case studies
A virtual supervisor for more consistent production
A two-month manufacturing pilot reportedly reduced per-batch error margins from ±5 kg to ±1 kg by connecting process controls with operational expertise.
Turning production knowledge into a working, adaptive supervisor.
The challenge
A food and beverage manufacturer wanted to improve production consistency, efficiency and quality assurance. Small deviations in ingredient handling accumulated into waste and inconsistent batches.
What we built
The MVP focused on optimising hopper setpoints on a single production line. Icebreaker brought together PLC controls, Panalogy’s behavioural twin technology, the plant’s operational knowledge base and agentic models.
The virtual supervisor incorporated human shift-supervisor expertise into a learning process, combining autonomous assistance with human oversight within existing operator workflows.
Reported pilot outcomes
- Two months
- Time to a working pilot, according to the project partner’s account.
- ±5 kg → ±1 kg
- Reported reduction in per-batch error margins on the pilot process, supporting more consistent quality and less waste.
- A path to expansion
- The pilot supported a plan to extend the system across the wider production line, including hopper, vacuum and related infrastructure.
Scope of the result
These results relate to the initial hopper pilot. The project partner projected substantial annualised savings from wider application; those projections are distinct from savings already realised or measured across a full production line.