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AI agent for automation engineers

Controller Program Version Compare Agent

Keep the repository equal to what really runs, with every difference explained

MonitoringIT and developmentOperations
See how it worksGet access
Controller Program Version Compare Agent: what goes in, what the agent does and what you get

What it does

A technician fixes a problem at 2 a.m. by changing the controller, and the repository never hears about it. Weeks later the stored backup is wrong. On a schedule, this agent reads the program from each controller, using read-only access, and compares it with the stored version. It lists differences by routine, tag and setting, and ignores values that are meant to change, such as counters. For each difference it searches change records, tickets and shift notes for a matching reason. It asks the owner of the machine to explain any change with no record. The engineer decides which version becomes the new baseline and approves the update of the repository. Edge case: a difference is only a comment change, so the agent labels it as harmless.

How it works

Follow the arrows from top to bottom. The orange dashed arrow is the loop: when a check fails, the agent goes back and tries again.

Start and resultWhat it doesA check on its own workWaits for your OKGoes back and retries
Yes, continueApprovedYes, continueNoNo 1 STARTS WHEN Weekly schedule or maintenance visit 2 USES A TOOL Read the program from each controller in read-onlymode 3 USES A TOOL Compare it with the stored baseline 4 DOES List differences and remove ignored tags andcomments 5 USES A TOOL Search change records and tickets for eachdifference 6 CHECKS THE RESULT Does each difference have a matching record? If not: ask the machine owner to explain the changeswithout a record. Back to step 4. 7 DOES Rank differences by effect on machine behavior 8 YOU APPROVE Engineer chooses which version becomes the baseline 9 USES A TOOL Update the repository and record the reason 10 CHECKS THE RESULT Does a new comparison show no unexplaineddifferences? If not: repeat the read and list the remainingdifferences. Back to step 2. 11 RESULT Comparison report and updated baseline
Read the steps as a list
  1. Weekly schedule or maintenance visit
  2. Read the program from each controller in read-only mode
  3. Compare it with the stored baseline
  4. List differences and remove ignored tags and comments
  5. Search change records and tickets for each difference
  6. Does each difference have a matching record?If not: ask the machine owner to explain the changes without a record. Back to step 4.
  7. Rank differences by effect on machine behavior
  8. Engineer chooses which version becomes the baselineThe agent waits here for your OK.
  9. Update the repository and record the reason
  10. Does a new comparison show no unexplained differences?If not: repeat the read and list the remaining differences. Back to step 2.
  11. Comparison report and updated baseline

How it decides

It ranks differences by effect on machine behavior and treats any logic or setting change without a change record as needing an explanation.

  • Ignore counters, timers and process values
  • Treat logic and setpoint changes as high impact
  • Label comment-only changes harmless
  • Raise unexplained high-impact changes the same day

Make it yours

Every agent is a starting point. You choose these settings for your own situation.

  • Controllers and schedule
  • Tags to ignore
  • Where change records are kept
  • How impact is ranked
  • Who owns each machine

What keeps you in control

It always asks you first

  • Engineer approves the new baseline
  • Engineer approves any write back to a controller

Hard limits

  • Read-only access, never write to a controller
  • Never delete an older baseline

It stops when

  • Done: the repository matches the controllers and all differences are explained
  • Stop: a controller is unreachable or access is refused

Set it up

We guide you through the set-up, step by step

Members get the full set-up guide for this agent. No technical skills needed: you copy, paste and upload.

10 minto set it up in your AI
5 AIsChatGPT, Claude, Copilot, Gemini, Grok
  • One set of instructions to paste into your AI, with the clicks for ChatGPT, Claude, Microsoft 365 Copilot, Gemini and Grok
  • The agent then walks you through connecting your own data, one source at a time
  • A downloadable copy with the flow chart, the rules and the full guide
Get access to this agent

An example run

What happensThe weekly scan of 14 controllers found 3 differences on a packaging line. A comment edit was harmless. A conveyor speed setpoint changed from 1.2 to 1.5 with a ticket from a shift lead. A timer preset on a filler had no record, so the check failed. The owner said an operator adjusted it after a jam. The engineer made the live version the baseline and the rescan was clean.

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