Field Engineering Experience
However elegant an engineering problem looks in the lab, the real exam happens on the factory floor — under pressure, with dozens of stakeholders waiting. AIOR's foundation rests on this reality: understand the field before proposing solutions.
The real problems are invisible on paper
Many projects start because the spec is ready — but real failures surface during installation. Vibration on the line, ambient-light fluctuation, how room temperature affects PLC cycle time — none of these are written at the office. The AIOR team goes on-site, spends hours by the line, talks with maintenance operators and only then starts engineering.
Software is engineering — by another name
An anomaly-detection camera on a line may look like a software project — but it's also mechanical alignment, optical design, lighting angle and electrical noise. The AIOR software team doesn't write code in isolation; it trains models from field data, ships them back to the line, watches real-world performance and re-grounds the model where needed.
What we actually do, step by step
- Site discovery: 1-2 days of observation; existing PLC, sensors, SCADA, MES are mapped.
- Data capture: 1-2 weeks of camera, vibration, temperature, current data under production conditions.
- Hypothesis check: A small prototype validates whether the proposed solution is feasible.
- Production integration: PLC comms (OPC-UA, Modbus), MES log writing, observability via Grafana / WMS.
- Commissioning + training: Docs, videos and on-site training for maintenance, QA and operators.
- Warranty period: Prioritised support for the first 90 days; live anomaly / deviation watch.
Industry applications
Defect detection in textile weaving, post-assembly QC in automotive sub-tier, surface-flaw detection in plastic injection, label reading on food packaging lines — all examples of field engineering meeting software. Each demanded different lighting, speed and tolerance; none of them came off-the-shelf.
An approach that reduces risk
Spending time on-site looks expensive, but it leads to firmer decisions that prevent two costly surprises later: rework and operational loss. Half a day of line downtime usually exceeds the total cost of all the site visits combined. AIOR's way of working is built on the math of that equation.