Machrion

Production use cases

MAP across real
production environments.

Evidence from deployment

Five production deployments across multiple lines, process areas, PLC platforms, and robot systems.

Company, site, line, product, and machine identifiers have been anonymized.
5Production deployments
32 hrsFewer recorded downtime hoursFirst month after deployment vs. prior month.
2PLC platform families
3Robot platform families

Multiple production lines · Multiple process areas

Based on total recorded downtime hours across the five deployed machines, comparing the month before deployment with the first month after deployment.

Five production deployments

Different stacks.
One recovery principle.

Each deployment was configured around the actual machine state, existing recovery procedure, and approved control boundary.

CASE 01

Recovery downtime

Machine / control stackMitsubishi PLC + FANUC Robot
Measured recovery improvement
Challenge

Frequent light-curtain-triggered machine stops.

Analysis found that approximately 90% of the observed recoverable downtime in this application came from four recurring, relatively simple error categories.

The operator recovery procedure for these conditions was already based on a fixed SOP.

MAP deployment

MAP was configured around predefined machine conditions and approved recovery workflows.

MAP proceeds only when predefined safety and machine permissive conditions are satisfied.

Manual recovery can vary by operator experience and sequence consistency.

Outcome / validationRelevant recovery downtime was reduced to approximately 30% of baseline in this measured production application.
CASE 02

Different robot stack

Machine / control stackMitsubishi PLC + Mitsubishi Robot
Different robot platform
Challenge

Frequent light-curtain-triggered recoverable interruptions.

Recovery behavior followed a known and repeatable SOP.

MAP deployment

Applied the same machine-aware, approved-recovery philosophy to a different robot/control configuration.

Outcome / validationValidated on a different robot platform.
CASE 03

Cross-platform deployment

Machine / control stackSiemens PLC + Siemens Robot
Cross-platform deployment
Challenge

A similar repeatable machine-recovery requirement existed on a different automation platform.

MAP deployment

Adapted the MAP recovery approach to a Siemens PLC / Siemens robot environment.

Outcome / validationValidated beyond the Mitsubishi / FANUC control stack.
CASE 04

Operator knowledge and staffing

Machine / control stackMitsubishi PLC + FANUC Robot
Standardized recovery knowledge
Challenge

High operator turnover increased training burden.

Machine stops could require an operator to locate a line lead before the issue could be relayed or escalated.

The line lead was not always immediately available.

MAP deployment

Converted known recovery knowledge and approved procedures into a machine-specific guided workflow.

Outcome / validationRecovery knowledge standardized in a machine-specific workflow.

Reduced dependence on individual operator familiarity and line-lead availability for known recoverable conditions.

CASE 05

Different process area

Machine / control stackMitsubishi PLC + FANUC Robot
Cross-process deployment
Context

This deployment took place in a different production and process area from the earlier machines.

Challenge

Similar recurring recoverable machine conditions appeared in a different production context.

MAP deployment

Applied the MAP recovery framework in another process environment.

Outcome / validationRepeated in another production context.

Demonstrated that the approach could be repeated beyond a single production line or process area.

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