A manufacturing organization undergoing expansion faced significant operational inefficiencies due to outdated production processes and limited automation capability. Manual workflows, inconsistent process control, and equipment-related variability were preventing the facility from reaching targeted throughput levels and increasing productivity demands. The internal engineering team lacked specialized automation and controls expertise required to design and integrate a modernized process control system capable of improving performance and supporting scalable growth. The absence of automated process visibility also created challenges in maintaining quality consistency and responding quickly to production deviations. Delayed upgrade execution threatened production schedules, increased operational costs, and limited the company’s ability to capitalize on rising market demand. Leadership sought an experienced partner capable of delivering end-to-end engineering and automation support, overseeing system integration from design through commissioning, and ensuring full operational readiness with minimal downtime.
Fusion was selected to lead the automation system implementation due to our specialized engineering capability, process optimization expertise, and proven ability to support complex manufacturing transformation initiatives. We deployed a cross-functional team including controls engineers, PLC/SCADA specialists, process engineers, and commissioning support personnel. Fusion partnered closely with production, maintenance, and operations teams to define technical requirements, evaluate system architecture, and establish performance goals. Our engagement included responsibility for engineering design, programming, configuration, testing, and commissioning activities as well as knowledge transfer to internal teams to ensure sustainable long-term operation. Fusion’s collaborative and structured execution model allowed the organization to modernize production infrastructure without interrupting ongoing operations.
Fusion developed a comprehensive automation implementation plan aligned to production priorities and operational constraints. We evaluated existing equipment and workflow design, identified automation opportunities, and configured a process control solution designed to increase output reliability and reduce variability. Our engineering team designed PLC logic, developed SCADA interface screens, defined control sequences, validated system responses, and performed staged testing to confirm performance accuracy. Full integration was executed with minimal downtime, utilizing phased installation windows to protect production continuity. Fusion provided on-site commissioning and troubleshooting support and delivered training sessions to enable smooth handover and internal capability development. The project emphasized measurable throughput improvement, quality stabilization, and reduction of manual interventions. Fusion’s team remained engaged through post-launch stabilization to ensure consistent performance and rapid issue resolution.
Result & Measurable Impact
The upgraded system now supports scalable production growth.
We provide capability, problem-solving, and services — with speed and cost-efficiency at the core
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