Automatic Loss Capture

In high-speed manufacturing environments, even a few seconds of unplanned stoppage can have a significant impact on productivity, quality, and cost. AI4M’s Automatic Loss Capture solution empowers factories to detect, analyze, and prevent these hidden losses using a combination of industrial automation data and cutting-edge AI technologies.

Fusion of PLC Stop Codes and ML-Based Insights

Our system intelligently fuses PLC stop codes with machine learning algorithms trained to recognize patterns in high-frequency PLC parameters. This enables automatic tagging of stoppages with contextual reasoning — not just when and where a line stopped, but why it truly did. Logical stops from PLCs are enriched with deeper insight through pattern recognition of physical phenomena such as torque spikes, current surges, speed dips, or temperature anomalies — often undetected by conventional logic.

Strategic Visual Intelligence: Machine Vision and CCTV

We deploy a network of strategically placed cameras, including both machine vision and CCTV systems, to complement PLC data with visual context. Using advanced AI techniques like detection, segmentation, classification, and action recognition, the system captures and classifies losses arising from the 4Ms:
- Man – Operator errors, delays, or unsafe behavior
- Machine – Mechanical issues, wear and tear, misalignment
- Method – Procedural inconsistencies, changeover delays
- Material – Defects, blockages, or feed inconsistencies

These visual insights are automatically correlated with PLC events and timestamped to build a unified timeline of loss events.

Benefits at a Glance

- Real-time visibility into micro-stoppages and chronic losses
- Root-cause insights beyond standard PLC stop codes
- Loss tagging with zero manual input
- Video-backed evidence for training and continuous improvement
- Improved OEE and faster problem resolution

With AI4M's Automatic Loss Capture system, your factory gains a powerful lens to uncover hidden inefficiencies and unlock true operational excellence.