Quality and production · demo with sample data
Extrusion control that predicts profile dimensions before they become scrap
For extrusion plants: live line variables, profile dimensions projected by a model, and a suggested adjustment that a person applies before scrap is produced.
What it solves
The problem
Line variables were read on the machine's panels and adjusted at each shift's discretion. An out-of-tolerance profile measurement was not noticed until quality control, when there was already scrap, and no record showed what had changed for each production order or why.
What it does
An agent layer that reads the PLC and profile scanner without replacing them. It monitors variables against their ranges, sends alerts through WhatsApp, uses a model to project profile measurements by zone and suggests which variable to change and by how much. A person decides whether to apply an adjustment, close a production order or enable writing to the PLC.
The result
The entire line is visible on one screen, profile deviation is anticipated with a suggested adjustment, and every production order retains its events, adjustments, alerts and report, with a reference number and a person responsible.
How it looks
Run by the system
It reads PLC variables and profile scanner measurements, compares them with their ranges, checks the startup status indicator, projects the measurement for each zone, proposes adjustments within limits, sends WhatsApp alerts by severity, builds the production order's traceability record and generates its PDF report.
Decided by a person
Which adjustment is applied or rejected and why, which alert is acknowledged, when a production order is closed, each variable's range and classification, when the model is retrained and whether automatic writing to the PLC is ever enabled.
- The line in viewPLC variables and profile measurements on one screen, with their status.
- Adjustments before scrapThe model projects the measurement and suggests what to change; a person decides.
- Production orders with traceabilityEvents, adjustments, alerts and a PDF report for each production order, with a person responsible.
- The PLC does not change settings on its ownAutomatic writing is behind three safeguards and is currently turned off.
“This project began at a profile extrusion plant where each shift adjusted the line at its discretion and discovered scrap during quality control.”
Variables were read on the machine's panels, adjustments depended on the experience of the person on shift, and there was no record of what changed for each production order. The profile measurement was checked later, when the material was already out of tolerance.
What would it look like in your operation?
We review it with you in 30 minutes using your processes and systems.
