Automated Industrial Solutions - Honolulu, Hawaii

Automated Industrial Solutions

Precision Engineering for Hawaii's Industrial Future

Honolulu, Hawaii

What is Industrial Automation?

Industrial automation is the backbone of modern civilization—not just a tool for manufacturing, but the invisible force that powers our everyday lives. Sophisticated control systems manage everything from wastewater treatment plants and energy grids to manufacturing lines and critical infrastructure. They optimize processes, ensure safety, reduce waste, and keep essential services running 24/7/365—often without anyone noticing until something goes wrong.

In Hawaii, where infrastructure resilience and efficiency are paramount, industrial automation isn't just about productivity. It's about reliability, sustainability, and ensuring our island communities have the resources they need, when they need them.

How We Help

Consulting

Strategic guidance on automation projects, from feasibility studies to technology selection. We help you make informed decisions that align with your operational goals and budget.

Planning

Detailed project planning and system design tailored to your facility's unique requirements. We work with you to create roadmaps that minimize downtime and maximize ROI.

Programming

Expert PLC and HMI programming for new installations or legacy system upgrades. We speak the language of Rockwell, Siemens, and other major platforms.

Commissioning

Thorough testing and startup services to ensure your systems run flawlessly from day one. We validate performance and train your team for long-term success.

Support

Rapid troubleshooting and emergency response when systems fail. With 14 years of field experience, we diagnose problems fast and implement lasting solutions.

Training

Comprehensive operator and technician training programs. We empower your team to maintain, troubleshoot, and optimize their automation systems with confidence.

Proven Results Across Industries

Real problems. Real solutions. Real impact.

With over 200 unique sites and clients served, here are some of the highlights.

Tesla tray line
Manufacturing

Tesla Manufacturing

The Challenge: A single bottleneck was throttling the entire tray line's performance, creating downstream delays and limiting production capacity.

The Approach: Rather than recommending expensive hardware upgrades, the cell's reload sequence logic and motion profile was analyzed and optimized.

The Outcome:

Cut cycle time from 60 seconds to 30—a 50% speed increase across the entire line with zero capital expenditure. Pure software optimization delivered massive throughput gains.

Electronics Manufacturing

Military-Grade PCB Chemical Coating Line

The Challenge: Chemical dip line could only process one basket at a time due to gantry timing limitations and unreliable sensor feedback, severely constraining throughput.

The Approach: Redesigned the gantry motion sequencing to allow concurrent basket operations and diagnosed/replaced problematic sensors that were causing false faults.

The Outcome:

Enabled three baskets to run simultaneously—tripling throughput overnight with no additional equipment investment. Turned a major production constraint into a competitive advantage.

PCB coating line
Flying cutoff saw system
Manufacturing Recovery

Louisiana Pacific – Post-Hurricane Recovery

The Challenge: Floodwaters destroyed six PLCs throughout the facility. Most critically, the high-speed flying cutoff saw required complete logic reconstruction to track a moving encoder instead of its previous stationary configuration.

The Approach: Rewrote control logic for all six PLCs, including complex coordinate translation for the flying saw. Translated motion profiles, rewrote positioning algorithms, and prepared for first-shot startup.

The Outcome:

Systems started successfully on the first attempt. The new moving-encoder configuration delivered dramatically tighter tolerances and major reductions in scrap material—turning disaster recovery into a performance upgrade.

Process Industries

Paper Mill Turnaround

The Challenge: During a critical planned shutdown, a malfunctioning 4-20 mA analog loop threatened to derail the entire retrofit schedule. Plant personnel suspected the new field equipment.

The Approach: Systematically traced the signal path and performed voltage/current measurements to isolate the fault. Proved the issue originated in the existing plant DCS, not the new equipment.

The Outcome:

Corrected the DCS configuration issue and kept the entire retrofit on schedule. Turned a skeptical plant manager into a believer through methodical troubleshooting and clear communication.

Paper mill control panel
Wastewater pump station VFDs
Wastewater Infrastructure

Wastewater Pump Station VFD Failures

The Challenge: Four 100 HP variable frequency drives had catastrophically failed within one year at a critical wastewater pumping station—each costing $60K. The pattern suggested a systemic problem.

The Approach: Performed detailed electrical inspection beyond just the VFDs themselves. Used systematic tug testing on all control wiring terminations to find loose connections.

The Outcome:

One loose 120 VAC control wire was the culprit. One tightened terminal ended the failure cycle—zero failures since. Saved the utility from ongoing replacement costs and restored critical infrastructure reliability.

Automotive Manufacturing

Tier 2 Automotive Supllier Stamping

The Challenge: Building-sized press producing Ford bumper frames had been down for five days. Multiple technicians had attempted fixes. Production losses were mounting by the hour.

The Approach: Took time to understand the full backstory and sequence of events. Investigated the VFD's human interface module and discovered intact parameter backups that had been overlooked.

The Outcome:

Restored the backed-up VFD parameters and had the line stamping ten parts per cycle again in under fifteen minutes. The plant manager's reaction? He cheered like his team just won the Super Bowl.

Automotive stamping press
Industrial crane system
Heavy Industry

Greif Paper Mill – Woodyard Crane

The Challenge: After a complete drive and control system rebuild, a 30-ton crane was stopping randomly mid-swing due to wireless communications dropouts—creating serious safety and productivity concerns.

The Approach: Investigated RF interference sources throughout the facility. Identified that an onsite truck loading camera system was operating on conflicting frequency bands.

The Outcome:

Changed wireless frequency bands to eliminate interference—completely solving the dropout issue. What started as an emergency call-out transformed into "you're our guy" status, leading to additional service calls for other systems.

Waste Management

Atlantic Waste Management

The Challenge: New landfill leachate water treatment plant required complete commissioning of sludge loading pumps and jet aeration blowers—critical systems for environmental compliance.

The Approach: Comprehensive commissioning including control system validation, equipment performance testing, and operator training on the new systems.

The Outcome:

Successfully commissioned all systems, bringing the new treatment plant online and enabling the facility to meet strict environmental regulations.

Water treatment facility
Entertainment & Safety

Kings Dominion – Delirium Ride

The Challenge: A faulty VFD in a twin, torque-control, load-sharing configuration left the massive pendulum ride inoperable. With thousands of park visitors daily, downtime meant potential revenue loss and disappointed guests.

The Approach: Thorough investigation revealed manufacturer defects in power control sensing circuits that required complete VFD replacement. Initiated a warranty claim with the distributor for rapid replacement delivery.

The Outcome:

Reinstalled, rewired, and recommissioned the drive system. The ride was safely returned to service with full functionality and load-sharing capability restored.

Let's Solve Your Challenge

Whether you're facing an emergency shutdown or planning your next automation project, let's discuss how we can help optimize your operations.