CHAPTER 03 · BUILD
Agents Shipped Inside the Existing Stack
The first system, and the one right behind it, shipped inside the plant's existing historian and CMMS — no new sensors, no new platform. Each one is real and running.
THE AGENTS · 3 FOR THIS WORKFLOW
This plant needed two. The count isn't a package — it's however many distinct jobs the work splits into. Each agent is a separate identity with its own scoped tools and permissions.
Sensor Briefing & Remediation
Predictive Maintenance
Batch-Quality & Energy Optimization
IT DOESN'T STOP AT A REPORT
The Agent Takes the Action
A report is one thing these agents produce. Most of what they do is take the next action inside the plant's own systems — a person approves anything that carries risk.
Open the maintenance work order
A bearing-drift signal drafts the work order in the CMMS, pre-filled, awaiting a tech's sign-off.
Order the replacement part
Raises the parts requisition so it's on the shelf before the planned window, not after the breakdown.
Schedule the swap
Books the fix into the next planned downtime slot instead of scrambling for one.
Log the failure pattern
Writes the confirmed pattern back to the searchable equipment history automatically.
PRODUCTION TRACE
Sensor Briefing & Remediation
Every step below runs against the plant's real data — the exact sequence, in order.
3
Briefings generated
7
Checks accepted
5
Sensor flags reviewed
2
Cross-shift notes carried forward
3 items need your judgment
Ingest
AutomatedLive sensor data pulled from vibration, temperature, and acoustic feeds across every line, every few minutes — no new hardware, no new wiring.
Fan out by role
AutomatedOne data pull becomes three briefings — plant manager (strategic), shift supervisor (execution), maintenance tech (what to check first) — each grounded in the same numbers.
Ground every claim
AutomatedEvery flagged reading cites the exact sensor trace or historical pattern behind it, not a general opinion.
Supervisor review
Reviewer inputEach recommended check is one-click accept or reject. Rejections become training signal for tomorrow's briefing.
Tomorrow's diff
AutomatedThe next briefing opens with a diff against today's accepted checks — did it catch anything, what changed.
REAL OUTPUT · PREDICTIVE MAINTENANCE
One Example, Fully Processed
When a job calls for a written artifact, this is what the system produces — everything it finds, structured for the action it triggers next.
Line 3 Extruder Motor
Vibration + acoustic monitoring · Risk scored every 15 min · Local model, no cloud round-trip
Fleet Health Scan — Line 3
| Machine | Signal | Risk Score | Est. Remaining Life | Confidence |
|---|---|---|---|---|
| Extruder Motor A | Vibration — bearing frequency drift | High | ~9 days | 93% |
| Extruder Motor B | Acoustic — normal | Low | 120+ days | 97% |
| Conveyor Drive 3 | Vibration — normal | Low | 90+ days | 95% |
| Filler Pump 2 | Acoustic — cavitation signature | Watch | ~30 days | 71% |
| Packaging Servo 5 | Vibration — normal | Low | 100+ days | 98% |
Fleet Summary — for Maintenance Planning
5 assets scanned on Line 3. Extruder Motor A shows a bearing-frequency drift pattern consistent with early-stage failure — about 9 days of remaining life at current load. Filler Pump 2's cavitation signature is a lower-confidence read and worth a manual listen before scheduling work.
Tough Calls — Maintenance's First Look
WAVE 2 — IN BUILD
Batch-Quality & Energy Optimization — What's Next
Batch-quality deviations and energy costs are tracked in two different systems that never talk to each other — a slow changeover to chase a quality spec can quietly double a line's energy cost for the run.
The agent proposes a changeover-sequencing adjustment; a constraint solver checks the math against both quality tolerance and energy cost. Nothing ships on an LLM's arithmetic — the solver's answer is the answer, the agent just explains it.
Worked example the solver evaluates today in testing
Line 2 and Line 3 both queue a changeover at 2:15 PM. Four sequencing options scored by projected quality-risk and energy-cost delta:
WHAT CHANGED
Time returned
~85% of manual monitoring time
Supervisors got the time back for coaching and changeovers, not for screen-watching.
Operating complexity
Reactive breakdown response became a reviewed, prioritized checklist
Where this stands
First system live in 45 days
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