Advisory vs integrated modes: choosing the right retrofit path

When adding automated positioning ahead of a multi-saw, mills often ask whether to stop at advisory mode or connect fully into the controls. Both options deliver yield gains, but they differ in scope, risk, and payback.

Advisory mode

The system calculates the optimal offset and angle and displays it for the operator or PLC to execute. It leaves multi-saw set points untouched.

• Best for: lines with limited downtime windows or controls that are difficult to modify.
• Benefit: fast deployment; immediate reduction in operator variability.
• Trade-off: still relies on timely operator action, though the decision is no longer subjective.

Integrated mode

Positioning data drives actuators and, where supported, adjusts multi-saw set points directly.

• Best for: modern PLC environments or mills planning other automation upgrades.
• Benefit: closed-loop control that maintains quality across shifts and species changes.
• Trade-off: requires deeper controls work and coordinated change management with production.

Making the call

• Assess controls access: Do you have documented PLC programs and safe integration points?
• Consider uptime: Can you accommodate a planned window for commissioning and validation?
• Define the ROI trigger: Advisory mode often pays back fastest; integrated mode locks in the full upside long term.

At xception.io we configure both modes. We typically start advisory on legacy lines and design toward integration as controls are modernized.