From the Initial Idea to Lifelong Support of Your System
MSG Solutions is more than a machine builder: we are your partner throughout the entire lifecycle of your production system. From the initial analysis through concept development, design and manufacturing to on-site commissioning and ongoing service – everything is handled by a single source. And at every step, we combine mechanical engineering with our own measurement technology, so your system is equipped with a digital twin, inline quality assurance, and data-driven process optimization from the very start. Since 1998, customers in steel and pipe production, the automotive industry, and construction supply worldwide have trusted this end-to-end process.
Analysis & Consulting
Every project begins with an open conversation: what do you want to achieve? Where are the bottlenecks? What quality requirements must be met? Our experienced engineers analyze your existing process, assess the condition of your systems, and identify optimization potential – technically and economically. We bring our dual competency in mechanical engineering and measurement technology from the very start: where can inline measurement make your process more transparent? Where can a digital twin save manual inspections? At the end of this phase, there is a clear recommendation: new build, modernization, or targeted expansion – with a concrete cost-benefit comparison and realistic timeline.
Concept Development
In the concept phase, we translate your requirements into a technical solution. Our designers create 3D system layouts, define material flow, specify processing stations, handling systems, and measurement technology positions, and simulate cycle times and output rates. You receive a detailed concept with 3D visualization, interface documentation, and performance forecast – before the first bolt is turned. This way, you can evaluate the solution, align internally, and invest with confidence. For complex projects, we use virtual commissioning: the control software is tested on the digital system model before the real system is built.
Design & Manufacturing
Detailed design, manufacturing, and pre-assembly – everything happens at our facility in Schmallenberg. Our teams work in parallel on mechanics, electrical engineering, and software development to keep lead times short. Every component is manufactured according to design specifications and pre-assembled and tested at our facility. This includes mechanical assemblies and welded structures, control cabinet construction and electrical installation, PLC programming and control integration, and calibration and pre-testing of our inline measurement technology (TWINEX ScanEnd, TWINEX ScanOut, TWINEX ScanIn, TWINEX Straightness, TWINEX SurfOut). Through maximum pre-fabrication at our facility, we minimize on-site installation time and ensure your system is already 90% tested upon setup.
Integration & Commissioning
Our assembly and commissioning teams install your system on-site, integrate it into existing material flow, and network the control with your MES/ERP system. This is followed by a structured commissioning process: mechanical adjustment, electrical testing, software validation, measurement technology calibration, and cycle time optimization. Only after successful acceptance with defined performance parameters do we hand over the system to your team – including comprehensive training for operators, maintenance staff, and quality managers. You receive complete documentation: circuit diagrams, software backups, maintenance plans, and calibration protocols.
Service, Maintenance & Optimization
MSG Solutions supports your system throughout its entire lifecycle. Our after-sales program includes predictive maintenance with defined intervals and digital wear monitoring, remote maintenance via VPN access for fast fault diagnosis and software updates, spare parts supply with guaranteed delivery times, short-notice on-site deployment worldwide for unplanned downtime, and continuous process optimization based on your production data and measurement technology evaluations. Beyond that, we support you with future expansions, modernizations, and integration of additional measurement technology – so your system produces optimally not only today but also in five or ten years.
Frequently Asked Questions About Process & Service
How does a project at MSG Solutions work?
In five clearly defined phases: 1) Analysis & consulting with cost-benefit assessment, 2) Concept development with 3D layout and cycle time calculation, 3) Design & manufacturing with pre-assembly in Schmallenberg, 4) Integration & commissioning on-site, 5) lifelong service with maintenance, remote maintenance, and optimization.
What distinguishes the MSG Solutions process from other machine builders?
At MSG Solutions, measurement technology is part of the process from the very beginning. Already in the concept phase, we plan inline measurement stations, and during manufacturing, the measurement systems are pre-assembled and calibrated. No other special machine builder offers mechanical engineering and measurement technology from a single source.
Does MSG Solutions offer remote maintenance?
Yes, via secure VPN connections, we can—by arrangement with the customer—access your system control, diagnose faults, install software updates, and optimize process parameters without the need for travel and with minimal downtime.
How quickly can MSG Solutions be on-site for unplanned downtime?
We guarantee short-notice response times. In urgent cases, our service technicians are deployable worldwide within 24–48 hours. Through remote maintenance, many problems can already be narrowed down or resolved before on-site deployment.
Can MSG Solutions maintain or modernize systems from other manufacturers?
Yes, we also handle maintenance and modernization of third-party systems. Especially for control modernization (PLC migration) and the subsequent integration of measurement technology, we have extensive experience.
What training does MSG Solutions offer?
After every commissioning, we train your operators, maintenance staff, and quality managers on the specific system. Additionally, we offer refresher courses and specialist training for measurement technology and controls.
How does predictive maintenance work?
Through digital wear monitoring and evaluation of measurement data from ongoing operation, we identify maintenance needs before unplanned downtime occurs. This way, you plan maintenance windows proactively and avoid costly failures.