Case Studies

The Problem   A large battery manufacturer needed a robotic palletizing system to automate the machine-to-pallet transfer of stacks of metallic plates, a process duplicated across multiple facilities. The manual process created ergonomic and safety concerns due to repetitive handling and lead dust exposure. Tight cycle-time requirements and multiple SKUs…

Implementing functional safety upgrades across a global aluminum manufacturing operation. A global aluminum extrusion manufacturer set out to evaluate and improve machine safety across more than 20 facilities. The initiative focused on identifying risks and implementing machine safety controls that would better protect employees while supporting safe, efficient production. The…

Automating aerospace drilling and cutting to improve throughput, precision, and safety. Meggitt Polymers & Composites needed to significantly increase production. The existing drilling and cutting process was labor-intensive, creating challenges with accuracy, throughput, and safety. Concept Systems designed and integrated a fully automated robotic drilling system using a FANUC M-710…

Leading process controls integration for a greenfield sweet potato processing facility.   Building an Award Winning Plant with Process Controls As consumer demand for frozen sweet potato fries grew, a food manufacturer invested in a greenfield processing facility to expand production capacity. Concept Systems served as lead integrator, coordinating the…

An OnGuard Collision Avoidance System Case Study Utilizing Concept Systems innovative collision avoidance system Painting planes is done by skilled artisans who need to work quickly and accurately. As they work, they travel along the plane on movable platforms. They get very close to the plane, but the platforms must…

A Machine Vision Case Study Box sorting innovative machine vision solution Inline sorting of variable-sized boxes for mixed products is a common challenge on automated packaging lines in many production facilities. The Problem: Multi-sized Boxes Boxes traveling down the line needed to be sorted into one of three stackers, depending…

An HMI Upgrade Case Study Achieve high production rates and efficiency with a HMI upgrade National Frozen Foods wanted an HMI upgrade for a vegetable blending system that used a dial system to manage the ratio of vegetables. It consistently receives top-level food safety scores and meets strict US Department of…

A CNC Controls Retrofit Case Study Automating a process using a custom Computer Numerical Control system Due to their critical nature, key parts of rocket engines must be X-rayed to ensure their integrity and thus their safety. The process traditionally has been time-consuming and inefficient. Even with the most skilled…

A Vision-Guided Workcell Case Study Making a system more efficient, safe and profitable with a vision guided workcell For this coffee roaster, the robot moving bags from pallets to the conveyor was a weak link. It often ripped bags, spewing beans on the floor. Plus, it relied on older technologies, using…

A Controls Retrofit Case Study Controls retrofit brings entire system up to speed with zero downtime Replacing obsolete hardware at Tillamook Creamery with a controls retrofit leads to the execution of a new plan to mitigate risk and eliminate production downtime. The Problem Tillamook, a longtime partner of Concept Systems,…

A Control Systems Upgrade Case Study Replace Outdated Controls For More Efficient, Safe Fuel Handling A control upgrade leads to a safer and more efficient system. A Fuel Farm contained five storage tank, as well as equipment to transfer fuel to aircraft and load and offload supply trucks. Its outdated…

A Safety Remediation Case Study Extrusion Press Line Safety Remediation Designing, engineering, and implementing a new safety control system in a safety remediation project for a Hydro aluminum plant. The Problem: Safety hazards need remediation A plant in Yankton, SD, makes aluminum products owned by Hydro. At this plant, a…

A PlantPAx and Automation Consulting Case Study Developing the New Standard for Systems with PlantPAx As part of building a new greenfield plant, a global frozen potato supplier wanted to standardize its French fry process and packaging control through all of its facilities. It required a platform built on a…

A Robot Integration Case Study Six-Axis Robot Integration Increases Accuracy and Safety Nucor Steel is a successful company with a rich history as one of the nation’s largest producers of steel products. And yet demand for its products outpaced its ability to accurately inventory the billets used in its manufacturing process.…

A Robotic Retrofit Case Study Upgrading existing machinery in a robotic retrofit to increase accuracy and quality Rise Baking Company outside Atlanta makes and decorates cakes that it sells to large supermarket chains. Responding to these retailers’ requests for more intricate decoration on the cakes usually required handwork. The company…

A Robotic Workcell Case Study Moving a New Product to Market with a Robotic Workcell Vestcom helps retailers maximize the shelf edge as it serves more than 70 percent of retail food, drug and mass merchants in the U.S. It identified an opportunity to reduce labor costs for hanging shelf…

A Random Bin Picking Case Study Automated Random Bin Picking Solution Provides Safety & Process Optimization Automating labor-intensive factory tasks with the use of bin picking robots prioritizes worker safety and increases profit. The problem At a truck and axle manufacturing plant in North Carolina, an operator was tasked with…

A Complex Controls Upgrade Case Study Redesigning An Aircraft Paint Hangar System The manufacturer wanted to improve accuracy and efficiency, and eliminate costly delays caused by the need to repark aircraft during the painting process. The Problem The customer wanted to improve the air-handling system to make aerospace painting and curing more…

In today’s manufacturing environment, efficiency, flexibility, and responsiveness are critical to staying competitive. Modular robotic automation can help manufacturers streamline production, adapt to changing needs, and reduce the time and complexity associated with traditional automation projects. By combining configurable workcells with proven robotics, controls, vision, and safety technologies, manufacturers can…

For more than 25 years, Scott VanDelinder has played a pivotal role in helping Concept Systems deliver complex automation projects while developing the engineers on his team. As a Principal Engineer and Project Management Professional (PMP), Scott’s career reflects a unique blend of technical expertise, disciplined execution, and an

Written by Dharma Prime, Senior Controls Engineer   Welcome to another installment of our series on Rockwell Automation FactoryTalk Optix. This article will cover the basics of user interface (UI) objects, compare the available buttons with their counterparts in FactoryTalk View, and discuss some of the more advanced features that…

David Skidmore has spent nearly four decades solving complex manufacturing and automation challenges across aerospace and industrial environments. While he often jokes that he graduated from the “School of Hard Knocks,” his career reflects a deep foundation of hands-on engineering experience, practical problem-solving, and long-term customer partnerships. David began

When failure isn’t an option, experience matters. For over 25 years at Concept Systems, Sergei Furduy has built a career around exactly that – delivering automation solutions in environments where precision, safety, and reliability are non-negotiable. From aerospace crane systems to nuclear applications and advanced carbon fiber manufacturing, his

From Paper Mills to Process Control   If Ron Schiedler’s career had a headline, it might read: steady hands, high standards, zero shortcuts.  Ron’s path into automation started in pulp and paper, an industry known for unforgiving environments, massive equipment, and systems that leave little room for guesswork.   For 13 years in pulp…

Bob O’Brien: Legacy Automation Expert in Wood Products At Concept Systems, Principal Engineers represent the highest level of technical leadership in our organization. More than senior project contributors, they are trusted advisors, system integrators, and mentors whose work impacts not just one project but the direction of our company. From developing robust safety

The Intern Experience | From Intern to Engineer By Isaac Young, Controls Engineer, OIT MECOP Intern, 2025 (second from the left in the picture above) I joined Concept Systems during my second MECOP internship while finishing my senior year as a computer engineering student at Oregon Institute of Technology. Over six months, I worked

Team Insights From a Week of Innovation The 2025 Rockwell Automation Fair was a week of collaboration, innovation, and hands-on learning for the Concept Systems team. For many, it was their first time experiencing the scale of Rockwell’s sessions, labs, keynotes, and technology showcases — and each person walked away with

Written by Brandon Chan, OSU MECOP Intern, 2025 On my third day of joining the company, one of my coworkers had coordinated to have an April Fools’ themed potluck. Although I didn’t have much prepared, just a box of chocolate macnuts from back home, they welcomed me with open

Removing the Blindfold: Manufacturing Data Collection with Ignition Author: Ruvim Turchik, Senior Engineer “You can have data without information, but you cannot have information without data.” —Daniel Keys Moran Even with data collection practices in place, plant managers can be left blindfolded to bottlenecks in their manufacturing process. Manufacturing facilities…

Concept Systems had a dynamic week in sunny Anaheim, California, at the 2024 Rockwell Automation Fair this November. The event sparked valuable conversations with new connections across the Southwest and strengthened relationships with our long-standing partners.  Chad McDowell, Technical Resource Director, participated in a panel at the inaugural New Capacity…

Written by Isaac Grossberg, Software Engineer  To get the most out of Rockwell’s FactoryTalk Optix, you need to get familiar with dynamic links. These links are the backbone of automation and data flow in Optix, transforming your UI from static to dynamic. Let’s break down how dynamic links work and…

Written by Isaac Grossberg, Software Engineer Read Part 2 of our FactoryTalk Optix series about OOP.  One of the best things about using Rockwell Automation’s FactoryTalk Optix platform for developing HMIs is how you can tweak and enhance functionality through NetLogic. This feature lets you tap directly into the .NET…

Written by Isaac Grossberg, Software Engineer Introduction to FactoryTalk Optix Part 1 Welcome back to the second blog in our series on FactoryTalk Optix! If you missed the first post, where we covered the basics of FactoryTalk Optix and its core elements, you can read it here.   Today, I’m excited…

Written by Isaac Grossberg, Software Engineer FactoryTalk Optix is a powerful platform from Rockwell Automation designed to enhance your HMI and data visualization capabilities. If you're looking to elevate your Industrial Internet of Things (IIoT), edge computing, and data management, this platform has a lot to offer. FactoryTalk Optix extends…

During Automate 2024 our CEO, Steve Strong, and portfolio manager Evan Gonnerman, gave a successful talk about building robotic systems with modular designs. They explained that these systems produce higher ROI, provide a lower time to production, and offer a more reliable technical backbone for your automation system.   Following the…

What is Retrofitting? Retrofitting is the process of updating or upgrading existing machinery or systems to improve functionality, efficiency, and performance. Instead of investing in entirely new equipment, retrofitting allows you to leverage your existing infrastructure while incorporating modern technologies and methods. It's a cost-effective way to enhance productivity and…

Concept Systems has provided manufacturers with innovative automation solutions and system integrations for more than 20 years. Concept’s updated brand reflects its growth over the past two decades. It expresses a bold new look and feel of a business with the expertise and leadership capable of creating groundbreaking change as…

Our Project Methodology is a proven process to ensure they are completed on time, on budget and to customer expectations Our project management method is based on real-world experience and ensures open communication, so all those involved have an up-to-date understanding of each other’s expectations and responsibilities. Our methodology

Selecting components for UL508A industrial control panels can seem difficult, but knowing these methods makes it easy. There are several ways to go about selecting hardware that is listed for use in a UL508A enclosure.  Every device that is UL listed has 2 pieces of information attached to it.  The…

How Manual Painting Impacts a Company and How an Automated Painting System Improve Processes The way that parts and products are painted today in general industry typically involves a process that is a very manual in nature. It includes operators prepping parts, loading parts, painting parts, and management of part…

The Fundamental Questions to Ask at the Start of an Industrial Control Enclosure Design It’s one of the first questions asked when beginning an industrial control enclosure design. Are we using circuit breakers or fuses to protect our equipment? How does one choose what to specify? What are the pros…

What is Industrial Automation? In today’s factories and shop floors, industrial automation is everywhere and it is difficult to imagine a production line without automation. Industrial automation uses control systems and equipment, such as computer software and robots, to perform tasks that were historically done manually. These systems operate industrial equipment automatically,…

A process control system involves ensuring that a continuous manufacturing process is predictable, stable, and consistently operating at the target level of performance with only normal variation. A properly planned and executed process control system can yield incredible benefits to manufacturers. Here are just four of those benefits: How Process…

Robots have been around for many decades, and robotic technologies continue to rapidly advance. Today, robotics are used to increase the efficiency of all kinds of manufacturing processes. Today’s robots use sensors that enable them to see, hear, and even feel their surroundings. Robots are capable of adapting and making decisions to…

Industrial automation is a rapidly growing field that is transforming the way many industries operate. However, for those new to the industry, the terminology and jargon used can often be confusing and overwhelming. Whether you’re an engineer, a technician, or a business owner, this guide will provide you with the…

What do amusement park rides, factory assembly lines, sawmills, food processing plants, and robotic work cells all have in common? They all rely on Programmable Logic Controllers (PLCs) for automation and control. PLCs are specialized industrial computers designed to monitor inputs, execute programmed logic, and control output devices in real-time.…

We’re thrilled to be named a 2024 System Integrator Giant by Control Engineering, whose prestigious annual list ranks the top 100 system integrators among companies listed in the CFE Media Global System Integrator. The list supplies important information regarding the wide range of systems integrators ready to address the

ATX West, one of the premier automation manufacturing shows, is coming to Anaheim, CA and Concept Systems is going to be there. Our team is eager to learn about your manufacturing challenges and share how our customized automation services can help you create more cost-effective and safer workflows. Click