Why logic is more important than statistics

The industrial age has made Europe the workbench of the world. But with sensor technology and digitalization, production has become a data game. In tens of thousands of factories, plants and infrastructure projects, everything is now counted and measured: temperatures, vibrations, energy consumption, running times, maintenance cycles. The statistics are unprecedented - but the logic is often lacking. Those who only count today usually have no control. The future decides now: Whoever sets rules wins.

The statistics trap: measuring without acting

In the machine room of digitalization, measurements are constantly being taken. Every production line, every valve, every pump sends data. Dashboards show statuses, trends and threshold values. But while transparency increases, action often fails to materialize.
Example from the energy supply: A control system reports overheating, the log notes the event, but nobody acts - because there is no logic behind what to do. Valuable time passes, data is archived, but nothing happens.

Keyword alarm management: studies show that over 60% of all alerts in control centers are ignored . In the end, statistics are good for KPIs and monthly reports - but dangerous if plants really have to react. Without mappable rules, reporting remains the maximum and the ability to act remains the goal.

Logic turns data into action

The real leap in quality is when numbers become rules. Decision logic (decision automation) means: "Temperature > 80 °C" becomes an exact, reproducible system behavior: The pump is throttled, the maintenance service is informed, the alarm is documented, perhaps a safety protocol is activated. The principle is simple - and ingenious: if-then logic that combines context, target and action:

• Threshold detection: alarm only occurs when the rule is triggered (e.g. temperature, pressure, power consumption).
• Context dependency: Situations can be differentiated according to time of day, operating load, production status.
• Escalation management: Rules define how alarms are forwarded; integration into maintenance software or ticketing can be automated.

Systems and platforms: Evaluation of modern approaches

Today, innovative companies use a wide range of decision-making platforms:

• DMN (Decision Model and Notation) - industry standard for decision logic in clear, tabular models. Instead of complex code, rules are presented visually - comprehensible, verifiable and documented. In practice, DMN is used in automated release processes, for example: a production system checks whether all the quality parameters of a component are within tolerance. If this is the case, approval is granted, otherwise an inspection order is automatically generated. Each step is stored in an audit-proof manner . DMN therefore offers the perfect balance of transparency and control - ideal for regulated industries such as automotive or pharmaceuticals.
• BPMN engine - describes processes graphically and enables people, machines and software to be linked. A BPMN engine such as Camunda takes control of these processes and ensures end-to-end automation - from the start of a process to the result. Example: In a production facility, a quality sensor automatically triggers a workflow. Camunda controls the notification to the shift supervisor, documents the process, calls up an external test script and stores the results in the ERP system. The result is a seamless, auditable process chain with clear responsibilities.
• No-code/low-code automation - enables specialist departments to design automations themselves - without programming knowledge. Workflows are created, tested and rolled out via graphical interfaces using drag & drop . A typical example: In a logistics company, the scheduling department configures a rule that automatically books replacement shipments and informs customers in the event of late deliveries. The big advantage: ideas can be implemented within hours instead of weeks and pilot projects can be scaled up quickly. This creates new degrees of freedom - IT is relieved, innovation is accelerated.
• Edge computing - shifts decision-making logic to where it is needed: directly to the machine or system. Crucial when there is no stable cloud connection or latencies would be risky. Example: In a wind farm, the control system on the turbine reacts independently to gusts of wind or temperature peaks without first starting a cloud query. This keeps the system safe even if the grid is interrupted. Modern edge platforms also offer audit functions: Every rule, every action and every change is logged locally. They therefore combine real-time capability with traceability - a must for safety-critical environments.

These architectures have been tried and tested in practice: systems such as Camunda excel in terms of workflow complexity and integration capability, DMN in terms of traceability and standardization, no-code in terms of speed and user-friendliness and edge computing in terms of real-time capability - but to date, there are hardly any platforms that offer all of these criteria without compromise and from a single source.

In-depth practical examples

After the technical classification of the platform types, it becomes clear what it means when decision logic works in practice. The following examples take up real implementations - they show how actionable processes are created from data, which reduce costs, increase safety and reduce complexity.

Energy optimization in refrigeration logistics - Lineage Logistics (USA/EU)

Lineage Logistics, one of the world's largest operators of deep-freeze warehouses, has equipped its European sites with the Ndustrial Nsight® platform. Instead of controlling defrost or cooling cycles according to fixed time intervals, they are now adjusted based on rules: Outside temperature, product type, warehouse occupancy and current electricity prices are all factored into the decision. The AI predicts peak loads and automatically shifts energy-intensive processes to more favorable time windows. As a result, the energy intensity of the systems has fallen by over 30% and maintenance costs have been significantly reduced thanks to more even load distribution. The system works fully automatically, documents every control decision and is transparent for operators via a dashboard - an example of how decision-making logic instead of statistics creates real savings.

Municipal pumping stations - retrofit and emergency logic with ifm moneo (Germany)

A municipal water and wastewater company in southern Germany has retrofitted over 100 pumping stations with sensors and ifmmoneo edge gateways. The pumps used to run continuously - now they regulate themselves based on weather forecasts, fill levels and energy prices. The logic reacts to defined scenarios: If the level rises when heavy rain is forecast, reserve sumps are opened and emergency pumps are activated; if consumption falls, units are automatically shut down. The system documents all interventions in an audit-proof manner and only informs the on-call service if a real intervention is necessary. This has reduced the number of false alarms by 40 % and energy consumption by around 20 %. For the operator, this means greater safety, lower costs and a new culture of proactive action.

Together, the two projects show how decision-making logic allows systems to act autonomously and resiliently - regardless of the sector. Whether it's the food chain or municipal infrastructure: automation is not created by more data, but by smart rules that translate responsibility into software. Industrial manufacturers rely on edge control with DMN models: Faulty components are detected by vision systems and automatically rejected according to clear logic - without additional manual decision-making.

Advantage for operators: control and foresight

• Plant safety: Automated escalation reduces downtime and protects employees.
• Compliance: All processes are documented; audits and requests from authorities become a by-product.
• Efficiency: Resources and maintenance are managed as required.
• Innovation: Rules and regulations can be adapted or expanded at any time - without having to restart the system.

Integrators: From project stress to platform service

Integrators benefit in particular: once developed, logic modules can be used multiple times thanks to open standards. Platform models turn individual projects into repeatable services that increase margins and quality.

Conclusion: end-to-end integration in real time

The time of statistics is over. Those who bring logic to machines are setting the new European standard for resilience, efficiency and innovation. The evaluation of modern automation platforms shows that individual technologies (DMN, BPMN, No-Code, Edge) each cover sub-scenarios - but only a platform that integrates all of this creates holistic added value.

VION combines rule-based control (controllable like DMN), comprehensive workflow capability (BPMN), rapid implementation (no-code), decentralized real-time response (edge) and full auditability and interoperability. The platform is retrofittable, scalable, secure and can be configured independently of role and location - and turns passive data streams into active, controllable action.

Big data is worthless without smart rules - and only those who translate their processes into functioning decision-making logic and rely on a platform like VION will survive on the global market tomorrow. The future will be decided where systems not only count, but also act.