Dedicated library for legacy quality-data operations.
Case study · Tire manufacturing · Mexico
Modernizing a production-critical palletizing system.
A phased replacement of an unstable legacy application connected to quality data, SQL Server, RPC and two Allen-Bradley PLCs.
Approved anonymized screenshot pendingPLC
Quality validation · Conveyors · Palletizing
SystemCritical packaging flow
Duration3 months
Axyz team3 specialists
Core stackWPF · .NET · SQL · PLC
The challenge
Application failures could stop conveyors and accumulate product.
The palletizing area depended on a Basic application that validated tire quality before storage and final pallet assembly. When it froze or lost communication, packaging could not continue normally.
- Frequent application freezes
- Lost database connections
- Slow or interrupted legacy RPC communication
- Unreliable PLC communication
- Conveyor stops when required tire data was missing
- Manual removal of accumulated product
Why custom software
No off-the-shelf product covered the process and integrations.
The replacement needed to preserve specialized quality logic while reliably connecting the systems that controlled the process.
- SQL Server process information
- Quality information obtained through RPC
- Reading from and writing to Allen-Bradley PLCs
- Local records and technical traceability
- Structured diagnostics for support
The solution
A WPF/.NET application with specialized, reusable integration libraries.
Read and write communication with two Allen-Bradley PLCs.
SQL Server integration and local SQLite tire records.
Reusable structured logging and technical text files.
PLC logic changes and diagnostic error codes.
Two conveyor speeds to clear accumulated product faster.
Deployment
Validation in production conditions without a primary data migration.
Primary process information remained in the external SQL Server database. The new application was released in phases and tested during approximately three production-approved windows.
This allowed communication, logic and line behavior to be validated before the replacement became the active system.
Results
Better stability, supportability and production flow.
Results remain qualitative until the client approves quantified metrics.
Errors retrieving tire quality information through the legacy service were reduced.
Rework and manual inspections associated with communication failures decreased.
Structured logs and error codes improved troubleshooting.
Modern architecture reduced risk from application freezes and connectivity failures.
Two conveyor speeds helped clear accumulated product more quickly.
RPC, PLC and logging libraries can support other industrial applications.
What this demonstrates
Software, data and automation delivered around production reality.
- Modernization of software directly supporting production flow
- Preservation of business logic and industrial integrations
- Reusable components for RPC, PLC and logging
- Phased deployment coordinated with production
- Practical desktop, data and automation experience
Your current system
Does your operation depend on unstable or difficult-to-maintain software?
Axyz modernizes industrial applications while preserving critical logic, integrations and production continuity.