The manual answers. Even at 3am.
PLC programs, SCADA, wiring diagrams and machine manuals become one thing you can ask in plain words — inside the factory network, no cloud, nothing leaving the site.
Ask the Box
- Why did alarm 4.16 trip, and how is it reset?
- Which interlocks prevent this motor from starting?
- On which pages does K12 appear, and which devices does it control?
- What does the manual say about replacing the seals?
Answers cite the document they come from.
Everyday work, on the Box.
During a stop, the meaning of an alarm is scattered across the HMI text, the tags, the PLC program, the panel schematic and the memory of a few people. Rebuilding it by hand costs exactly the time the line doesn't have.
The Box reads Rockwell Studio 5000 projects and Ignition exports, recognises components and tags on electrical schematics and describes the figures in manuals. The technician asks in plain words and gets the logic chain, the spot in the program and the schematic sheet.
The Box explains and suggests; it never writes to the PLC. Lockout/tagout and safety procedures remain the plant's own.
What the Box does in a plant
The work split by activity: for each one, what the Box does and what comes out.
Alarm diagnosis
Ask about an alarm the way you'd ask a colleague: the Box traces it from the HMI text to the rung that raises it and tells you cause, reset conditions and consequences.
What comes out
- Candidate logic cause
- Reset conditions
- Rungs and tags involved
Schematics and spare parts
Components, terminals and cross-references recognised on multi-page schematics; spare-part codes checked against the bills of materials.
What comes out
- Component pages and references
- Upstream and downstream components
- Spare parts list
Manuals and procedures
Machine manuals and operating instructions searchable down to their figures: the answer comes with the page it was taken from.
What comes out
- Cited manual passage
- Step-by-step procedure
- Training questions
Logs and machine history
Log files grouped by error signature and time windows compared; with Ignition connected, tag history and active alarms too.
What comes out
- Event timeline
- Recurring errors
- Tag history
Energy and reviews
Consumption, baselines and energy reviews: the assistant checks coverage and deviations and drafts from the installed templates.
What comes out
- Periodic consumption check
- Draft energy review
- Deviations from the baseline
Quality and acceptance
Operating procedures, non-conformity reports and acceptance reports start from the company templates.
What comes out
- Standard operating procedure
- Non-conformity report
- Acceptance report
Ask about an alarm the way you'd ask a colleague.
The Box reads Rockwell Studio 5000 projects and Ignition exports: for any alarm it tells you what raises it, where in the program, and what to do to clear it.
Alarm diagnosis
Ask "alarm 4.16" and get cause, reset conditions and consequences, with the rung interpreted and a flowchart.
Tag cross-reference
Who writes and who reads a tag: the complete usage map to understand dependencies before touching the logic.
Ignition HMI texts
Find the alarm starting from the phrase the operator reads at the machine: Ignition texts are indexed and linked to bits.
Explore the project
Overview of programs and routines, search across project files and ladder logic reading with an instruction glossary.
One vertical use case: production and plants. When real-time factory data matters.
For manufacturers: the Box reads line tags, alarms and machine history and answers in plain words — how the shift went, why an alarm fired, where production is being lost.
Production dashboard
Tags, history and alarms processed locally
94%
Stable OEE
81%
Vibration threshold
68%
Thermal anomaly
Process signals
AI priorities
Check Line C motor bearing before the next shift.
Correlate scrap on batch 428 with the 09:40 recipe change.
Reduce oven 2 setpoint to return inside the energy profile.
Predictive maintenance
Reads history, thresholds and machine patterns to anticipate stoppages and suggest interventions.
Quality control
Connects batches, parameters and non-conformities to explain deviations and likely causes.
Clear alarms
Summarizes alarm chains, priorities and operational context in natural language.
Operational decisions
Turns line data into actions for shifts, energy, scrap and throughput.
Ignition integration. From gateway to local AI.
The Box connects to Ignition 8.3 and later in minutes, with no code in the Designer. From there the assistant reads tags, history, alarms and queries.
Admin token
Paste gateway URL and API token only to install the project.
ai_api project
The Box installs the project on the gateway by itself: nothing to write in the Designer.
Runtime key
Operational calls use a dedicated key, not the admin token.
Supported operations
Ignition data ready for chat, reports and widgets
Built for OT environments.
The integration separates setup and runtime, reduces persistent credentials and keeps the gateway inside the industrial network.
The admin token is used only for project import and is not stored.
The ai_api project can be reinstalled, overwriting the previous version.
Runtime operations expose only the functions the assistant needs.
Ignition sees. IntelligenceBox understands.
Ignition collects and controls field data. IntelligenceBox reads it and answers questions about how the line is doing.
Ignition
Collects and controls field data
- Captures tags from PLCs and sensors in real time
- Historises everything in the Tag Historian
- Generates and notifies alarms (email, SMS, voice)
- Displays HMIs, dashboards and reporting
IntelligenceBox
Answers questions about that data
- Answers questions in natural language
- Correlates data with internal manuals and documents
- Generates ready-to-send reports, PPTX and Excel
- Forecasts and flags deviations from targets
The result: ask “how is Line 2 doing?” and the answer arrives in seconds, at the line, without leaving your network.
From a question to a decision, right on the line.
Five real scenarios on top of your existing Ignition projects — same field data, a new natural-language interface.
Run time & alarms
How is Line 2 doing today? Are there any open alarms?
What IntelligenceBox does
- Reads Ignition's Tag Historian and alarm journal
- Computes run time, stoppages and shift availability
- Lists active alarms with priority and duration
- Answers right away, by voice or chat, on the line
Line 2 — morning shift: run time 94%, 3 micro-stops (28 min total). 1 active alarm: spindle over-temperature (6 min).
Energy consumption
Prepare April's consumption presentation for the energy manager.
What IntelligenceBox does
- Generates a consumption PPTX, ready to send
- Produces consumption certificates for reporting and audits
- Suggests energy-management scheduling (loads and time bands)
April_Consumption_2026.pptx — generated in 12 s
Maintenance
'Overcurrent' alarm on belt 3: what's the correct procedure?
What IntelligenceBox does
- Acquires the alarm from the journal with code, asset and timestamp
- Links the motor manual, the asset's history and the spare-parts sheet
- Suggests the procedure: isolate, check the mechanical load, verify the thermal setting
The right procedure reaches the operator the moment the alarm fires.
Forecasts
At today's pace, will I close the week within the production target?
What IntelligenceBox does
- Compares actual production with the weekly target
- Projects the close at the current pace and flags the gap
- Cross-references consumption and production over the same period
- Exports an Excel file ready for management control
92% of the expected pace — estimated close: Fri 17:40, ~3% below target.
Documents
What's the bolt tightening torque for the DN80 flange?
What IntelligenceBox does
- Semantic search across every document, scans included (OCR)
- Concise answers with a reference to the document and page
- Index and contents stay local: no external uploads
For the DN80 PN16 flange the torque is 95 N·m, in 3 cross passes, M16 8.8 bolts. Source: flange_manual.pdf · p.42
What changes on the plant floor.
From fragmented data to answers, reports and decisions — without anything leaving your network.
Reports in minutes
Consumption, downtime and KPIs generated on demand. Hours of copy-paste become seconds.
Decisions on the line
Line status and forecasts one question away, without opening a dashboard.
Less downtime
Alarms correlated with manuals and history: the right procedure reaches the operator immediately.
Energy efficiency
Consumption always under control and load scheduling to cut the bill.
Data kept safe
Everything stays on the factory network: nothing to justify in an audit, no usage-based costs.
Ready from day one
It connects to the Ignition you already run. Nothing on the plant gets touched.
Already in the app
Assistants, templates and archives designed for this work: you start from there, not from a blank page.
Assistants
Plant maintenance
Alarms, machine logs and manuals: from what happened to what to do.
Schematics and spare parts
Reads schematics, checks part codes and prepares spare-parts lists.
Industry and energy
Manuals, operating parameters, consumption and reviews: support for operators, process engineers and energy managers.
Document templates
- Standard operating procedure (SOP)
- Non-conformity report
- Acceptance report
- Energy review
- Management review — energy
- User manual
- Technical specification
- Project risk analysis
Folders and archives
PLC / SCADA programs
Rockwell Studio 5000 projects (.ACD/.L5X) and Ignition tag exports.
Electrical schematics
Components and connections recognised on every sheet.
Technical manuals
Figures and diagrams described, so images can be found too.
System logs
Errors classified by type, starting from the recurring ones.
Useful analysis types
Use cases to start from
Each one is real work: what goes in, what the Box does, what stays with people.
Industrial maintenance and PLC diagnosis
Query Rockwell projects and Ignition tags to reconstruct alarm logic and prepare a technical review with program references.Operations & industryMaintenanceOperationsITElectrical schematics and panel documentation
Make multi-page schematics, cross-references and component tags searchable to support intervention planning.Operations & industryMaintenanceOperationsLog analysis and IT troubleshooting
Group error signatures, compare time windows and prepare investigation hypotheses while keeping technical logs in your environment.IT & analysisITOperationsTraining and onboarding tutor
Create a tutor grounded in manuals, policies and approved material that explains and always points back to the official source.People & collaborationPeopleOperationsMaintenanceData, tables and decisions
Explore management-system exports, spreadsheets and operational datasets through reproducible analysis and team-readable results.IT & analysisData & controllingFinanceLeadership
The Box explains; it doesn't command
It reads programs and history to speed up diagnosis. The plant stays in the hands of the people who run it.
See how the Box is built- No automatic writes or changes to the PLC.
- Lockout/tagout and safety procedures stay binding: qualified staff verify the diagnosis.
- Schematics and programs cited are those of the loaded revision: the Box always shows where it reads from.
The systems to connect
The plant systems and technical archives that usually come in first.
Let's see it on your documents.
Half an hour on a video call, on a case from your sector, with no commitment.