Predictive Maintenance · Supply Chain Optimization
Rockwell Automation wanted to add AI across the production asset life cycle so its automation products could improve design efficiency, operations, throughput, yield, quality inspection, maintenance decisions, and equipment lifespan without requiring users to manually code or analyze every condition.
Reported impact
Rockwell reports that embedded AI improves automation system development efficiency, enables no-code quality inspection, supports anomaly-based maintenance decisions, and can increase throughput and yield while extending asset lifespan.
Rockwell Automation is embedding AI directly into its industrial automation portfolio rather than treating AI as a separate product line. In its programming environment, Rockwell added generative AI that converts natural-language instructions into code to speed automation system development. When production data is not yet available, Emulate3D simulation can act as a training environment. On the plant floor, the FactoryTalk Analytics family adds LogixAI, VisionAI, and GuardianAI capabilities. VisionAI uses camera feeds to learn what good and bad product states look like for no-code quality inspection. ControlLogix controllers, already deployed at large scale, act as data aggregation points where learning and adaptation can be applied. For maintenance, GuardianAI analyzes motor-current sensor data from variable-frequency drives and motion systems, then integrates with Fiix CMMS to recommend the needed work order. In logistics, Plex MES manages OTTO Motors AMR fleets while AI-based optimization improves throughput and yield.
Natural-language prompts are turned into automation code in Rockwell's programming environment, with Emulate3D supplying simulated training data when production data is unavailable. In operations, camera images feed VisionAI for quality inspection, while ControlLogix controllers aggregate plant data and motor-current sensor readings from drives and motion systems feed GuardianAI for anomaly detection. Those maintenance findings flow into Fiix for work-order decisions, and Plex manages OTTO Motors AMR fleets with AI-based optimization.
"And if you don't yet have any production data, you can use an Emulate3D simulation as a training environment."
"By integrating GuardianAI with the Fiix by Rockwell Automation [computerized maintenance management system], you can determine what work order is necessary."
"Prescriptive recommendations can increase throughput and yield. The difference between a feasible and an optimal solution can be 10%."
"VisionAI was introduced for quality inspection, with no programming necessary. 'Point a camera at a product coming down a conveyor. It learns what 'good' looks like and what 'bad' looks like.'"
"We currently have 3 to 4 million programmable logic controllers in operation, generating massive amounts of data."
"We've introduced generative AI in our programming environment, turning natural language into code. This improves the efficiency of automation systems development."
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