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Case Studies
AI manufacturing Case Studies — Search 1,100+ Real…
Real-world AI implementations in manufacturing with measurable results. Browse AI for Manufacturing's database of case studies by industry, use case, and technology.
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Monsanto
Monsanto Doubles Seed Conditioning Lines and Cuts Development Time 40% with PlantPAx
40%
Development time reduction
2 to 4 lines
Production lines doubled
Production Planning & Scheduling
Food & Beverage
by Rockwell Automation
Liberty Primary Steel
Liberty Primary Steel Increases Structural Steel Production Capacity by 40% with Drive and Control Upgrade
40%
Production capacity increase
Process Optimization
Metals & Mining
by Rockwell Automation
Anonymous Fortune 500 Food Manufacturer (via Kirby Risk Corporation)
Food Manufacturer Reduces Unplanned Downtime 75% and Saves $70K/Year with GuardLink Safety Technology
75%
Unplanned downtime reduction
$70,000/year
Annual cost savings
Safety & Compliance Monitoring
Food & Beverage
by Rockwell Automation
The Royal Mint
Royal Mint Commercializes Precious Metal Recovery from E-Waste with PlantPAx DCS
Process Optimization
Metals & Mining
by Rockwell Automation
Repsol
Repsol Upgrades Safety Instrumented Systems in Ecuador to Meet Corporate Safety Standards
Safety & Compliance Monitoring
Energy & Utilities
by Rockwell Automation
Volga
Volga Reduces Control Panel Wiring Time by 66% with EtherNet/IP In-Cabinet Solution
66%
Wiring time reduction
36%
Panel size reduction
Process Optimization
Industrial Machinery
by Rockwell Automation
Anonymous Aerospace Manufacturer (via Concept Systems Inc.)
Aerospace Manufacturer Achieves Flexible Aircraft Paint Hangar Collision Avoidance with OnGuard Software
Within 4 inches of aircraft
Crane positioning accuracy
Safety & Compliance Monitoring
Aerospace
by Rockwell Automation
HMC Products
HMC Products Redesigns Medical Test Kit Packaging Machine Saving Customer Millions
Production Planning & Scheduling
Medical Devices
by Rockwell Automation
Anonymous Korean Metal Recycler
Korean Recycler Simplifies Motor Control and Reduces Cost with Intelligent EtherNet/IP Solution
Process Optimization
Metals & Mining
by Rockwell Automation
Green Tokai Co.
Green Tokai Gains Real-Time Production Visibility with Plex ERP After Eliminating Paper-Based Systems
Production Planning & Scheduling
Automotive
by Rockwell Automation
Quimikao
Quimikao Achieves Increased Production Efficiency and Improved Quality with PlantPAx DCS
Process Optimization
Chemicals
by Rockwell Automation
Qualtech
Qualtech CIP Systems Scale with Artisan Cheesemaker Growth Using Scalable Control Platform
Process Optimization
Food & Beverage
by Rockwell Automation
Pyradia
Pyradia Pilot Coating Line Achieves Multiple Coating Mode Changeovers Daily for Adhesive R&D
3–4
Coating modes testable per day
Process Optimization
Chemicals
by Rockwell Automation
Pulsar Srl
Pulsar Deploys FactoryTalk OEE Measurement Platform for Tissue Converting Industry
Process Optimization
Consumer Goods
by Rockwell Automation
University of Maine Process Development Center
University of Maine Process Development Center Modernizes Paper Web Handling to Eliminate $20K/Event Downtime
$20,000
Cost per downtime event
Predictive Maintenance
Industrial Machinery
by Rockwell Automation
Taiwan Pulp Molding (TPM)
Taiwan Pulp Molding Increases Yield from 70% to 95% After Implementing Rockwell Automation
70% to 95%
Yield improvement
30%
Productivity improvement
Process Optimization
Packaging
by Rockwell Automation
PTL Machinery
PTL Continuous Melters Enable Fast Changeover and Low Power Consumption in Chocolate Processing
1–2 hours
Changeover time
1–2 hours
Cleaning time
Process Optimization
Food & Beverage
by Rockwell Automation
Med-Con / Foodmach
Med-Con Achieves 60-Fold Increase in Surgical Mask Production During COVID-19 Emergency
3 million masks/week
Weekly production capacity
60x
Production capability increase
Production Planning & Scheduling
Medical Devices
by Rockwell Automation
Maga Active
Maga Active Reduces Machine Footprint 40% While Achieving 205 Parts/Minute on Irrigation Dripper Assembly
205 pieces/minute
Throughput achieved
40%
Footprint reduction
Production Planning & Scheduling
Industrial Machinery
by Rockwell Automation
CSBio
CSBio Delivers Flexible DCS-Based Peptide Synthesis Control for Pharmaceutical Scale
Process Optimization
Pharmaceuticals
by Rockwell Automation
Anonymous International Cement Company Subsidiary
International Cement Company Increases Throughput 5.7% and Reduces Power 4% with Advanced Process Control
5.7%
Throughput increase (mill #11)
3.5 KWh/ton
Power consumption reduction
Process Optimization
Industrial Machinery
by Rockwell Automation
Heaven Hill Distillery
Heaven Hill Distillery Gains Real-Time Visibility and Lays AI Analytics Foundation
Process Optimization
Food & Beverage
by Rockwell Automation
Anonymous Rare Earth and Metal Products Manufacturer
Rare Earth Mining Facility Unifies 14 Buildings on Single Process Control System
Process Optimization
Metals & Mining
by Rockwell Automation
Dunlop Aircraft Tyres
Dunlop Aircraft Tyres Transitions from Reactive to Predictive Maintenance with CMMS
Predictive Maintenance
Aerospace
by Rockwell Automation
Anonymous Ethanol Manufacturer (Agricultural Energy)
Ethanol Producer Increases Production 12% with Predictive Analytics
12%
Ethanol production increase
9.9%
Energy efficiency improvement
Process Optimization
Chemicals
by Rockwell Automation
DuPont
DuPont Semiconductor Solvent Plant Improves Batch Throughput and Revenue with Modern Batch Control
~40%
Programming Configuration Time Reduction
Process Optimization
Electronics
by Rockwell Automation
DuPont
DuPont Upgrades Biopharmaceutical Plant to PlantPAx DCS in Three Weeks for Increased Availability
3 weeks
Migration Duration
Process Optimization
Chemicals
by Rockwell Automation
GrafTech
GrafTech Saves Steel Customers $100K-$1M Annually with EMI Analytics for Electric Arc Furnaces
$100K-$1M+
Estimated Annual Customer Savings
Predictive Maintenance
Metals & Mining
by Rockwell Automation
Eli Lilly
Eli Lilly Reduces HMI Recovery Time 95% with Thin-Client FactoryTalk View Migration
4-8 hours to 5 minutes
HMI Recovery Time Reduction
70%
Projected Development Time Reduction
Process Optimization
Pharmaceuticals
by Rockwell Automation
Strand Products
Strand Products Achieves 40% Revenue Growth After Plex ERP Implementation
40%
Revenue Growth Post-Implementation
7% YoY
Gross Margin Improvement
Process Optimization
Aerospace
by Rockwell Automation
Summer Garden Food Manufacturing
Summer Garden Food Manufacturing Eliminates Hidden Downtime with Plex Smart Platform
Predictive Maintenance
Food & Beverage
by Rockwell Automation
Teddie Peanut Butter (The Leavitt Corporation)
Teddie Peanut Butter Achieves Real-Time Visibility and Cloud MES for Global Growth
Process Optimization
Food & Beverage
by Rockwell Automation
North American Corn Wet-Milling Plant
Food & Beverage Plant Cuts Waste by $500,000 in First Year with PlantPAx DCS Upgrade
$500,000
First-Year Waste Reduction
Process Optimization
Food & Beverage
by Rockwell Automation
Fluorsid
Fluorsid Halves Chemical Waste and Reduces CO2 Emissions with PavilionX Model Predictive Control
50%+
Waste Reduction
Process Optimization
Chemicals
by Rockwell Automation
Pro-Vac
Pro-Vac Fleet Services Reduces Fleet Downtime 27% with Fiix CMMS
27%
Fleet Downtime Reduction
17%
Route Planning Efficiency Improvement
Predictive Maintenance
Industrial Machinery
by Rockwell Automation
Noosa Finest Yoghurt
Noosa Finest Yoghurt Increases Production Capacity 300% and Reduces Lost Batches 95%
300%
Production Capacity Increase
95%
Lost Batch Reduction
Process Optimization
Food & Beverage
by Rockwell Automation
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