Recipes and parameters
Associate settings with the product and identify the conditions under which processing takes place.
Technologies
Integrated control, robotics, vision and data to manage the process and support its evolution.
Integrated technologies, from operation to system evolution
Control, robotics, vision and data work together to operate the solution. Technology choices consider the process, the people who will use the plant and production continuity, including in the event of faults or changes in operating conditions.
The architecture connects the different functions and defines signal and information exchange, including with existing machines and systems from other manufacturers. Interfaces and responsibilities are clarified alongside the scope of supply.
01 · Different functions, coordinated together
Control and coordination
Sequences · states · operating configurations
Each function exchanges states, results, commands and parameters with the control system.
-
Handling
Transfer the product -
Robotics
Manipulate and execute -
Processing and assembly
Transform and join -
Vision and inspection
Verify the product -
Identification
Recognise and track
Each function communicates with the control system. The arrangement represents relationships, not the order of operations.
02 · Understand, decide and share
The operator, diagnostics and factory systems exchange information with the control system to manage production.
OperatorUnderstands the status and takes action
Diagnostics and AIDetect faults and support decisionsProduction dataRetain history and results
Factory systemsExchange orders and information
The functions shown are selected and connected according to the project.
Control and operator interface
The control system coordinates sequences and operating modes; the interface provides access to recipes, parameters and information needed for operation. Their organisation follows the activities of the people who operate and maintain the plant.
Machine states, alerts and diagnostic tools help explain a fault and identify where to intervene. Access, settings and available information are defined around roles and operating needs. The interface also identifies the alternative configurations provided, their limitations and the actions needed for recovery.
Vision and identification
An inspection result becomes valuable when the system knows how to use it. Linking vision, identification and control associates information with the product and the point in the sequence where it is needed.
The data to exchange, required response times and handling of results are defined: continue processing, correct a reference or request verification. An unreadable image or uncertain result must also have a planned response that the operator can understand.
Product recognition, guidance and inspection
Data that follows the product
Identification and results
Link identifiers, operations and results to reconstruct relevant steps and analyse faults.
Factory interfaces
Define which information to exchange with supervisory and management systems, through agreed interfaces and responsibilities.
The value of data depends on the decisions it helps inform: reconstructing an event, comparing processing conditions or identifying recurring faults. Acquisition, retention and access are defined according to the intended use and project scope.
Simulation and Digital Twin
Virtual studies can help compare layouts, sequences and interactions before testing the physical system. Model detail is chosen according to the question being addressed and the data available. The study may include station unavailability, buffer capacity and line behaviour in an alternative configuration.
3D modelling, simulation and Digital Twins serve different needs. Each project defines the aspects to represent, any connections with the real system and the checks required to compare the model with plant behaviour.
Explore studies and trials
IOCCO software / Industrial AI
Process intelligence, production continuity, skills
IOCCO software combines process knowledge and artificial intelligence to configure production, address faults and support people.
AI, control and the operator interface work together: from product data to parameter selection and adaptation of operating conditions. Bag Furnace and LeanLam are practical applications of this expertise, developed around process needs.
Assisted configuration
The software connects product characteristics and processing requirements to support parameter definition and production setup.
Adaptive control
When faults occur, the software recalculates and applies parameters in the stages designed for this purpose. Responses stay within permitted operating conditions and are coordinated with the plant control system.
On-the-job training
AI guides configuration and fault response step by step. Operating guidance helps people with different levels of experience understand activities and develop greater independence.
Further reading: GTI Asian Glass Vidrio
Resilience and production continuity
The ability to respond to unexpected events comes from integrating software and plant architecture.
Backup devices, alternative stations and intermediate buffers provide practical response options. The control system coordinates these resources to limit the impact of a fault and support the return to nominal conditions.
Fault
detected→Check
available alternatives→Setup
reconfigured→Continuity and
recovery
detected→Check
available alternatives→Setup
reconfigured→Continuity and
recovery
A suitably designed line can transfer processing to an equivalent station or use a buffer during a temporary interruption. Alternative configurations are verified at the design stage, maintaining safety and quality requirements, even at reduced capacity. When continued operation is not possible, the system manages shutdown and subsequent recovery.
Industry 4.0 and 5.0: connectivity, people and resilience
Industry 4.0 connects machines, sensors, control and factory systems. Exchanging states, recipes and results makes the process observable and traceable, providing a basis for diagnostics, coordination and operating decisions.
Industry 5.0 builds on this foundation with three design objectives: human centricity, sustainability and resilience. Technology is also assessed by how it helps people work, use resources and respond to unexpected events.
People
Clear interfaces, training and well-defined roles help people recognise plant status and take action, including under unusual conditions.
Sustainability
Consider energy, materials, waste and component life under actual operating conditions and alternative configurations.
Resilience
Plan responses to faults and reconfiguration options to limit interruptions and restore production capacity.
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