation’s Ignition platform as the integration backbone between the customer’s MES and their plant-floor equipment, unifying two operator interfaces into one, and giving Operations accurate production reporting and a live view of sellable inventory that the business could act on.

Challenge

A global confectionery manufacturer operating 25+ plants across North America needed a Manufacturing Execution System (MES) built for the complexity of their production environment — one that could scale across every facility and adapt faster than any off-the-shelf solution could.

Solution

Our Controls & Digital Services (CDS) team delivered a fully customized MES Proof of Concept on Inductive Automation’s Ignition platform, built collaboratively through weekly working sessions, a transparent Azure DevOps environment, and a rapid feedback loop that replaced months of waiting with days of iteration.

Challenge

A global food producer sought a scalable way to extract and contextualize data from its newly deployed FactoryTalk AssetCentre systems. This would provide enterprise-wide visibility into thousands of automation assets.

Solution

Leveraging our unique partnership with Rockwell Automation, CONVERGIX developed an Enterprise Asset Management System using FactoryTalk DataMosaix. This solution aggregates and contextualizes AssetCentre data to provide comprehensive enterprise-level reporting. Our team also supports the adoption of this system through proactive change management practices.

Challenge

Life safety systems (LSS) are a crucial component of semiconductor fabrication. Still, they are complex to design and install since fabrication occurs in ultra-clean, multi-level facilities and installation requires coordination among numerous contractors and vendors. Any misstep at this stage can delay startup and result in lost revenue.

Solution

At CONVERGIX, we bring proven expertise, disciplined coordination, and consultative insight to design and integrate LSSs accurately, on time, and without surprises. Our teams combine extensive design reviews, flexible resourcing, and clear communication to minimize cost and risk while keeping schedules on track.

Challenge

When a global motion technology company won a high-profile program to supply battery packs for a high-profile autonomous EV, they needed an automation partner capable of delivering advanced assembly and testing systems while remaining flexible enough to adapt to constant change.

Solution

Leveraging our deep expertise in battery module and pack assembly, as well as our proven project management excellence framework, we designed both a prototype line and a full-scale automated assembly and testing system for this supplier. This ensured reliable, scalable production despite receiving more than 30 engineering change requests during the project.