Rugged Solutions LIVE REPLAY 616-951-5338 info@getruggedsolutions.com --:--:--
Manufacturing automation · Test systems · Warehouse production

Unlock the full potential of your operations — and watch it run.

This console is live: five real assembly and test cells from an automotive manufacturing line, streaming recorded production data through the same OEE pipeline we build for our clients.

Schedule a Consultation View the line ↓

Plant Floor — Rockford P2

awaiting data…

Cell OEE — trailing 2 h

availability × performance × quality

Cell State Timeline — trailing 2 h

-2 h-1 hnow

Environment — instrumentation rack

1-wire temperature probes
What our clients say

Measured in their numbers, not ours

+90% OUTPUT 1,500 → 2,900 PACKAGES / HOUR — SAME MACHINE, NEW SOFTWARE

“After Rugged Solutions rewrote our OEM machine software, it increased output by 90% from 1500 packages/hour to 2900 packages/hr. The machine's speed now makes the rest of the line equipment the bottleneck.”

Shawn K.Plant Engineer, Our Daily Bread
3-DAY CUTOVER COMPLETE WCS REWRITE · 20 YEARS OF SERVICE · NO PROBLEMS SINCE

“Rugged Solutions has worked on additions and maintenance to our software for 20 years. The last upgrade was a complete rewrite of the Warehouse Control System and [it was installed] in three days! No problems since.”

Kye K.IT & Database Admin, Distribution for Pro Hardware
6 YEARS · 6+ PROJECTS SUCCESS ON EVERY OCCURRENCE

“I have had the pleasure of working with Tom for about 6 years now, on 6+ projects … with success on every occurrence. Tom provides a higher level of service… from start to finish, and provides exactly what you want… I personally have learned a large amount from Tom [in a wide range of applications from automation & robotics to electronics & programming]. I look forward to continue to learn more with Tom for the upcoming years on future projects…!”

David P.Automation Maintenance Tech II, Byrne
2+ YEAR PROJECTS, ON TIME WCS + INVENTORY SOFTWARE · MILESTONES KEPT ACROSS DYNAMIC SCHEDULES

“Rugged solutions has been an integral partner in providing warehouse control system and inventory management software, training, and support for us over the past several years. We value the efficiency and on time milestone deliverables throughout dynamic project schedules that on most projects span 2+ years. Not only does Tom bring a lot of experience and skill to the table but he excels at the ability to clearly communicate the software design, functional, and benefits to key stakeholders on a project.”

Brett A.Project Manager, [An Integrator]
FULLY AUTOMATIC ASRS MULTIPLE CRANES + CONVEYORS DELIVERED AS ONE SYSTEM

“Tom has been an essential part of our team creating and delivering the software to run our automated solution consisting of multiple cranes and conveyors, integrating and connecting them to a fully functioning automatic storage and retrieval facility. He has been more than helpful and very patient with explaining the functionality of the software and what can be expected from the system to some of our team that are not experienced in software development.”

Andrew S.Project Manager, [An Integrator]
MENTOR & PROJECT LEAD IDEAS THAT LAND WITH TECHNICAL AND NON-TECHNICAL AUDIENCES

“Tom is a great mentor and project lead. His knowledge of automated manufacturing technology is impressive… [He] is an excellent teacher and a pleasure to work with. Tom also is great at presenting ideas to people with both technical and non-technical backgrounds. I would recommend him to anyone looking for help with automation or software-based solutions.”

Isaac R.Analytics Engineer, Dematic
LEADERSHIP THAT LISTENS MULTIPLE SUCCESSFUL WCS PROJECTS, BUILT AND MAINTAINED TOGETHER

“In my last few years working under Tom I have learned a ton about designing/writing WCS software, identifying problems and troubleshooting, and collaborating effectively. We have built and maintained multiple successful projects together. I got to know Tom on both a professional and personal level, and one of the things I respect most about him is his willingness to accept feedback. Not only does he invite criticism, but I have noticed him make positive changes in our day-to-day operations. This is essential for great leadership. If you are looking for an expert for your next industrial automation project, Tom is your guy.”

Donald H.Software Engineer, [An Integrator]
UNIQUE SOFTWARE SOLUTIONS A RESOURCE FOR CUSTOM AUTOMATION PROJECTS AND MACHINES

“Tom is a team player who provides unique software solutions. His extensive knowledge and experience are valuable resources to our custom automation projects and machines.”

Mike T.Engineering Manager, Criterion Manufacturing Solutions
EXTRAORDINARY DEPTH EVERYTHING AUTOMATION, COMPUTER SOFTWARE, AND MORE

“Tom is an extraordinary leader and teacher in our project. He has incredibly deep knowledge in everything automation, computer software, and all things of the sort… I would recommend him to anyone looking for consulting in automated manufacturing technology.”

Ben W.Data Analyst, STARS
FIRMWARE TO FULL SYSTEM EMBEDDED DESIGN, PC SOFTWARE, SYSTEM DESIGN AND DEBUG

“Tom [is] an embedded engineer. He is versatile with ability to perform on embedded firmware design, PC software, system design and debug. His variety of skills helped him stay in demand with our customers. He is a great leader and team member as well, a very responsible and hard worker.”

Shawn I.President, DornerWorks
THE EMBEDDED GUY RECOGNIZED IMMEDIATELY — A VALUABLE ASSET FOR ANY TEAM

“I worked with Tom and recognized him immediately as the guy who knows everything about embedded systems… He is a valuable asset for any engineering team.”

Mark S.Embedded Systems Engineer, DornerWorks
LIVE AT THE CUSTOMER, FAST SORTATION SYSTEM INSTALLED AND RUNNING VERY QUICKLY

“Tom is one of the best Systems Engineer and Software Developer I have worked with. He is dedicated, self motivated, takes pride in his work, and has great troubleshooting skills… We installed [our sortation system] at the customer site and had it up and running very quickly.”

Dave G.Software Engineering Manager, Dematic
Case studies

Operations we've transformed

Real-world projects where our solutions optimized efficiency, enhanced automation, and drove growth. Two of them have live mocks on this site — click through.

Warehouse Control System

An ASRS crane-system integrator needed a WCS to run a 3-crane aluminum-roll storage and shipping facility and integrate with ERPs for order fulfillment.

View live mock →

Manufacturing Optimization

Retrofit of a production line for heavy-duty cement data-center floor tiles: Allen-Bradley PLC and HMI, two FANUC R-2000 robots, and a Keyence vision system.

View live mock →

Assembly, Tester, and OEE

Transformed a decades-old manual assembly process: plastic welding, quality inspection, electrical testing, printing, labeling, and boxing — with full OEE reporting.

Live above — this page ↑

Electrical Tester UL962A

A leading electrical appliance manufacturer faced the challenge of aging test equipment for critical UL962A compliance. Their legacy system, built in the 1970s, lacked modern features and was becoming increasingly expensive to maintain. Worse, it provided no information about the testing process and testing results.

ERP Integrations

Automated order creation and product configuration, streamlined shipping information management, enhanced package sorting for faster fulfillment, improved inventory tracking and storage optimization.

Vehicle Chassis Dynamometer

A leading integrator of vehicle chassis dynamometers sought to modernize their highly successful control system, originally designed in the 1990s — a system vital for tier-1 automotive testers and manufacturers.

Prototype Product Development

Rugged Solutions excels in developing innovative prototype solutions. We bring ideas to life with a focus on accuracy and cost-effectiveness.

Medical and Aerospace

Rugged Solutions partners with clients in the demanding aerospace and medical industries, delivering innovative, high-performance solutions.

The Rugged Solutions process

Analysis → Acquisition → Action

Core

Analysis

Identify bottlenecks and unlock potential through process analysis.

  • On-site process review
  • Detailed process analysis report
  • Prioritized list of improvement opportunities
  • Estimated potential ROI for each improvement
TIMELINE · 2–4 WEEKS
Cornerstone

Event Acquisition & Recording

Establish a robust data cornerstone for taking action.

  • Event-driven data collection system
  • Secure data collection and reporting
  • Exactly the pipeline feeding this page
TIMELINE · 6–8 WEEKS
Hammer

Actionable Results

Optimize performance and drive continuous improvement through data and action.

  • Measurable gains in OEE, quality, and cycle times
  • Improved worker productivity and ergonomics
  • ROI-driven investment — let's talk
TIMELINE · ONGOING
Services

Industrial excellence through automation

Innovative Automation

SCADA, cloud-based systems, ERP, MES, and more — streamlined, efficient operations.

AI & Machine Learning

Pattern recognition for industrial manufacturing and processing: efficiency, accuracy, precision.

Custom Electronics & Embedded

Custom electronics and embedded systems tailored to your unique requirements.

Reduced Downtime

Cycle-time reduction plus SPC and OEE strategies keep operations running smoother, faster, more reliably.

Condition Alerting

Real-time alerts via text, email, or your platform of choice — proactive maintenance, immediate response.

Built for Longevity

Systems engineered to stay maintained and in operation for 20+ years.

FAQ

Frequently asked questions

What industries does Rugged Solutions serve?
Primarily automotive manufacturing, with broad experience across manufacturing and warehousing. If your operation is similar, this process applies to you.
Maintenance and support?
We engineer systems to be maintained and in operation for long periods — in some cases 20+ years. We serve you as long as you want or need.
What geographic region does Rugged Solutions serve?
Primarily Michigan and the surrounding states — Wisconsin, Minnesota, Illinois, Indiana, Ohio. With remote technology we serve customers anywhere in the United States: TN, NY, UT, CA, SC, and more.