A packaging line keeps faulting mid-changeover. Nobody on shift wrote the ladder logic — and with Rung, nobody has to, to understand it.
Line 6 packages three SKUs on a rotating changeover schedule. Twice this week, the case palletizer has faulted mid-changeover — no safety event, but each fault costs a changeover cycle, and a growing shrug from whoever's on shift. The engineer who wrote the palletizer's ladder logic left the company three years ago; the comments in Studio 5000 are sparse, and the two controllers on the line — the palletizer and the case packer — talk to each other through produced/consumed tags nobody currently on staff has fully traced.
Instead of scheduling a two-day OEM site visit, an engineer exports both controllers' programs and asks Rung to explain what's actually happening.
Every step here is a local, read-only file parse — nothing ever connects to a live controller. →
Plain language — no ladder-logic literacy required.
Parses both L5X exports — tags, comments, rungs.
Follows the handshake tag across both controllers.
Plain-English root cause, and exactly where to fix it.
The engineer never connected to a live controller, and never sent proprietary ladder logic anywhere it shouldn't go.
The trace and the explanation are sitting in the session transcript — the next engineer who hits a produced/consumed tag race on this line starts from an answer, not a blank Studio 5000 project and three-year-old comments.
An engineering estimate, not a lab result — every line, program, and failure mode differs. It's the shape of the problem this capability is built to compress.
| Criteria | Without Rung | With Rung |
|---|---|---|
| First look at the logic | ✕Hours reverse-engineering sparse-commented rungs by hand | ✓Parsed and explained in under a minute |
| Who's needed | ✕The programmer who left, or an OEM field visit | ✓Whoever is on shift, on the terminal they already have |
| Escalation path | ✕OEM support ticket or contractor site visit (days, per typical SLA) | ✓None required for this fault |
| Program exposure | ✕Sometimes — proprietary ladder logic pasted into a general AI chat tool | ✓None — files parsed locally, read-only, never connects to a live controller |
| Root cause found | ✕Trial-and-error changeover retries, sometimes "fixed" by luck | ✓Traced to a specific produced/consumed tag race across both controllers |
This is a composite scenario grounded in real ladder-logic and produced/consumed-tag failure modes, not a specific customer's numbers — every line and program differs. The value here is measured in time and OEM dependency avoided, not a fabricated dollar figure.
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