03 / PROJECT RECORD
Deployed, measured, documented.
A selection of delivered programs. Every engagement closes with signed FAT records, as-built documentation, and a measured baseline — so the numbers below are ours to show and yours to audit.
PROJ.014
Electronics manufacturing · 2025
High-speed assembly cell
THE BRIEF
A Tier-1 electronics OEM was running a mixed-vendor assembly line where each of fourteen cells spoke a different control language. Changeovers were manual, fault diagnosis took hours, and throughput was capped by the slowest station.
The brief: unify the line under one control architecture without a full shutdown — the plant could only release stations one at a time, in production windows.
What we delivered
- Control architecture spec covering all fourteen cells — one standard, one codebase pattern
- Conveyor, vision, and safety systems integrated under a single HMI layer
- Phased cutover plan: two cells per release window, zero missed production slots
- Operator and maintenance training pack with fault-code reference library
- Post-ramp optimization pass on the three slowest stations
MEASURED RESULTS
31%
Cycle-time reduction across the line
14
Robotic cells on one control standard
0
Missed production windows during cutover
Proof on file
- Signed factory acceptance test records for all fourteen cells
- Before/after cycle-time measurement logged per station
- As-built control documentation and full source handover
PROJ.017
Industrial facility · 2025
Power efficiency retrofit
THE BRIEF
A regional industrial facility was carrying a cooling and distribution load that had grown by accretion — a decade of add-ons, no single drawing, and an energy bill nobody could decompose.
We were asked to find the waste without pausing production, and to prove any improvement against a measured baseline rather than a supplier's datasheet.
What we delivered
- Full load survey and metered baseline across cooling and distribution
- Redesigned distribution layout with staged switchgear replacement
- Cooling control logic rebuilt against measured duty cycles, not nameplate ratings
- Continuous sub-metering so the facility owner can audit the delta themselves
- Twelve-month performance review with the client's own facilities team
MEASURED RESULTS
22%
Measured energy reduction, year one
16 wks
Survey to signed handover
100%
Load points sub-metered and documented
Proof on file
- Metered baseline report agreed with the client before work began
- Post-retrofit draw data covering a full seasonal cycle
- As-built single-line diagrams and control logic handover
PROJ.009
Electronics validation lab · 2024
Environmental test bench
THE BRIEF
An electronics manufacturer's validation lab was queueing two weeks behind production. Tests ran on bench rigs built by whichever engineer needed them, so results were repeatable only by luck.
The mandate: standardize the test bench itself, automate the measurement chain, and get sign-off time from weeks to days.
What we delivered
- Reference test-bench design with fixtured, repeatable test setups
- Automated measurement chain — instrumentation, logging, and report generation
- Test-sequence library covering the lab's full qualification matrix
- Calibration schedule and drift checks wired into the bench controller
- Training and sign-off protocol adopted by the whole lab team
MEASURED RESULTS
9 days
Average sign-off queue, down from 14
38
Test sequences standardized
1
Bench standard across the lab
Proof on file
- Repeatability study: same unit, three benches, matching results
- Commissioning record with instrumentation calibration certificates
- Full bench documentation pack handed to the lab lead
PROJ.021
Food-grade facility · 2026
Production line integration
THE BRIEF
A food-grade manufacturer was adding a second production line into a live plant. The new line's equipment came from three suppliers, none of whom had ever integrated with the site's existing hygiene, safety, and traceability systems.
Falkor was brought in as the single integration authority — one contractor accountable for the whole line behaving as one machine.
What we delivered
- Single integration architecture spanning three equipment suppliers
- Washdown-rated control enclosures and cabling to food-plant standard
- Traceability hooks from line PLCs into the site's batch system
- Safety circuit design validated against the site's existing zones
- Commissioning done overnight so day production never stopped
MEASURED RESULTS
3→1
Supplier systems unified under one HMI
0
Hours of daytime production lost
6 wks
From equipment arrival to full-rate run
Proof on file
- Integration acceptance test signed by all three suppliers
- Hygiene and safety audit passed at first inspection
- Batch-traceability test report from the client's QA team
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