Process Optimization

I’ve spent the last decade redesigning operator interfaces on high‑mix production lines, and one lesson keeps coming back: the best HMI is the one that feels like it was made for the person standing in front of it. When I talk about operator‑centric HMI redesign, I mean more than a prettier screen — I mean interfaces that reduce cognitive load, guide correct actions, and let operators do their jobs with confidence and minimal training....

Read more...

When I was first asked whether a 30% reduction in machine cycle time was realistic, my immediate reaction was: “It depends.” But after running pilots across automotive and food plants, I’ve learned that combination of prescriptive maintenance and edge analytics often delivers that kind of impact — provided you focus on the right failure modes, design fast feedback loops, and tie actions to operator workflows.Why prescriptive maintenance...

Read more...

I’ve spent the last decade on plant floors and in control rooms watching the same pattern repeat: when variability or rising scrap shows up, the knee‑jerk response is to order new sensors, replace valves, or spec a higher‑precision actuator. Sometimes hardware upgrades are warranted, but often the source of waste sits in the control logic itself — poorly tuned loops, aggressive feedforward that never fires, or interlocks that introduce...

Read more...