Rockwell Automation is integrating AI-powered visual inspection with its Plex quality management software, as manufacturers look to use artificial intelligence to detect defects while building a more complete record of production quality.
The US industrial automation group said its API-enabled integration between Plex Quality Management System (QMS) and FactoryTalk Analytics VisionAI is available now. The system connects existing or new camera-based inspection systems with Plex QMS, allowing inspection results to be recorded alongside other quality data.
The integration is designed to improve defect detection while providing greater traceability, product serialisation and a record of inspection history. Rockwell said conventional visual inspection can be only about 80 per cent effective and often does not retain a detailed history of inspections.
The move reflects a broader shift towards using AI not simply to automate individual manufacturing tasks, but to connect those tasks with the software and data used to manage production.
“AI plays a critical role in Rockwell’s industrial autonomy strategy,” said Devin Burke, Group Product Manager at Rockwell Automation. “With predictive intelligence, manufacturers can shift from scripted automation to adaptable autonomy as systems learn, adjust and collaborate across software, hardware and workers.”
The company is also expanding AI capabilities elsewhere across its manufacturing software portfolio, including Cloud-based manufacturing execution systems (MES), Edge AI and digital twins.
Rockwell’s latest report on scaling MES across the enterprise predicts that 42% of manufacturing processes will be AI-supported within the next year, highlighting the growing role of AI in production operations.
The Plex platform has also recently added an AI-powered authoring agent that can turn CAD files and other technical assets into step-by-step digital work instructions for frontline workers.
Another AI agent within Plex’s reporting and analytics tools allows users to query operational data in natural language and identify potential risks or issues.
“At Rockwell Automation, we’ve built a context-rich industrial data foundation shaped by years of manufacturing expertise,” said Manu Ravichandran, Senior Product Manager at the company. “This foundation gives manufacturers the structure, context, and scalability needed to operationalise advanced analytics and AI across complex operations.”
