Process Characterization for Industrial Intelligence
Understand how processes behave and act earlier to improve throughput and yield
Flexxbotics turns real-time production data into a live operating model for manufacturing performance
Discover How it WorksTurns production data into early warning signals
Our software turns raw factory signals into intelligent predictions for immediate action
Process Characterization is the Flexxbotics solution for profiling production variables, setting baselines, and detecting drift before defects or downtime occur.
Most plants are constantly fire fighting
Teams know when throughput, quality, or deliveries are off, yet “why” is often unclear. Process variation across millions of variables in materials, machines, tools, operators, and conditions makes root cause hard to isolate.
- Unanticipated downtime impacting output
- Quality issues without warning
- Yield loss that's hard to resolve
- Prolonged troubleshooting
- Tribal knowledge locked up in a few experts
How It Works
01
Profiles Actual Production
Captures detailed variables and settings during live production across machines, tools, operators, and runs
02
Sets Process Baselines & Rules
Defines variable target values, control limits, and operating behaviors to detect process changes
03
Detects Drift & Triggers Response
Identifies deviation patterns as they emerge and escalates for defect and downtime avoidance
01
Profiles Actual Production
Customer Results Realized
Capacity Increase
0
Throughput Improvement
0
Downtime Reduction
0
Get Data-Driven Results
- Reduces unplanned downtime by detecting process drift earlier
- Improves yields by isolating conditions that cause variation
- Scales production know-how by capturing process behavior
- Shortens root cause troubleshooting
- Enables AI training and inference
The ability to reduce feed rates as loads increase and tie loads to individual tools and set limits is powerful.
Rex Kelly
Manager of Program Management, Orizon Aerostructures
Process Intelligence You Can Actually Use.
Flexxbotics turns live production variables into structured process profiles, baselines, and drift signals so your teams can detect issues earlier to prevent defects, downtime, and yield loss.
Makes your production workforce more scalable and proactive
Functionality in the Process Characterization solution draws on capabilities in the Flexxbotics Platform
Process Variable Capture
Collects granular protocol data streams of individual variables on each piece of equipment across the factory
Semantic Contextualization
Data signals are structured by part, process, machine, operation, shift, operator, material, tool, and more
Baseline Profiling
Target values and control limits for every variable are based on actual production runs
Predictive Problem Detection
Drift and anomaly conditions that cause defects and downtime trigger immediate escalations
Proactive Correction
Variable adjustment recommendations for real-time review and immediate action before issues occur
Industrial AI Foundation
Process profiles provide a basis for autonomous control and AI-driven prescriptive optimization
Works in Your Plants. Fast.
Flexxbotics operates securely with all the equipment, processes, and systems in your environment.
Process Characterization does not replace existing SCADA, MES, QMS, or PLCs. It creates process trend intelligence to complement and extend those systems for real-time intervention and AI-ready manufacturing.
Interfaces With
0
Makes & Models
Scales Across
Millions
of Variables
Deploys With
SAP
Oracle, Siemens & More
Flexxbotics Process Characterization profiles live production variables to establish process baselines, operating limits, and drift conditions that enable earlier intervention, prescriptive optimization, and support Industrial AI.
Make Your Factories AI-Ready
Create the process intelligence foundation required for optimization