iLEAN Edge · AI on the plant floor
iLEAN Edge — 29 documented use cases.
Edge is the terminal that lives on the line: it sees, decides and triggers the actuator in milliseconds, with no dependence on connectivity. These are its documented use cases. Each page follows the same discipline: the real problem, how it fits the IRIS system, a before/after table and an impact estimate to be validated with your numbers.
iLEAN Edge on real lines.
Every case is written for the person who runs that line — with the numbers the committee asks for.
Agitator motor current in viscous reactors
iLEAN Edge reads agitator motor current in a viscous chemical reactor, anticipates blade seizure and prevents the lost batch. The person signs off.
See the case → Edge use casesAGV proximity safety at warehouse intersections
iLEAN Edge anticipates AGV crossings at regulated warehouse intersections: zero near-miss and ISO 3691-4 traceability, without replacing…
See the case → Edge use casesBiscuit oven bearing thermography AI
iLEAN Edge runs thermography on the conveyor bearings of the biscuit tunnel oven: it warns days before seizure. The person signs the intervention.
See the case → Edge use casesCataphoresis rinse conductivity on anodized aluminum
iLEAN Edge tracks final rinse conductivity in cataphoresis on anodized aluminum and keeps cosmetic rejects to a minimum, without touching the line.
See the case → Edge use casesCeramic glaze tunnel kiln temperature with AI
iLEAN Edge measures the real zone-by-zone curve of the glaze tunnel kiln and keeps shade and flatness stable between loads, without touching the…
See the case → Edge use casesCIP dosing pump vibration in cheese plants
iLEAN Edge reads the CIP dosing pump vibration in a cheese plant and anticipates cavitation before it contaminates the batch. No line changes.
See the case → Edge use casesCNC spindle bearing thermography for aerospace | iLEAN
iLEAN Edge watches the CNC spindle bearing with continuous thermography: the bearing is changed on schedule, not on breakdown, without stopping…
See the case → Edge use casesCobot proximity in small appliance assembly | iLEAN
iLEAN Edge grades cobot speed by operator proximity in small appliance assembly cells: human cadence without stopping the cobot every few minutes.
See the case → Edge use casesCompressed air leak ultrasound in automotive
iLEAN Edge with ultrasound maps compressed air leaks across multi-plant automotive workshops and ranks them by real consumption, not by discovery…
See the case → Edge use casesCoriolis flow in aseptic UHT dairy filling
iLEAN Edge cross-checks Coriolis mass flow with the batch recipe to guarantee dosing in aseptic UHT dairy filling, unit by unit, without stopping…
See the case → Edge use casesExtruder motor current AI for PE/PP lines
iLEAN Edge analyses the PE/PP extruder motor current and anticipates screw jamming without stopping the line — the operator acts before the downtime.
See the case → Edge use casesHot stamping press hydraulic pressure AI
iLEAN Edge tracks hot stamping press hydraulic pressure and prevents die breakage from cold blanks. The person signs; the die does not break.
See the case → Edge use casesInline pH in acid neutralization reactors
iLEAN Edge reads inline pH in the acid neutralization reactor and prevents overshoot — zero excess reagent, zero downstream corrosion.
See the case → Edge use casesKTL degrease bath conductivity with AI
iLEAN Edge tracks the KTL alkaline degrease bath conductivity online in automotive and warns before paint is lost in the e-coat oven.
See the case → Edge use casesLNG cryogenic pump vibration with AI
iLEAN Edge reads cryogenic LNG pump vibration to predict bearing failure without breaking the cold chain. The person signs off.
See the case → Edge use casesLobe pump vibration in meat transfer
iLEAN Edge reads the vibration of the lobe pump transferring viscous meat batter in cured meat plants to prevent a mid-recipe stop. The person…
See the case → Edge use casesMagnetic flow meter in reagent dosing with AI
iLEAN Edge reads reagent magnetic flow in industrial wastewater plants and holds over-dosing before discharge — pH and conductivity within the…
See the case → Edge use casesMicroelectronics cleanroom humidity
iLEAN Edge tracks microelectronics cleanroom humidity cell by cell to prevent ESD and rework on thin boards, with a per-batch dossier for the auditor.
See the case → Edge use casesMuffle furnace temperature in steel tempering
iLEAN Edge tracks muffle furnace temperature in steel tempering and leaves the tempering curve auditable without touching the PLC. A person signs off.
See the case → Edge use casesMulti-cavity injection mold pressure AI
iLEAN Edge closes hydraulic pressure per cavity in multi-cavity injection molds and keeps short shots out of scrap. The person signs off.
See the case → Edge use casesNitrogen leak ultrasound in wine bottling
iLEAN Edge with ultrasound detects the nitrogen leak in wine bottling inertisation before oxygen reaches the batch — the loss is avoided, not counted.
See the case → Edge use casesPalletizer motor current in beverage lines
iLEAN Edge reads the motor current of the beverage end-of-line palletizer and warns before the late alarm. Shift ends with no stop. A person signs.
See the case → Edge use casesPowder metallurgy press hydraulic pressure AI
iLEAN Edge tracks hydraulic pressure on the powder metallurgy compaction press and keeps parts in tolerance shift after shift. The person signs.
See the case → Edge use casesPVD booth extractor bearing thermography
iLEAN Edge watches the PVD paint booth extractor bearing with a thermal camera: the curing oven stays up and the line keeps running. The person…
See the case → Edge use casesSMT reflow oven thermal profile with AI
iLEAN Edge tracks the SMT reflow oven thermal profile board by board to keep every PCB inside the IPC window — no tombstoning, no BGA cracks.
See the case → Edge use casesStamping press operator presence in risk zone
iLEAN Edge detects operator presence in the risk zone of a stamping press and blocks the cycle in milliseconds, without losing stroke cadence.
See the case → Edge use casesSteam leak ultrasound in refineries Edge
iLEAN Edge with ultrasound scans the refinery saturated steam network: it finds failed traps and leaking joints, ranks them by kg/h and saving…
See the case → Edge use casesTanning bath pH control with AI
iLEAN Edge measures tanning bath pH in the tannery drum and keeps the leather batch uniform across shifts — the master tanner's eye, kept as…
See the case → Edge use casesVortex steam flow in AI food pasteurization
iLEAN Edge reads the vortex steam flow of the plate heat exchanger and keeps food pasteurization in band — no under-processing, no scorched product.
See the case →All 30 cases in ilean edge
The complete listing, unpaginated. Each link goes to the specific case: the problem as it shows up on the plant floor, how the IRIS schema solves it and what was measured.
- A seized conveyor bearing at 250 °C is not a spare part — it is eight hours of oven downtime.
- AGV proximity at regulated warehouse intersections — zero near-miss and ISO 3691-4 traceability.
- AI thermography on the aerospace CNC spindle — the bearing is changed on schedule, not on breakdown.
- Beverage end-of-line palletizer — the shift ends with no stop because the motor current warned days earlier.
- Cobot proximity to the operator in small appliance assembly — human cadence without stopping the cobot.
- Coriolis flow in aseptic UHT filling — dosing is measured in grams per unit, not at end of shift.
- Edge ultrasound for compressed air leaks in automotive — the ones that bleed most, first.
- Edge ultrasound on the refinery steam network — traps and joints, kg/h, immediate saving.
- Edge ultrasound on wine bottling inertisation — catch the leak before the batch oxidises.
- Final rinse conductivity in cataphoresis on anodized aluminum — one haze and the part is cosmetic scrap.
- Hot stamping press — the die does not break on a cold blank, because someone looked at the hydraulic pressure in time.
- Iberian ham curing chamber humidity — the right rind, or a Reserva batch off target.
- If the cryogenic pump fails, the cold chain breaks — and the shipping window goes down with it.
- If the extractor bearing goes, the booth loses negative pressure — and the oven goes down with it.
- Inline pH in acid neutralization reactors — the set-point is not chased from the control room, it is held in the reactor.
- KTL degrease bath conductivity — one out-of-band reading, one batch of paint lost in e-coat.
- Magnetic flow meter in reagent dosing — discharge is adjusted in the reactor, not at the inspection.
- Microelectronics cleanroom humidity — one sensor out of band, one thin board into rework.
- Muffle furnace temperature in steel tempering — hardness is not prayed for, it is measured and signed.
- Multi-cavity injection mold — per-cavity hydraulic pressure keeps short shots out of scrap.
- Operator presence in the risk zone of a stamping press — automatic cycle inhibit without losing rhythm.
- PE/PP extruder motor current with AI — anticipate the jam without stopping the line.
- Powder metallurgy compaction — parts in tolerance shift after shift, not just in the SPC sample.
- SMT reflow oven thermal profile — every PCB has its own window, not the one of the last board in.
- Tanning bath pH — a uniform leather batch should not depend on which shift walks in.
- The CIP dosing pump is cavitating and nobody hears it — until the next batch comes out with detergent residue.
- The transfer lobe pump jams halfway through the recipe — and the batch is left hanging on the stuffer.
- Tunnel kiln temperature in glazed ceramic firing — stable shade and flatness between loads.
- Viscous chemical reactor — the agitator motor current tells the batch's story before any alarm does.
- Vortex steam flow on a plate heat exchanger — pasteurization stays in band instead of being corrected afterwards.
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