Industrial Automation · Berlin

Control. Monitor. Decide.

We engineer control, monitoring and data systems for manufacturing — connecting the shop floor with management in real time.

average downtime reduction
23%
average downtime reduction
to a first live dashboard
2–4 weeks
to a first live dashboard
typical ROI payback
12 months
typical ROI payback

Partners & clients

  • Siemens
  • Beckhoff
  • Rockwell
  • ABB
  • KUKA
  • Mazda
  • Geely
  • NIO
  • BYD
  • SAIC

Services

Six practice areas, one accountable partner

From the controller on the machine to the dashboard in the management meeting.

01

PLC & SCADA Engineering

Greenfield builds and legacy retrofits, with cutovers planned to avoid production downtime.

Siemens TIA PortalBeckhoff TwinCATRockwell Studio 5000

02

Industrial IoT & Edge

Edge gateways that collect machine data securely and feed it into cloud dashboards.

MQTTOPC UASparkplug B

03

MES & Production Analytics

Real-time OEE, shift-level downtime analysis and quality metrics for every line.

OEEDowntime analysisQuality KPIs

04

Predictive Maintenance

Vibration, current and thermal analytics with machine-learning fault prediction — fix issues before they stop the line.

Condition monitoringMachine learning

05

Robotics & Vision

Cobot programming and machine vision for automated quality assurance.

CognexKeyenceURKUKAFANUC

06

Energy Monitoring

Submetering, consumption analytics and reporting for energy management systems.

SubmeteringISO 50001

Case studies

Results from the shop floor

Tier-1 automotive supplier, DACH

Real-time OEE dashboard

Machine data from 14 Siemens PLCs collected via OPC UA, processed at the edge and visualised in a live OEE dashboard. The data revealed a recurring pneumatic fault that was then resolved.

−23%
downtime
14
PLCs connected
Duration: 10 weeksOPC UASiemensEdgeOEE

German municipal operator (NDA)

SCADA retrofit for water treatment

Phased replacement of an end-of-life SCADA system across three sites — with zero downtime during cutover — plus automated regulatory reporting.

−70%
emergency callouts
0
downtime during cutover
Duration: 22 weeksSCADARetrofitReporting

Process

From plant audit to handover

  1. Step 1

    Plant audit

    On site, we assess machines, controls, data sources and the biggest sources of loss.

  2. Step 2

    Roadmap

    A prioritised plan with scope, effort and expected payback for each step.

  3. Step 3

    Build & commission

    Engineering, testing and commissioning — planned around your production schedule.

  4. Step 4

    Handover

    Documentation, training for your team and ongoing support.

Contact

Got a plant problem?

Tell us about your line, your machines and what’s slowing you down. We’ll come back with concrete next steps.

Talk to us directly

Email
info@cognoor.de
Phone
+49 1514 3332408
Message us on WhatsApp
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