Emerson From Scrap Waste to Self-Correcting Systems: Performance Revolution in Manufacturing with Edge AI

[Elif Özaksu]

## A New Era in Manufacturing: Instant and Effective Solutions with Edge AI
Increased globalization, labor shortages, supply chain problems, and sustainability pressures create a complex picture for manufacturers. Companies looking to overcome these challenges must improve quality, reduce scrap and emissions, and maintain efficiency. However, the expert personnel required to achieve these goals are often insufficient.

### The Limits of AI and Digitalization in Industrial Manufacturing
Artificial intelligence (AI) and machine learning (ML) technologies can close the gap on the path to operational excellence. However, many AI solutions are cloud-based and tied to a location for high processing power and unlimited scalability. Cloud solutions are often unsuitable for industrial applications due to latency, weak connectivity, security issues, and costs. A real-time feedback loop is essential in production lines, and cloud connectivity cannot provide this performance.

### The Necessity of On-Premise AI (Edge AI) in Industry
Industrial real-time operational technology (OT) workloads operate differently from general information technology (IT) workloads. Current industrial AI cycles collect data, analyze it, make decisions, and automatically direct corrections, creating closed-loop systems in modern factories.

AI instantly detects anomalies and automatically corrects machines, virtually eliminating scrap.

For example, if image processing systems have cameras capturing between 30 and 100 images per second, even millisecond delays can lead to errors. Tolerating delays with multiple lines and cameras is almost impossible. If the cloud connection is lost, production stops completely.

### Risks Posed by Cloud Connectivity
Some industrial facilities are located in remote areas with poor connection quality. In such places, cloud-based AI applications lead to interruptions and inefficiency. Furthermore, many manufacturers do not want to send their data to the cloud for trade secret and legal reasons. Cloud services are often considered "someone else's computer," raising security concerns.

Transferring high-bandwidth video and images to the cloud can be costly.

### Advantages of On-Premise AI Processing

• Latency is reduced as all operations are performed within the facility.
• Operational costs decrease.
• Data privacy and security are ensured.

### The Right Processors for Industrial AI
Although artificial intelligence is often associated with graphics processing units (GPUs), GPUs are more efficient in AI training. For industrial AI, specialized processors running at the edge can make real-time inferences with low latency.

### The Role of Emerson's PACSystems IPC and SiMa.ai AI Processors
Emerson's next-generation industrial PCs are equipped with specialized SiMa.ai processors that provide on-premise AI acceleration. This combination instantly detects machine processes, provides quick feedback to controllers, and prevents errors without the need for cloud connectivity.

• While GPUs have high power consumption, these AI accelerators consume less energy.
• They can operate 24/7 without using fans.
• They provide highly efficient and fast data processing.

### Durable and Long-Life Platforms in Industry
Industrial PCs are resistant to harsh environmental conditions (dust, vibration, temperature) and can operate without fans. They also offer the advantage of long life and certification, minimizing equipment replacement issues.

### Emerson Industrial PC Features

• Certified and durable design
• Multi-core x86 processor
• Support for Industrial Ethernet and fieldbus protocols
• Infrastructure suitable for closed-loop AI systems

### Example AI Application: Pipe Banding Vision System
A thermoplastic pipe manufacturer monitors the pipe banding process with an AI-based vision system.

• Banding errors can be detected immediately, and automatic corrections can be made.
• Problems caused by human error and labor shortages have decreased.
• 100% inspection is provided, reducing scrap by one hundred percent.
• Different pipe diameters can be monitored.
• Quality and compliance are recorded through video recording.

### The Spread of AI in Industry
The use of this system can be extended to many sectors, such as laser welding alignment, automotive adhesive applications, life sciences packaging inspection, oil and gas leak detection, and mining and recycling optimization.

With Edge AI, production processes improve performance, while costs and delays decrease. Emerson's industrial AI solutions are key to real-time, secure, and efficient production.