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VEXPLOR

VEXPLOR Manufacturing AI OS · Dark Factory OS (Factory OS)

AI decisions reach the equipment only through the interlock

VEXPLOR passes an AI decision through an authority check and a virtual verification first. A command outside the permitted range is not sent to the PLC.

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3D illustrative scene

2026 signed contracts
₩3.65B
2025 revenue
₩1.40B
Government autonomous factory program
In progress
Industry solution areas
21

Control loop

AI commands beyond the permitted range are discarded at the interlock and never reach the valve

Every AI command is first compared with the permitted range at the interlock. Only a command inside the range waits at the permissive point for the next scan cycle, then passes to the PLC and the valve. A command beyond the range is discarded at the interlock, and the PLC and valve do not move.

3D illustrative scene

LIVE CONTROL / LOOP 101

Control loop P&ID

Transmitter01
AI decision02
Interlock03
Permissive04
PLC05
AOpen +8 ppWithin range
Permissive
BOpen +40 ppOut of range
Interlock
FIELD / TC-101
Cooling water control valve0pp
Scan cycle
01

Open +8 pp · passed the interlock

Held at permissive
02

Sent to PLC on next scan cycle

Applied
03

Open +40 pp · out of permitted range

Blocked (command discarded)
Tags, values and times in this drawing are illustrative.
One P&ID sheet carries two AI commands. Command A (cooling valve open +8 pp) passes the interlock, waits at the permissive point until the next scan cycle, then reaches the PLC and opens the valve. Command B (open +40 pp) is beyond the permitted range, is blocked at the interlock (command discarded) and never reaches the PLC.

Executive questions

Three questions executives ask before connecting AI to equipment

  • Can older equipment be connected?

    PLCs that only speak serial (RS-485, RS-232) are integrated through an edge gateway together with OPC-UA and TCP/IP equipment. MES is connected in both directions.

    Drawing reference TT-101

  • What happens if the AI issues a wrong command?

    A command is checked against authority levels (L0 to L4) before it goes to the equipment. Commands outside the permitted range are not sent to the PLC, and the reasoning can be traced in an inference log.

    Drawing reference I-101

  • Can a process change be rolled back if it turns out wrong?

    Process changes are verified with standard virtual commissioning scenarios before they are applied to the PLC, and applied changes come with a rollback safeguard.

    Drawing reference P-101

Authority levels

Control handed to AI widens step by step, not all at once

At first the AI does not touch the equipment. It starts in Shadow Mode, where AI judgments are compared side by side with expert judgments, then rolls out as recommendation (L1) in year one, execution after approval (L2) in year two and automatic execution (L3) in year three.

  1. Shadow ModeAI judgment compared with expert judgment only
  2. Year 1L1 · Recommend
  3. Year 2L2 · Execute after approval
  4. Year 3L3 · Automatic execution

  • L0 View

    Reads data only

    Commands sent to equipmentNone

  • L1 Recommend

    Analyzes and recommends

    Commands sent to equipmentNone

    Year 1

  • L2 Execute after approval

    Executes after a person approves

    Commands sent to equipmentCommands a person approved

    Year 2

  • L3 Automatic execution

    Executes automatically within policy

    Commands sent to equipmentCommands within policy

    Year 3

  • L4 Emergency response

    Acts immediately on a safety threat

    Commands sent to equipmentSafety action commands

For regulated industries, authority levels are aligned with governance requirements such as IATF 16949.

Virtual verification

Process changes run in a virtual factory before they reach equipment

Testing process conditions on the real line stops the line while you test. VEXPLOR runs several assumptions side by side in a virtual factory and applies only the change that passes verification to the PLC.

A white scale model of a press cell (press, conveyor, robot arm, safety fence) on a work table in a dark stamping plant, with the real press line blurred behind it

AI-generated concept image

A concept image that uses a scale model as a metaphor for virtual verification. It is not a physical mock-up or a customer site; verification runs in the VEXPLOR 3D digital twin software. See the actual product screen →
  • Compares equipment failure, material delay, rush order and bottleneck scenarios side by side
  • Verifies with 6 standard virtual commissioning scenarios before applying to the PLC, with a rollback safeguard
  • Runs hybrid DES+ABS simulation on a 3D digital twin
  • 85% simulation accuracy — confirmed at a demonstration site against real line data

3D illustrative scene

SIMULATION LAB / 01

What-If comparison

Virtual factorySCENARIO A
Confidence62%
Misses temperature target
Open +8 pp · PassedPLC
Scenarios, response curves, confidence scores and decisions are illustrative examples. Tags, values and times in this drawing are illustrative.

Proof

VEXPLOR has demonstrated AI decisions executed as real equipment control

  • Demonstrated

    AI → PLC direct control

    Demonstration equipment

    AI decisions executed as real equipment control commands

    Direct control of real equipment confirmed

  • In progress

    Government autonomous factory program

    Mass production plant

    MES · digital twin · AI autonomous control · AAS · edge

    85% simulation accuracy (demonstrated) · simultaneous sync of heterogeneous equipment demonstrated

  • Completed

    Smart factory build

    Manufacturer

    Large-SME win-win smart factory program

    Output per hour and process defect rate improved (per completion report)

Customer names, equipment configurations and result figures are not disclosed. Autonomous control through authority checks and virtual verification is being built and verified at the autonomous factory site.

VEXPLOR Suite

Six VEXPLOR Suite modules share one control loop

The loop above is not one product but six modules. Modules that receive signals, decide, check authority and verify virtually sit on one loop, while the no-code kernel Logic Studio and DataFlows build business apps and analyses.

3D staged scene

CONNECTED INTELLIGENCE / 02

Module boundaries

Control loop01 — 04
VEXPLORFACTORY OS
No-code kernel · analysis05 — 06
MODULE / 01

Connect

Receives field signals

  • Integrates RS-485, RS-232, OPC-UA and TCP/IP protocols through an edge gateway
  • AAS (IEC 63278, IEC 61360) asset standardization · bidirectional MES integration

  • Connect

    TT-101

    Receives field signals

    • Integrates RS-485, RS-232, OPC-UA and TCP/IP protocols through an edge gateway
    • AAS (IEC 63278, IEC 61360) asset standardization · bidirectional MES integration

  • Insight

    UY-101

    Decides

    • Simultaneous Graph, Vector, SQL and Doc search with multi-hop reasoning
    • Blocks hallucination by agreement across evidence and finds root causes by causation, not correlation

  • Core

    I-101

    Checks authority

    • Five authority levels L0–L4 · human approval at L2
    • Commands outside the permitted range are not sent to equipment

  • Vision

    P-101

    Verifies virtually

    • 3D digital twin · hybrid DES+ABS simulation
    • PLC apply after virtual commissioning · 85% simulation accuracy (demonstrated)
    Details — Vision

  • DataFlows

    UY-101

    Designs analyses

    • Node-and-wire workflows · 70 compute nodes in 12 categories
    • Deploys analysis results as REST APIs

  • Logic Studio

    Builds business apps as the no-code kernel

    • Design a schema and DDL, APIs and screens are generated (6-stage auto deployment)
    • 21 industry solutions · 1,539 standard tables · 22 relation types
    Details — Logic Studio

A two-minute recording of all eight menus operated live in the demo plant

Product screen recording · demo plant, simulated data

Recorded while operating the actual screens, with nothing generated or composited. It plays muted when it scrolls into view; turn on sound in the player. Captions are in Korean.Watch on YouTube (new window)

Assessment

An adoption assessment decides which of your equipment to connect to AI first

Tell us about the equipment and systems you run today and the work you want AI to take on, and we review together where to start.

Request an assessment(opens in a new window)

contact@wace.me+82-70-4730-0629