MaintAIn Solution Overview

MaintAIn brings together two things reliability engineers usually have to hunt for separately: a live view of breakdown and preventive-maintenance data, and an assistant that can answer questions about the equipment in plain English (or by voice), grounded in the plant's own documentation and history.

Reliability Dashboard

Reactive Maintenance — breakdown counts, fault categories, chronic issues, filterable by line, machine, category and time period.
Preventive Maintenance — cleaning/inspection/lubrication task status (overdue / due soon / on track), filterable by machine, responsible role and reason.

AI Assistant — Text & Voice

Ask questions by typing, or by speaking to it directly.
Answers are grounded in maintenance manuals, operational procedures and troubleshooting guides — not the model's general knowledge.
Every answer shows which document(s) it came from, with the source excerpt available to view alongside the answer.
Can also reason over root-cause questions ("why does X keep failing?") by combining breakdown history, preventive-task records and the documentation together.

Both the dashboard and the assistant sit behind the same sign-in used across the rest of the tool — nothing here requires a separate login or account.

How It Works

The assistant doesn't rely on general AI knowledge to answer plant-specific questions — it retrieves the relevant passage from the actual source documents first, then answers from that passage, and shows its source. This is what keeps its answers accurate and checkable.

Your question

→

Find relevant documents

→

Answer grounded in what was found

→

Answer + cited source

At a very high level, every question — typed or spoken — follows the same four steps end to end:

The question is sent to the agent (Agent Engine for text, or the in-app voice agent for speech).
The agent searches the relevant document store(s) for the passages that best match the question, and — for recurring-failure questions — also pulls matching records from the breakdown/preventive maintenance data.
The agent composes an answer using only what it retrieved, never from general knowledge.
The answer is returned with its source(s) attached, so it can be checked against the original document.

Where it runs: everything runs on Google Cloud, inside Unilever's own cloud project — no plant data or documents leave that environment to answer a question.

The documents (embeddings)

Each source document is broken into passages and stored, along with a numeric representation of its meaning (an "embedding"), in Google Vertex AI's managed document-retrieval store — one store per document area (maintenance / operational / troubleshooting). This is what the assistant searches to find the passage most relevant to a question, before it ever generates a reply.

The assistant (agent)

The text assistant runs as a managed AI agent on Google Vertex AI Agent Engine, hosted separately from the rest of the application. The voice assistant runs on Google Cloud Run, alongside the dashboard and its API, since real-time voice needs a continuously-open connection rather than a request/response call.

The documentation the assistant draws from is organized into three areas, so it can pull from the right one for the type of question being asked:

Maintenance Operational procedures Troubleshooting

For questions about recurring failures ("why does the gripper sensor cable keep breaking?"), the assistant additionally looks at the historical breakdown log and the preventive-maintenance task list, so its answer reflects what has actually happened on this line — not just what the manuals say should happen.

Current Architecture

End to end, the PoC is five stages: the plant's own source records and documents go in, get prepared and indexed, are made searchable by a Google Cloud AI stack, and come back out through the dashboard and assistant a user actually sees.

PoC Sources

Selected knowledge documents, structured & unstructured intake

Breakdown records
Machine logs & fault categories
CIL task register
Manuals & SOPs

→

Data Preparation

Structured & unstructured intake

Breakdown/CIL records loaded into the reliability database
Manuals & SOPs indexed into the knowledge corpus
Metadata & filters — source, page, machine
Chunking with source metadata for text & tables

→

AI Stack

Google Cloud · Vertex AI, grounded reasoning

Vertex AI RAG Engine — corpus management & retrieval orchestration
Embeddings — multilingual, per-chunk
Vector search — high-scale similarity search
Gemini on Vertex AI — grounds every answer in retrieved context

→

Application Layer

What users see

PoC web application — connects users securely to the assistant & dashboard
AI Maintenance Assistant — troubleshooting, RCA, operational & maintenance Q&A
Unified Maintenance Dashboard — single view of status, incidents, schedules & performance

→

PoC Outputs

Handled automatically

Fault categories & historical incidents surfaced automatically
RCA evidence & analysis, preventive-maintenance tasks
Source citations with linked evidence — every match traced to its source, page & machine

Included knowledge

Breakdown / resolution history & fault categories
Operational & SOP guidance, operating & safety procedures
Maintenance schedules & preventive-maintenance (CIL) tasks
Fault codes, changeover & operating guides

Single view of

Breakdown / resolution history
Troubleshooting Q&A
Machine status
Performance insights

Using the Assistant

By text

Open the Assistant page, type a question, and get a written answer with source citations you can click to see the original document excerpt.

By voice

Say the wake phrase "Hello Maintain" to start talking. The assistant stays listening for the rest of the conversation — no need to repeat the wake phrase for follow-up questions — and it will let you know before it goes back to sleep after a period of silence.

What kind of questions can I ask?

Anything about the A11/A12 line's equipment, procedures, fault history, or preventive-maintenance tasks — e.g. "What's the CIL frequency for the heater controller?" or "Why does the gripper sensor keep failing?"

What happens if it doesn't know the answer?

It says so, rather than guessing — it only answers from what it can find in the plant's documentation and data, and declines questions outside that scope.

Can I trust the sources it shows me?

Yes — every citation links back to the real document and passage the answer was drawn from, so you can verify it yourself.

Column	Key	Description
id	PK	Generated ID, one per distinct line.
line_code		The line code as it appears in both source files — "A11" or "A12".

id	line_code
L1	A11
L2	A12

Column	Key	Description
id	PK	Generated ID, one per physical machine per line.
line_id	FK	Which line this machine sits on → DIM_LINE.
machine_name		Primary name — the two source systems sometimes spell the same machine differently.
alias		The other source system's name for the same physical machine — e.g. "Pester"/"Wrapper", "Deo"/"Deo Filler", "Coder"/"Inkjet".

id	line_id	machine_name	alias
M30	L1	Pester	Wrapper
M13	L2	Deo	Deo Filler
M22	L1	Line	General
M2	L2	AP Filler	—
M12	L2	Crimper	—

Column	Key	Description
id	PK	Generated ID, one per sub-assembly per machine.
machine_id	FK	Which machine this sub-assembly belongs to → DIM_MACHINE.
subassy_name		e.g. "Outfeed conveyor", "Capper Outfeed", "Change Parts".

id	machine_id	subassy_name
S11	M30	Outfeed conveyor
S24	M30	Air Motor
S12	M30	Infeed Conveyor x 4 Lane Conveyor
S10	M9	Capper Outfeed
S6	M17	Change Parts

Column	Key	Description
id	PK	Generated ID, one per fault category.
theme_name		One of six categories: Safety & guarding, Electrical & controls, Software & comms, Pneumatic & fluid, Mechanical, Other/unclassified.
keyword_rules		The keyword-matching rule used to assign a breakdown's free-text description to this category.

id	theme_name
T1	Electrical & controls
T2	Mechanical
T3	Other / unclassified
T4	Pneumatic & fluid
T5	Safety & guarding
T6	Software & comms

Column	Key	Description
id	PK	Generated ID.
role_name		Operator, Electrician, or Craft — the three job functions used across the preventive-maintenance task list.

id	role_name	usage
R1	Operator	637 of 1,466 CIL tasks require this role — the most common.
R2	Electrician	422 of 1,466 CIL tasks.
R3	Craft	407 of 1,466 CIL tasks.

Column	Key	Description
id	PK	One row per incident.
date / year / month		When the breakdown occurred.
line_id / machine_id / theme_id	FK	Which line, machine and fault category this incident belongs to.
breakdown		Free-text description of the fault symptom.
resolution		Free-text description of how it was resolved.

id	date	machine_id	theme_id	breakdown	resolution
BD1	2026-03-05	M30	T5	Panel had been blown out and cardboard dust blew up a power supply.	On power supply replacement guard door circuit would not reset. Relay auxiliary sticking and Sick safety module needed a complete power-down to reset.
BD10	2025-02-28	M18	T3	Overfill setting on A11 Heuft was not rejecting the overfilled test can.	Changed setting from 227 to 190. Tested OK.

Column	Key	Description
id	PK	One row per task.
line_id / machine_id / subassy_id / tbc_by_role_id	FK	Which line, machine, sub-assembly and required role this task belongs to.
last_done / next_due		When the task was last completed, and when it's next due.
frequency_days		How often the task recurs, in days (0.5 = twice daily).
status		Overdue / due soon / on track — computed live from next_due, unless a manual override has been set for that task.
task_description / reason		What the task is, and why it's done (e.g. Housekeeping, Minor Stops, Product Quality).
people_required / running_static / expected_min / annual_min		Staffing and time-on-task figures for the task.
completed_by / ppe_needed / tools_and_products / procedure		Who typically completes it, and what's needed to do so.

id	machine_id	task_description	reason	next_due	status
CIL7	M17	Clean all change parts using all purpose cleaner and a dry cloth.	Housekeeping (5S)	2026-08-10	overdue
CIL869	M17	Conduct a basic panel check — water/dust ingress, panel secure, no foreign objects.	Breakdowns	2026-11-17	on_track
CIL1045	M9	Check all push buttons / lamps / indicators are working correctly.	Breakdowns	2026-09-15	due_soon (manual override: "Completed")

Table	Column	Key	Description
DIM_USER	id	PK	One row per user account.
DIM_USER	user_name / email / active		Account details.
BRIDGE_USER_ROLE	user_id, role_id	PK FK	Composite key — lets one user hold multiple roles → DIM_USER, DIM_ROLE.
BRIDGE_USER_ROLE	assigned_date		When the role was assigned.

id	user_name	email	active
U1	J. Smith	j.smith@example.com	true
U2	R. Patel	r.patel@example.com	true

user_id	role_id	assigned_date
U1	R1	2026-09-01
U1	R3	2026-09-01
U2	R2	2026-08-15

A set of 80 realistic questions — covering safety procedures, maintenance tasks, changeover planning, drive troubleshooting, and root-cause/breakdown-history analysis — was run against the assistant, and every answer was checked against a verified reference answer from the source documents and data.

Total Questions

Passed

Failed

83.8%

Overall Accuracy

8–45s

Avg. Latency

Accuracy by category

Operations & Safety

16 / 18 · 88.9%

Maintenance

13 / 17 · 76.5%

Planning & Changeover

13 / 14 · 92.9%

Troubleshooting

6 / 7 · 85.7%

RCA & Breakdown History

19 / 24 · 79.2%

Where accuracy is weakest — RCA & Breakdown History (5 of 13 fails): mostly false negatives, where a real matching record existed but the data lookup didn't surface it, plus two cases of the assistant drawing conclusions from too small a slice of the historical data instead of the full record set. See the Failure Analysis tab for each case.

All 80 test questions, their category, and the pass/fail outcome. Failure reasons are summarized here — see the Failure Analysis tab for the full detail on each.

#	Category	Question	Result	Notes
1	Operations & Safety	where are the estop buttons on this machine	Pass	Matches documented reference answer.
2	Operations & Safety	whats the door release button for near doors 1 and 6	Pass	Matches documented reference answer.
3	Operations & Safety	if the guard door lamp is on but the hmi still shows closed, am i ok to start	Pass	Matches documented reference answer.
4	Operations & Safety	gas alarm cleared, how do i restart from the main panel, step by step	Pass	Matches documented reference answer.
5	Operations & Safety	whos supposed to investigate a gas alarm, me or the electrician	Pass	Matches documented reference answer.
6	Operations & Safety	do i need to fully evacuate for every gas alarm or just some	Pass	Matches documented reference answer.
7	Operations & Safety	before i open a guard door what am i supposed to check on the hmi	Pass	Matches documented reference answer.
8	Operations & Safety	can i put my whole body inside the machine guard to fix something quick	Pass	Matches documented reference answer.
9	Operations & Safety	theres a job that isnt covered by any written procedure, what do i do	Pass	Matches documented reference answer.
10	Operations & Safety	gas card is reading 4, is that ok to restart on	Pass	Matches documented reference answer.
11	Operations & Safety	who approves changes to the sop document itself, and is that the same as the document owner	Fail	Real SOP cover page has the owner field blank - only 'Approved by: Process Engineer' is filled. Answer asserts an equ...
12	Operations & Safety	can new operators use this sop as their only training or do they need someone with them	Pass	Matches documented reference answer.
13	Troubleshooting	whats a safety open fault on the drive and whats the first thing i should check	Pass	Matches documented reference answer.
14	RCA & Breakdown History	we've got a pester guard door 12 alarm that wont reset even after craft used the override switch, whats fixed this before	Pass	Matches documented reference answer.
15	RCA & Breakdown History	A12 pester keeps throwing false RHS safety switch faults, we've had this before right, what did they find	Pass	Matches documented reference answer.
16	RCA & Breakdown History	hold-down motor's throwing a bus fault on A11 pester again, is it actually the motor or the same issue as before	Pass	Matches documented reference answer.
17	RCA & Breakdown History	just had an axis A pac robot exceeded limit alarm on the pester, then axis B did the same right after, what did we do last time	Pass	Matches documented reference answer.
18	RCA & Breakdown History	splicer 1 ropex temp controller's in alarm and wont reset on A11 pester, whats the fix from last time	Pass	Matches documented reference answer.
19	RCA & Breakdown History	is there a logged 'category 5 gearbox' failure on the pester pick and place, or have we not seen that	Fail	Real matching incident exists (ID450, gearbox bearing seizure) - false negative on SQL lookup.
20	RCA & Breakdown History	last time we had a coder EHT fault trip repeatedly, what did we end up doing, swap the whole thing or just clean it	Fail	Real breakdown record exists describing repeated EHT trips and ink leaks - false negative.
21	RCA & Breakdown History	out of the 29 breakdown records analysed, whats the biggest category and whats the actual repeat theme behind it	Fail	Source document's own stated breakdown shows Mechanical (13 records, 45%) as the clear biggest category - answer invented ...
22	RCA & Breakdown History	whats our single biggest downtime hit across all the breakdowns thats been logged, and how long did it cost us	Fail	Doesn't answer the question asked - repeats the wrong 'biggest category' answer instead of stating a downtime du...
23	RCA & Breakdown History	any record of us actually having a phase-to-ground fault, like F038 or F039, happen on the pester specifically	Pass	Matches documented reference answer.
24	Maintenance	how often do the pester sealing unit seals actually need changing, and whats the colour setup	Pass	Matches documented reference answer.
25	Maintenance	what tools do i need before i check the toothed belts on the pester	Pass	Matches documented reference answer.
26	Maintenance	what do i need to grab before doing a seal change on the sealing unit	Pass	Matches documented reference answer.
27	Maintenance	whats involved in isolating the machine before i start the toothed belt check	Pass	Matches documented reference answer.
28	Maintenance	before i fit the axis zeroing jig, do i need to calibrate anything first	Pass	Matches documented reference answer.
29	Maintenance	which axis do i zero first on the pester axis zeroing jig, and is there anything to be careful of	Pass	Matches documented reference answer.
30	Maintenance	after fitting new seals on the sealing unit, how do i know the job's actually good, and any tips for getting them in	Fail	Response contained an unrelated sealing-bar validation answer instead of B-axis speed settings - answer/question misalignment.
31	Maintenance	whats the actual jogging procedure for zeroing the b axis, like the speed settings	Pass	Matches documented reference answer.
32	RCA & Breakdown History	we're getting double packs or a bad seal seam after fitting new seals on the sealing unit, whats the known cause	Pass	Matches documented reference answer.
33	Maintenance	whats the smp procedure for cleaning the probe and coil on the pester	Pass	Matches documented reference answer.
34	Maintenance	whats the procedure for the thermography check on the servo motor drives	Pass	Matches documented reference answer.
35	Planning & Changeover	what film width do we run for the posh cap 250ml format	Pass	Matches documented reference answer.
36	Planning & Changeover	whats the collation pattern for the carla cap 150ml format, like how many go in a pack	Pass	Matches documented reference answer.
37	Planning & Changeover	whats the product dimension for polaris 100ml, just the can size	Pass	Matches documented reference answer.
38	Planning & Changeover	outside case dimensions for the carla cap 150ml format	Pass	Matches documented reference answer.
39	Planning & Changeover	does the incoming speed at infeed change between formats or is it always the same	Pass	Matches documented reference answer.
40	Planning & Changeover	whats the drawing number used for all these formats	Fail	Real answer: film width does change (190mm to 220mm). Repeat of a previously-flagged failure on this exact question.
41	Planning & Changeover	which formats actually run at a different film width than most of the others	Pass	Matches documented reference answer.
42	Planning & Changeover	is the collation ever anything other than 2x3 across all the formats we run	Pass	Matches documented reference answer.
43	Planning & Changeover	whats the output rate at discharge, and does it change by format	Pass	Matches documented reference answer.
44	Planning & Changeover	what machine types is this format list actually for	Pass	Matches documented reference answer.
45	Planning & Changeover	compare the outside case dimensions for carla cap 150ml and posh cap 250ml	Pass	Matches documented reference answer.
46	Planning & Changeover	how many of the format settings actually change going from format 1 to format 2 on the changeover list, roughly	Pass	Matches documented reference answer.
47	Planning & Changeover	whats the outside case dimensions for vic 250ml, straight off the format list table	Pass	Matches documented reference answer.
48	Operations & Safety	what does the risk assessment say the residual risk rating is for the guard interlock system	Pass	Matches documented reference answer.
49	RCA & Breakdown History	how many breakdown records are in the full A11/A12 log	Pass	Matches documented reference answer.
50	Operations & Safety	is the wrapper the same thing as the pester machine on this line	Pass	Matches documented reference answer.
51	Maintenance	why do we have to isolate both pneumatically and electrically before the toothed belt check, isnt electrical isolation on its own enough	Fail	Contradicts the real documented reason (compressed air stays pressurized after electrical isolation) - reads as a fabricated te...
52	Maintenance	What's the procedure for zeroing the A/B axis on the Pester?	Pass	Matches documented reference answer.
53	Maintenance	How do I replace the sealing unit seals on A12?	Pass	Matches documented reference answer.
54	Maintenance	What does the thermography check on the Pester servo drives involve?	Pass	Matches documented reference answer.
55	Maintenance	How do I clean the Pester temperature probes and heater coils?	Pass	Matches documented reference answer.
56	Maintenance	What tools are needed to replace the conveyor link on the infeed belt?	Fail	Only lists tools; omits the isolation and post-repair function-check steps the documented SMP procedure requires.
57	Maintenance	How is the missing-cap sensor set up on A11/A12?	Fail	Describes the sensor's general location/function but gives no calibration steps - wrong document/agent used, not the actua...
58	Operations & Safety	What does the Pester Pick & Place area's Gripper Head Safety Sensor do?	Fail	Declines the actual question, then substitutes an answer about a different, unrelated sensor (Safety Laser Scanner).
59	Operations & Safety	How long does the Therm tunnel take to reach operating temperature during startup?	Pass	Matches documented reference answer.
60	Planning & Changeover	What film width is used for the 'Carla Cap 150ml' product changeover?	Pass	Matches documented reference answer.
61	Operations & Safety	What should I check before starting the machine according to the startup SOP?	Pass	Matches documented reference answer.
62	Operations & Safety	What is documented about disconnecting electrical energy on the PEWO-pack 600?	Pass	Matches documented reference answer.
63	Troubleshooting	What does fault code F004 mean on the PowerFlex 525 drive?	Pass	Matches documented reference answer.
64	Troubleshooting	What does fault code F005 indicate and what should I check?	Pass	Matches documented reference answer.
65	Troubleshooting	What does the DC Bus Voltage parameter (b005) show on the drive?	Fail	States b005 shows 'Process Fract' - this is incorrect; b005 is the DC Bus Voltage reading. Retrieved the right docume...
66	Troubleshooting	What causes an F007 Motor Overload fault and how do I resolve it?	Pass	Matches documented reference answer.
67	Troubleshooting	What does an F013 Ground Fault mean on the drive?	Pass	Matches documented reference answer.
68	Troubleshooting	What does fault code F029 Analog In Loss mean?	Pass	Matches documented reference answer.
69	RCA & Breakdown History	How many breakdowns has A11 had in total?	Pass	Matches documented reference answer.
70	RCA & Breakdown History	How many breakdowns has A12 had in total?	Pass	Matches documented reference answer.
71	RCA & Breakdown History	How many breakdown records exist for the Pester machine?	Pass	Matches documented reference answer.
72	RCA & Breakdown History	How many breakdown records exist for the Capper machine?	Pass	Matches documented reference answer.
73	RCA & Breakdown History	Which machine has the most CIL preventive-maintenance tasks?	Pass	Matches documented reference answer.
74	RCA & Breakdown History	How many CIL tasks are marked Safety Critical?	Pass	Matches documented reference answer.
75	RCA & Breakdown History	How are CIL tasks split across Operators, Electricians, and Craft?	Pass	Matches documented reference answer.
76	RCA & Breakdown History	How many CIL tasks fall under the 'Breakdowns' reason category?	Pass	Matches documented reference answer.
77	RCA & Breakdown History	Why does the Pester gripper keep breaking down?	Pass	Matches documented reference answer.
78	RCA & Breakdown History	Why does the Pester tunnel keep tripping into emergency exhaust?	Pass	Matches documented reference answer.
79	RCA & Breakdown History	Why does Capper keep breaking down?	Pass	Matches documented reference answer.
80	RCA & Breakdown History	What's the most common root cause of breakdowns on the Kuka robot?	Fail	Only 1 incident used to build a full RCA conclusion, when the Kuka robot has significantly more breakdown records in the full l...

All 13 failed test cases, with a recommended fix for each.

#	Category	Question	Why it failed	Recommended fix
1	Operations & Safety	who approves changes to the sop document itself, and is that the same as the document owner	The response states the approver 'is also identified as the document owner' - this specific equivalence is not written anywhere in the source. The owner field being blank and the approver field being filled are two separate facts; treating a blank field as 'the same as' a filled one is an inference the document does not support.	Restrict the answer to facts explicitly stated per field; don't let the model infer that two separate document fields (approver, owner) refer to the same person.
2	RCA & Breakdown History	is there a logged 'category 5 gearbox' failure on the pester pick and place, or have we not seen that	The response states no matching records exist. A real record does exist for this machine and fault type (gearbox); it was likely missed because the query searched for the literal fake term 'category 5' rather than the actual fault description.	Match breakdown-log searches on the described symptom (e.g. "gearbox", "bearing") rather than a literal invented category label; add fuzzy/synonym matching to the SQL lookup tool.
3	RCA & Breakdown History	last time we had a coder EHT fault trip repeatedly, what did we end up doing, swap the whole thing or just clean it	The response states the data-gathering step returned nothing usable for this question. A real, directly matching record exists in the same source document used successfully for other questions in this set.	Same fix as #2 - broaden the breakdown-log search so a real matching record (by machine + fault keyword) isn't missed when the exact phrase isn't in the text.
4	RCA & Breakdown History	out of the 29 breakdown records analysed, whats the biggest category and whats the actual repeat theme behind it	The response reports a 3-way tie at 7 incidents each between different category names (Robot/Gripper/Axis, Safety Interlocks, Heating/Temperature) - this doesn't match the document's own stated category breakdown at all. It appears to have invented its own grouping instead of reading the document's existing Category Pareto table.	Have the RCA tool read the source document's own existing summary table (e.g. "Category Pareto") directly instead of re-deriving a category breakdown from raw records.
5	RCA & Breakdown History	whats our single biggest downtime hit across all the breakdowns thats been logged, and how long did it cost us	The response doesn't answer the question at all - it repeats the same wrong 3-way-tie category answer from the previous question and never states a downtime duration. The real answer (480 minutes, a specific named event) is explicitly stated in the source document's own summary section.	Add an answer-relevance check so the agent verifies it actually answered the question asked (a duration) before returning a reused answer from the prior turn.
6	Maintenance	after fitting new seals on the sealing unit, how do i know the job's actually good, and any tips for getting them in	The response describes checking the gap between a sealing bar and clamping bar (0.2-0.5mm) and spraying a silicone separating agent before insertion - this is content from the general Translation manual's sealing-BAR servicing section, a different component and different document to the one this SMP-specific question needed.	Improve document disambiguation between similarly-named procedures (sealing bar vs. sealing unit) - tighter chunk labeling/metadata so retrieval doesn't cross-match the wrong component.
7	Planning & Changeover	whats the drawing number used for all these formats	The response gives "21385-10000" - this is the Changeover List's own project/document reference number (from its title "Changeover list: 21385-10000"), not the Format List's drawing number that the question asked for. Two different documents' reference numbers were confused.	Same fix as #6 - tag retrieved passages with their source document name and prefer an exact document-title match for numeric/reference-number lookups.
8	Maintenance	why do we have to isolate both pneumatically and electrically before the toothed belt check, isnt electrical isolation on its own enough	The response states electrical isolation 'causes the air system to exhaust via an air dump valve' and that pneumatic isolation is only about parts 'coming to rest in a safe position' - this is the opposite of what the source says. The real hazard is that air pressure is NOT automatically exhausted by electrical isolation alone; it stays stored, which is exactly why pneumatic isolation is a separate required step.	Increase retrieval coverage (top-k) for safety-critical sections and add a fact-check pass comparing the generated answer against the retrieved passage before returning it.
9	Maintenance	What tools are needed to replace the conveyor link on the infeed belt?	The tools listed are correct and properly cited. It's marked as a fail because the question is being graded against the full expected procedure, which also requires isolating the machine first and checking the repair afterward - both omitted here.	Prompt tuning: for procedure questions, require the full documented step sequence (isolation, task, verification) rather than stopping at the first matching sub-section (tools).
10	Maintenance	How is the missing-cap sensor set up on A11/A12?	The response describes the sensor's general location and function (mounted above the scroll, stops the machine if a cap is missing) - this is accurate as far as it goes, but it's a general SOP description, not the specific SMP calibration steps the question asked for. Wrong document was used.	Same fix as #6/#7 - improve document routing so calibration-specific SMPs are preferred over general SOP descriptions when the question asks "how is X set up".
11	Operations & Safety	What does the Pester Pick & Place area's Gripper Head Safety Sensor do?	The response says it doesn't have information on this specific sensor, then substitutes a description of a completely different sensor (the Safety Laser Scanner, from the Machine Safety section) as if it were relevant. The real Gripper Head Safety Sensor is documented elsewhere in the same SOP and was not surfaced.	Add a guardrail against substituting a different, unrelated entity when the exact one asked about isn't found - the agent should say it doesn't know rather than answer about something else.
12	Troubleshooting	What does the DC Bus Voltage parameter (b005) show on the drive?	The response states b005 shows "Process Fract" - a different parameter/value entirely. This is a direct factual contradiction, not just an incomplete answer: the right document was retrieved, but the wrong field or row was read from it.	Improve table/row extraction accuracy for tabular fault-code documents so retrieval returns the correct field value, not an adjacent one.
13	RCA & Breakdown History	What's the most common root cause of breakdowns on the Kuka robot?	The response builds its entire root-cause conclusion from just 1 incident record, when 29 real records exist for this machine. This is a severe data undercount - the SQL query likely returned a small, unrepresentative slice of the real data, and the RCA synthesis presented that single record as if it were the complete picture.	Fix the SQL query's row limit/aggregation for RCA lookups so root-cause synthesis is built from the full matching record set, not a small unrepresentative slice.

Four pages, one solution

Capability Overview

Data Model & ER Diagram

Evaluation Report

Scope & What's Next

Reliability Dashboard

AI Assistant — Text & Voice

How It Works

The documents (embeddings)

The assistant (agent)

Current Architecture

PoC Sources

Data Preparation

AI Stack

Application Layer

PoC Outputs

Included knowledge

Single view of

Using the Assistant

By text

By voice

DIM_LINE

DIM_MACHINE

DIM_SUBASSEMBLY

DIM_THEME

DIM_ROLE

FACT_BREAKDOWN

FACT_CIL

DIM_USER & BRIDGE_USER_ROLE (illustrative)

Accuracy by category

How this scales beyond one line

Fix & Close a Maintenance Issue

Predict & Prevent Failure

Investigate & Learn Across Lines

Shared architecture foundation (one across every line)

Enterprise Systems & Sources

AI-Ready Data Products

Context & Semantic Layer

Agent Layer / Shared Intelligence

MaintAIn Control Tower