Delivered Solutions
We design and deliver customized industrial automation solutions that combine innovation, reliability, and compliance. Each project reflects our commitment to solving real-world challenges through robotics, vision systems, IIoT, and smart control, helping industries achieve higher efficiency, accuracy, and traceability.
Multi Point Visual Inspection With Robot
Designed and deployed a robotic inspection system for engine cylinder heads with an integrated conveyor and cabin-based fixture. The system inspects 14 critical points using a COGNEX vision camera and evaluates pass/fail conditions. Passed parts move forward for further processing, while failed parts are automatically diverted to a rework station through a 90° fixture rotation. Control and automation were implemented using Mitsubishi PLC, HMI, and Robot, ensuring high accuracy, repeatability, and reduced manual inspection efforts.
ELIGHT – Next-Generation OEE Monitoring & Reporting Software
ELIGHT redefines OEE monitoring by offering a cutting-edge digital solution designed for the modern factory floor. ELIGHT leverages intelligent software architecture and flexible integration capabilities to provide unparalleled visibility and control. Our focus is on empowering decision-makers with actionable insights derived from real-time data, minimizing the complexities typically associated with industrial monitoring.
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Real-time Visibility
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Minimal Hardware Dependency
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Customizable Dashboards
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User-Centric Design
Pick-to-Light Poka-Yoke Station
Pick-to-Light Poka-Yoke Station with ELIGHT Integration
Developed a Pick-to-Light Poka-Yoke assembly station integrated with ELIGHT software and a mechanical assembly station to ensure full proof operations. The system guides operators with illuminated indicators for correct part selection and sequence, eliminating errors in the assembly process.
To enable part traceability, the station is equipped with a barcode scanner and serialization system, ensuring every assembled part is uniquely identified and tracked throughout the process. ELIGHT software provides real-time monitoring, error logs, production analytics, and performance reports, helping achieve error-free assembly, improved process accountability, and compliance with quality standards.
Sticker Labeling Machine Upgradation with 21 CFR Part 11 Compliance
Executed a complete automation upgradation of a sticker labeling machine to meet stringent 21 CFR Part 11 compliance requirements. The project included full programming of PLC, servo drives, printing head, and peripheral devices to ensure seamless and precise labeling operations.
Integrated the machine with the ELIGHT Smart Vision System for advanced inspection, covering Pharmacode verification, OCR (Optical Character Recognition), and OCV (Optical Character Verification) to maintain high standards of quality assurance.
The solution is fully compliant with 21 CFR Part 11, ensuring secure electronic records, audit trails, and user authentication. Additionally, the system generates batch reports as per compliance standards, providing traceability, reliability, and regulatory adherence for pharmaceutical operations.
Portable Powder Bed Fusion Metal 3D Printer
Developed for the Raja Ramanna Centre for Advanced Technology (RRCAT), this indigenous machine represents a significant step in accessible, localized metal additive manufacturing. Designed as a highly compact and portable system, the printer utilizes Powder Bed Fusion (PBF) technology to fabricate complex, high-precision metal parts layer by layer. The system is housed in a robust, self-contained, and mobile unit, making it an excellent tool for research, prototyping, and specialized manufacturing within the AIC pi-Hub ecosystem.
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Laser & Optical System: At the heart of the printing process is a 150-watt Class IV Yb-Doped Fibre Laser. This powerful laser is paired with a highly accurate Galvo Scanner, allowing for rapid and precise steering of the laser beam across the powder bed to melt and fuse the metal powder into the desired geometry.
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Motion Control & Automation: To ensure the microscopic precision required for metal 3D printing, the mechanical operations—including the recoater (spreader) mechanism, hopper plate indexing, and build plate adjustments—are driven by industrial-grade Mitsubishi PLC and Servo systems. This guarantees reliable, repeatable, and smooth operation during the layer-by-layer material deposition.
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Centralized Control Software: The complete operation of the machine is governed by the Elight SCADA software. Acting as the main brain and Human-Machine Interface (HMI), Elight SCADA provides operators with an intuitive touch-screen dashboard to monitor real-time parameters (like hopper/build plate position and laser status), execute prints, and manage safety overrides.
Significance and Operation
As an "Indigenously Developed DAE Technology," this printer simplifies the typically massive footprint of industrial metal 3D printers into a versatile, portable workstation. As seen in the operational demonstration, the system flawlessly orchestrates the spreading of a fine metal powder layer followed by the high-intensity laser melting process, allowing for the creation of everything from structural prototypes to finely detailed custom engravings.
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Automated Electro Plating Line
Our fully automated, 20-meter Hard Chrome Plating Line is a complete Special Purpose Machine (SPM) engineered to deliver high-precision surface finishing while strictly protecting operators from hazardous fumes.
Key Features & Capabilities:
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100% In-House Mechanical Design: The entire mechanical framework of this massive system was custom-designed and developed from the ground up at our own facilities.
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Precision Robotics on a 20m LM Rail: Two tailored robotic gantries travel along a continuous 20-meter single LM (Linear Motion) rail structure. Driven by Mitsubishi PLCs and Servo motors, they guarantee pinpoint positional accuracy during rapid transfers.
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Complete 13-Station Process: An end-to-end automated cycle handling everything from rigorous part cleaning and reverse etching to the final chrome deposition.
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High-Capacity Power: Equipped with 8 high-amperage DC rectifiers (600–1000 Amps) to ensure superior, high-adherence plating.
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Centralized Control & Built-in Safety: Governed by our intuitive Elight SCADA software, the system completely automates the dipping and transferring process. This eliminates manual handling, maximizes efficiency, and isolates workers from dangerous hard chrome fumes.
Proven Industrial Success We have successfully installed and commissioned two of these comprehensive plating lines for Avirat Techno & Sahaya Pvt. Ltd. at their Dewas Plant, providing a highly reliable and safe production environment.
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PI SCAN: The Ultimate Edge Device for Industrial Traceability & Control
The PI SCAN is a fully customized, standalone edge-computing device engineered to deliver flawless child part traceability across machine shops and dynamic assembly lines. Powered by our Elight software, PI SCAN acts as the central nervous system for your local stations, ensuring every component is tracked, verified, and recorded with absolute precision.
Designed with flexibility at its core, PI SCAN bridges the gap between the shop floor and top-floor management, offering limitless customization to meet your exact operational demands.
Core Capabilities & Hardware-
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Standalone Intelligence: Operates independently with its own robust hardware architecture and local SQL database at each station, ensuring zero data loss and high-speed processing without relying entirely on network stability.
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Versatile I/O Control: Comes equipped with built-in 8 Digital Inputs/Outputs and 2 Analog Inputs, allowing for direct, low-latency control of local machine mechanisms and sensors.
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Universal Hardware Integration: PI SCAN serves as a universal translator on the shop floor. It simultaneously communicates with and drives data from a vast array of devices, including:
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Various PLC brands and protocols
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Advanced Camera & Machine Vision Systems
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1D/2D Barcode and ID Scanners
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RFID Readers
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Precision Measurement Gauges
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Enterprise-Ready Connectivity While highly capable at the edge, PI SCAN is built to scale. It seamlessly pushes real-time production and traceability data upwards, integrating effortlessly with:
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Main Plant Servers and Web-level Cloud Servers
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Ignition SCADA platforms
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Enterprise MES (Manufacturing Execution Systems)
Value-Added Features-
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Digital Daily Maintenance: Moving beyond just traceability, PI SCAN incorporates an integrated Daily Maintenance Check Sheet, ensuring operators complete critical pre-flight checks before production begins, reducing downtime and tool wear.
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Future-Proof Customization: No two manufacturing floors are exactly alike. PI SCAN's flexible architecture allows for deep, ongoing customization to adapt to new hardware, changing customer requirements, and expanding production lines.
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