Industrial AI Success Stories: Because Even My Title Needed Machine Learning
Production and Operations
This session brings industrial automation to life through two real‑world AI applications—one powered by generative AI and one driven by machine learning. Attendees will see how these technologies are already reshaping design workflows and production‑level decision‑making inside modern manufacturing environments.
We’ll explore how generative AI accelerates early‑stage design, reduces iteration cycles, and helps engineers move from concept to configuration with surprising speed. Then we’ll shift to the production floor, where machine‑learning models enhance operational performance, detect issues earlier, and support smarter, data‑driven decisions.
The session includes interactive demonstrations that let participants experience simplified versions of the actual tools and workflows used in the field. These hands‑on moments make the technology feel tangible and highlight what it really takes to integrate AI into established industrial systems. Attendees will walk away with practical insights, implementation considerations, and a clearer picture of how AI delivers value today.
Key Takeaways
- A clear understanding of what AI actually is
- Practical insight into real‑world AI implementation on the factory floor
- First‑hand experience through interactive demonstrations
Transcript from Summit:
Session Transcript
Good morning, everyone, and thank you, Jake, for that introduction. So, yes, hi, I'm Dominique. Most people call me Dom. I am a technology consultant on our software and control team for Rockwell Automation. If you are unfamiliar with us at Rockwell Automation, we are the largest industrial automation and industry 4.0 company in the world. We are a global company, however, I am local support here in Iowa. I live here in Des Moines, and I help support our Iowa and Minnesota regions for adopting and sharing about our technology here. I specifically focus on our information software, such as AI and things like that. Yeah, so my goal today is to be able to give some real life examples of how AI can be implemented on the factory floor today. And we'll run through some scenarios of that and some challenges. I also do have a live demo. A couple, I have some videos, a live demo. I hope the live demo works out well because that is our agenda. Generative AI demo. So I'm going to start with some modern production challenges that we see today on the plant floor. The first one is a big one, workforce and skill shortages. So when Splice, and so if it even went off a little bit of their tolerance, they were able to go in and check their process and set up and fix whatever they needed to. Okay. I'm going to show you some demos now. Is there any, how much time do I have? Okay, we got 20 minutes. Perfect. Is there any questions that I can answer while I'm pulling these up? The first example was rolling. Yeah. I tried to get a live dump, oh wait, nope, that's not the right one. Ohh. Okay. I tried to get a live demo of this as well, but our training course instances was not agreeing with me the past couple of days, so I was not able to. So I'm going to be clicking through here. Okay. So when you open up Logix AI, this is the first screen that you're going to see. You are defining your prediction and connecting to your control module. From there, what they're doing now, once they're connected to their controller, they're selecting those inputs that they think are impacting the process. Of whatever output they are trying to predict, you're also able to, in the first screen here, I'm going to go back. So you can either do a manual algorithm or we actually have pre-built in ones as well for boilers, generators, and pumps if there is a specific piece of equipment that you're looking to monitor. So right now, they're selecting those tags, and they are going to select the tags that they think are affecting those processes. So these are our input tags at the bottom here, and they're also selecting their output variable. So the thing that they are trying to predict. From there. They also set limits for those tags. That's very important for Logix AI to do as well. I'm going to pause on this screen here. It's just going to give you a summary. So again, we have our output tag. They're trying to predict the mass flow of their model and our inputs. They have a running, they have a speed, they have a running tag. And a couple of other, I don't know what the other ones do, but those are their input tags, and then they're putting limits on those tags, which logic say I does need those limits to be able to evaluate. And they're going to finish that up. And then it did not show it in here, but... They also created the prediction during this time as well. For the model, they're exporting that prediction. And then they're going or exporting that model, they're putting it back into their actual Studio 5000, into their code, their logics file. I'll skip that, it's showing the inputs. And then also kind of the cool thing about Logix AI, if you're familiar with our HMI face plates, we do have the ability to tie directly into an HMI as well with the ViewME or ViewSC software. I don't know if they have a trend in here, but... Yeah. OK. So, I just wanted to give you guys a taste of what that software actually looked like. Design Studio, this might, I was hoping this won't close, but it might take a little bit to open. Live demos are always really fun. Yeah, you showed us you have the Buehler generators and pumps. Is there any other, can you bring in your own plan on? Yes, yes, there was a manual option on there, like an open option, yep. Is there like a standard you follow on that? Not necessarily, I will say it does have to be. like some kind of physical system. The other example that I didn't put in this PowerPoint is called Perfect Fill. So it was another quality thing where they were just like a little bit out of tolerance or they were really trying to zone in on their fill level on a bottle. So then they were using that fill level as their output, and then whatever inputs they put in, I'm not really sure. Can you bring your natural instruments or your... All the map, the map works simulate into it, and then hook it up. What can you both simulink and natural instruments is like you model physical systems? Oh. That's a good question. I'm not sure. So we do have... We have a software as well. That's our digital twin. It's called Emulate 3D. So it might work with that specifically. I'm not sure about any other kind of software. Yes. Can I answer any other questions while this opens? Yes. I teach the first. before they transfer to a four-year university. And I'm just wondering, as somebody in industry, what AI understanding, tools, engineering, technology, AI skills should my students be prepared for before they enter the workforce? Oh, that's a really good question. I just think the ability to just realize the tools that are out there or what's coming, that's what's really important. To be honest, in industrial automation specifically, there are companies that, you know, are really looking ahead in the future and trying to implement these things. Pella is a great example. However, I'm still seeing a lot of plants that are still running on PLCs from like the 50s and 60s. So I just feel like industrial automation as a whole, as an industry, we are a little bit behind the game, I guess, when it comes to adapting these newer technologies. But just Being aware that they do exist and that they're out there, and... Yeah, exactly, yeah. Okay. Like, I'll add on to that a little bit before we get into this. I wasn't originally planning on getting my business analytics certificate at all, but then it ended up being the best classes that I took for my career. Um... Yeah, for what I'm doing today, mostly because I am focusing on our info software here. But yeah, just being able to actually understand as well how those algorithms are working in the background, that's helped me understand then how this software is at least functioning. It's like I don't need to be doing any of that data scientist, data analyst stuff, but at least I understand how it is functioning in the background. I heard someone call it as a first-class citizen, yeah. CIRAS. Yeah, now you've got readers and think about how you're gonna sign out what kind of data you want for analysis. I tell my students that I don't think that AI is going to replace engineers anytime soon, but you know how to use AI are going to replace engineers who don't. Exactly. Yeah, I would agree with that. I do try to expose them to some, but I just want to make sure I'm giving them the leg up that they need. Yeah. Yeah. Yes. Build your system, but it already got. Uh-huh. Yeah. Sorry. So, I'm going to show it can it can help build. It is this is this is our so logic say I was my machine learning example, so it's taking in that data, it's creating a physical like math algorithm out of the data that we fed it to predict an output. This is our example of Gen AI. Three to do more questions. I just want to make sure the end of my recording has been. Ohh, OK. Can you say that you are automating the training? Yes, yes. And that's training your model with most of the effort, and I believe they're automating that part for you and on the industrial application. Yes. So, that's what Logix AI was doing; it was taking in those inputs, it was cleaning the data in the background, doing that analysis, and then coming out with a model that we can plug back into our system. This is Design Studio. So this is where we're going to talk about our generative AI example. I'm really about at saying that word, obviously. So you can see here that I have all of this code. And again, I'm in sales now. I'm not a technical person. I have no idea what this is. what this is doing. So I'm going to ask Copilot. I did try this a little bit earlier, and it did need a specific task to look at. So I'm going to say, what is going on with? Routine sip. Anh. This might take a little bit to analyze. I did already run this through, so we'll wait for it, but... I said, what does this code do? And it said, you're not being specific enough, Dominique. I need a better example than that. So then I said, okay, what is this piece of code doing? And you can see here, I won't read through all of it, but it does a really, really good job at documenting what that piece of code is doing. So it even told me it could go through it line by line, and I was like, no, thank you. but it's saying I have my output. It's a pump output control, pretty much. It is requesting feedback, and then it's, yeah, it summarized it. So it says it provides a manual on-off auto mode, drives a single pump DO channel based on the auto demand. And then it sends a request done, once that code is done through. So again, if your engineers really, really, really don't like documenting code, this is a really good way to summarize that. Or in my case, if you have a creative coder, me, I'm a creative coder. It can help just kind of debug and actually tell you what's going on with that code. Okay, I did have a prompt that I'm going to put in here. So this is the other thing, the Gen AI. So I'm going to ask it to create a new smart object definition. I'm giving it a couple of tags and just telling them name it whatever they want. And then in the main routine, oh, it does not have a program A, so I'm wondering if it will throw a flag or create one. It's going to provide logic for a fault light output and a reset button. I have not tried this yet. So we'll see how it goes. And then after this, I'm also open to taking If anybody has a prompt that they want to throw in, we can see if it... Outputs what we need it to. While that is going, we'll multitask a little here. I know I didn't talk again, I just focused on two of the many softwares that we have. Is there any specific thing on our plant floor here that, yes. I'd be curious to hear more about your predictive maintenance, of course. Yeah. So when it comes to predictive maintenance, we have one software that's currently out. It is called, I'm going to go back into PRES. Can everybody see that OK? No. Okay. Yes. Okay, good. This is our main out-of-the-box software. It's called Guardian AI. What it's meant to do is monitor the physical assets that you have on the plant floor. So the main ones that are built in are pumps, motors, blowers, and fans. It is currently only compatible with our PowerFlex 755 line of drives. We have a new line coming out, the 525s. It will also be compatible with that. But it uses that drive. It's using some of the high availability data from the firmware. And it's doing, again, fancy math, it's a four-year analysis on there to look at that drive signature. It's creating a baseline utilizing clustering, utilizing an AI algorithm. And then from there, it's able to detect an anomaly before it's necessarily seen by an operator or before an asset actually fails. So it will send out an alert through your HMI or through email to tell you, hey, let's say we use a fan. Hey, I think fan one is failing right now. And it also has embedded first principle faults in there as well. So it won't only tell you, hey, I think your fan is failing, or I'll use a pump. It won't only tell you, hey, I think your pump is failing. It will say, hey, I think your pump is cavitating. You should go check on that or have somebody check on that. Yes. Using a fan as an example. Oh, sorry. Sorry. Yeah. No, go ahead. Using a fan as an example, what specific sort of items is it monitoring on the fan? You know, vibration, key, voltage draw? I mean, what's it? It's only, the only data that it's using is the three-phase current that's coming from the drive. Yes, we are, we're coming out with a new vibration module. Soon, and that will be able to tie into Guardian AI, but we don't have the ability to specifically do vibration monitoring right now. Is there any data that the AI is doing this better than stable traditional monitoring system? Sorry, can you repeat that? data showing that using the AI to look at the data on the vibration of the current that's working. Here's a graph, you can see temperature go off, you can see vibrations go off. I don't have, oh, the question was, is AI a better way to monitor these systems than traditional monitoring, like looking for temperature spike, vibration spike, et cetera. Potentially, the thing with Guardian AI, for example, is that it might be able to catch those spikes faster than your traditional monitoring before something actually fails and then your retrospect looking like, oh, hey, what's going on there? Any other 5 minutes? OK, let's go back here. Let's see, do we have a program A? Another question? Yeah, go ahead. Is there no bolt-on option or is it Rockwell Automation? I, it's just Rockwell Automation. The. It said it created it, but I'm not seeing anything. Hmm. Do we see? All smart objects. Okay, well that worked well. Braly. Yeah, exactly. Let's see. In other words, how do you? What's your arrangement with with your partners? Is it is it? Impact-based, is it time and hours? You or your team, or how's that? That's a great question. I'm gonna, while that's working, and while I'm actually trying to get my demos to work, I will go on to this last slide here. Okay. Fantastic question. So asked on the commercial side, what does the team look like? What do partners look like? Things like that. We have a great partner network at Rockwell. So if you're familiar with Van Meter, they are our authorized distributor in Iowa. They have fantastic resources. They do a bunch of classes. They have their complete own team of software specialist account managers, things like that, that can help you pick whatever softwares or if you have any specific problems you're trying to solve, they're great to reach out to. We do have teams at Rockwell. So I actually, I'm no longer a technology consultant. I just switched roles to become an account manager. So I'm focused on industry in Iowa here now. But any of our technology consultants, we do have teams on the software control side and on our intelligent device, so drives and things like that as well. We have a couple of resources in Iowa. Happy to come in, talk to you. We're free. for, at least to start, to just talk you through solutions and things like that. System integrators, we also have a ton of great system integrators that we're partnered with. In Iowa, interstates is going to be our biggest one here. So they're also great partners with us when our technology, when it comes to adapting these kinds of things. It did not answer your question. OK, or I think so. It sounded like you would be willing to come in and visit any of us who already say have. on hand. Yeah, and see what we have and then you'll come up with the other. Yeah, 100%. Yeah, I do have, I do have business cards up here. So feel free, feel free to take any, reach out to me. I can, I can help you at least get to the right resources if I'm not necessarily the right resource.