Our case studies demonstrate how Ewan Automation delivers measurable results across diverse industries. Here are selected highlights from our 500+ project portfolio:
Automotive — BIW Welding Line Upgrade
A Tier 1 automotive supplier needed to increase welding line throughput by 35%. We redesigned the control architecture using Siemens S7-1500 PLCs with PROFINET, integrated 24 FANUC welding robots, and implemented real-time quality monitoring with Cognex vision systems. Result: 42% cycle time reduction, 99.8% line uptime, ROI in 14 months.
Pharmaceutical — Validated Batch System
A global pharma manufacturer required a 21 CFR Part 11 compliant batch control system for a new oral solid dosage facility. We delivered a Rockwell FactoryTalk Batch solution with full electronic records, electronic signatures, and automated batch reporting. Result: 100% validation pass rate on first audit, 30% yield improvement, zero FDA observations.
Food & Beverage — High-Speed Packaging
A beverage producer needed to increase packaging line speed from 180 to 250+ PPM. We upgraded the line control system with B&R Automation, added high-speed vision inspection, and implemented OEE monitoring. Result: 280 PPM sustained, 99.5% traceability coverage, 25% waste reduction.
Energy — Substation SCADA
A regional utility needed to modernize 15 substations with IEC 61850 compliance. We deployed an Ignition SCADA system with ABB RTU560 units, implemented cybersecurity per NERC CIP, and integrated with the existing EMS. Result: 99.99% SCADA availability, full IEC 61850 compliance, 60% faster fault detection.
Logistics — Automated Warehouse
An e-commerce fulfillment center needed a 500K+ pallet position AS/RS system. We integrated AutoStore shuttle technology with a custom WES, connected 40+ AMRs, and implemented SAP EWM integration. Result: 20,000 PPH sortation, 50% labor cost reduction, 99.9% inventory accuracy.
