Mama’s Life Products
Background
Mama’s Life Products was attempting to implement automation in their mixing and pouring processes, which were previously entirely manual. Their goal was to improve efficiency, consistency, and throughput in production.
Tilism Design Studio (TDS) was brought in to take over the project after a previous vendor’s attempt at automation had failed. The system was underperforming, required frequent manual intervention, and caused production bottlenecks and quality inconsistencies. TDS was tasked with stabilizing operations and delivering a cost effective automation solution without replacing all existing equipment.
Challenge
Completely manual mixing and pouring processes causing inefficiency
A failed automation attempt by a previous vendor
Existing machinery and tooling could not be easily replaced due to cost constraints
Inconsistent output and quality issues
Limited documentation and poor system integration
Need to minimize downtime during the transition
The client required a solution that automated critical steps while preserving existing investments.
Our Approach
TDS conducted a detailed technical assessment of the existing manual and semi-automated processes, equipment, and control logic. Rather than a full system replacement, we implemented a retrofit-first strategy to control costs and reduce implementation time.
Key steps included:
Mapping the manual mixing and pouring processes and identifying bottlenecks
Reverse-engineering existing mechanical and electrical systems
Redesigning automation logic using a simplified and robust PLC architecture
Retrofitting existing machinery with new sensors, actuators, and safety interlocks
Improving material handling and sequencing to reduce manual steps
Integrating quality checks directly into the automated process
Solution Delivered
Retrofitted and upgraded the existing system instead of full replacement
Implemented a reliable PLC-based control system with clear fault diagnostics
Added sensors for real-time monitoring and improved process control
Optimized cycle times through improved sequencing and motion control
Reduced manual intervention while maintaining operator flexibility
Delivered a scalable design for future expansion
Results
Significant improvement in system reliability and uptime
Increased production throughput without additional floor space
Reduced labor dependency and operator fatigue
Lower capital expenditure by reusing existing equipment
Faster return on investment compared to a full new automation solution
Mama’s Life Products regained confidence in their production process and achieved a stable, repeatable operation aligned with their growth plans.
Why Tilism Design Studio
This project highlights TDS’s ability to:
Take over and fix failed automation projects
Retrofit and optimize existing equipment to save costs
Bridge the gap between manual processes and modern automation
Deliver practical, production-ready solutions—not just concepts
At TDS, we specialize in solving real-world manufacturing problems with smart engineering, hands-on execution, and a focus on long-term value.
Services Used: Process Automation · PLC Programming · Retrofit Engineering · Sensors & Controls · Mechanical & Electrical Integration
