SAP to enable autonomous process control for scalable manufacturing autonomy

Flexxbotics has expanded its capabilities, allowing companies running SAP to achieve new levels of production autonomy through Autonomous Process Control (APC). By extending SAP environments with standardised autonomous manufacturing software, the company allows closed-loop automation capable of adjusting production processes in real-time based on inspection, test, and sensor feedback.

The company's approach directly connects plant assets, automation, robots, inspection systems, and sensors into SAP-driven production workflows – transforming traditionally siloed automation cells into fully orchestrated, enterprise-connected systems for autonomous manufacturing. The result is precision quality, higher yields, improved compliance, and scalable 'lights-out' production across complex factory environments.

"Increasing manufacturing autonomy requires more than conventional hardware automation - it demands closed-loop digitalisation that unifies SAP with machines, robots, and real-time quality feedback," said Tyler Bouchard, CEO and co-founder of Flexxbotics. "By extending SAP with Autonomous Process Control, companies can finally scale automation in a standardised and sustainable way to improve throughput, quality, and profitability."

The company works securely with SAP S/4HANA and SAP Digital Manufacturing, as well as older ECC environments, to operationalise fully automated production with:

• Bi-directional controller interoperability across machines, PLCs, robots, inspection systems, sensors, and other factory assets
• Orchestration of multi-machine automated production lines and cells driven by SAP
• Real-time closed-loop process adjustments driven by inspection and test feedback
• Contextualised production data capture for compliance, genealogy, SPC, and Industrial AI data sets for training and inference

This standardised approach replaces costly one-off, point-to-point integrations and custom cell programming that have historically limited automation scalability and created data silos outside the enterprise IT architecture.

Companies using Autonomous Process Control with Flexxbotics Report:

• Defect reductions exceeding 30%
• Yield improvements of 25–45%
• Improved throughput and faster cycle times
• Cost of Quality reductions of 20% or greater
• Increased EBITDA margins

The company has published a new white paper – 'Attaining New Levels of Manufacturing Autonomy through Autonomous Process Control for Companies Running SAP' – which details the APC framework, SAP production data flow architecture, implementation best practices, and business outcomes across regulated and high-precision industries, including aerospace, defence, semiconductors, automotive, and life sciences.

The paper outlines how standardised autonomous manufacturing platforms enable closed-loop control in production and form the foundation for factory AI-driven initiatives.