Case Study: Large North American Electrical Component Manufacturer boosts production and extends line life with Advanced Technology Services

ATS Adds Years to Life of Component Manufacturer’s Aging Production Line at 90% Project Cost Savings

Large North American Electrical Component Manufacturing Company faced an aging production-line control system on its main line, where a PC-based controller running an orphan operating system could no longer be upgraded. Power interruptions caused network crashes and manual robot resets, and many control components were obsolete. The company turned to Advanced Technology Services (ATS) for a modern automation integration solution that would work with existing production equipment.

Advanced Technology Services (ATS) designed and installed a new PLC-based control system, reusing key existing assets such as the Allen-Bradley Flex I/O modules and Kuka gantry robot drive motors, while adding a new mobile teach pendant and replacing outdated panels with plug-in equivalents. ATS also improved safety circuits, performed off-site testing, and provided manuals and electrical drawings. The result was higher production output, easier maintenance support going forward, and a project cost estimated at less than 10% of a full line makeover.