Process Automation

Overview

Every industrial environment is different — from the layout of machines to the flow of materials, the nature of inspections, and the complexity of human–machine interaction. Tailor-Made Automation Use Cases enable industries to implement highly customized, AI-driven automation solutions built specifically for their operational needs, workflows, and equipment setups. Whether it's automating a unique inspection step, creating custom logic for material movement, improving workstation efficiency, or adding AI vision to a specialized process, Flagman delivers end-to-end engineered solutions that solve real problems with precision and reliability. These solutions are ideal when off-the-shelf systems don't fit, or when existing machinery and processes require a fully personalized, intelligent automation layer.

The Challenge

Most factories face unique challenges that standard automation systems cannot address. Common challenges include:

Key Challenges

• Non-standard workflow sequences
• Machine-specific inspection requirements
• Specialized tools or fixtures
• Space or layout constraints
• Hybrid manual + automated operations
• Customized safety logic
• Legacy equipment that needs modern intelligence

Flagman Solution

A one-size-fits-all approach often leads to gaps in quality, safety, and efficiency. Tailor-Made Automation ensures every step, every process, and every rule matches the exact operational requirement of your plant. Flagman engineers study your process in detail — observing workflow, machine behavior, operator interaction, space constraints, timing requirements, and SOPs. From here, a custom AI workflow engine is designed to automate exactly what your process needs. This may include detecting specific movements or operations, validating tool or component presence, checking material orientation or labeling, monitoring time-based sequences, triggering alarms or machine responses, controlling conveyors, motors, or actuators, enforcing manual inspection or loading steps, mapping multi-zone workstations, and guiding operators with visual feedback. All custom rules, thresholds, and logic are programmed into a central dashboard, allowing supervisors to update or refine parameters anytime.

Key Features

• Fully personalized logic where every automation rule is built specifically for your process, not adapted from a generic template
• AI-powered visual detection using computer vision to validate movements, placement, quantity, orientation, and process steps with high precision
• PLC/SCADA integration allowing custom automation to trigger machine holds, interlocks, alarms, or workflow transitions
• Multi-zone, multi-step mapping supporting complex workstations with multiple inspection points or actions
• Operator guidance providing visual and audio cues to guide operators through the correct workflow
• Real-time deviation alerts for missed steps, abnormalities, incorrect material handling, or unsafe actions
• Dashboard configuration enabling supervisors to fine-tune rules, thresholds, sequences, and alerts directly from the interface
• Audit-ready data logging recording every activity, deviation, and machine response for traceability and quality reviews

Benefits