Customer Case Studies

Relationship: 14+ years, since 2012. Scope: A corporate engineering standard applied to every well-site automation platform in the United States and the Middle East, with a low-carbon ventures business on the same stack. The stack in place: Industrial connectivity – TOP Server enterprise-wide; Symbol Factory for HMI graphics. Industrial data ops – Cogent DataHub for secure data collection, MQTT and cloud pilots, and data-lake integration in the low-carbon business. Industrial AI – jonjon.ai with Arabic support; a unified namespace and chatUNS.ai roadmap under way. The problem being solved: flow-measurement (EFM) data must export reliably for a regional platform migration to proceed; field teams in two countries and two languages need answers without opening a case; new low-carbon assets need a data layer that reaches the cloud securely. Challenges overcome jointly: 41 support cases in a year brought down to three open items in a joint in-person review; EFM exporter stability fixed in TOP Server 7.1; jonjon.ai adoption cut support demand sharply during 2026; licenses consolidated and reconciled to servers through the activation portal; a DataHub OPC DA connectivity issue resolved.

Relationship: 14+ years, since 2012. Scope: Operating service centers that each support 20 to 100 facilities; Cogent DataHub deployed in North America, Europe and Asia. The stack in place: Industrial connectivity – plant SCADA (Siemens WinCC) at each site. Industrial data ops – Cogent DataHub moving alarm and process data from plants to the operating service centers; AspenTech IP.21 historian; N3uron scoped to normalize alarms into a unified namespace. Industrial AI – jonjon.ai onboarding for the engineering team; a chatUNS.ai alarm agent designed for cross-site alarm intelligence. The problem being solved: remote operating centers need resilient, secure data from dozens of plants each; alarm data lives locally at each site, so alarm health cannot be compared across plants; older DataHub versions and OPC DA connections have to migrate to v11 and OPC UA without disrupting operations. Challenges overcome jointly: a DataHub architecture that has carried site-to-center data for more than a decade across three regions; a v9/v10-to-v11 migration guide and an OPC DA-to-OPC UA plan; an alarm-intelligence design: counts by critical, advisory, maintenance and bypass, stale and unacknowledged durations, answered in plain language.

Relationship: 14 years, since 2012. Scope: Sites in the United States, Canada and Spain; 47 license activations since 2025. The stack in place: Industrial connectivity – TOP Server Modbus and Allen-Bradley suites feeding the MES servers; Symbol Factory. Industrial data ops – Cogent DataHub with OPC UA. Industrial AI – jonjon.ai in use. The problem being solved: MES servers depend on TOP Server, so a configuration or licensing fault stops production reporting; servers are rebuilt and licenses transferred regularly, and a transferred license must not come back time-limited; OPC UA certificate exchange between DataHub and its clients has to work under site security policy. Challenges overcome jointly: TOP Server errors on an MES server resolved the same day; corrupt user-management and license-utility states repaired; license transfers, broken bindings and new activation IDs for the Modbus and AB suites handled across US, Canadian and Spanish sites; DataHub OPC UA certificate exchange errors worked through; 41 support and jonjon.ai cases since 2025.

Relationship: 11 years, since 2015; the N3uron deployment went live in 2026. Scope: One US adhesives plant on N3uron with three edge nodes and a central node, and a runway of 40 plants (160 sites worldwide); TOP Server at a European site. The stack in place: Industrial connectivity – N3uron modules for Siemens PCS 7, Foxboro DCS and several Allen-Bradley families, OPC UA and OPC DA, plus a custom Mettler Toledo scale module; TOP Server in Europe. Industrial data ops – N3uron edge nodes feeding a central node and an MQTT broker, the foundation of the plant's unified namespace. Industrial AI – not yet deployed. The problem being solved: creating links in the previous OPC server was click-heavy, and tag organization lived in spreadsheets; data has to be retrieved inside several security zones before it can be centralized and piped to the cloud; licensing cost and .NET-heavy installs slowed every new connection. Challenges overcome jointly: a lighter install and templated tag onboarding that inherits through the tree to the central node and cloud; MQTT data-type and OPC DA issues resolved on site by Software Toolbox engineers; a scaling playbook for the next 40 plants, sponsored by the regional automation organization.

Relationship: 12 years, since 2014. Scope: Solar sites, substations, power plants and battery storage across the United States; 145 license activations since 2025. The stack in place: Industrial connectivity – TOP Server as the standard driver layer for distributed assets, configured remotely through its API. Industrial data ops – N3uron scoped for edge-native, store-and-forward collection and a unified namespace for battery storage. Industrial AI – jonjon.ai access for the engineering team. The problem being solved: hundreds of unattended sites must be connected the same way without engineering each one; configuration changes have to be pushed at fleet scale rather than site by site; remote sites lose connectivity, and data must survive the gap. Challenges overcome jointly: a templated TOP Server deployment replicated across the fleet, with license logistics handled through the activation center; remote configuration automated through the TOP Server API; 112 support cases resolved since 2025 as the fleet expanded.

Relationship: 11 years, since 2015. Scope: Energy-market and asset-monitoring operations in the United States; the TOP Server and DataHub installed base extended with N3uron in 2026. The stack in place: Industrial connectivity – TOP Server. Industrial data ops – Cogent DataHub; N3uron as the new integration platform. Industrial AI – not yet deployed. The problem being solved: an incumbent integration gateway was reaching end of life in the middle of a platform migration; required features sat on the vendor roadmap, and custom development was off the table; the migration had to run on a short, low-risk commitment. Challenges overcome jointly: a three-month subscription carried the migration; roadmap gaps were covered with standard configuration instead of custom code; full deployment on N3uron with templated, repeatable configuration; implementation services from Software Toolbox throughout the switch.

Relationship: 3 years, since 2023. Scope: 13 North American plants, part of a global OPC Router estate. The stack in place: Industrial connectivity – TOP Server. Industrial data ops – OPC Router at every site, with a redundant server for the North American instance and a path to inray's ProNubs subscription platform. Industrial AI – not yet deployed. The problem being solved: production data has to reach SAP-driven workflows reliably from every plant; each site buys and runs its own licenses, so the integration pattern must be simple enough to replicate locally; perpetual licenses bought site by site need a path to subscription without stranding the investment. Challenges overcome jointly: one OPC Router pattern deployed and supported across 13 plants, with the vendor engaged on the account; redundancy added for the North American instance; a transition path to ProNubs designed with credit for existing perpetual licenses.

Relationship: since 2024. Scope: US manufacturing; OPC Router rolled out in stages over 15 months. The stack in place: Industrial connectivity – plant OPC UA servers. Industrial data ops – OPC Router for workflows between plant systems and IT, with watchdog monitoring of connection status. Industrial AI – jonjon.ai in use. The problem being solved: data integrations in a GxP environment need to be visual, documented and repeatable; OPC UA sessions run under strict user access, so a denied session has to recover without manual intervention; a small automation team needs answers fast and needs the platform to stay lean on CPU and memory. Challenges overcome jointly: OPC UA connection and access-denied session errors resolved, with watchdog alerts tuned to flag real connection loss; reading elements of tag arrays and OPC Router method calls corrected; logging configured for traceability; high CPU and web-management-service memory usage investigated and resolved; 15 support cases since 2025, three through jonjon.ai.

Relationship: 13 years, since 2013. Scope: 47 plants on OPC Router across mechatronics, mirrors and lighting, seating, exteriors and powertrain divisions in North America and Europe; more than 15 divisions served. The stack in place: Industrial connectivity – plant OPC servers feeding OPC Router. Industrial data ops – OPC Router subscriptions with backup licenses at every site; templated workflows from PLC to database and MES. Industrial AI – jonjon.ai in use by plant engineers; chatUNS.ai and a unified namespace under evaluation in the powertrain division. The problem being solved: 350 decentralized factories each built their own data pipelines, and the enterprise needs one way to move PLC data into databases and MES; rolling the same workflow to dozens of plants means templates, mass edits and version control, not one-off configuration; a large estate exposes platform limits: database memory, trigger behavior on large tables, log visibility. Challenges overcome jointly: 242 support cases since 2025 handled through a formal escalation path and monthly developer syncs with inray; platform improvements driven by the supplier's scale: a MongoDB memory cap, CSV import and export for templates, Microsoft Teams integration, live log streaming and database change triggers; redundant backup licenses at every site and prorated additions as plants join.

Relationship: 13 years, since 2013. Scope: One vehicle assembly plant in the US Midwest; 92 license activations since 2025. The stack in place: Industrial connectivity – TOP Server, with OmniServer for non-standard devices. Industrial data ops – Cogent DataHub for MQTT publishing and OPC Router; N3uron scoped to collect edge data at a flat cost per site. Industrial AI – chatUNS.ai positioned on top of the namespace. The problem being solved: plant data has to reach an MQTT unified namespace, but per-instance licensing grows with every new source; edge collection should be templated and standard, not rebuilt per line. Challenges overcome jointly: a TOP Server-to-MQTT architecture reviewed jointly and documented; 12 support cases since 2025; licenses activated and transferred self-service; an edge-collection design with N3uron that keeps licensing flat as sources grow.

Relationship: 14 years, since 2012. Scope: Plants in North America, South America, Europe and Asia (United States, Brazil, China, India, Mexico); 88 license activations since 2025. The stack in place: Industrial connectivity – TOP Server Manufacturing Suite with Siemens, Allen-Bradley ControlLogix and Fanuc FOCAS drivers for PLCs and CNC machine tools. Industrial data ops – N3uron configured with the plant and digital-manufacturing teams in 2026. Industrial AI – jonjon.ai in use. The problem being solved: engine, generator and turbo plants on different continents need the same connectivity layer so corporate digital-manufacturing tools work everywhere; machine-tool data (Fanuc FOCAS over Ethernet) and PLC data have to come through one server at line speed; licenses move as servers are rebuilt and must be back the same day. Challenges overcome jointly: Siemens driver performance testing and a FOCAS Ethernet fix completed with plant engineers in 2026; TOP Server v7 adoption, including a hash-value licensing issue resolved and the quick client locked down on production servers; emergency activation of the Manufacturing Suite and 46 support cases resolved since 2025 across six entities in five countries.

Relationship: 13 years, since 2013. Scope: Steelmaking and finishing mills in the United States. The stack in place: Industrial connectivity – redundant TOP Server pairs (OPC Power Server) with Yokogawa and other controller drivers; OmniServer for legacy serial devices with 32-bit real decoding. Industrial data ops – Cogent DataHub with Gamma scripting for mill logic; OPC Router; OPC Data Client (QuickOPC) for in-house applications. Industrial AI – not yet deployed. The problem being solved: mills run decades of equipment generations, from current PLCs to serial gauges and instruments that need custom decoding; mill engineers build their own logic and applications on the data layer, so scripts, data types and client libraries have to behave predictably; data has to reach level-2 and corporate systems through redundant servers that fail over cleanly. Challenges overcome jointly: DataHub scripting issues worked through with mill engineers: data-type setting, script log visibility, scripts not disconnecting on reboot, point deletion, and a crash-and-exception case; OPC DA against a redundant TOP Server pair restored; OmniServer 32-bit real decoding and QuickOPC client errors resolved; 52 support cases since 2025, with temporary licenses issued during a TOP Server v6 upgrade.

Relationship: 13 years, since 2013. Scope: Cement plants across the United States and Canada, brought on one plant at a time. The stack in place: Industrial connectivity – plant OPC servers. Industrial data ops – Cogent DataHub v11 OPC Tunneller with redundancy at each plant; OPC Data Logger. Industrial AI – not yet deployed. The problem being solved: each plant has to move process data to corporate systems securely, without DCOM, one plant at a time as budgets allow; tunnels must stay up through network hiccups and fail over when a server does; a fleet on mixed DataHub versions has to converge on v11 without a plant going dark. Challenges overcome jointly: OPC Tunneller and redundancy configured plant by plant; tunnel time-outs and OPC DA disconnections diagnosed and resolved; v10-to-v11 upgrades and CSV configuration imports supported as plants came on; license-free upgrade eligibility confirmed and no-license states cleared; 28 support cases since 2025.

Relationship: 13 years, since 2013. Scope: Fabs and assembly sites in five countries across North America and Asia; 53 license activations since 2025. The stack in place: Industrial connectivity – OmniServer for tools and instruments with non-standard ASCII protocols; TOP Server for PLCs. Industrial data ops – Cogent DataHub; OPC Router. Industrial AI – jonjon.ai in use. The problem being solved: fab equipment and facilities devices speak protocols no off-the-shelf driver covers; servers are migrated and rebuilt continuously, and every move breaks a license binding that has to be recovered fast and in the right time zone; after a restart OmniServer must come back with topics reinitialized, not in emergency mode. Challenges overcome jointly: OmniServer license recoveries and re-registrations handled across US and Asian sites, including re-licensing planned ahead of server migrations; emergency-mode and topic-reinitialization behavior after restart diagnosed and resolved; 66 support and jonjon.ai cases since 2025, with support-contract license files kept current across five countries.

Relationship: 13 years, since 2013. Scope: US manufacturing and R&D plus plants in Southeast Asia. The stack in place: Industrial connectivity – TOP Server Allen-Bradley Suite (ControlLogix, DH+, DF1, Ethernet) on the lines, licensed by hardware key where needed. Industrial data ops – Cogent DataHub as an OPC UA server for secure remote access; OPC Data Logger. Industrial AI – not yet deployed. The problem being solved: remote clients need line data over OPC UA without exposing OPC DA and DCOM across the network; logged production data has to land in the database reliably from an OPC UA source; hardware-key and transferred licenses must survive line rebuilds and plant-to-plant moves. Challenges overcome jointly: OPC UA network security addressed with DataHub, including remote-client visibility of the DataHub OPC server and OPC DA remote connectivity fixes; OPC Data Logger tag browsing against the OPC UA server resolved; hardware-key licensing errors and license transfers handled across the US and Asia; 16 support cases since 2025.

Relationship: 14 years, since 2012. Scope: Can-making plants in the United States, with multi-plant DataHub deployments added in 2024 and 2025. The stack in place: Industrial connectivity – TOP Server. Industrial data ops – Cogent DataHub OPC Tunneller and OPC UA server, with Gamma scripts for environmental monitoring data. Industrial AI – not yet deployed. The problem being solved: line and environmental data has to cross plant-to-corporate network boundaries without DCOM configuration or opening firewalls to OPC UA directly; scripts that calculate and move environmental values must keep working across DataHub version upgrades; licenses have to be recreated quickly when servers are replaced. Challenges overcome jointly: DCOM errors eliminated by tunnelling OPC traffic through DataHub; a side-by-side review of OPC UA through the firewall versus the DataHub Tunneller settled the architecture; Gamma scripts (datahub_read) carried from DataHub v10 to v11 with Software Toolbox engineers; DataHub service and licensing issues resolved and TOP Server licenses recreated during server replacements.

Relationship: 4 years, since 2022. Scope: Furniture plants in three European countries and components plants in Europe and Asia; five countries in all. The stack in place: Industrial connectivity – TOP Server alongside AVEVA System Platform in the furniture business; TOP Server and OmniServer in the components business, with Omron FINS, Beckhoff and Siemens drivers. Industrial data ops – OPC Router in a redundant pair in the components business; N3uron scoped for a unified namespace at a Central European plant. Industrial AI – chatUNS.ai scoped for OEE loss intelligence and quality early warning at that plant. The problem being solved: lines mix Beckhoff, Omron and Siemens controllers that all have to report into one platform; data flows in the components business cannot stop, so the integration layer needs redundancy; engineers need notifications in Microsoft Teams and temporary licenses during commissioning. Challenges overcome jointly: 54 support cases resolved since 2025 across Europe and Asia; temporary licenses issued through the activation center; the Omron FINS driver validated; two working demos built on site in one session: a unified namespace with energy management, TOP Server and System Platform.

Relationship: 13 years, since 2013. Scope: Hundreds of TOP Server instances across a US data-center fleet; 563 license activations since 2025. The stack in place: Industrial connectivity – TOP Server with redundant backup licenses, covering Modbus power meters, BACnet building systems, SNMP network devices and Allen-Bradley cooling PLCs. Industrial data ops – N3uron evaluated as a containerized connectivity option, with a TOP Server-to-N3uron project converter. Industrial AI – jonjon.ai for self-service troubleshooting. The problem being solved: every new data center needs the same device data on day one, without a bespoke integration per site; power, cooling, building and network equipment speak different protocols and must feed one DCIM and operations view; hundreds of licenses have to be transferred, recovered and kept on support as hardware is refreshed. Challenges overcome jointly: a repeatable connectivity standard that site teams deploy themselves, with license moves and recoveries self-served through the activation center; an upgrade path from TOP Server 6 to 7 for Active Directory integration, advanced tags and alarms, and current ControlLogix firmware; fleet-wide maintenance that keeps every site on supported, security-patched releases.

Relationship: 14 years, since 2012. Scope: 200 licensed Software Toolbox products in use; a master agreement standardizing connectivity across about 290 data centers; purchasing entities in 19 countries across the Americas, Europe, Asia-Pacific, the Middle East and Africa. The stack in place: Industrial connectivity – TOP Server for building management (BACnet), power (Modbus) and network (SNMP) data, deployed directly and through integration partners. Industrial data ops – N3uron and a unified namespace scoped for alarm management (40,000 to 52,000 alarms). Industrial AI – jonjon.ai for engineers in 10 languages; chatUNS.ai agents for incident management in pilot design. The problem being solved: operations teams on every continent need the same device data, in the same shape, from very different building systems; alarm volumes outrun what people can triage, and incident timelines, customer communications and SLA impact are assembled by hand; a vendor-centric architecture had to become an operator-owned platform. Challenges overcome jointly: 266 support cases resolved at a 97.3% satisfaction score over the relationship; a license inventory and activation portal that gives one view of licenses across regions; a joint design for AI agents that detect site-health events, draft operations-center communications, build incident timelines and estimate SLA impact, starting at one pilot site.

Relationship: 12 years, since 2014. Scope: One regional water utility in the western United States; 23 license activations since 2025. The stack in place: Industrial connectivity – TOP Server (OPC DA and OPC UA server instances) with the OPC Server Remote Configuration client and the Simulator Suite for testing. Industrial data ops – Cogent DataHub; OPC Data Logger writing process data to the database. Industrial AI – jonjon.ai in use. The problem being solved: a SCADA system cutover had to happen without a gap in treatment and distribution data; a lean team must keep communications stable across upgrades (TOP Server 6 to 7), server moves and hardware failures; engineers need a safe way to test changes before they touch production. Challenges overcome jointly: demo licenses issued for the migration cutover so old and new systems ran side by side; emergency activation IDs turned around the same weekend when licenses had to be rebuilt; intermittent communication and OPC UA server-instance issues diagnosed and resolved; a TOP Server v6-to-v7 analysis delivered ahead of the upgrade; the Simulator Suite and remote configuration set up so changes are rehearsed and pushed without a site visit.