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Engineering Portfolio

Projects engineered for production

Real machine retrofits, automation systems and plant technologies—shown through the challenge, engineering work and practical result.

CNC & Machine Retrofit

Before and after views of a VMC CNC control retrofit
Replacement CNC control panel
New control panel
Servo and spindle drives installed for the retrofit
Drive installation

VMC Retrofit

VMC control and drive retrofit

Industry
Auto components manufacturing
Machine / System
Vertical machining centre
Scope
CNC control, servo axes, spindle drive, ATC logic, electrical integration and accuracy trials.

The Challenge

An obsolete CNC and unreliable drives were causing repeated stoppages, while replacement spares were difficult to source.

Our Solution

Mektronix replaced the CNC, axis servos and spindle drive, rebuilt the ATC logic and recommissioned the complete machine.

Technology / System

  • CNC control & HMI
  • AC servo drives
  • Spindle drive
  • ATC PLC logic

Project Execution

  1. Survey
  2. Engineering
  3. Installation
  4. Programming
  5. Testing
  6. Commissioning

Result

The machine returned to production with restored positioning accuracy and locally available spares.

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Engineer working on a conventional lathe CNC conversion
CNC conversion control equipment
Control integration
Old and modernized operator controls
Before / after

CNC Conversion

Conventional lathe converted to CNC

Industry
General engineering
Machine / System
Conventional centre lathe
Scope
Mechanical conversion coordination, CNC integration, axis drives, operator controls and safety validation.

The Challenge

Manual operation limited repeatability and made batch components dependent on operator skill.

Our Solution

The lathe was converted with ballscrews, a modern CNC, servo axes, MPG, electrical panel and a new safety circuit.

Technology / System

  • 2-axis CNC
  • Servo motors
  • MPG pendant
  • Safety relays

Project Execution

  1. Survey
  2. Mechanical planning
  3. Panel build
  4. Programming
  5. Trials
  6. Handover

Result

The converted machine now delivers repeatable batch turning with simpler setup and safer operation.

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Industrial Automation

Automated special purpose machine in a manufacturing cell
SPM automation panel
Control panel
Industrial communications used in the automation cell
Plant connectivity

SPM Automation

Special purpose machine automation

Industry
Automotive assembly
Machine / System
Pneumatic assembly and inspection station
Scope
Control philosophy, panel engineering, PLC/HMI software, field wiring, trials and operator training.

The Challenge

Manual sequencing caused inconsistent cycle times and defects could pass without reliable poka-yoke checks.

Our Solution

Mektronix engineered the PLC sequence, HMI screens, sensing logic, pneumatic controls and production counters.

Technology / System

  • PLC
  • HMI
  • Pneumatics
  • Poka-yoke sensors
  • Cycle counters

Project Execution

  1. Process study
  2. Engineering
  3. Panel build
  4. Programming
  5. Machine trials
  6. Commissioning

Result

The station achieved consistent cycle time, guided operation and traceable rejection counts.

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PLC & Control Systems

PLC and SCADA system used for a control migration
New PLC hardware for migration
PLC hardware
Industrial network equipment
Network integration

PLC Migration

Legacy PLC and SCADA migration

Industry
Process manufacturing
Machine / System
Plant utility and process control system
Scope
I/O audit, program recovery, PLC migration, HMI/SCADA development, documentation and live cutover.

The Challenge

An undocumented, unsupported PLC created a high breakdown risk and prevented the maintenance team from making changes.

Our Solution

The old program was reverse-engineered, rebuilt on a supported PLC and connected to new operator and supervisory screens.

Technology / System

  • Modular PLC
  • HMI
  • SCADA
  • Industrial Ethernet
  • VFD communication

Project Execution

  1. I/O survey
  2. Logic study
  3. Offline engineering
  4. Panel retrofit
  5. Cutover
  6. Documentation

Result

Obsolescence risk was removed and the maintenance team gained a documented, serviceable control system.

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Digital / Software Solutions

Production monitoring dashboard showing manufacturing data
Mobile production monitoring application
Mobile view
Industrial networking for machine data collection
Machine network

Production Monitoring

Production monitoring dashboard & app

Industry
Packaging production
Machine / System
Multi-line plant monitoring system
Scope
PLC data collection, network architecture, dashboard development, mobile views and user training.

The Challenge

Production and downtime information was collected manually and reached supervisors too late for corrective action.

Our Solution

Machine signals were connected to a web dashboard and mobile view with shift output, downtime reasons and live status.

Technology / System

  • PLC data gateway
  • Industrial Ethernet
  • Web dashboard
  • Mobile application

Project Execution

  1. Data study
  2. Network setup
  3. Development
  4. Machine connection
  5. Validation
  6. Rollout

Result

Supervisors can now see output and downtime causes during the shift instead of waiting for month-end reports.

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Solar & Energy

Industrial rooftop solar project at a manufacturing plant
Solar monitoring and protection equipment
Protection & metering
Remote energy monitoring display
Remote monitoring

Solar & Energy

Industrial rooftop solar plant

Industry
Manufacturing facility
Machine / System
Grid-connected rooftop generation system
Scope
Shadow study, structure design, electrical engineering, approvals, installation and monitoring.

The Challenge

High daytime energy demand was increasing operating cost, with no plant-level visibility of generation performance.

Our Solution

Mektronix completed system design, inverter selection, protection, net-metering documentation and remote monitoring integration.

Technology / System

  • PV modules
  • String inverters
  • AC/DC protection
  • Energy monitoring

Project Execution

  1. Site survey
  2. Design
  3. Approvals
  4. Installation
  5. Testing
  6. Grid synchronization

Result

The facility reduced grid consumption and gained clear remote visibility of daily energy generation.

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