APEX INDUSTRIES
OEM
OUR KNOWLEDGE AND EXPERIENCE
We have worked with many machine builders in our 20+ years in business. We serve as a partner throughout the project based on our deep expertise in a variety of projects. Our team will work from kickoff to signoff to make sure it’s successful.
CASE STUDY
A local machine builder won a project for a car frame assembly line. The line needed to be completely automated, with 50+ robots assembling and welding different components together. The customer specifications included non-standard hardware.
We worked with the machine builder to scope and design the controls for the assembly line. Our engineers became the experts on the non-standard hardware and successfully integrated the components.
The assembly line now lives at the customer’s plant, producing high-quality car frames at the expected cycle time. The operator-friendly interfaces, clear fault messaging, and extensive diagnostics we designed ensure high line uptime.
APEX INDUSTRIES
Food and Beverage
OUR KNOWLEDGE AND EXPERIENCE
The food and beverage industry requires automation with a focus on quality, reliability and repeatability. We work with various manufacturers throughout the production process from batching, processing and packaging to casing, conveying and pallletizing. We deliver innovative solutions to processes that result in better uptime and higher-quality products.
CASE STUDY
A food manufacturer was installing a new line to make breadcrumbs. The customer purchased several new mechanical systems without electrical components to deliver bulk ingredients to a dough mixer.
We worked with the customer and equipment suppliers to integrate a variety of mechanical components and design a single control system. We fabricated the electrical panels, field-wired the system, and programmed it to the customer’s specifications to deliver a turnkey solution.
- The customer now has one seamless system to deliver all the bulk ingredients to their breadcrumb dough mixer. Operators, maintenance personnel, and engineers can easily control the system using our intuitive design and interface.
SUCCESS STORY
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APEX INDUSTRIES
high-volume panel build
OUR KNOWLEDGE AND EXPERIENCE
We have become a trusted source for high-volume panel builds with quality workmanship. Our skilled electricians, inventory management, and debugging and startup capabilities produce turnkey panels that only require the customer to them plug in.
CASE STUDY
An AGV manufacturer asked us to complete high-volume panel builds because they did not have the internal capacity to fulfill their orders. The engineering design was complete, and they needed us to build and ship the panels to their customer.
We handled everything from ordering materials to shipping the completed panels on time to the customer. We built, tested and validated each of the panels so they were turnkey when they arrived at the customer’s facility.
Since the initial order, the AGV manufacturer placed several additional orders with us because the customer continues to grow and sell more products.
APEX INDUSTRIES
electrical installation
OUR KNOWLEDGE AND EXPERIENCE
Our skilled electricians can fulfill a wide range of electrical tasks for machines or plants. We can provide complex cable runs, machine wiring, and terminating control panels. The end product will be visually appealing and functionally correct.
CASE STUDY
A Japanese company completed the factory acceptance test of their machines that were installed in a manufacturer in Michigan. The size and complexity of the project required a team of electricians to be on the road for months to re-terminate the electrical.
We worked with the Japanese company to provide the electricians to wire the machines. We worked with the company to read the prints, understand the complexity of the machines, and ultimately power up the machines. We also went online with the machines and assisted in the IO check and basic debugging so the Japanese company’s electricians and engineers were able to spend minimum time on the road.
The end customer now has functioning machines in their plant with quality electrical craftsmanship. Additionally, they have peace of mind that we understand their new equipment and can debug or troubleshoot it without someone flying to Michigan from Japan.
APEX INDUSTRIES
Material Handling
OUR KNOWLEDGE AND EXPERIENCE
Material handling requires quick and accurate automated solutions for each step of a product’s path to achieve optimal workflow. By thoroughly analyzing how materials move through processes, our engineers improve throughput and minimize waste.
CASE STUDY
A palletizing robotic cell could not keep up with the line feeding it. The conveyance system would often be full, causing long and difficult line stoppages because of the complexity of the upstream processes. The customer decided to run the line at 90% capacity to avoid bottlenecks and keep everything running.
We analyzed the system and discovered the problem in the conveyance system, not the robotic cell. We also determined the optimal material path required an additional conveyor system in the robotic cell. We scoped, integrated and executed the project, providing a turnkey solution for the customer.
The upgraded line keeps pace with the upstream processes and can handle the line running at 110%. This margin stopped the line from backing up and brought higher throughput.
SUCCESS STORY
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APEX INDUSTRIES
Automotive
OUR KNOWLEDGE AND EXPERIENCE
We have solved production challenges for automotive manufacturers and their suppliers for 30+ years. Our expertise yields machines and processes that deliver high-quality parts under cycle time. Our emphasis on operator safety impacts every aspect of our engineering process so people go home to their families safely at the end of each day.
case study
- A tier-1 automotive supplier won the production of a complex part and sourced an OEM that Apex has partnered with to build the machine. Cycle time requirements were very difficult, machine uptime was a priority, the process included difficult robotic welds, & operator interaction was required at different points.
- Apex & the OEM worked with these contrasting requirements to develop a methodical & thorough design, with great emphasis on operator safety. The design included the latest safety-rated hardware to ensure reliability, safety zone partitioning which removes hazards only from the zone of a safety breach, and robot safety that allows the operator to interact with the robotic station in a safe & controlled manner.
- The machine was successfully installed and has been running parts at cycle time. The methodical & thorough process of safety design has paid dividends as no operator safety incidents have occurred.
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SUCCESS STORY
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APEX INDUSTRIES
FURNITURE
OUR KNOWLEDGE AND EXPERIENCE
The furniture manufacturing industry provides different complexities due to the aesthetic nature of the products. We are a leader in this industry because of our years of expertise in automation and robotics. Our engineers work with multidisciplinary teams to ensure products meet specifications.
case study
A furniture manufacturer had a 12-station forming line with hardware at the end of its lifecycle. The outdated programming on the machine forced operators to clear out every station whenever they applied power. Poor fault messaging, undocumented changes, and unlabeled cables and wires significantly prolonged maintenance downtime.
We worked with the manufacturer to meet their production and equipment needs simultaneously. We replaced all the machine’s hardware with current models, including the safety equipment. We split the upgrade into several weekend installations, with the machine running production each Monday morning.
Since the upgrade, the total throughput of the machine increased while the scrap material decreased. The operators no longer need to empty the machine every time they apply power. Additionally, robust fault messaging, updated documentation, and correctly labeled cables reduce downtime significantly.
SUCCESS STORY
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APEX INDUSTRIES
Pharmaceutical / medical
OUR KNOWLEDGE AND EXPERIENCE
Finding a partner that understands the complex regulatory environment of medical device assembly is critical because it has a meaningful impact on people’s health and wellness. Our engineers collaborate with regulatory teams to meet documentation and validation requirements and partner with leading third-party validation companies to provide fully validated equipment.
case study
We partnered with a machine builder on an inspection machine for non-industry standard RFID chips. The frequency of the chips required particular readers that were not built for automation.
Working with the reader manufacturer and the machine builder, we developed a software package to transpose the jumbled RFID information into meaningful data that the inspection machine and the operators could understand.
The customer no longer must manually scan each RFID chip and sort it based on the tag information. Now they can place hundreds of chips in the machine at one time and wait for the filled packages of verified chips to come out. The machine is doing this redundant and monotonous task with higher throughput than the manual process.
SUCCESS STORY
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APEX INDUSTRIES
Manufacturing
OUR KNOWLEDGE AND EXPERIENCE
We have worked in the manufacturing and automation industry for 30+ years. We have a wide range of experience that includes concept projects, working with third parties to deliver high-quality machines, and integrating components into existing manufacturing processes. We can assist with any manufacturing need.
case study
A customer asked us to implement the PLC end of a data tracking system to get better analysis of two packaging lines, each with multiple branches, totaling 80+ PLCs between the two lines. The customer had existing data tracking at a machine or PLC level, but no data to track the performance of the entire system.
We performed research at a machine and system level and determined how to categorize, store, and display data for the system. We also learned how each machine contributed to the system and developed analytics for the 80+ PLCs to give the customer data to make informed decisions about the plant.
Our customer is now able to view historical data for the lines in an easy-to-understand graphical display. They can monitor this data for the entire system, with each piece of equipment showing its status in addition to the specific faults. The new data has given the customer the information they need to understand and optimize their system.
SUCCESS STORY
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APEX INDUSTRIES
Battery
OUR KNOWLEDGE AND EXPERIENCE
We have many years of engineering experience with battery and energy storage applications. Battery and energy storage automation involves integrating robotics into strategic areas to save time, increase capacity, and protect employees from dangerous conditions and repetitive tasks. Our engineers work with customers to design the best solution using the latest technology.
case study
A battery core wrapping machine was dropping the cores in the middle of the cycle. Each time a part dropped, the operator would stop the machine, pick up the spilled pieces, and manually reset the machine. The operators were unhappy, many parts were being wasted, and machine downtime was high.
We analyzed the machine’s process and discovered the flaw that caused the cores to drop. Although the components were atypical, we restructured the machine sequence to eliminate the possibility of dropped parts.
Since implementation, the cores have not dropped in the middle of the machine’s cycle. The operators are satisfied, and the machine’s downtime is significantly lower.
SUCCESS STORY
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APEX INDUSTRIES
Building Materials
OUR KNOWLEDGE AND EXPERIENCE
Building and construction materials must be precise and accurate. We provide thoughtful solutions by understanding our customers’ goals and how we can partner with and empower them. We build everything we make so customers know their solution is as unique as the problems they bring to us.
case study
A local steel truss manufacturing company needed custom software to streamline their processes and remove redundant and repetitive work for their employees in both the office and shop.
We worked with the customer to determine their goals and how we could create software to assist them. We worked to develop a suite of business management applications to manage projects through the entire sales lifecycle, from the moment a lead is generated to the implementation of the trusses.
The applications we developed gather data at critical stages in the project lifecycle to give the customer greater visibility to growth opportunities. Each update to our software has resulted in clear efficiency gains and positive feedback from users.
SUCCESS STORY
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APEX INDUSTRIES
Self-Care Products
OUR KNOWLEDGE AND EXPERIENCE
Manufacturing self-care products needs to be done with an extreme emphasis on process uptime. With experience in a variety of industries, Apex provides customers fresh insight & perspectives into their processes throughout the entire project lifecycle. Our goal is to maximize efficiency through maximizing machine uptime & minmizing downtime.
- An international self-care product manufacturer contacted Apex to update their existing floss lines. At that time, every day started with 2 hours of downtime to heat raw materials to correct temperatures. The temperature control was individual to each piece of equipment which required operators to monitor several pieces of equipment simultaneously & manually intervene in the manufacturing process if necessary.
- While the scope was to update the line with new hardware, Apex took a fresh look at the process, suggesting then later implementing a variety of improvements. The temperature control was consolidated into a single controller so operators only monitor the machine & not each component. The process of starting heaters & maintaining temperature throughout the day was automated so the line was ready to run with the day started. Trends, data screens, & analytics were added to the process to give the business a better understanding of machine downtime. In addition to this, safety was upgraded to the latest industry standard, ensuring that hazards were safely removed.
- The upgrade fulfilled the desire for up-to-date hardware that will be supported for many years. Additionally, they received process improvements that resulted in more machine uptime & a lighter load on operators. After running production for a short time, Apex was awarded the upgrade on their second line to implement the same improvements.
SUCCESS STORY
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