Bond-line vision
Classifies gaps, squeeze-out and primer misses along the full bite line.
Capability by capability
The complete list of what Footeon senses, decides, controls and records across a footwear plant — grouped by the physical step it belongs to.
Cutting room
Where the most expensive material in the shoe is either used or wasted.
Perception
- Per-hide scanning with scar, brand-mark and hole detection
- Grain direction and stretch mapping
- Textile and synthetic roll defect detection
- Usable-area scoring per hide
Control
- Defect-aware nesting across the live size curve
- Blade and laser cutter path generation
- Cut-order sequencing against downstream demand
- Automatic re-nest when a hide is rejected
Upper assembly
The craft-heavy middle of the line, where drift is invisible until the shoe is on a foot.
Stitching
- Stitch tension monitoring and control per station
- Skipped-stitch and pucker detection
- Seam alignment and edge-distance measurement
- Thread-lot correlation with seam failure history
Lasting
- Heat and tension profiles per leather and textile lot
- Toe, side and heel lasting deviation measurement
- Last-set wear tracking and replacement alerts
- Fit deviation flagged before bonding
Sole, mould and bond
Density, geometry and adhesion — the three properties customers feel in year two.
Moulding
- Compression and injection recipe control for EVA, PU and rubber
- Density and hardness variance control per cavity
- Cure-time optimisation against cycle-time targets
- Short-shot and flash detection
Bonding
- Primer and adhesive process-window calculation per lot
- Humidity- and temperature-aware activation control
- Press pressure and dwell control
- Bond-line vision on every pair with gap classification
Features compose into one run
Individual capabilities are only useful if the lot moves through them coherently. The orchestrator is the feature that makes the rest work.
View as table
| # | Node | Agent | Depends on | Status |
|---|---|---|---|---|
| 01 | Twin simulate | Yield-and-Energy | — | SUCCEEDED |
| 02 | Cut and nest | Cut-and-Nest | Twin simulate | SUCCEEDED |
| 03 | Stitch upper | Stitch-and-Upper | Cut and nest | SUCCEEDED |
| 04 | Mould sole | Mold-and-Sole | Stitch upper | SUCCEEDED |
| 05 | Last upper | Last-and-Bond | Mould sole | SUCCEEDED |
| 06 | Bond sole | Last-and-Bond | Last upper | APPROVAL |
| 07 | Inspect pair | Quality-and-Fit | Bond sole | SUCCEEDED |
| 08 | Finish and pack | Robot-and-Assembly | Inspect pair | SUCCEEDED |
Inspection that covers every pair
Sampling misses the pair that comes back. Footeon inspects all of them.
Fit and dimensional metrology
Measures girth, length, heel height and toe spring against the last and the spec.
Cosmetic scan
Detects glue marks, scuffs, colour mismatch and stitching cosmetics under controlled light.
Return-risk scoring
Predicts per-pair warranty risk from bond, fit and material history, and routes accordingly.
Rework routing
Sends each held pair to the specific rework operation it needs, with the evidence attached.
Per-pair traceability
Hide, thread lot, EVA lot, adhesive lot, operator and setpoints, retained per pair.
Yield, energy, changeover and twin
The plant-level features that turn station control into plant economics.
Shoe-and-line twin
Simulate nest, recipe, lasting and bond window before the run; auto-optimise both.
Changeover scheduling
Sequence models and colourways to minimise setup, mould swaps and last changes.
Energy per pair
Press, oven and conveyor energy optimised against quality and cycle constraints.
Line balancing
Station-level takt balancing solved against live station health and staffing.
Supplier scorecards
Hide, thread, EVA and adhesive lots scored by the defects and rework they cause.
Yield forecasting
Projected leather yield and first-pass yield for a lot before it is released.
Features your auditor cares about
Autonomy is only sellable inside a plant if it is bounded, evidenced and reversible.
Graduated autonomy
Set observe, recommend, act-with-approval or act per agent, line and parameter.
Approval workflows
Route validated-parameter changes to named roles with evidence attached.
Immutable audit log
Every action, approval and setpoint write, retained for the liability window.
Citations on outputs
Every recommendation cites the datasheet clause, spec or historical run behind it.
Guardrails
Schema and range validation on tool calls; fail-closed to last known-good recipe.
Model rollback
Signed artefacts and one-command rollback per line if a model regresses.
Features are visible as tool calls
If a capability exists, you can see it invoked, evidenced and logged.
- 09:14:02 hide.scan(batch="LH-2291", hides=64, sensor="line-b/cam-01")
- 09:14:19 64 hides mapped · 1,842 defects marked · mean usable area 91.2%
- 09:14:20 nest.optimize(pattern="velo-trainer-2", size_curve="EU36-46", objective="yield")
- 09:14:33 nest v7 · leather yield 87.4% (+8.3 pts vs baseline) · solve 12.3 s
- 09:18:44 cutter.execute(table="CT-2", nest="v7", blade_profile="leather-1.8mm")
- 09:22:56 2,412 parts cut · 0 out-of-tolerance · scrap 12.6% (plant baseline 20.9%)
- 09:41:10 stitch.monitor(stations=14, thread_lot="TL-77")
- 09:52:18 3 skipped stitches detected on lateral overlay · 3 uppers re-run · 0 escapes
- 10:03:02 press.set_recipe(press="P-3", recipe="R-08", dwell_s=214)
- 10:12:53 midsole density 0.24 g/cm³ ±1.8% · 0 short shots
Every line is real, copyable text and is announced politely to screen readers.
Reading the stream
Each feature maps to a tool family: nest.*, stitch.*, mold.*, bond.*, quality.*, robot.*, yield.*.
Full tool reference in the docs.
What these features add up to
Feature lists do not pay for themselves; yield, returns and changeover do.
- +8.3 points of leather yield on defect-aware nesting
- −71% delamination-driven returns after bond-window control
- 98.2% first-pass yield across inspected pairs
- −46% changeover time between models and colourways
Features reach your existing machines
No capability requires replacing equipment.
Cutting and nesting
- Atom cutting tables
- Comelz CZ series
- Zünd G3
- Lectra Versalis
- Generic CNC / G-code
Stitching and lasting
- Programmable stitchers
- Lasting machine PLCs
- Toe / side / heel lasters
- Conveyor MES signals
- Barcode and RFID pair tracking
Moulding and bonding
- Compression press controllers
- PU / EVA injection lines
- Primer and cement stations
- Activation ovens
- Press pressure and cure sensors
Plant systems
- SAP and Oracle ERP
- PLM (Centric, PTC)
- MES / MOM systems
- OPC UA, MQTT, Modbus TCP
- Historian (PI, Ignition)
Connectors ship as versioned adapters. Anything not listed is reachable through OPC UA, MQTT, Modbus TCP or the Footeon REST/gRPC API.
Feature questions
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It stops and asks. Every agent runs at a configured autonomy level: observe, recommend, act-with-approval, or act. Bonding, lasting and any parameter under a brand or safety validation defaults to act-with-approval, and every approval is written to an immutable audit log with the sensor evidence that triggered it.
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Agents are bounded by guardrails and schema validation, they cite the datasheet or spec clause behind a decision, and they fail closed to the last known-good recipe. Continuous evaluation against golden datasets gates every model and prompt change in CI before it reaches a plant.
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Line at $8,000 per line per month for one workflow, Factory at $55,000 per month for the whole loop, and Enterprise from $350k to $4M ACV for multi-site networks with custom material, last and bond models. Outcome-based components are available on leather waste, rework and returns.
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Yes — and they are exactly where bond control earns its keep. Recycled EVA, bio-TPU and mono-material uppers shift adhesion behaviour and process windows; the twin simulates the new window and the bond agent holds it as lot chemistry drifts.
See these features run on your line
A line assessment maps every feature above onto your stations, materials and constructions.