The Evolution of Production Line Monitoring and the Role of AI in it

By Christian Dager – Sales Leader at TIDAS Automation
[email protected]

Production line efficiency is a cornerstone of successful manufacturing operations. Over the years, the methods used to monitor these lines have undergone significant evolution. What once relied on manual observation and paper-based logging has transformed into real-time data analytics powered by sophisticated software and artificial intelligence (AI). This transition has enabled manufacturers to maximize efficiency, reduce downtime, and improve overall equipment effectiveness (OEE).

The Critical Role of Monitoring Systems

Historically, production line monitoring was a tedious process. Operators would track machine performance manually, recording data in notebooks and spreadsheets. This approach was prone to human error, delays, and inefficiencies in troubleshooting and decision-making. In many cases, manufacturers relied on scheduled maintenance, rather than real-time issue detection, leading to unexpected breakdowns and production halts.

Modern manufacturing demands a more proactive approach. Real-time monitoring systems allow manufacturers to:

• Enhance Efficiency: Immediate data visibility enables quicker adjustments to optimize production rates, improving overall throughput and minimizing bottlenecks.

• Reduce Downtime: Predictive alerts and diagnostics help identify issues before they lead to costly stoppages, allowing for more effective maintenance scheduling and improved equipment reliability.

• Improve OEE: Availability: Ensures that equipment is running as often as possible by identifying downtime sources and minimizing disruptions. Performance: Measures whether the production line is running at optimal speed by detecting inefficiencies such as slow cycles or minor stops. Quality: Monitors defect rates and helps maintain consistency, reducing rework and waste.

• Ensure Quality Control: Automated tracking reduces defects and inconsistencies by ensuring process stability, leading to better end-product reliability and customer satisfaction.

The Evolution of Monitoring Solutions

Over time, numerous systems have emerged to address the challenges of production monitoring. Some of the most widely used include:

• Traditional PLC-Based Monitoring: Many factories still rely on Programmable Logic Controllers (PLCs) combined with SCADA (Supervisory Control and Data Acquisition) systems to collect and visualize production data. While effective, these systems often require dedicated engineers to interpret data and manually configure monitoring parameters.

• Enterprise-Level Monitoring Solutions: Some companies provide comprehensive monitoring platforms that integrate with existing control systems, though they often require additional costly hardware installations and software licenses, making them less accessible to smaller operations.

• Allen Bradley Monitoring Systems: Some solutions depend on Allen Bradley add-on modules, which must be integrated into production lines, adding both expense and complexity to implementation. These modules often require specialized knowledge for proper setup and maintenance, further increasing operational costs.

A New Era: AI-Powered Monitoring

While existing monitoring solutions provide valuable insights, many require expensive hardware and complex installation. Olis is changing the landscape by offering a highly accessible, soon-to-be AI-powered monitoring solution that eliminates many of these traditional barriers.

Why Olis Stands Out:

• Minimal Hardware Requirements: Unlike competitors that require additional modules or servers, Olis operates with just a tablet, reducing upfront costs and installation time. This means companies can begin monitoring their production lines with minimal investment (maybe just a camera or two) and without overhauling their existing infrastructure.

• Direct PLC & Robot Controller Integration: Olis connects straight to the PLC or Robot Controller, instantly processing data without requiring extra third-party hardware. This plug-and-play approach reduces the complexity of implementation and allows for immediate insights into production performance.

• AI-Driven Insights: Olis is working on implementing AI to diagnose issues in real-time and provide actionable solutions based on historical and live data. Instead of relying on engineers to manually analyze logs, Olis will interpret machine signals and highlight anomalies, allowing operators to respond proactively. Users will be able to set automatic alerts and get AI recommendations.

• Remote Monitoring with Camera Integration: For enhanced troubleshooting, Olis incorporates camera-based remote monitoring, allowing operators to visually pinpoint problems and reduce the need for on-site intervention. This is particularly beneficial for large-scale operations where production lines span multiple locations. Users can access their system and see the status of their robot from virtually anywhere!

• Emergency Support: In critical breakdown situations, Olis will have AI that can quickly analyze error signals and suggest solutions, eliminating the need to contact the original equipment manufacturer (OEM) for support. This ensures faster recovery times and minimal production loss, making Olis a game-changer for industries where downtime translates to significant financial losses. End users can also share the Olis app screen with remote support for instant troubleshooting.

The Future of AI in Manufacturing

The evolution of production line monitoring has moved from manual logbooks to AI-driven, real-time analytics. While many existing solutions require expensive hardware and complex integration, Olis is revolutionizing the industry with an accessible, efficient, and soon to be AI-powered approach. By offering real-time diagnostics, remote monitoring, and intelligent troubleshooting, Olis helps manufacturers maximize uptime, improve OEE, and reduce operational costs.

As the industry continues to embrace AI, solutions like Olis will become essential in maintaining competitive and resilient manufacturing operations. Are you ready to take your production monitoring to the next level?

At Tidas Automation , we take pride in including Olis in our robotic solutions, so that the customer can have it built-in from the get-go. Come join us be a part of this evolution!