Manufacturing moves fast. Systems age. Processes break. And what worked ten years ago doesn’t work today.
At Flexware Innovation, our Automation Team works inside manufacturing environments every day, which means we see these challenges as they unfold. That vantage point gives us a clear view of where operations typically get stuck and what it takes to move them forward.
That’s why, rather than simply focusing on installing new hardware or writing code, we partner with manufacturers to modernize operations, connect the shop floor to the top floor, and keep production running smarter, safer, and stronger.
Here’s a look at the methodology behind our work, and how it drives meaningful change.
We Start with the Right Mindset: Problem Solvers First
Our team thrives on complex problems. Whether it’s a legacy control system nobody has documentation for, a production line that needs real-time data integration, or a safety system that’s no longer compliant, we don’t shy away from the tough stuff.
We have engineers with backgrounds in manufacturing, integration, the military, and field service. That real-world experience matters. It means when a project gets messy — and they often do — we know how to adapt, adjust, and deliver.
At the end of the day, we like making things work better. And we take pride in solving problems the right way, not the easy way.
We Offer Comprehensive Services
Our automation services cover a lot of ground. Here are some of the things we work on every day:
- Legacy Upgrades: Replacing outdated PLCs, SCADA systems, and safety controls with modern, supportable solutions
- Shop Floor to Top Floor Integration: Pulling machine data up into MES and ERP systems so management can make better, faster decisions
- OEE and Real-Time Data Visibility: Building systems that track performance metrics and give operators and leadership actionable insights
- Safety System Assessments and Remediation: Identifying risks and designing safer, compliant processes to protect workers
- Troubleshooting and Maintenance Support: Helping customers diagnose, debug, and fix issues that cause downtime
- Control Panel Build and Design: Designing and building UL Certified control panels tailored to each customer’s needs, with a focus on reliability, clean design, and long-term maintainability
- Automation Layer Assessment: Providing a deep dive into your existing control systems, infrastructure, and communication protocols to uncover inefficiencies, identify risks, and map out a clear modernization plan
We’re not locked into one brand or one way of doing things either. We work across platforms, Allen-Bradley, Mitsubishi, Banner, Ignition, you name it. Because the goal isn’t to push products. It’s to solve the problem with the best-fit solution.
We Ensure Our Projects Have Real Impact
Our work is focused on delivering measurable and lasting improvements. Here are a few examples of what that looks like in practice.
- Food Production Plant Modernization: We planned and executed a phased legacy system upgrade over the course of a year without ever shutting down production. It took working weekends and coordinating across contractors, electricians, and internal teams to pull it off.
- Utility Infrastructure Overhaul: We’re helping a major utility provider upgrade obsolete controllers across the country. In addition, we integrated all data into corporate-level dashboards for nationwide visibility.
- Order Tracking and Traceability: We built an OEE and MES system that not only tracks product counts but also stops the machine automatically when an order is complete, improving efficiency and traceability.
Every project is unique, but our mindset is always the same: Find the best solution. Build it right. Deliver it with pride. See more examples here.
Building the Future, One Solution at a Time
Manufacturing is only getting faster, smarter, and more demanding. So, if you’re still relying on legacy systems, disconnected data, or outdated processes, now’s the time to get ahead.
Flexware’s Automation Team is here to help you modernize, integrate, and future-proof your operations — with engineers who’ve been there, solved that, and are ready for what’s next. Connect with us today and let’s get to work.
