Industrial machine diagnostics
Systematic fault-finding across electrical and control systems: intermittent faults, phantom stops, drives tripping on start, sensors that work only on second shift.
For plant managers, maintenance & controls engineers
Factory Floor Machine Diagnostics & Controls Retrofits
We diagnose and repair industrial control systems at component level — PLCs, HMIs, drives, power supplies and the boards inside them. On site across the Miami Valley, with bench-level board repair when the OEM tells you the part is twelve weeks out.
Production line down right now?
Call the dispatch line. Do not fill in a form.
A quote request is the wrong tool when a machine is stopped. Call and describe the fault — we triage on the phone and tell you whether it is a site visit, a board pull, or something your maintenance team can clear in ten minutes.
What we fix
Diagnostics, repair and controls work
Six disciplines, one call. Most plants end up with three vendors and a lot of finger-pointing between them. We cover the electrical, the electronic and the software side of the same fault.
Circuit board & component repair
Board-level repair of control boards, interface cards, power supplies and drives. Reflow, component replacement and trace repair instead of a full assembly swap.
PLC & HMI programming
Ladder logic changes, I/O additions, HMI screen rebuilds and program recovery when the original source code is long gone.
Drives, servos & power
VFD and servo drive faults, DC bus problems, power supply failures and the wiring that causes half of them.
Automation & panel builds
Control panel design and build, sensor and conveyor integration, safety circuits and machine sequencing that operators can actually run.
Retrofit & controls upgrades
Replacing obsolete controls on a machine whose mechanics are still sound — including custom interface boards to tie existing hardware to new controllers.
Does this sound like your week?
The faults that cost the most
Every one of these has a cheaper answer than "buy a new machine".
- An intermittent fault nobody can reproduce when the engineer arrives
- The OEM says replace the board — with a 12-week lead time
- The machine is down and there are no drawings, no schematics, no source code
- The HMI is obsolete and there is no spare on the shelf
- A drive trips on startup and resets fine, so production keeps running it
- A mechanically sound machine is scrapped because the controls are unsupported
How a repair call works
Four steps back to production
Call & triage
Describe the fault on the phone. We tell you immediately whether it is a site visit, a board pull or a quick clear.
On-site diagnosis
We trace the fault through the electrical and control system and isolate it to a component, not a guess.
Repair or bench work
Fixed on site where possible. If it is a board, it comes to the bench for component-level repair.
Back in production
Machine verified under load, and you get a written account of what failed and why.
Rates
Published, not negotiated
Industrial work is quoted before it starts. You approve the number, and the number does not move because the fault was harder to find than expected.
Industrial Repair & Automation
$200/ hour
PLC and HMI troubleshooting, SCADA debugging, component-level board diagnostics.
Board-Level Bench Repair
Quotedper board
Priced after inspection. Usually a fraction of a replacement assembly — and no lead time.
After-Hours & Emergency
1.5×standard rate
Evenings, weekends and holidays — $300/hr. A line down at 2 AM does not wait for Monday.
- ✓ 2-hour minimum on all on-site visits — covers travel anywhere in the Miami Valley and into Michigan.
- ✓ Quoted up front. You approve the number before any work begins — no open-ended hourly surprises.
- ✓ Repair instead of replace. Board-level diagnostics often save the cost of an entire assembly.
Recent work
Machines we have brought back
A press brake whose original controls were obsolete but whose mechanics were fine, and a fertilizer loadout plant that now runs from a single tablet. The full write-ups, with photos, live in the project log.
Questions
Industrial repair & automation — FAQ
Can you repair a board the OEM will not sell separately?
Often, yes. We inspect the board, identify the failed component and quote the repair. If it cannot be saved, you have lost an inspection fee, not an assembly.
Do you work on machines with no documentation?
Frequently. We reverse-engineer the circuit and control logic, then write the documentation your maintenance team never had.
How fast can you get on site?
Call the dispatch line and we will tell you honestly. Emergencies are triaged on the phone first, because some faults clear in ten minutes.
Do you cover Michigan as well as Ohio?
Yes. Dayton and the Miami Valley are home base; we still travel into Michigan, and the 2-hour minimum covers the drive.
Not urgent?
Request a callback
For planned work, retrofits and quotes, send the details here. For a stopped machine, call the dispatch line instead — it is faster.
- (937) 226-9466Dayton & the Miami Valley — 24/7 dispatch
- (989) 286-5123Michigan
- urang@urangit.comSend board photos, nameplates and fault codes
- Mon–Fri 8:00 AM – 5:00 PMAfter-hours at 1.5× standard rate
Got a machine nobody else will touch?
Send the details and we will tell you whether it is repairable, retrofittable, or genuinely time to replace it.