Failed Automation Recovery
+ Brownfield Retrofits
Why Good Hardware Fails
We know the story. You bought a solution that turned into an even bigger problem. The demo looked perfect, but now that it’s on your floor, there is a clear disconnect between the defined problem and the desired solution.
In some facilities, we find these expensive assets hiding in "dark, dungeon-like" sections of the plant—literal paperweights that operators have given up on.
We’re not here to sell you hardware. We’re here to deliver a solution. If it doesn’t work, we’ll make it right. We bridge the gap to take you from "it should work" to "it does work."
Turnkey Integration + Troubleshooting Services
1. Failed System Integration + Project Recovery
- The Problem: You have a "paperweight", a new measurement solution or automation cell that falls short of delivering value. Often, the previous integrator couldn't make the different pieces of hardware talk to each other, or the system wasn't designed for the reality of your floor.
- The Fix: We deploy engineers to diagnose why your underperforming asset isn't delivering. We don't just guess; we look for the root cause of the disconnect.
- The Result: We recover the value of your capital expenditure. We work with you to reduce risk through a clearly defined execution plan.
2. Brownfield Retrofits / Legacy Equipment Modernization
Do you have reliable mechanical assets that are digitally obsolete? Don't rip and replace. Our Brownfield retrofit strategy, or more generally called Legacy Equipment Modernization, keeps your proven equipment in place while upgrading the "brains."
We treat your legacy equipment as a scalable platform. We layer on modern sensors and controls directly onto your existing assets using open standards like IO-Link and OPC-UA. This allows us to extract data from older machines without locking you into proprietary systems.
Crucially, we are controller-agnostic. Automadex selects the hardware that works for your problem, rather than forcing a specific brand. Whether you use Rockwell Automation/Allen-Bradley, Siemens, Omron, or legacy controls, we work with what you have without forcing a platform change.
3. OEE Data Extraction + Continuous Improvement
You cannot improve what you cannot measure. Many "failed" integrations are actually just information gaps. We utilize Continuous Improvement (CI) methodology to turn your machines into data generators.
We don't just extract data; we translate it into the three core metrics of Overall Equipment Effectiveness (OEE):
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Availability: Is the machine actually running, or is it stalled on changeovers?
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Productivity: Is it running at the rated speed, or are you losing throughput?
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Quality (Scrap): Are you producing good parts, or just producing waste faster?
From Data to Action: Collecting these metrics is only half the battle. If your floor team cannot interpret the data instantly, they cannot improve it. We focus on Operator Usability, translating complex OEE calculations into simple, intuitive visualizations. This empowers your operators to make the right decisions the moment a problem arises, without needing to decipher complex charts.
Our Methodology:
Zero-Based Analysis
We don't believe in "silver bullet" solutions. We believe in finding the hidden losses in your value stream through a transparent, phased approach.
- The Audit (Zero-Based Analysis): We walk your floor to identify stranded assets. We perform a "zero-based" analysis: comparing exactly what raw material comes in the back door versus what product goes out the front. If the numbers don't match, we find where the value is bleeding out—often in unrealized scrap or inefficiency.
- The Definition: We collaborate with your team to accurately re-define the problem statement, ensuring we aren't just treating symptoms.
- The Roadmap: We provide a fixed-cost plan to get that asset online. No open-ended billing.
- The Delivery: We execute the solution. We are done only when the deliverables are met and the Return on Investment (ROI) is tracking.
- The Partnership: Our relationship does not end after commissioning. We build long-term partnerships to ensure the solution adapts as your production grows. We’ll partner on any next problems, giving you the right solution, the first time.
Frequently Asked Questions
Why choose Brownfield retrofits over full equipment replacement?
Brownfield Retrofits (or Legacy Equipment Modernization) upgrade the "brains" of existing machines rather than building new from scratch (Greenfield). Instead of the massive cost and downtime of a full replacement, we layer modern sensors onto your already reliable equipment, often achieving the same data capabilities for a fraction of the price.
What are the hidden risks of replacing legacy manufacturing equipment?
Beyond the sticker price, replacement triggers disposal fees, complex rigging, and process re-validation. However, the most overlooked costs are often digital: integration risks (getting new protocols to talk to the existing line) and operator retraining on new HMI standards, which often causes a dip in throughput while the team relearns the machine.
A Brownfield Retrofit avoids these variables by keeping the mechanical and operational baseline your team already knows.
Can I extract OEE data from legacy PLCs without changing the code?
Yes. We utilize open standards like IO-Link and OPC-UA to layer modern data extraction tools onto legacy PLCs (Rockwell, Siemens, Omron). This allows us to calculate OEE metrics without risking downtime by touching the delicate, existing control logic.
What is the "Zero-Based Analysis" method for automation recovery?
Unlike standard audits that look at machine speed, our Zero-Based Analysis compares total raw material input against finished goods output. This methodology identifies "hidden" losses—such as micro-stops or unrealized scrap—to pinpoint exactly where a stalled project is bleeding value, often justifying the cost of recovery in months.
What is the first step to fix a stalled automation project?
The first step is identifying the "Disconnect"—the gap between the hardware's capability and the floor's reality. We provide a fixed-cost diagnostic roadmap to determine if the failure is mechanical, electrical, or data-related, ensuring you know the exact path to ROI before committing to further spend.