Smart Factory

Smart Factory is a unified digital environment for managing manufacturing. It connects production lines and machines, the warehouse, employees, orders, documents, and ERP and MES data. AI helps analyze performance, spot deviations, and carry out authorized routine actions.

A machine stoppage, a shortage of materials, or rising defects can disrupt the production schedule. When information arrives late, the time to solve the problem shrinks and the delivery date is at risk. Smart Factory helps identify risks before they become disruptions and respond quickly to problems that have already occurred.

The system connects events on the shop floor with production plans, inventory, and order costs. The team sees what could affect output and can act before a delivery deadline is missed.

For shop-floor work, the system helps teams:

• receive shift assignments and instructions at terminals near the line;
• record output, defects, and downtime causes without entering data twice;
• check material availability and locate batches in the warehouse;
• submit equipment maintenance requests and track their progress;
• receive notifications about tasks and line events.

For production management, the system helps teams:

• compare planned and actual output, line utilization, and costs;
• monitor quality, downtime, and equipment condition;
• track inventory and order fulfillment in one system;
• learn about risks and deviations that need a decision;
• assign owners and check the results of their work.

Cortex Intellect implements Smart Factory end to end: we assess the site, select and connect equipment, integrate it with ERP and MES, configure the AI agent, and train the team. One team is responsible for design, launch, and support.

Smart Factory can include an AI agent that employees or managers can ask questions and give instructions in plain language from a computer, terminal, or phone. The agent uses data from ERP, MES, the warehouse, and equipment. Its access to data and actions is limited by assigned permissions.

For example, you can ask the AI agent to:

• “Find out why Line 2 was idle this week and prepare a short report for the production manager.”
• “Compare the plan with output for this shift and show which operations fell furthest behind.”
• “Check the stock of materials for Order 2841 and whether it will last until the next delivery.”
• “If a machine’s temperature or vibration exceeds the limit, create a diagnostic request.”

The agent finds information in connected systems, shows which data supports its answer, and suggests next steps. It can perform authorized actions itself and routes decisions that need a person to the responsible employee. All actions are recorded in the system history. Smart Factory can also be extended with other AI solutions.

We begin by assessing the production site: we review processes, existing software and devices, and where data is still entered manually. Then we choose priority scenarios and prepare an implementation plan. Smart Factory is connected in stages so production lines can keep running.

Cortex Intellect manages the project from assessment through support:

1. Design. We study the site, define production scenarios, data collection points, and network and infrastructure requirements.
2. Equipment. We select, supply, and install controllers, sensors, scanners, terminals, and cameras for the plant’s specific tasks.
3. Integration. We connect equipment with ERP, MES, warehouse software, and other existing systems. When needed, we build additional software modules and connect an AI agent.
4. Launch and support. We test the system during real shifts, train the team, and support the solution after launch.

Where possible, we keep existing equipment and software: we check compatibility and connect them to Smart Factory. If new devices are needed, we select ready-made products or design devices and embedded software for the task. We can also develop ERP and other software for production processes.

Smart Factory connects production data and helps each employee do their job:

• Executives monitor output, costs, and order completion, and see risks that need a decision.
• Shift supervisors track plans and line utilization, assign tasks, and investigate deviations.
• Operators receive work orders and instructions, confirm operations, and report faults.
• Warehouse employees use scanners to receive, move, and pick materials.

The system can be used on a computer, terminal, tablet, or smartphone, depending on working conditions. Access rights, notifications, substitutions, and activity history are configured to the company’s rules. Available functions and workflows can be adjusted as processes change.

Smart Factory software connects production operations with accounting and planning. Order, material, and cost data is complemented by events from lines, warehouses, and quality control stations. We can improve existing software, build missing components, and connect everything to equipment in one system.

The Smart Factory software stack may include:

• Manufacturing ERP. Links orders and specifications with purchasing, inventory, and production costs.
• MES and work order management. Sends tasks to lines, records completed operations, and shows deviations from the shift plan.
• Downtime and maintenance tracking. Records machine stoppages, duration, and causes, and supports maintenance schedules and repair requests.
• Quality control and traceability. Records inspection results and defects and tracks a batch through production stages.
• Materials management. Shows inventory and movements between the warehouse and shop floor and supports scanner operations.
• Shop-floor tools. Show tasks and instructions on terminals and allow operators to confirm work or report faults.
• AI agent. Helps investigate delays, check order data, and prepare summaries for responsible staff.
• Integrations. Send events from PLCs, SCADA, and sensors to MES, ERP, and other company systems.

The solution depends on your production needs. You can start with one line or area, validate it during a real shift, and then connect other processes and equipment.