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Welcome everyone to another episode of Dynamics Corner Brad, can AI do more than just put words together?
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I'm your co-host, Chris.
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And this is Brad.
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This episode was recorded on July 25th 2025.
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Chris, chris, chris, can AI do more than put words together?
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Ai can do a lot, and AI is all over the place these days.
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I know we often focus and talk about how AI can help you within your ERP software, but AI can help you outside of the ERP software and with us.
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Today we had the opportunity to speak with Brian DuBois about AI and manufacturing.
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Good afternoon, sir.
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How are you doing hello, hello, doing well.
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How?
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How are you Doing very well?
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Thank you, very well.
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Thank you for taking the time to speak with us.
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I was just talking with Chris, I have two new obsessions and I don't know how I got into these obsessions.
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Someone told me I'm a year late on one of them.
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I'm into making sourdough bread.
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Okay, yeah, you're way behind, man, I'm way behind, so I made my own starter this week.
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I think one day I made three loaves, I don't know.
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And the funny thing is I hey, you got to keep it alive man, you got to keep alive this starter.
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I do.
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I have the starter, I keep it and I get scientific.
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Like I measure the flour, I measure the water.
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I measure the water, I stir it, I track it.
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When you keep going, you stop caring about measuring those stuff, you just do it, man.
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No, it's going well.
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And then now I'm practicing the designs, but I'm practicing.
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I think I finally have the recipe that I like.
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I don't know if it's the flour, the air or what, but this stuff.
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I fed the starter this morning and four hours later it had already doubled in size.
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It's like a ferocious flower eating.
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Yeah they're alive man, they're alive.
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I know they're alive, but I'm not going to feed this thing frigging four times a day.
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You have to, no, I can't.
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You don't have to feed it four times a day, do you?
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No, you kind of have to keep an eye on it.
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There's a point.
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It's not really more of a time, it's more like when you see it rise and you know you got to remove some of the stuff.
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Yeah, it's when it doubles in size.
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I don't know.
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Everyone says when it doubles in size you have to take it in half.
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So this thing doubled in size in four hours.
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Like, take it in half.
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So this thing doubled in size in four hours.
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Like it started, you know, you put it in, you wait 24 hours.
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Well, 10 days I, you take whatever it's seven to ten days for it to to grow finally or to become alive.
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Okay, and then the first day I did it was like a little slow.
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And then I'm like, dang, this is fast.
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So it's like 12 hours it doubled.
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And then I started baking and then I'm doing this and now it's like four hours is doubling like it's a full-time job.
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The um.
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The other obsession that I have is I've been messing with raspberry pies.
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I have that also.
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You're like a decade behind sir listen, I am an old man so I'm a little behind the times, but at least I'm behind the times and I'm able to follow, because now I am a vibe coding ai pi app creating person.
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I am creating so many things.
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I bought all these like hats to put on it about the sense hat, but the e-paper I knew nothing about python.
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I still know nothing about python, but you should see the stuff that I'm doing because you'll pick it up.
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No, I am picking it up, but ai does everything for you, right that's true.
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You see what?
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Python is such a popular thing that ai knows a lot about it.
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You can literally yeah, like you said just vibe code with Python.
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Yes, yes, I mean, I have the sensor, I'm tracking the temperature.
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I didn't know anything.
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I said okay, write something to track the temperature from the Sense hat.
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Okay, now save it to a CSV file.
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Okay, I need to display a web page.
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So I went through, installed Apache on the Pi in a Docker container.
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I have a JavaScript that reads a flat file it's our csv file of temperatures and goes which is ai.
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And what are you?
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What are the temperatures?
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Oh, this is.
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Is it the sourdough?
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Is that the temperature?
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No, I shifted.
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No, it's the temperature I track the temperature of temperature, humidity and pressure of my house okay as well as track the temperature of the system.
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So I made little graphs for it, so it was all AI driven, and with that, mr Brian.
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Sir, would you mind telling us a little bit about yourself?
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Sure can.
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So, brian Dubois, I'm the director of industrial AI for a company called Rovisis, so we are a system integrator and we are focused exclusively on manufacturing and industrial customers.
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So, you know, I like to kind of you know I love AI, I love talking about this stuff, but I do like to kind of narrow the scope somewhat so we can go anywhere with this conversation about AI.
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But you know, I don't know anything about AI in fintech, I don't know anything about AI in healthcare, but AI in the industrial space.
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I am an expert in that, both in terms of what's possible today and how we can apply AI in the industrial space today, but also kind of where things seem to be going in leveraging AI in manufacturing.
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So, yeah, happy to be here today.
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Thank you.
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Thank you for taking the time to speak to this.
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Ai is showing up everywhere and AI is one of those terms that is like oh, I know AI, or you know AI, it's so broad.
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It's just like what people used to say is oh, you're an IT guy, yeah, and they didn't understand that IT, you know, information technology, has so many different areas and AI.
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As we've been going through this journey of talking with individuals about AI, I've also learned that AI has many different facets to it.
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There's many pieces of it that comprise AI and AI.
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As you had mentioned, it's not just helpful with using the tools to create emails or creating the tools to create emails or creating the tools to.
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We can talk about generative AI towards the end.
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I know that's a favorite topic of yours, so we'll jump on that.
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But AI in the manufacturing space can you tell us a little bit about some of the advances in AI, and even now, or what we should call it, maybe within the manufacturing space?
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Yeah, and actually what to call it is an interesting question.
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So typically when I present on this, I talk about three categories of AI in the manufacturing space.
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The first one I have dubbed traditional AI.
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Now, it sounds kind of funny to talk about traditional AI in a space in an industry that is really just now starting to adopt AI, but the reality of it is is that in this category are algorithms and ML models that have actually been around in the manufacturing space for quite a while 10, 15 years.
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So this comprises things like anomaly detection.
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So if you guys are familiar with that, that's where you hook up a model to the process.
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It needs no a priori knowledge and it just starts monitoring the process and it can start to tell you when things go abnormal.
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Now, importantly, it can't tell you why things are going abnormal.
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All it can say is is based on everything I'm seeing today, it doesn't look like it did yesterday.
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So that's anomaly detection.
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When you're looking at anomalies, are you looking at anomalies for time, anomalies for output, like what are you measuring or what is a good?
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measure.
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Yeah, an anomaly detection algorithm can really do any of those things, so it can look at.
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It could be maintenance, so it could be looking at the RPMs or the current draw of a drive or something like that to determine whether or not it's the same as it was yesterday.
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It could be looking at temperatures, pressures of the process, saying things are not going the way they did yesterday.
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And it can typically.
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It can typically pick up on those, those trends, faster than a human operate, even an experienced human operator can, because it's looking for very nuanced correlations between a lot of different variables.
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So that's anomaly detection.
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Are these IoT devices that kind of collects all that data and then that's what it's doing it's just collecting all this information and see if there's any anomalies.
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It is, yeah, and it's interesting because five, seven years ago there was that big push around IoT and you guys remember that and everyone was talking about IoT.
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What's IoT?
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Internet of Things.
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Internet of Things and then there was an industrial Internet of Things, so there was iIoT that was being marketed to my industry, and the interesting thing about it is that now, fast forward five years we are not seeing the adoption of IoT like I think that like everyone thought was going to happen, and part of the reason why is that we already have sensors, we already have instrumentation, we already have all of these things and they flow through what's called the control system, which is the system that actually makes everything move and work inside the plant, and that's all been around for 30 plus years.
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So IoT was just kind of an adder on top of that.
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And there were some very specific things where it was an interesting choice to have it.
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You know it's actually Brad you brought up like humidity and temperature.
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Those are the types of things where we could slap an IoT sensor in.
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It was cheaper than trying to network all of that through the control system and great.
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So now we've got a couple extra data points that we can use, but the vast majority probably over 85% of the data coming from the plant floor comes from the existing instrumentation, sensors and things that we already have.
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So anomaly detection oftentimes to get back to your question.
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We can oftentimes just use the data sources and the data trends that exist on the plant floor today and we can send that into the anomaly detection model without having to add a whole lot of extra sensors and instrumentation.
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Another area where IoT got a lot of play was around predictive maintenance.
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So this was the idea that I can attach one of these IoT modules to a drive, to any kind of rotating equipment, and it would determine vibration, it would determine temperature, it would you know, and so and there's been some adoption of that, but not the uptick that I think a lot of people anticipated around IoT.
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So that's anomaly detection.
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We're still talking about traditional AI.
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Another category under that would be the predictive models.
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So anytime you hear the word predictive, they're pretty much all the same.
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So predictive quality, predictive maintenance, predictive set point the idea is that you're going to take large volumes of very clean, very correlated data, you're going to send them into a model and ultimately, you're going to be able to learn how to predict a single value.
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Now, that's all it will ever be able to do, right?
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So in the case of predictive quality, what's the quality of this batch going to be before I complete it?
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Right, in the case of predictive maintenance, how many days until this piece of equipment is going to go down You're going to be able to predict a single value.
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Now, importantly built into that prediction is that someone has to know what to do with that prediction, right?
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So if I can predict that the quality of this batch is going to be low, it's going to be off spec.
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Somebody has to know what to do to be able to fix that right.
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What additives do we need to increase the temperature, reduce, you know, the pressure?
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They have to know what to do with that, with that information.
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But that's the predictive category and then the final subcategory.
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Under traditional AI I typically lump in all the vision stuff.
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And again, but vision's been around for a long time in the industrial space.
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So we've been doing vision, we've been doing object detection for a long, long time.
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Even defect detection we've been doing for 15 years.
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I will say that the vision systems have advanced quite a bit in the last couple years and so we can do more with it.
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But the other thing that I kind of emphasize with clients that I talk to about this is that vision systems should really be another source of signal.
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So you should be as typical vision system.
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You should be able to get four to ten new signals coming off of that.
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Not just I detect that there's an object here, but how many of those objects and where are they placed, and maybe heat signatures and things like that, an angle of a certain thing coming through a conveyor.
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Let's get all of that data and send all of that back to the control system so that we can make better decisions with it.
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So again, that's traditional AI, and then I can talk about the other two here in a second, unless you guys had any questions about that.
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I have lots of questions with all of this because I could see within a facility the savings that they could have with incorporating AI, and you said a lot of this could be used with the existing controls that you have on the floor.
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How does it, how would one know or begin to go down this road to see how they could incorporate AI into their existing structure?
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And then another question I'll ask.
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I like to ask a lot of.
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I stack on the questions because I get excited about this.
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I hear you mentioned the word model.
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Right, this is another one of those.
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So I hear the two biggest words.
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I hear when I, when I hear uh ai, is ai or a phrase, I guess you could say and model.
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So what is a model and how does one know which is the most appropriate model to use and where do these models come from?
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Yeah, okay, so there's a lot there to unpack.
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Yes, let's address the model thing first.
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So, a model we use these terms even I use these terms kind of sloppily so we talk about AI very broadly, but I don't even know that anyone has really categorically said here's everything that's in AI and here's everything that's not in AI.
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Right, so you could throw in things like decision trees and rules-based systems.
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When I was in college, many, many years ago now, I took a course on AI and at the time neural networks were kind of out of vogue and at the time rules-based systems were what it was all about.
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So everything we learned about in this AI class was all about rules-based systems and we barely talked about neural networks.
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Now, fast forward, many decades later, and neural networks have come back very strong and are at the heart of a lot of these models.
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But ultimately, I guess, if I had to kind of very broadly look at it, a machine learning model, an ML model, is something that you can put inputs in and it's going to leverage those algorithms and then it's going to give you some kind of output back out.
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Now, typically that's in the form of a prediction, but in the case we've seen with GPT models.
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That's going to be in the form of effectively guessing what the next word is and completing those phrases and sentences with those next words.
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In the case of autonomous AI, which is the next category of AI that we're going to talk about, it is really doing, it's perceiving the current state of the system and then it's making a decision about the next best move that you can make.
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So we'll talk about that here in a second.
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I want to address another question you had, though, about where are we getting all this data from and where do people start?
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So most people underestimate the amount of data that they already have in their plant, in their facility.
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They are typically collecting orders of magnitude more data than they realize.
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If they're not collecting any data at all, then they've kind of missed the boat and they missed the messaging over the last two decades.
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So when I started I've been with Rovis's for 25 years now so when I started my career in the early 2000s, we were still educating everyone as to why they should collect this data right, and I remember I'll never forget I had a customer who said well, we just throw out the data, why would we keep this data right?
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And now, 25 years later, that sounds kind of quaint, but that was the mindset back then, like why are we going to spend this money to collect this data?
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What in the world would we ever do with it?
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Right?
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So now the good news is is that most manufacturing customers drank the Kool-Aid, and in the last two decades, they have been collecting all of that data from the plant floor.
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So they typically have lots and lots of data and, again, everything on the plant floor, especially within the last 10, 15 years, everything on the plant floor is smart, right?
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This is smart equipment, smart assets.
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It can give you.
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You know, when I started my career, we were still dealing with very, very old equipment that could maybe give you 10 data points.
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Now, every piece of equipment can give you like 100 data points.
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It can self-monitor, it can give you all kinds of information about how it's performing.
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So we've got actually lots of data.
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It's rare it does happen sometimes, but it's rare that we have to add more instrumentation or sensors.
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We typically have all the data we need to do what we want to do with it.
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Oftentimes, though, that's necessary, but it's not sufficient.
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So we've got all that data from the plant floor.
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We've captured it all in these time series databases that we call historians.
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When I started in this career I knew nothing about historians, but they are dominant in this space.
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They're time series databases and we use them all over the place and we can gather that data from those time series databases.
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But we have to bring them into, we have to build data sets out of them, and oftentimes we're taking data from the plant floor and we're mixing in IT data.
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So think of data like from the systems you guys typically deal with the dynamic systems, the ERP systems, your supply chain, from the systems you guys typically deal with the dynamic systems, the ERP systems, your supply chain, or mixing that data in to build a complete data set, a complete picture into what it took to make that particular product.
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Now, with that data set, now we can start to use that to train those ML models that we were talking about to be able to make predictions.
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So I'll give you an example of that.
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We had a customer and they do supplements, like powder supplements, and so they fill these plastic tubs with powder, right.
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And so they came to us and they said look, we've got an issue where we'll run.
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You know, we'll fill these containers right, we'll fill these containers.
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Right, you mentioned supplements.
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I just have to interrupt.
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Yeah, when you talk to them, can you tell them I'm interested in hearing this but can you tell them, when they make those containers, to not put that little lip around it so that you can't like pull the last of it out.
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Because, you fill that up.
00:18:36.185 --> 00:18:40.663
You always you could scoop it out you can scoop it out, but then at the very end, dump it out.
00:18:40.845 --> 00:18:50.291
Nor can you scoop it out, because the scoop that they put inside is not small enough to get to the little round proper shape see this is.
00:18:50.393 --> 00:18:51.978
Everybody knows what I'm talking about.
00:18:51.978 --> 00:18:53.000
I will feed all this back.
00:18:53.742 --> 00:18:56.549
Well, they should use ai how to be more efficient with that stuff.
00:18:56.589 --> 00:19:03.981
Come on, yes yes yes, so I don't waste my supplement because I can't get it out and oftentimes I like flip it upside down.
00:19:04.021 --> 00:19:11.107
I bang it because I try to pour it into the other container, because I don't have enough left and you're getting it all over the counter and I wasted it right.
00:19:11.127 --> 00:19:14.143
So if you just pass that along, I will pass that on I'll pass that on.
00:19:14.624 --> 00:19:25.492
So they're filling these containers and they're going in there and and they're running a whole batch of the powder and no problems feels, fills fine, same batch, same skew, same everything.
00:19:25.492 --> 00:19:31.530
And they start filling you know the next batch into the containers and the filler jams up.
00:19:31.530 --> 00:19:42.951
Well, when that happens, it is hours and hours of downtime for them to clear the line, clear the fillers, get everything reset and restart the process and they're like banging their head against the wall.
00:19:42.951 --> 00:19:48.026
They're like we don't understand what's going on, why these fillers are constantly jamming Again.
00:19:48.026 --> 00:19:50.565
All indications are that we're running the exact same product here.
00:19:50.625 --> 00:19:51.648
So what is the problem?
00:19:51.648 --> 00:19:56.167
So that's the kind of problem where all the easy solutions have already been tried.
00:19:56.167 --> 00:19:58.179
Right, they've tried all the easy stuff.
00:19:58.179 --> 00:20:05.320
Now they're looking to AI to try to tease apart that problem and so.
00:20:05.320 --> 00:20:10.167
But to be able to understand what the actual problems are there and get to that root cause, we've got to look at a lot of different data sources.
00:20:10.259 --> 00:20:32.073
So we've got to build data sets, like I said that, pull together data and in the end and I don't remember exactly what it was, I'm paraphrasing, but it was basically like when the raw material was from this supplier and it sat in the warehouse for this long and the humidity was this and this particular filler had not been maintained in X number of days or whatever.
00:20:32.180 --> 00:20:33.606
That's when we see this right.
00:20:33.606 --> 00:20:36.269
That's when we get this perfect storm where the filler clogs up.
00:20:36.269 --> 00:20:48.612
Well, okay, but all those things, all those data points that I just talked about you can imagine all the different data, all the different places we've got to go to actually be able to build a data set that captures that.
00:20:48.612 --> 00:20:55.431
So now we can leverage data science to actually tease that apart and find out what the root causes are.
00:20:55.431 --> 00:21:00.049
So we give them that report and they're like, oh, thank God, this is it, this is what we needed.
00:21:00.049 --> 00:21:01.701
But then we don't stop there.
00:21:01.701 --> 00:21:24.994
We take it to the next level and now we build an ML model that we can then hook up, we can operationalize, we can hook it up to the plant floor so that it can monitor when that perfect storm is coming, so that they can now have some early warning as to, hey, hang on, you're getting into that situation where you know all the pieces are falling into place, where you're going to start to get into jams on the filler.
00:21:25.816 --> 00:21:29.117
You know you had made a, you had made a comp, you made a comment about.
00:21:29.117 --> 00:21:35.472
You know, using there's already a lot of data and you can use those existing data.
00:21:35.472 --> 00:21:44.686
I think that's a big problem right now, at least in my experience, where they want to put more data in but they fail to understand what you already have.
00:21:44.686 --> 00:21:52.468
So let's start with what you already have and get the most out of that and then, like you said, slowly bring in other data points.
00:21:52.468 --> 00:21:58.786
If you are trying to solve other things, or maybe you realize, okay, we've used all this data, we need a little bit more.