Consumer Packaged Goods · Assembly & Final Pack

Microstop Root Cause Elimination

Go from patching microstops to eliminating them, reducing the rate from 12.4 to 2.8 per 1,000 units.

−77%

Microstop Rate

From 12.4 to 2.8 stops per 1,000 units, with 3 root causes eliminated versus patched for the first time in 2 years

+12 pts

OEE Recovery

Assembly cell OEE from 76% to 88% sustained over 8 weeks post root cause fix

+3.4×

MTBF Improvement

Mean time between failures extended from 2.1 to 7.2 hours after servo torque signature-guided maintenance

How Allie Works Here

From signal to action in real time.

Production OptimizationPredictive Maintenance

The Production Optimization agent classifies each microstop by duration, axis, and upstream component state using a decision-tree model trained on 6 months of historian data. Rather than logging 'conveyor jam' generically, it identifies that 71% of jams correlate to one specific Bosch Rexroth gripper axis torque spike pattern that occurs when component tray presentation is off by more than 1.2mm. The Predictive Maintenance agent monitors all 6 servo axes for torque signature drift, predicting gripper wear with sufficient lead time to schedule replacement during a planned PM window rather than reactively.

Machines & Connectivity

OT-connected, protocol-native.

Bosch Rexroth IndraDrive Servo System

Bosch Rexroth

EtherNet/IP

Servo-driven assembly pick-and-place with 6 axes; each axis generates current and torque tags

Cognex DataMan 370 Barcode Reader

Cognex

EtherNet/IP

Assembly verification scanner confirming component identity at 3 stations on the assembly line

Allen-Bradley CompactLogix 5380

Rockwell Automation

EtherNet/IP

Assembly cell PLC controlling all servo sequences, I/O, and upstream accumulation buffers

Process Variables

The signals Allie monitors and moves.

Signal Name	Historian Tag	Unit	Baseline	Optimized	Target
Pick-and-Place Cycle Time	`ASSY01.PP.CYCLE`	ms	420–680	405–430	Tighter
Microstop Duration per Event	`ASSY01.MSTOP.DUR`	s	8–45	8–12	Lower
Microstops per 1,000 Units	`ASSY01.MSTOP.RATE`	stops/1K	12.4	2.8	Lower
Servo Torque at Gripper Axis	`ASSY01.SRV.TRQ`	Nm	±18%	±5%	Tighter

Pick-and-Place Cycle TimeTighter

ASSY01.PP.CYCLE

Baseline: 420–680 ms→ 405–430 ms

Microstop Duration per EventLower

ASSY01.MSTOP.DUR

Baseline: 8–45 s→ 8–12 s

Microstops per 1,000 UnitsLower

ASSY01.MSTOP.RATE

Baseline: 12.4 stops/1K→ 2.8 stops/1K

Servo Torque at Gripper AxisTighter

ASSY01.SRV.TRQ

Baseline: ±18% Nm→ ±5% Nm

In the Field

"a Tier-1 personal care product manufacturer running a 6-axis servo assembly cell at 95 units/min target rate"

Deployed at a Tier-1 personal care product manufacturer running a 6-axis servo assembly cell at 95 units/min target rate. The results above reflect production data from the 60–90 day period following full deployment.

−77%microstop rate

+12 ptsoee recovery

+3.4×mtbf improvement

Next Step

See what your lines are actually capable of.

A 30-minute operational assessment. We review your OT/IT setup, identify the highest-ROI deployment, and deliver a scoped pilot proposal.

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