Industrial Mechanical Maintenance
Gearbox rebuilds, bearing replacements, belt and chain drives, conveyor repairs, motor swaps. We carry common spares and can typically restore a production line the same day.
Result: £50k saved on horizontal saw repair vs. OEM full replacement at Mersen UK
Electrical Installation & Upgrades
Distribution boards, containment, power runs, and machine hook-ups. From a single circuit to a complete factory fit-out — designed, installed, tested, and certified to BS 7671.
Result: £25k/year reduction in maintenance costs through improved PPM scheduling
Commercial & Industrial LED Retrofit
Warehouse high-bays, factory floor panels, office downlighters, and external floodlights. Free survey to demonstrate payback period.
Result: 50% energy reduction at Norit UK — payback within 18 months
AMI Lidder — Production Monitoring Dashboard
Reverse-engineered an undocumented VIPA/Siemens PLC and built a four-tab web dashboard (Live, Analytics, Diagnostics, Maintenance) deployed on a £200 mini PC as a production-line kiosk. Real-time OEE, animated digital twin, Pareto analytics, and integrated maintenance scheduling.
Result: Full production visibility delivered in 2 weeks — vs £30,000+ for commercial SCADA
A-Frame Dispensing — Error Analytics Platform
Full-stack web application tracking errors across 1,100 automated dispensing channels. Pareto/ABC analysis identified 49 Class A channels driving 80% of errors. Heatmap visualisation, Microsoft Teams alerts, PDF shift reports, and role-based access.
Result: Technical error rate reduced from 0.85% → 0.34% through targeted maintenance
Lidding Machine — Jam Reduction
Root cause analysis identified a recurring mechanical failure mode on an automated lidding machine. Implemented targeted modifications without new parts or capital expenditure.
Result: Jams per shift reduced from 8 → 1 (87.5%), downtime from 24 min → 3 min
AC Unit & BMS Fault Diagnosis
Diagnosed locked rotor condition on AC compressors (300A vs 30–45A normal) and traced a BMS signal fault to disconnected LonWorks controllers left by a previous contractor. Full technical report with cost-compared replacement options.
Result: Production area maintained at temperature, contractor negligence documented