CASE STUDIES
Real projects. Real results. See how HOAK Labs has helped clients across Pakistan reduce downtime and recover critical systems.
500+
Devices Repaired
98%
First-Fix Success Rate
48hr
Average Turnaround
PKR 50M+
Client Savings Generated
Proven Results
Each project represents a customer whose production was restored, costs were saved, and trust was earned.
Siemens MICROMASTER 440 Fleet Overhaul
The Challenge
A major textile mill had 12 Siemens MICROMASTER 440 VFDs failing intermittently, causing frequent production stoppages and quality defects in yarn production.
Our Solution
HOAK Labs performed full diagnostic analysis identifying power capacitor degradation and IGBT driver board faults as the root cause. All 12 units were systematically overhauled over a scheduled maintenance window.
Result
100% success rate. Production downtime reduced by 85%. Estimated savings of PKR 2.4M per year in lost production.
Legacy PLC Migration — Food Processing Plant
The Challenge
An aging Allen-Bradley PLC-5 system controlling a high-speed filling line was becoming unreliable with spare parts no longer available. The client needed a migration path without halting production.
Our Solution
HOAK Labs developed a phased migration plan to CompactLogix platform, with complete program translation, I/O remap, and parallel testing. The cutover was executed during a planned shutdown weekend.
Result
Seamless migration completed in 54 hours. System uptime improved from 87% to 99.2%. Full remote monitoring capability added.
Multi-Axis Servo Drive Recovery
The Challenge
A packaging machine manufacturer had a critical Fanuc servo drive system fail, affecting a customer installation. The original supplier quoted 8-week lead time for replacement.
Our Solution
HOAK Labs received the failed drives, performed component-level diagnosis identifying a failed power stage and corrupted parameter memory. Repair was completed within 4 days including full load testing.
Result
Machine operational within 5 days vs 8-week replacement. Client saved 90% on repair vs replacement cost. Machine has run 14 months without fault.
Data Centre Synchronizing Controller Repair
The Challenge
A data centre's DSE 8610 synchronizing controller failed during maintenance, leaving the facility relying on a single generator without proper load sharing and synchronization protection.
Our Solution
Emergency on-site attendance within 2 hours. DSE module diagnosed with CPU board failure. Component replaced and system recalibrated and recommissioned on-site.
Result
Full redundancy restored within 6 hours of initial call. Zero data loss or service interruption. Annual maintenance contract established.
Siemens TP2200 Comfort Panel Restoration
The Challenge
Cement plant's primary process HMI suffered touchscreen failure and corrupted project data. The OEM quoted 16 weeks delivery for a replacement panel at high cost.
Our Solution
HOAK Labs replaced the damaged touchscreen overlay, recovered and re-flashed the project data from backup, and performed full functional testing against the SCADA system.
Result
Panel fully operational within 10 days. Cost was 30% of replacement price. Customer data fully recovered.
DC Drive Fleet Maintenance — Steel Mill
The Challenge
A steel processing facility had 8 aging DC drives showing signs of deterioration with no local repair capability and long overseas repair times.
Our Solution
HOAK Labs established a preventive maintenance schedule, cleaning, inspecting, and recalibrating all drives. Two units required armature firing circuit board repairs.
Result
All drives restored to optimal performance. Zero unplanned failures in subsequent 12 months. Annual contract signed.
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