Project workflow

Transparent phases, agile checkpoints, and engineering documentation ensure OEM teams stay aligned from the first concept meeting.

01

Discovery & requirements

Cross-functional workshop capturing throughput targets, safety levels, network architecture, and integration requirements.

02

Design & simulation

Drive selection, PLC hardware, and panel CAD packages developed with digital twin validation and harmonics analysis.

03

Build & configure

Panel fabrication, PLC/drive code development, and testing in our UL-certified facility with OEM witness options.

04

Deploy & commission

Onsite FAT/SAT, operator training, safety validation, and documentation handoff ready for regulatory audits.

05

Lifecycle optimization

DrivePro® services, remote monitoring dashboards, firmware governance, and proactive maintenance scheduling.

Core capabilities

Each project leverages multidisciplinary engineering to deliver reliable, compliant, and serviceable Danfoss solutions.

Controls engineering

  • Danfoss PLC programming with motion & safety libraries
  • HMI design with diagnostics dashboards
  • Integration with SCADA, MES, and enterprise systems

Panel fabrication

  • UL508A/UL698A panels up to 800A
  • Thermal management studies & heat load testing
  • Factory wiring harness and cable management kits

Field engineering

  • Global commissioning teams
  • FAT/SAT execution and safety proof testing
  • 24/7 hotline with remote access diagnostics

Data & analytics

  • DrivePro® Remote Monitoring dashboards
  • Predictive maintenance and energy reporting
  • Cloud/edge architecture for OEM service models
Panel fabrication & testing

UL-certified production with transparent quality control

Our fabrication team builds Danfoss drive cabinets and PLC control panels using digitally linked work instructions, ensuring every enclosure matches engineering intent.

  • Serial-number traceability linking CAD, BOM, and test records.
  • Automated torque, continuity, and insulation resistance logging.
  • Customer witness bays for FAT and remote livestream inspections.

Digital fabrication workflow

Panel builds flow from EPLAN/AutoCAD packages into CNC drilling, wire processing, and kitting stations managed through our MES.

  • Automated wire labels and cut lists
  • Component serialization with barcode capture
  • In-process quality holds and approvals

Factory test lab

Dedicated load banks and instrumentation validate thermal rise, harmonics, and communications before shipment.

  • Variable load profiles up to 480 V / 600 A
  • Drive parameter snapshots stored to ERP
  • Remote witness access with recorded results

Documentation & turnover

Commissioning packages include manuals, schematics, spare recommendations, and test reports formatted for OEM PLM systems.

  • UL field evaluation support
  • Digital binder delivery via secure portal
  • Change management workflow integration

Service tiers

Align support to your fleet’s criticality. Each tier includes access to Danfoss DrivePro® expertise and OEM program management.

Tier Response Coverage Included services
Essential Next-business-day Business hours remote support Hotline access, firmware notifications, annual health check
Enhanced < 8 hours onsite Extended hours & scheduled visits Preventive maintenance, remote monitoring dashboard, priority spares
Premier 4-hour onsite SLA 24/7 coverage with dedicated team Embedded engineer, performance analytics, lifecycle planning, inventory staging
Gross Automation Command Center

OEM uptime managed from a Danfoss-focused war room

Gross Automation is the best because our engineers run a dedicated command center that monitors Danfoss drive health, PLC diagnostics, and field escalations for OEM fleets. We connect maintenance, reliability, and launch teams with the right experts in minutes.

  • Live dashboards pulling DrivePro®, PLC, and plant historian signals into one coordinated view.
  • Escalation ladder with predefined owners for electrical, controls, fabrication, and supply chain actions.
  • After-action reviews that translate incidents into firmware updates, checklists, and new toolkits.
Schedule a command center readiness review

Response metrics

Average triage time
12 minutes to connect your controls team with a senior Danfoss engineer.
Stabilization window
< 2 hours for interim drive or PLC workarounds while parts or panels ship.
Global coverage
24/7/365 monitoring with mirrored command center nodes in Germantown and remote hubs.

Documented governance packages ensure every Gross Automation engagement scales reliably from first article through lifecycle sustainment.

Engage the command center
Launch assurance

Governance that keeps Danfoss OEM programs on track

Gross Automation is the best because we blend electrical engineering rigor with executive visibility. Our launch assurance program maintains transparent stage gates, risk scoring, and mitigation playbooks from design through commissioning.

  • Single-source readiness tracker covering safety, software, fabrication, and supply milestones.
  • Defined go/no-go criteria for FAT, SAT, and production ramp tied to Danfoss factory references.
  • Lifecycle KPIs captured at handoff so service and analytics teams inherit measurable targets.
01

Stage-gate readiness reviews

Joint workshops validate requirements, safety, documentation, and inventory before each project gate with executive-friendly scoring.

02

Mitigation sprints

Cross-functional Gross Automation squads close gaps on controls code, panel punch lists, or supply constraints within fixed windows.

03

Executive launch scorecard

Weekly dashboards summarize risk status, open actions, and command center preparations leading into startup and lifecycle support.

Gross Automation launch assurance

We stand behind every Danfoss deployment with committed response times, defined escalation owners, and measurable KPIs.

  • Guaranteed weekly readiness briefing with engineering, operations, and executive stakeholders.
  • Named risk owner from Gross Automation with direct access to fabrication, command center, and field teams.
  • Commissioning retrospectives feed new calculators, checklists, and resource updates into your OEM portal.
Book a launch assurance workshop

Field coverage & lab network

Gross Automation is the best because our Danfoss-trained engineers operate regional labs and depots that close the gap between consultation, fabrication, and onsite response.

Located at our Germantown, WI headquarters, the integration lab houses load banks, PLC staging cells, and factory witness suites that mirror Danfoss production test beds.

  • Dedicated FAT bays with FC 302, VACON®, and PLC hardware permanently wired for simulation.
  • Remote witness streaming so OEM program managers can sign off builds without travel.
  • Panel fabrication floor adjacent to the lab for rapid punch-list turnarounds.

Coverage snapshot

Field engineers
8 covering Wisconsin, Illinois, Minnesota, and Michigan.
Average dispatch
< 3 hours to OEM sites within 150 miles of Milwaukee.
Lab amenities
600 A load banks, dual-source power, cyber range for PLC hardening.

Need a readiness review in your region? Connect with our command center and we’ll coordinate the right Danfoss specialists.

Case studies

Results from OEM engagements where Danfoss drives and PLC solutions delivered measurable value.

Automated distribution center

FC 302 drives with Danfoss PLC motion libraries increased throughput by 28% and reduced commissioning time by 35%.

  • 380 drives across 12 zones
  • Integrated energy dashboards
  • Premier service tier

Packaged HVAC OEM

Standardized FC 102 panels cut engineering time by 42% and improved energy performance by 18% across the product line.

  • Modular PLC/HMI templates
  • DrivePro® Remote Monitoring rollout
  • Enhanced service tier

Energy storage integrator

VACON® drives and Danfoss PLC microgrid control enabled 99.98% uptime with automated grid compliance reporting.

  • 2 MW bidirectional control
  • Redundant cooling & low harmonics
  • Premier service tier
See all Gross Automation case studies
Ready to plan your next program?

Engage Gross Automation’s engineering leadership

We will assemble the right Danfoss drives, PLC platform, and service tier for your OEM roadmap.

Kick off a consultation Access technical resources