Case Studies

Throughout more than 25 years helping solve complex OT/IT challenges, our approach to integration goes beyond just finding a solution that works. We’re passionate about helping customers adopt technology that works the way they work, and that they can take ownership of after we’re done. Check out our customer success stories below!

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MATERIAL HANDLING / WAREHOUSING

MOBILE ROBOTS AND LOGISTICS AUTOMATION IN MANUFACTURING MATERIAL HANDLING & WAREHOUSING

Increasingly organizations are introducing automation into their logistics operations using automated guided vehicles (AGVs) and autonomous mobile robots (AMRs). Over the past several years, Flexware Innovation has assisted customers with this effort by leveraging Ignition to integrate these vehicles into their existing ecosystems. This integration typically includes interfacing with automation/control infrastructure, inventory management systems, and other line-of-business applications. Learn more about this solution.

Ignition
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UTILITIES / WATER / WASTE WATER TREATMENT

LARGEST PUBLICLY TRADED U.S. WATER/WASTEWATER COMPANY BENEFITS FROM ENTERPRISE SOLUTION

More organizations are bringing Information Technology (IT) and Operations Technology (OT) together to assist in business decisions at every level of the organization. American Water teamed up with Flexware Innovation to create an Ignition ecosystem for SCADA/HMI standards, central data collection and analysis, and integration with other backend systems to support data-driven decision-making across the company. Learn more about this solution.

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Pharmaceutical Automatic Inspection Machine

PHARMACEUTICAL MANUFACTURING

GLOBAL PHARMACEUTICAL MANUFACTURER GAINS VISIBILITY INTO QUALITY & DELIVERY OF CONTRACT MANUFACTURERS

With the help of Flexware Innovation, a pharmaceutical manufacturer is working faster and smarter. By automating and streamlining their data collection and reporting processes, the company is gaining the speed, agility, and accuracy they need to respond rapidly to changing circumstances in their supply chain. Learn more about this business intelligence solution.

Ignition
food-bev-distillery

FOOD & BEVERAGE

INNOVATIVE SCADA SOLUTION

The growing demand for The Bardstown Bourbon Company’s (BBC) bourbon does not seem like it would be a problem, but it is when your SCADA system does not provide the real-time, operational insight you need. Read how Flexware worked with BBC to develop a new SCADA system with Inductive Automation’s Ignition platform to help them achieve real efficiency and production gains at their distillery.

Rockwell Automation
discrete-auto-parts-mfg

DISCRETE

LEGACY EQUIPMENT AUTOMATION UPGRADES

Flexware Innovation supported a large automotive parts distributor for several years when their outdated hardware went down causing a massive bottleneck, and reducing facility efficiency by half. Learn how Flexware engineered a solution allowing the customer to gain complete control over their system resulting in considerably less downtime.

Acumence
Can Making Case Study

CAN MAKING

TOTAL PRODUCTION VISIBILITY FOR BALL CORPORATION

Acumence by Flexware Innovation is an enterprise industrial intelligence platform that provides real-time production reporting. It was designed for high-speed, high-volume aluminum beverage can and end making. Explore how Ball Corporation uses Acumence to gain real-time data on downtime, production, and spoilage, ultimately improving efficiency by 3%.

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spark-mes-custom

DISCRETE

CUSTOM MANUFACTURING EXECUTION SYSTEM (MES) DEVELOPMENT AND DEPLOYMENT

In late 2019, Flexware Innovation collaborated with a Swedish-based worldwide leader in automotive technology to solve major pain points from an outdated Manufacturing Execution System (MES) within one of its subsidiaries, who delivers brake assembly solutions via 9 manufacturing sites. With SparkMES™, a scalable and fully customizable MES solution developed by Flexware and powered by Ignition, learn how this customer greatly improved overall equipment effectiveness (OEE).

Ignition
food-beverage-mfg-popcorn

FOOD & BEVERAGE

IGNITION OEE – TRACK & TRACE

Flexware Innovation collaborated with a large popcorn manufacturer in Northern America over the course of several years for controls-related support. Discover how the client was able to better identify downtime root causes and provide insight into production efficiency with the OEE solution Flexware implemented.

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OEE-Case-Study

PHARMACEUTICALS

VISIBILITY TO THE RIGHT METRICS, AT THE RIGHT TIME: MANUFACTURING OPERATIONS MANAGEMENT (MOM) SCORECARD

A global leader in healthcare products, sought to improve their manufacturing throughput, increase yields, shorten lead times, and improve efficiency. Company leaders engaged Flexware to help them identify strategies and implement technology solutions to achieve those goals. Improving overall equipment effectiveness (OEE) was important in their strategy to drive high-performance in their lean manufacturing operations. Learn more about this solution.

Ignition
Realtime-Data-Alarming-Reporting-Solution-RT

FOOD & BEVERAGE

REALTIME DATA, ALARMING, AND REPORTING SOLUTION ON THE WAY TO A SMART FACTORY

A manufacturer of consumer food products wanted to work towards a smart factory to visualize machine operations, monitor key alarm values, utilize OEE and downtime metrics, and perform reporting analysis across machine groups. Flexware developed an Ignition 8.0 Perspective application accessible from phone, tablet, or desktop environments. This solution also provides the framework for further enhancements such as predictive maintenance and predictive process monitoring. Read more about this real-time data solution.

Power-Bi
pet-nutrition

PET NUTRITION MANUFACTURING

MOVING FROM DATA TO DECISIONS WITH SHOP FLOOR BUSINESS INTELLIGENCE SOLUTION

A producer of pet nutrition products required real-time reporting from numerous servers and databases. In addition, the ability to modify the content of reports without a developer was required. Learn how Flexware utilized Power BI Premium to create a robust reporting platform to display graphical representations from a central location. This provided users with a better context of historical data, increased the reliability of decision-making, and allowed for precise forecasting.

  • factory-xxl
    We partnered with Flexware Innovation because of their expertise in the field of MES, their relationship and involvement with MESA, and their familiarity with ISA standards in this area. Flexware helped us articulate our requirements by educating our teams on what MES is, and how it can benefit our business. We believe it has been a great benefit to have a trusted advisor looking out for our best interest throughout this process. Our selection process has been very enlightening and educational due to help we received from Flexware's professionals.

    -Director of Manufacturing, Life Science Manufacturer

  • factory-xxl
    Flexware Innovation has been a technical ally, and trusted advisor on our automation, supervisory, and MES solutions. Even without prior knowledge of the product set we chose, they have executed very well. Their guidance in designing and implementing manufacturing systems has been invaluable to our team."

    -Senior Automation Consultant, Life Science Manufacturer

  • factory-xxl
    Our company has had a long history with Flexware. Flexware delivered many successful HMI/SCADA solutions in our facility in the late 1990’s. Most recently, Flexware is delivering a full MES solution to our facility and is instrumental in the start-up of 2 brand new manufacturing lines. Their technical expertise, vision, and work ethic are second to none."

    -MES Program Manager, Discrete Manufacturer

  • factory-xxl
    Flexware's vision for our company's shipping and receiving system was profound. Once implemented, the system helped our facility decrease our shipping errors to zero. Flexware demonstrated tremendous resolve to follow through on the project and complete it to our satisfaction. I highly recommend Flexware Integration as a partner."

    -Manufacturing Engineer, Discrete Manufacturer

  • factory-xxl
    I recommended that our IT and Operations groups partner with Flexware Innovation because they are an independent company that can function as an advisor to our organization. Their experiences and capabilities allow them to act as a translator and trainer between Information Technology and our business units. As part of a selection process for enterprise software, Flexware helped us understand the requirements, draft our requirements documents, and interview prospective partners. Their input and guidance throughout this process has been very beneficial to the leadership of our company."

    -President, Life Science Manufacturer

  • factory-xxl
    Flexware has helped create a strategic vision for our company as it relates to part marking and serialized tracking. With Flexware’s design and development experience, our company’s manufacturing operations will benefit greatly through improved product quality, risk avoidance, and through the use of true metrics and reporting."

    -Manufacturing Manager, Life Science Manufacturer

  • “Flexware Innovation helped educate us on the benefits of MES. We chose to implement a Commercial Off-the-Shelf (COTS) MES product with a global professional services firm. Our experience with the larger firm, and the resulting solution we have today falls short of meeting our needs. We are now partnering with Flexware for future phases of our MES design and rollouts. I am confident that we would have been much further ahead if we would have partnered with Flexware 3 years ago.”

    - Consumer Packaged Goods Manufacturer

  • “Flexware is the most professional and technically sound company I have worked with in my 20-year career. They were able to learn our business globally and bridge the gap between business needs and technology. They demonstrated the unique ability to titrate down our business needs to innovative solutions. They did not just execute work we asked them to do. They came to the table with alternative solutions, supporting data, and risk analysis that helped us make better decisions. Execution and communication were excellent. Overall business results were exceptional.”

    - Life Science Manufacturer

  • "Having tailored consulting where we are deficient is second to none.  In a very short amount of time, the ES Team closed gaps in my knowledge which aided me in making the changes needed with our cloud infrastructure."
    Director of IT
    Industry - Supply Chain
  • "We needed a PowerApps form to help with internal requests for product samples across multiple global sites. Natalie created a new form with multiple user-friendly views. Users have commented on how intuitive the form is to fill in. We have also seen during testing it is much easier to track the process of each request using what Natalie created. We are still piloting the process with one site with not enough requests completed by users for us to have firm outcomes. I very much appreciated Natalie’s IT skills and project management. I would highly recommend Flexware."
    Gavin O’Mahoney
    Senior Director at Eli Lilly and Company
  • I enjoyed this internship because the projects were very interesting and allowed me the opportunity to make them my own. Also, I very much liked the work environment, since everyone was positive and willing to help.
  • I did not expect myself to be working on such high importance and exciting projects. I always thought interns work on side projects that have little value to the company, but was pleasantly surprised by the projects I worked on.
  • The experiences I had as a Trailblazer were very insightful and I gained a lot more knowledge, in a very wide spectrum, than I ever thought I would.
  • I enjoyed this internship because the projects were very interesting and allowed me the opportunity to make them my own. Also, I very much liked the work environment, since everyone was positive and willing to help.
  • I did not expect myself to be working on such high importance and exciting projects. I always thought interns work on side projects that have little value to the company, but was pleasantly surprised by the projects I worked on.
  • The experiences I had as a Trailblazer were very insightful and I gained a lot more knowledge, in a very wide spectrum, than I ever thought I would.
  • The largest challenge I faced was learning new software in order to accomplish a projects I was assigned. Before this internship I was unfamiliar with SQL Server and Oracle Databases. In order to help my team with testing I had to be able to manipulate and navigate in these databases. I faced this problem by learning new skills and features of the software as I progressed in the project. By the end of the project, I felt I gained the necessary skills to do similar projects in the future.
  • The helpfulness of the Flexdogs, as well as the inviting family atmosphere in the office surprised me most during my time at Flexware. I enjoyed the interactions with my team and the other interns on a daily basis. I not only gained technical experience, but professional work habits.
  • I was surprised at how high the status of the Trailblazers was to the year-round employees. I felt I was valued and my work was appreciated. I also was surprised at how much free food there was.
  • I was surprised at the amount of meaningful work that I was given to do. I worked on multiple projects for clients that were deployed for use.
  • The type of person I would recommend to apply for the internship is someone who really appreciates Flexware’s core values. A person who does not require much assistance or guidance to complete a given task would be successful in the Trailblazer Internship program.
  • Working for Flexware Innovation as a Trailblazer intern is a unique and rewarding experience. Not only did Flexware take the time to introduce me to new concepts I hadn’t pursued before, such as creating a service in C# based around RFID technology, but they also care enough about their employees to help develop them personally and professionally. The professional development days were great, whether it was getting exposure to various facilities and industries Flexware works with, or sitting down with several admin level employees receiving advice from them on resumes, interviewing, or our personal LinkedIn profiles.
  • I enjoyed working at one of Flexware’s large food and beverage manufacturing customers and working with their automation team. Going into the summer, I knew very little about high power distribution systems. However, I can now say I know the factory’s power distribution better than most of their employees. I was also able to further develop my PLC programming skills in their automation lab. It has been an amazing experience being able to work with Flexware and the client to apply what I have learned in class while also working on important projects.
  • I really enjoyed the Trailblazer Program because it gave me the opportunity to do so much more than a typical internship. I worked on projects that mattered and developed professionally through plant tours and other fun activities such as the balloon launch.
  • From automation to business intelligence, Flexware gave me the opportunity to explore work in many different areas. It was a summer of trying new things and learning what I want and don’t want to do. Flexware is a unique internship where you not only get work experience but also build relationships, and develop professionally. Flexware spends time to make you a better employee by teaching you essential skills such as writing a resume, conducting yourself in an interview, and making good business decisions. It is a company that cares about their people. From day one I felt like part of the team and that I was working on something helpful to the company.
  • The Trailblazer Internship Program exposed me to so many facets of both business and engineering in industry. Flexware focuses on providing project work in areas of interest to each intern. The professional development days offer a variety of learning experiences and were one of my favorite components of the internship. The summer was filled with wonderful interactions with both FlexDogs and the other interns.
  • My Trailblazer experience was extremely rewarding. Through working at a local sheet metal manufacturer and professional development days at Flexware with the other interns, I have grown professionally, as well gained beneficial experience in the manufacturing side of engineering.
  • I really enjoyed my Trailblazer internship for several reasons. Firstly, I gained my skills working with Microsoft Calendar API, OAuth 2.0 Authentication mechanism, ‘Ignition’ SCADA system and ‘IQ FMEA’ framework for Failure – Mode effect analysis. Secondly, I developed my professional network and made money. Also, I made good friends. And, finally, Professional Development Days made Trailblazer Internship stand out!
  • People were always ready and willing to help me whenever I had a question or messed something up. Additionally, I enjoyed each of the Professional Development Days, as they provided us a way to interact with the other Trailblazers and allowed us to see the environment in which others were working. Other than the company tours, I also found the life and career skills days to be valuable, and they allowed us to grow in more than just technical ways. I especially liked the resume reviews, as this helped me to improve my resume and learn more about what recruiters are looking for.
  • Flexware Innovation helped educate us on the benefits of MES. We chose to implement a Commercial Off-the-Shelf (COTS) MES product with a global professional services firm. Our experience with the larger firm, and the resulting solution we have today falls short of meeting our needs. We are now partnering with Flexware for future phases of our MES design and rollouts. I am confident that we would have been much further ahead if we would have partnered with Flexware 3 years ago.”
    - IT Manager
    , Discrete Manufacturer
  • Our company has had a long history with Flexware. Flexware delivered many successful HMI/SCADA solutions in our facility in the late 1990’s. Most recently, Flexware is delivering a full MES solution to our facility and is instrumental in the start-up of 2 brand new manufacturing lines. Their technical expertise, vision,
    and work ethic are second to none.”

    - MES Program Manager,
    Discrete Manufacturer
  • We partnered with Flexware Innovation because of their expertise in the field of MES, their relationship and involvement with MESA, and their familiarity with ISA standards in this area. Flexware helped us articulate our requirements by educating our teams on what MES is, and how it can benefit our business. We believe it has been a great benefit to have a trusted advisor looking out for our best interest throughout this process. Our selection process has been very enlightening and educational due to help we received from Flexware's professionals."
    - Director of Manufacturing,
    Life Science Manufacturer
  • "I enjoy working at Flexware because of a few things. I appreciate that there is trustworthiness amongst our team. I am treated well and with respect. I enjoy the amount of transparency our leaders provide to the Flexdogs, and the importance of health in the company, both physically and financially. I also like the flexibility of being able to work from home, so I watch my son. Lastly, I simply enjoy the work I do and making a difference for a greater purpose.

    My favorite core value is "never stop learning." I can practice this not only on a daily basis in my personal life but at work as well. I am constantly challenged with new ideas and experiences that push me to learn more. My knowledge deepens with each project, and I enjoy taking on the unknowns."
    Natalie R.
  • "Working with Flexware for almost 4 years, I have seen myself grow as a professional in more than one way. Flexware embraces flexibility, not just in terms of location (remote or hybrid model), but also in the kind of work that you would like to do. I could nurture my career development by finding a suitable role that suits my personality, interests, and abilities. Flexware provides you with ample opportunities to widen your horizons and experiment with different aspects of technology.

    At Flexware Innovation, we believe in the kind of work we are doing for our customers, and how we can impact their businesses while doing so your contributions are recognized in the company frequently, and it does not have to wait for the bi-annual reviews, which gives a great sense of positivity and purpose to the work you are doing. The high-energy atmosphere, the transparent culture, and the constant leadership support without ever feeling that you are being micromanaged helped me grow as a true professional."
    Apurva S.
  • "In addition to our culture, I appreciate the wealth of opportunities we have to serve our company, customers, and each other, which leads to deep, mutually beneficial relationships.

    I love our core values, in particular, Say it Like it Is (with humility and respect), which allow us to dial in solutions quickly and efficiently while fostering transparency."
    Will T.
  • Jordan Valentine
    "I wanted to thank you all for the training last week. It was one of the best training classes I have attended in the past 15 years. The way the information was delivered, the help people were able to receive, and no question went unanswered it was all great, and I look forward to more classes if and when they become available. I definitely recommend this class for anyone wanting to get into Ignition."
    Jordan Valentine
    Smithfield Foods

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