About Us

OnlineWare Engineering provides System Integration Services for Industrial Processes and Environmental Automation and Data acquisition. Specifically projects requiring instrumentation, controls and software solutions. We offer experience in trouble-shooting or upgrading existing installations or can assist with projects involving new or pilot processes.

We specialize in the industrial sectors of Cleanrooms, Pharmaceutical or Biotech firms. As well as process heating. Our services range from Consultation, Initial Design, Selection of Control Elements, Software Development, Installation and Commissioning, and On-going Support and Training. We pride ourselves on developing cost effective, reliable and on-time results, using the latest technology and best quality components available..

Programming

OnlineWare Engineering provides complete manufacturing automation and product development software solutions to support a wide variety of projects of all sizes, across many sectors of industry.

Built on years of experience and technical expertise we can develop innovative approaches for control applications, data acquisition and embedded processor requirements.The scope of a project can range from the configuration of a "stand-alone" controller, to a "facility-wide" network interchanging process data across a variety of software platforms. We can provide the services to program most brands of discreet controllers and PLC’s including experience in programming according to IEC 61131-3.

Our programmers can develop visually appealing and intuitive graphical interfaces both for PC monitors or touch screen panels. Displays can be based on a “Windows Office” format or can be completely graphical, including animations. In many cases, “Web-Browser” interfaces can be developed to permit access either via an ethernet link or via the internet. 
 

Data acquisition of all operator, process and material usage can be automatically stored in a continuous database for production of batch, process analysis or alarm condition reports.

Data can be collected either automatically via the PC interface of the primary control system, or from discreet devices such as scales or other analyzers. Manual entry of data can be via keyboard, bar code readers or scanners. Hard copy reports can be printed using pre-formatted templates containing tables, graphs or text messages. 

Data can also be exported into other applications, such as spreadsheets for specific interpretation as required. Routines can be developed to automatically back-up databases to create copies on separate servers or other storage medium for
long-term archiving.

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Process Data Management

With today’s complex manufacturing processes it is vital to maintain production records that document the various parameters that are critical to proper quality. We have extensive experience producing detailed batch or continuous production reports.

Typical reports provide information such as material used, environmental conditions, operator identification and occurrence of alarms. We refer to this procedure as ‘PROCESS DATA MANAGEMENT’. All critical data is continuously written to, and archived in a database such as MS Access or SQL. From this stored data, reports can be generated automatically or on demand. These reports can provide production, quality control, or 3rd party agencies with the information needed to assure an efficient, quality and safe product.

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Recent Projects

White Sands, New Mexico

OnlineWare Engineering designed and installed an environmental control system at a NASA facility, and acted as project manager for the construction of a cleanroom facility built to manufacture and test a device for the transfer of liquid oxygen from the Space Shuttle to the International Space Station.

Austin, Texas

OnlineWare engineered and manufactured a PLC based HVAC control & monitoring system with graphic interface for this manufacturer of proprietary lithography systems used in "nanotechnology" applications.
 
  Leetsdale, Pennsylvania

 OnlineWare designed and installed a PC-based monitoring, recording and remote alarm notification system for this global company that
manufactures and markets blood processing systems
 
 Flowers, North Carolina

 OnlineWare engineered and installed a PLC and PC based control and monitoring system for environmental control, including airborne particulate measurement for the pharmacy facility at this world prominent medical facility
 
 Montgomeryville, PA

OnlineWare Engineering was contracted to engineer and build a special temperature control system for the uniform heating of a specialty gas flowing through a series of proprietary "special-alloy" high pressure cylinders for this manufacturer of integrated specialty gas solutions to the semi-conductor industry.
 
East Rutherford, NJ

OnlineWare Engineering upgraded an entire instrumentation, control, PC based graphical user interface and data acquisition system for various vacuum heat-treat furnaces used in the processing of metal alloy components of reconstructive orthopedic devices.
 
Waltham, MA

OnlineWare engineered and constructed a PLC based control system and a PC-based GUI alarm monitoring and
data-acquisition system for the pH waste neutralization of process waste water and VOC monitoring of solvent vapors in a manufacturing process for micro-surgical devices.
 
Shrewsbury, NJ

OnlineWare Engineering designed and installed a DCS based system for the HVAC control of a multi-suite cleanroom facility for
 this processor of human bone tissue. The FDA validated system included the archiving of all environmental and production data as well as LAN-wide process monitoring and report generation.
 
East Rutherford, NJ

OnlineWare Engineering designed an entire monitoring system for the highly complex manufacturing process of producing a proprietary spinal implant. The system involved the interfacing of a wide variety of control and laboratory instruments.

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Field Services

OnlineWare Engineering offers a wide variety of field services and support to assist our customers with general consultation, troubleshooting, installations, start-ups and equipment operation verification or validation.

We have worked with many customers to analyze existing processes and how and what options are available to improve performance. We have assisted in the purchase, installation and commissioning of capital equipment, by researching alternative manufacturers, their product offerings, and providing our customers with detailed product comparisons, in order for them to make an informed selection.

Onlineware has been called upon to investigate and correct difficulties with existing instrumentation and controls. We have been contracted to repair or upgrade existing controls, install and startup small installations, such as a single controller or recorder, to larger multiple PLC-based systems, complete with network communications, alarm monitoring and notification, data acquisition and report generation.

OnlineWare has performed and assisted to IQ/OQ validations and has experience developing software applications and support procedures to assist in achieving FDA’s 21 CFR Part 11 compliancy.

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