Project Management
Design & Build
Field Startup & Commissioning
Process Development
Service Support

Project Management

Organize, motivate and control resources, procedures and protocols to achieve our customers’ specific goals and deliverables within schedule and budget. Critical chain project management approach enables Falcon to control and deal with uncertainties, while taking into consideration limited availability of resources needed to execute every aspect of a project, regardless of its size.¬†Projects are planned and managed through the subordination of critical engineering resources and development of cost estimates and budget constraints while continously analyzying risk from beggining to end.

Mechanical Design

Design, development, build and test of mechanical devices, end-of-arm tooling, prototypes, fixtures and various system and modular components to customer specifications for advanced manufacturing systems and OEM equipment fabrication.  Our mechanical design capabilities can also help provide plant layouts and elevations drawings, assembly and detail dimensional drawings, 3D system layout and bill of materials.

Electrical design and drafting includes but not limited to control wiring, safety circuits, high/low voltage power, lighting, as well as remote I/O box, intermediary and main panel layout, robot reach studies, upgrades of legacy PLC’s / VFD’s / Servo Systems.


PLC’s: Siemens, Omron, Beckhoff, Allen Bradley, Schneider
Servo Motion Systems: ABB, Fanuc, Emerson, Allen Bradley, Schneider, Omron
PC Based Control
Human Machine Interface
Program conversion and upgrades
Parts Traceability
Stamping press lines
Robotic welding lines
Closure robotic lines
Robotic Material Handling
Sub-system integration


As a preferred robot integrator Falcon’s team members are trained in Robot Programming and Software Development for:
– Industrial Robots (ABB, Kuka, Fanuc, Kawasaki, Motoman, Nachi, ST Robotics, etc.)
– Collaborative Robots (UR, Baxter, Fanuc, ABB, Kuka, etc.)
– Scara Robots (Kawasaki, Adept, Yamaha, ABB, Epson, etc).
We also offer optimisation of robotic applications such as material handling, assembly, measuring and inspection, vision and force sensing, dispensing, arc and resistance welding.

Development of programs for Allen Bradley, Siemens, Omron and Schneider PLC’s in conformance with customer’s process and safety standards.

HMI, Motion Control, Vision Systems program development and applications.

We also do program conversions and upgrades.
Languages: C, C++, Ada, Java, Visual Basic
Development Tools: Labview, Matlab/Simulink, Misra-C
Data Management: MS SQL, MySQL
Data Storage/Analysis
Database Interface/SQLReport Generation
Graphical HMI front panel design
SCADA – supervisory control and data acquisition

Field Startup & Commissioning

Controlled and safe initial power-up of field equipment.
Commissioning of all process control and safetynetworks.
Complete checkout of field devices to the HMI, PLC and/or Robot.
Electrical debug and testing.
System dry runs.
System wet runs.
Verify equipment performance under load, parts run-offs and cycle time improvement.

Process Development

Falcon offers Process Development aimed at analyzing our customers’ manufacturing operations and evaluate their processes in order to recommend the best automation solution available to fully optimize every aspect of the production performance.
– Manufacturing Process Planning
– Operator/Machine Balancing Studies
– Prototype Process Planning
– Prototype Equipment Design and Build

Service Support

The array of our technical support includes:
– Program recovery
– Production support
– Hardware failure diagnostics
– Troubleshooting
– Wiring debug
– Robotic teaching
– Emergency parts and service
– Training and technical documentation