Work

Recent projects and pilots

Client names are withheld under NDA. The sectors, scope and numbers below are real, and we are happy to walk through any of these systems in a call.

AUTOMOTIVE, INDIA

Production execution system for an 18-station CNC machining line

The situation: A Tier-1 automotive components supplier with more than 250 CNC machines wanted to digitalize one machining line as a pilot before a wider rollout. The line runs 18 stations: laser marking, seven CNC operations interleaved with quality gates, washing, leak testing and final inspection.
What we built: A production execution system with a live line dashboard, real-time OEE, serial-level part traceability from first operation to final inspection, tool-life management with alerts at 80 and 95 percent of tool life, hourly loss reporting using the plant's 20 loss codes, and quality skip detection. Machine data comes from a custom FANUC FOCAS driver polling the line's CNCs.
Result: The pilot went from requirements to a running 18-station system in a matter of weeks and was demonstrated live on the shop floor, validating machine connectivity for the full 250+ CNC installed base.

AUTO COMPONENTS, INDIA

The situation: A leading auto-components group wanted to see what digitalization would look like on a gear-shifter assembly line of 29 machines, from shaft machining through welding, marriage stations and end-of-line testing.
What we built: An Ignition Perspective proof of concept, simulation-first, so the demo runs on the same tags and views that go live when the PLCs connect. It includes a live line overview with machine states and bottleneck flagging, OEE dashboards with four role-based views from operator to management, downtime Pareto, an Andon loop with material-request tickets, SLA countdowns and automatic escalation, and serial-level traceability with lot genealogy.
Result: A working demonstration across the full 29-machine line, with a connectivity plan for each machine and a retrofit path mapped for scale-up across four plants.

BIOSCIENCES, USA

The situation: A US biosciences manufacturer needed a monitoring SCADA for a vacuum cone dryer under 21 CFR Part 11 and GAMP expectations, with strict monitoring-only behaviour: no writes to the process from anywhere in the system.
What we built: An Ignition Perspective SCADA with a 255-tag display architecture, P&ID mimic screens, trends, alarms and reports. Every view was generated as code and checked by an automated validator that enforces the monitoring-only rule along with tag-path and reference integrity. Delivered with a 20-case FAT protocol and URS traceability.
Result: The project imported into the customer's gateway without errors and is connected to the live dryer controller over Modbus TCP.

WATER INFRASTRUCTURE, USA

The situation: A US instrumentation and controls firm serving water and wastewater utilities needed more engineering throughput than it could hire: bid packages, submittals and SCADA development across a continuous pipeline of municipal projects.
What we built: A retained engineering support model. We produce bid packages with scopes of work and cost schedules, Division 40 instrumentation submittals, and Ignition Perspective applications on a reusable template and inheritance design system. Every deliverable passes a formal QA review that checks each claim against source documents before it ships.
Result: Dozens of bids and submittals delivered since early 2026, plus production SCADA work on won projects, including a wastewater treatment plant and a multi-site well-performance dashboard.

TRAINING ASSET

The situation: Most MES training relies on slides and screenshots. Trainees learn faster when they can operate a live system with realistic production data and faults.
What we built: A complete Sepasoft MES training environment on Ignition, set in a fictional cereal plant: seven step-by-step labs covering ISA-95 modelling and work orders, OEE and downtime, SPC control charts, track and trace with a recall exercise, reporting, and bidirectional ERP integration with Odoo. The environment contains 46 Perspective views and 278 simulated tags, with production simulated every 2 seconds, in a codebase of about 28,000 lines.
Result: A ready-to-run programme with roughly 4 to 6 hours of hands-on participant time, used in our corporate MES training.

MULTIPLE CLIENTS

The situation: Engineering leaders keep asking the same question: where does AI tooling actually help an automation practice, and where is it hype?
What we built: Assessment engagements with working demonstrations on the client's own documents: P&ID to IO list extraction, RFP to scope-of-work drafting, URS to proposal generation, and code-generated Ignition views with a validation gate. Each assessment ends with an adoption roadmap and a governance model covering review gates and traceability.
Result: Clients get a grounded view of what the tooling can and cannot do, demonstrated on their own project material rather than canned examples.

Earlier delivery

Before Cogneta, Dhananjay Kulkarni delivered MES and SCADA programmes for some of the world's best-known manufacturers and operators.