Controller Programming, Training & System Integration
Fanuc R-30iB Plus. KUKA KRC4. Yaskawa DX200. ABB IRC5. Allen-Bradley ControlLogix. Siemens S7. RoboGuide. Senior-level execution for manufacturers who cannot afford downtime.
Controller Programming
Application-specific program development across all major controller platforms. Welding, palletizing, material handling, assembly, machine tending.
Controller Platforms:
Programming Scope
- Path teaching and motion optimization
- Multi-robot coordination and zone interlocking
- Vision-guided motion and adaptive programming
- Weld sequence optimization and parameter tuning
- Palletizing pattern development
- Safety system integration (DCS, SafeMove, FSU)
- Program backup, version control, documentation
- Legacy code refactoring and modernization
- Offline programming (RoboGuide, KUKA.Sim, MotoSim)
Robotics Training & Workforce Development
Hands-on operator and maintenance training for Fanuc, KUKA, Yaskawa, and ABB platforms. Build internal capability. Reduce integrator dependency. Accelerate production readiness.
Training Scope:
- Operator-level pendant training and safety protocols
- Maintenance and troubleshooting fundamentals
- Advanced fault diagnosis and recovery procedures
- Cell-specific deep dives for your equipment
- Program modification and backup procedures
- Vision system operation and calibration
Outcome:
Your team handles routine faults, program adjustments, and first-line troubleshooting internally—reducing expensive integrator call-outs and accelerating response to production issues.
Training Packages
1-Day Fundamentals
Operator-level training covering pendant basics, safety protocols, program execution, and basic fault recovery.
2-Day Advanced Troubleshooting & Recovery
Maintenance-focused training covering fault diagnosis, program corruption recovery, I/O troubleshooting, and system backups.
Custom Cell Deep Dive
Cell-specific training tailored to your exact equipment, applications, and team skill levels. Duration varies.
Offline Programming (Fanuc RoboGuide)
Develop and validate robot programs offsite using Fanuc RoboGuide simulation. Minimize production disruption during deployment. Arrive onsite with tested, validated code.
Offline Programming Scope:
- Full cell simulation and path development
- Cycle time estimation and optimization
- Collision detection and reachability analysis
- Program validation before deployment
- Weld sequence development and tuning
- Change management for existing programs
Outcome:
Reduce onsite commissioning time significantly. Programs arrive tested and validated—cutting days off your deployment schedule and minimizing production downtime during installation.
RoboGuide Capabilities
- 3D cell modeling and robot placement
- Motion path programming and optimization
- Interference zone detection
- Cycle time analysis and reporting
- Multi-robot coordination simulation
- Welding process simulation
- Material handling sequence development
- Program export to physical controller
- CAD import for accurate cell geometry
Consultations (Remote / Onsite)
Technical consultations for integration planning, system architecture review, cycle time optimization, and commissioning readiness. Get senior-level input before committing to major decisions.
Consultation Scope:
- Integration architecture and approach review
- Commissioning and launch readiness assessment
- Cycle time / throughput analysis
- Troubleshooting strategy for persistent issues
- Vendor selection and specification review
- System audit and optimization recommendations
Outcome:
Senior engineering perspective on your challenges—before you commit resources. Identify issues early, validate approaches, and make informed decisions without full project engagement.
Consultation Options
Remote Technical Consultation (60–90 min)
Screen share session to review documentation, discuss challenges, and provide recommendations.
Commissioning / Launch Readiness Review
Pre-launch assessment of integration documentation, safety circuits, and commissioning plan.
Cycle Time / Throughput Assessment
Analysis of current cell performance with specific recommendations for optimization.
Integration Architecture Review
Review of proposed system architecture, communication topology, and safety design.
System Commissioning
Full bring-up from mechanical installation through production runoff. I/O verification, safety validation, PLC integration, operator training.
Integration Scope:
- I/O mapping and signal verification
- Allen-Bradley ControlLogix / CompactLogix integration
- Siemens S7-1500 / S7-300 integration
- DeviceNet, Profinet, EtherNet/IP configuration
- HMI development (PanelView, Comfort Panel)
- Safety system validation (light curtains, area scanners)
Commissioning Process
System Verification
I/O checkout, network validation, mechanical checks
Program Development
Path teaching, cycle optimization, application tuning
Safety Validation
Guard circuit checkout, safety PLC verification
Production Runoff
Live validation, quality checks, cycle time verification
Training & Handoff
Operator training, maintenance documentation
Troubleshooting & Recovery
When your integrator can't figure it out, call us. Fault diagnosis, program corruption recovery, motion error resolution. 15+ years of production floor troubleshooting.
Line Down?
Production emergency? Call or text the direct line.
Call/Text: (213) 544-0049
After-hours support available for urgent downtime issues. Responses are best-effort and prioritized by severity.
Call NowTroubleshooting Scope
- Root cause analysis and fault diagnosis
- Program corruption recovery
- Motion error resolution (collision, singularity, joint limits)
- Communication fault diagnosis (fieldbus, EtherNet/IP)
- Servo and encoder troubleshooting
- Safety system fault recovery
- Vision system troubleshooting (Cognex, Keyence)
- Performance degradation analysis
- System health audits
Vision Integration
2D/3D vision guidance, part location, inspection, barcode reading. Camera selection, lighting design, calibration, robot-vision communication.
Vision Platforms:
Vision Scope
- Camera selection and mounting
- Lighting design and optimization
- Calibration and coordinate transformation
- Part location and pick guidance
- Pattern matching and template creation
- Dimensional inspection and gauging
- Barcode/2D code reading
- Robot-vision communication setup
- EtherNet/IP and discrete I/O integration
Controls & PLC
Allen-Bradley ControlLogix. Siemens S7-1500. Robot-PLC communication, HMI development, safety system integration.
PLC Platforms:
Controls Scope
- PLC program development and modification
- Robot-PLC communication setup
- HMI development (PanelView, Comfort Panel)
- Safety PLC programming (GuardLogix, F-CPU)
- Network configuration (EtherNet/IP, Profinet)
- DeviceNet and Profibus integration
- VFD and servo drive integration
- Data logging and OEE tracking
Engagement Models
Flexible options: emergency response, project-based, training, or ongoing support retainer.
Remote Support
VPN-based troubleshooting and program support. Hourly billing.
- Screen sharing & VPN access
- Quick turnaround
- Minimum 1-hour blocks
Onsite Day Rate
Dedicated onsite engineering for commissioning, recovery, or project work.
- Full-day engagement
- Travel included
- Complex system work
Retainer
Pre-purchased support hours with priority response.
- 10, 20, or 40 hour blocks
- Priority scheduling
- Discounted rates
Stop Waiting. Start Executing.
Direct access to senior-level robotics engineering. No sales layers. No junior resources.