Increasing Production Capacity by Scaling Expertise
The challenge for most modern manufacturers when increasing capacity is scaling the expertise of their most knowledgeable individuals across more machines, shifts, and factories. The Flexxbotics Platform removes this constraint to increasing production output by using software-defined factory technology that connects real-time production data to operating rules and autonomous actions to extend expert knowledge across plant operations.
Instead of simply reporting what already happened, Flexxbotics detects changing conditions, determines corrective responses, and enables controlled action before small issues become production losses. Production teams define where software can act autonomously, which automated responses are authorized, and when human-in-the-loop approval is required before real-time action is undertaken. This allows process adjustments to occur proactively while experienced personnel handle the exceptions which require their judgement.
By identifying and addressing production issues earlier, Flexxbotics reduces dependence on manual intervention and enables manufacturers to increase capacity and output while maintaining complete control and oversight.
“Increasing capacity isn’t just about adding more plants and equipment. Companies must scale their experts as well to truly drive ROI,” said Tyler Bouchard, CEO & Co-Founder of Flexxbotics. “Flexxbotics amplifies the know-how of your most experienced personnel across every operation with safety and control to achieve greater manufacturing autonomy.”
Proven Production Impact
Flexxbotics customers have realized measurable production performance gains across a range of operational metrics, including:
- PMI increased capacity by 125%.
- EIS reduced downtime by 89%.
- Ruland Manufacturing reached an 80% utilization rate.
- SpiTrex Orthopedics shortened lead times by 20%.
- Orizon Aerostructures cut rework and scrap by 40%.
“Data-driven autonomy scales the impact of our most knowledgeable people so we’re able to increase capacity even faster while we simultaneously raise quality,” said Rick Newell, Director of Advanced Manufacturing Technology & Innovation at Orizon Aerostructures.
Orizon Aerostructures manufactures some of the largest, most complex structural components and subassemblies in the commercial aerospace, defense, and space markets. As an advanced manufacturer and critical supplier to Lockheed Martin, Boeing, Blue Origin, and other industry leaders, the company is driving greater manufacturing autonomy in high compliance, precision production using Flexxbotics.
From Production Monitoring to Controlled Action
Unlike conventional monitoring systems, the Flexxbotics Platform creates real-time feedback loops across multi-plant operations enabling the platform to Connect, Detect, Correct, and Act.
Connect – Connect incompatible equipment and contextualize detailed industrial data.
Detect – Recognize deviations across processes, machines, tools, orders, and runs.
Correct – Identify risks and determine appropriate responses based on operating rules.
Act – Recommend, escalate, or execute authorized actions before issues become losses.
The Flexxbotics Platform combines a real-time control plane (FlexxControl) and edge software runtimes (FlexxEdge) with protocol-level drivers (Transformers) that use the FlexxCore interoperability technology to connect factory data, operating rules, and authorized actions for safe and controlled autonomous operations.
The Real-Time Control Plane for Manufacturing Autonomy
The real-time control plane, called FlexxControl, governs production responses and intelligent updates across machines, lines, and plants.
FlexxControl uses actual production context to identify process deviations and downtime risks, determine responses, and invoke human-authorized autonomous actions. It manages approvals and escalations, records decisions and actions for digital thread traceability, and defines where automation can operate independently and where human intervention is required.
This gives manufacturers a controlled path toward greater autonomy while preserving human authority and judgement over production decisions.
Connects the Factory From Data to Action
The platform also includes edge software, called FlexxEdge, with protocol-level drivers called Transformers.
FlexxEdge runs in the plants to process real-time events, contextualize production data, and coordinate closed-loop operations. Transformers address different machine incompatibilities by translating protocols and supporting controlled, bi-directional communication across more than 1,000 makes and models of industrial equipment. The core interoperability technology, called FlexxCore, provides the many-to-many compatibility with cross-vendor command mapping and data normalization.
These add closed-loop coordination and control to existing plant infrastructure without replacing the control logic or enterprise systems already running in the factories.
“Manufacturing autonomy depends on what happens in plants at the edge, where software has to communicate reliably with the machines and equipment actually running in production,” said Tyler Modelski, CTO & Co-Founder of Flexxbotics. “FlexxCore gives our edge software the interoperability needed to translate incompatible machine communications and provide the secure device interactions required to turn intelligence into action.”
Solutions for Manufacturing Autonomy
This latest platform release includes a set of solutions that companies can deploy individually or together.
Industrial Data Connectivity – Collects protocol-level signals and adds production context at the source to create AI-ready industrial data for training and inference.
Automated Production Tracking – Captures real-time production actuals across parts, orders, machines, operators, and shifts for more accurate insights and forecasting.
Process Characterization – Profiles live production behavior to establish baselines and operating limits and detects drift before defects, deviations, or downtime occur.
Autonomous Process Control – Proactively identifies production risks and anomalies and enables human-authorized corrective actions before problems cause production loss.
Together, the solutions move manufacturers from simply collecting industrial data for dashboards to production intelligence and ultimately controlled closed-loop action.
Creating the Foundation for Industrial AI
Industrial AI requires more than models and raw machine signals with unintelligible tags or context. Manufacturers need the operational capability to securely use AI insights for real-time production decisions with control and traceability.
Flexxbotics provides this critical foundation by capturing protocol-level variables and adding production context including part specifications, process operations, quality results, tooling, and an unlimited number of user-defined fields. Actual production behavior is then used to establish process profiles, baselines, and operating limits that enable predictive detection necessary to increase autonomous control.
This enables companies to use Industrial AI to augment expert analysis for optimization and expand the reach of human know-how while maintaining control over how recommendations and actions are implemented.
Works With Existing Systems
Flexxbotics works with existing ERP, MES, SCADA, PLCs and machine controllers to empower existing factory infrastructure with standardized IT/OT capabilities for closed-loop operations that enable greater levels of manufacturing autonomy.
The highly scalable and secure Flexxbotics Platform operates online or offline with store-and-forward persistence and encryption in transit and at rest.
The Flexxbotics Control Plane can be deployed on customer servers, the AWS Cloud or GovCloud, while the containerized Edge Software runs on standard gateways and industrial PCs in factory workcells and production lines.
Available Now
The latest release of the Flexxbotics Platform and solutions is now available.
Flexxbotics edge software is also available as a free production-ready download with no trial period or time limit, including the edge runtime, developer studio and API, and access to a wide range of open-source drivers on GitHub.
For more information, join Flexxbotics at IMTS in Booth 236044 located in the North Building, Level 3 or visit https://flexxbotics.com/platform-overview/
About Flexxbotics
Flexxbotics is the autonomous manufacturing platform for closed-loop production and Industrial AI. The Flexxbotics Platform turns high compliance environments from reactive to proactive by extending the knowledge of experienced plant personnel to enable intelligent operations and factory optimization at scale. The platform connects real-time production data to operating rules and authorized actions to increase capacity, improve yields, and reduce downtime by scaling human expertise. Visit www.flexxbotics.com to learn more and follow us on LinkedIn
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