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THE PRODUCT

The alarm says it stopped.Golain helps you understand why.

It starts with the controller programs, drawings, manuals and maintenance records you already have. Nothing working needs to be replaced.

What it reads:
On-wire PLC signalsSchematicsEPlansMaintenance recordsPLC programs / backupsVideo feeds / imagesTraining / machine manuals
See the machine evidence
AI-PRE · Line 09T+00s
  • Controller logic
  • Tag data
  • Schematics
  • Breakdown history
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Illustrative example: 41 seconds from the alarm to a supported answer, with the underlying evidence attached.

THE MACHINE EVIDENCE

We begin with what the machine

already knows.

The controller program and fault register describe how the machine was designed to behave. They often contain the meaning behind an alarm that a dashboard can only repeat.

03CONTROLLER PROGRAM · FB 15EXCERPT
1
FUNCTION_BLOCK FB 15
2
TITLE = STATION 05  PRESS-FIT NEST 2
3
NETWORK
4
TITLE = Check force window
5
      U     "IO/5";           // measurement good
6
      SPB   OK1;
7
      O     "NIO/5";          // measurement bad
8
      U(    ;
9
      O     "MAXF1/5";        // force F1 max
10
      )     ;
11
      SPB   HI;
12
      L     -16;              // FORCE TOO LOW
13
      T     "SR-5C";
14
HI:   L     -18;              // force too high
15
WE:   U     "5/FEHL";         // station fault
16
      R     "5/FREIG";        // reset release
FAULT REGISTER · DB_FAULT
SM145 : BOOL ; // force-travel St.3 not ready
SM146 : BOOL ; // force-travel St.3 bad n-times
SM153 : BOOL ; // St.3 value outside range
SM196 : BOOL ; // cylinder fault, fixture
SM236 : BOOL ; // spring-break control error
BOUND · LINE 12 → SM146
WHAT THE SHIFT RECEIVES

The evidence becomes a

clear order of action.

The controller reported a force fault. Golain checks that fault against the rest of the line, rules out what is working and tells the shift lead what to inspect first.

AI InsightsFirst-shift action report · M100 & M80 · 14 Aug 2026, 09:30–11:08 IST.
M100 · First shift · Batch 1501
M100 first shift: what to do
Fri 14 Aug 2026 · 09:30 – 11:08 IST · poller.db + maintenance.db · shift still running
In one sentence

M100 threw away too many parts this morning because the left-side gap camera at Station 9 (bellows fit) said the gap was too wide.

The press force was fine. The potting check was fine. The next machines were fine.

Ruled out
Press force · Station 9
✓ thread on, slide down, final press
In limits
Potting + height check
✓ M80 potting & M100 St.3, not today's scrap
2
M110 next weld
✓ 0 extra scrap, bad fits caught at M100
125
Line at 09:30
✓ running from night shift, not a cold start
Warm
Watch
Left gap · Station 9
▲ worst at 10:39, allowed 0.05 to 0.35 mm
1.41 mm
Bad parts this window
▲ 16% scrap of 146 parts made
24
Longest stop
▲ 09:58–10:28, gripper 9B5 not closing
30 min
M80 Bartec lane 2
▲ 10:53–11:03 empty, lanes 1 & 3 at ~0.05 g
0.000 g
Do these, in this order
Do 1stM100 · Station 9Clean the left gap camera window and lightCAMERA 2 on the shared Omron unit, tagged -9A13. The right side of the same camera is working, so the box itself is alive.
ThenM100 · Station 9Check the bellows sits straight before the pressSensor 9B03; gripper 9B5 / 9B02. A crooked bellows reads as a wide left gap even when the press force is normal.
VerifyM100 · Station 9Run and watch: left gap near 0.2 mm, not 1.2 mmStation 9 stops on the first bad gap. If it keeps stopping on code 310, the left gap is still wrong.
WHAT THE PRODUCT HELPS YOU IMPROVE

Less stopped time. More stable output.

WITH YOUR TEAM IN CONTROL

Golain does the evidence gathering and prepares the action. Your team checks the answer, makes the decision and records what actually worked.

01AVAILABILITY

Account for every stop

Count the short stops that never make the shift report, group repeats together and connect each loss to the machine evidence behind it.

MAKE HIDDEN DOWNTIME VISIBLE
02PERFORMANCE

Use your own best run as the target

Compare cycle time, quality and throughput with the best performance this line has already demonstrated, not a nameplate rate it has never sustained.

YOUR LINE'S EVIDENCE, NOT A GENERIC BENCHMARK
ONE INCIDENT · 41 SECONDS TO A CHECKABLE ANSWER

From a fault code to

a practical next step.
T+00sALARM

Force too low, third consecutive part

Repeated alarms are grouped into one incident and checked against seven weeks of this station’s history.

T+09sMEANING

The exact fault bit, its documentation, its station

The fault bit is matched to the machine’s own fault register and manuals: SM146, station 3.

T+27sROOT CAUSE

Force window missed: tool wear or window drift

The controller logic shows why the affected parts were routed to the reject bin.

T+41sACTION

Pull the rejects · compare force curve · recalibrate

A work order is raised with the evidence and inspection steps attached.

TICKET OPEN · 41 s AFTER THE ALARMEVIDENCE CHAIN ATTACHED
HOW THE LINE BUILDS A MEMORY

The next shift should not

start from the same alarm.
NOTICE · EXPLAIN · ACT · REMEMBER
01NOTICE

Repeated alarms are grouped into one incident instead of filling another alarm list.

02EXPLAIN

A likely cause and next action arrive with the machine evidence behind them.

03ACT

The result becomes a work order, inspection or operating change for the right person.

04REMEMBER

The verified outcome stays with the line, so the next shift does not start from zero.

See Golain work on

one recurring machine problem.

Bring a recent incident and the evidence you have. We will show how the product connects it, explains it and turns it into a checkable next action.

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ONE LINE · EXISTING DATA · DEFINED SCOPE