CognitioFlow · cognitive process automation for industrial & warehouse robotics News Changelog systems nominal

COGNITIVE PROCESS AUTOMATION · INDUSTRIAL & WAREHOUSE

The line should keep moving when the plan stops matching the floor.

CognitioFlow sits at the controls layer — between your PLC, SCADA, and MES — and gives machines the ability to reason through a deviation instead of halting on it. Adaptive routing, exception handling, and goal-directed control, without bypassing a single safety interlock.

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Runtime

Edge · controls layer

Protocols

OPC-UA · PROFINET · Modbus

Loop

Observe → interpret → decide → act

CF-WAREHOUSE-01 · work-celladaptive mode

Solutions by industry

Four floors. Four ways the plan goes wrong. One loop that recovers.

We start from the operating reality of each environment — the exceptions that stop a shift, not the feature list. Every solution runs the same closed loop: observe the process, reason a response, act through the existing controls, and fold the outcome back in.

IDX 01 · WAREHOUSE

Warehouse & fulfillment

Sortation jams, a missing tote, a last-minute order change. Fleet robots and sorters that re-route around the exception without stalling the floor.

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IDX 02 · MANUFACTURING

Discrete manufacturing

Assembly cells and machine tending that recover from part variance, a mis-fed blank, or tooling drift — instead of waiting for a reset.

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IDX 03 · LOGISTICS

Logistics & distribution

Dock scheduling, cross-docking, and parcel routing where the arrival sequence never matches the plan. Adaptive routing at the diverter.

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IDX 04 · ENERGY

Energy & utilities

Process plants and remote assets that hold setpoints through a feed change or a load shift — while safety interlocks stay intact.

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The cognitive loop

Scripted automation stops on a deviation. Cognitive automation reasons through it.

Most automation is written for the day it was commissioned. CognitioFlow runs a closed loop that reads the live process state, interprets what a deviation implies downstream, chooses a response that respects every interlock, and remembers what worked.

01 / OBSERVE

Read the live state

Subscribe to the PLC tag namespace and sensor telemetry — setpoints, but also the reality on the floor.

02 / INTERPRET

Model the situation

Turn raw signals into a working picture: what's out of tolerance, and what it costs downstream if ignored.

03 / DECIDE

Reason a response

Weigh goals, constraints, and interlocks to pick a next action — re-planning instead of halting the line.

04 / ACT & LEARN

Execute and fold back

Carry out the decision through the existing controls, then fold the outcome in so recovery gets faster.

Case studies

Scenarios, not slideware.

Three operating environments, three ways the plan broke. We describe what happened and how the loop responded — no invented company names, no invented metrics.

SCENARIO 01

Sortation recovers from a jammed diverter

A warehouse sortation line clears its own jam by re-routing downstream flow around the blocked divert, without a full stop.

Read the scenario → SCENARIO 02

Machine tending handles a mis-fed blank

A discrete-manufacturing work-cell detects a part outside tolerance and re-sequences the operation instead of faulting out.

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Process plant holds setpoints through a feed change

An energy process line re-tunes its targets mid-shift as the incoming feed drifts, with interlocks untouched.

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Integration

It speaks the protocols your floor already runs.

CognitioFlow installs at the controls layer and talks to your existing PLCs, drives, and historians — no rip-and-replace of the automation you've already certified.

OPC-UA information model EtherNet/IP CIP messaging PROFINET real-time I/O Modbus TCP brownfield bridge

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Standards & compliance

Reasoning never bypasses the guard.

Cognitive automation is still automation. It runs inside the same functional-safety and OT-security boundaries as everything else on the floor — and the interlocks are the one thing it is never allowed to override.

ISO 13849

Safety of machinery — control systems

IEC 61508

Functional safety of E/E/PE systems

IEC 62443

OT network & system security

ISA-95

Enterprise–control integration

From the field

We stopped trying to pre-script every exception and let the system reason instead. The first time it recovered from a pallet pattern we'd never seen — without a halt, without touching an interlock — that's when we understood what we'd been leaving on the table.

Pierre Martin · Director of Operations

regional third-party logistics

Contact sales

Tell us where your line stalls. We'll show you what it could recover from.

Bring a process, a PLC, and the exception that costs you the most downtime. We'll map how cognitive control changes the recovery path — no script, no slides, no invented numbers.

Talk to sales → Request a demo