FERSMEK
Modern industrial control room with process monitoring displays

Portfolio

300+ Projects. Every One Custom-Engineered.

A selection of representative projects across our five engineering disciplines and six industry verticals.

Projects shown are illustrative of typical engagements. Contact us for specific project references.

Error-Proofing Station Rollout — 100+ Stations, Automotive Assembly
Automotive

Error-Proofing Station Rollout — 100+ Stations, Automotive Assembly

Machine VisionPLC ProgrammingMES Integration

FERSMEK's assembly verification system is now deployed across more than 100 stations on car manufacturing lines. Each station integrates industrial cameras, barcode readers, part-presence sensors, and tightening tools (nut runners) with PLC logic — implemented across Siemens, Rockwell, Mitsubishi, and Omron platforms — to enforce correct assembly sequence and prevent fixture release on any error condition. Illustrative — customer name withheld.

Outcome
Over 100 error-proofing stations deployed across car manufacturing lines. Assembly defect escape rate reduced by 94% within the first 3 months of initial rollout.
NYTTI AGV Fleet — Heavy Pallet Logistics Deployment
Material Handling

NYTTI AGV Fleet — Heavy Pallet Logistics Deployment

AGVWMS IntegrationRobotics

FERSMEK commissioned a NYTTI AGV fleet to replace manual forklift transport of heavy pallets from production lines to multiple storage areas. The system uses Fleet Control with web-based dispatch on mobile devices, WMS integration for automated work-request generation, and ceiling-mounted CC cameras as active zone sensors. Illustrative — customer name withheld.

Outcome
Autonomous heavy-pallet transport between production lines and storage areas. Fleet Control System with mobile-accessible web UI. CC cameras used as intelligent zone sensors.
Automotive Seat Assembly Line Automation
Automotive

Automotive Seat Assembly Line Automation

PLC/SCADARoboticsMechanical

Flexible robot cell with Universal Robots UR10e, vision-guided part placement, and Siemens S7-1500 PLC control for 3 model variants without production stoppage.

Outcome
Cycle time reduced by 28%, zero rework rate at commissioning
Paper Reel AGV Logistics System
Pulp & Paper

Paper Reel AGV Logistics System

AGVWMS IntegrationMechanical

NYTTI AGV fleet with FERSMEK WMS/RCS integration, Siemens S7 PLC, and ERP connection via OPC-UA.

Outcome
3 NYTTI AGVs replacing 6 FTE forklift operators. 99.6% system uptime over first 12 months.
PCB Vision Inspection System
Electronics

PCB Vision Inspection System

Vision SystemsE&I

Cognex In-Sight vision system for solder joint inspection and component polarity verification. Inline conveyor integration with automatic reject handling.

Outcome
Defect detection accuracy >99.8% at full production throughput. Manual inspection eliminated.
Pharmaceutical Tablet Press Control System
Medical & Pharmaceutical

Pharmaceutical Tablet Press Control System

PLC/SCADAE&I

Rockwell ControlLogix PLC with FactoryTalk View SE SCADA, 21 CFR Part 11 compliant audit trail, and full validation documentation package.

Outcome
IQ/OQ/PQ validated. Zero regulatory findings on first TDGA audit.
Food Packaging Line Hygienic Conveyor System
Food & Beverage

Food Packaging Line Hygienic Conveyor System

MechanicalPneumaticPLC/SCADA

Stainless-steel conveyor designed for IP69K washdown. Festo pneumatic accumulation gates, OEE monitoring via Ignition SCADA, and automatic format changeover.

Outcome
IP69K certified. Line running at 120 packs/min. OEE improved from 71% to 86%.
Electronics ASRS Installation — Cappsel
Electronics

Electronics ASRS Installation — Cappsel

Material HandlingWMS Integration

Cappsel vertical carousel with pick-to-light, ERPNext integration for automatic replenishment, and full audit trail for component traceability.

Outcome
9,000 SKU Cappsel system in 4m². Pick accuracy 99.97%. Inventory carrying cost reduced 23%.

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