Expose hidden behavior
Explore input combinations, interlocks, and logic interactions that are easy to miss when choosing test cases manually.
PLC verification + real-time behavior monitoring
Approve behavior.
Monitor it live.
QualityHero analyzes PLC logic and explains possible behaviors in plain English. Engineers approve intended behavior as a versioned contract. The real-time monitor checks machine signals against that baseline and reports deviations with the evidence needed to investigate.
✓ Structured Text + Ladder Diagram
✓ Engineer-approved baseline contracts
✓ Actionable alarms with counterexamples
Analyze logic→
Approve intent→
Baseline a version→
Monitor behavior
From engineering intent to operating evidence
Behavior needs a clear reference. Before and after deployment.
Discover what the PLC can do, decide what it should do, and keep that decision connected to the machine as it operates.
Make intent explicit
Review behaviors in plain English and approve the intended ones. Baseline that contract against a specific software version.
Recognize deviations live
Compare observed machine behavior with the approved baseline. Investigate an alarm using the inputs, outputs, and expectation behind it.
Industrial code has a real-world cost
PLC software issues don't stay inside the codebase.
When control logic fails in production, the consequence can be physical downtime. Industry data gives teams a reason to verify behavior before deployment and investigate deviations during operation.
2025 State of Industrial DevOps
Software behavior has a direct connection to production outcomes.
Copia's 2025 survey of industrial leaders and managers reports that industrial code issues are a major source of downtime — while downtime itself carries multi-million-dollar hourly impact.
Source: Copia Automation, The 2nd Annual State of Industrial DevOps Report (2025). Figures shown are reported by Copia from its industry survey.
$3.63M
Average cost of industrial downtime per hour
Reported in Copia's 2025 State of Industrial DevOps.
45%
of downtime directly attributable to industrial code issues
A reason to verify intended behavior and investigate deviations in production.
One workflow, from code to operation
Analyze. Approve. Baseline.
Monitor. Investigate. Improve.
The engineer-approved contract connects development decisions to runtime evidence. Every update starts from the behavior already accepted.
01 / ANALYZE
Discover possible behavior
Analyze supported Structured Text or Ladder Diagram logic and inspect the concrete inputs and outputs behind each finding.
02 / APPROVE
Decide what is intended
Review plain-English descriptions and approve the behaviors the system is expected to follow.
03 / BASELINE
Bind intent to a version
Save the approved behavioral contract as the baseline for that software version.
04 / MONITOR
Compare live operation
Read machine signals and compare observed behavior with the approved contract for the deployed version.
05 / INVESTIGATE
Act on the counterexample
See which expectation was violated, the triggering inputs, and the resulting outputs.
06 / IMPROVE
Review changes and deploy
Fix the code, review new behaviors and regressions, approve a new baseline, and deploy the updated version.
Intended baseline contracts
Your engineering intent, captured for every version.
A baseline contract is the engineer-approved set of intended PLC behaviors for a specific software version. It gives analysis and live monitoring a shared reference for expected behavior.
✓
Approval stays with the engineerReview the discovered behaviors and explicitly decide which ones represent intended operation.
✓
Intent is tied to a software versionKnow which approved contract belongs to the code running on the machine.
✓
Review what changedAfter a code update, focus on new behaviors and regressions relative to the existing baseline. Approve the next contract before deployment.
EXAMPLE CONTRACT✓ Approved
INTENDED BEHAVIOR
When the reject arm is active, the conveyor must remain stopped.
✓Approved by the engineer
✓Baselined for software v1.0
✓Reference for live comparison
After a code change
New behaviorsRegression
Review the differences. Approve a new version of the contract.
Real-time behavior monitoring
See when live behavior
breaks the approved contract.
QualityHero compares incoming PLC signals with the intended baseline for the deployed software. A deviation becomes an actionable alarm with the violated behavior and the counterexample that explains it.
PLC signals→Approved contract→Behavior alarm
01
Observe the machine as it operatesRead available input and output signals and evaluate them against the active baseline contract.
02
Understand what deviatedConnect the alarm to a specific approved behavior, software version, and machine.
03
Investigate with concrete evidenceInspect the triggering inputs and observed outputs, then use that counterexample to guide the code review.
04
Close the loop after a fixReanalyze the updated logic, approve the behavior changes, and monitor against the new version's baseline.
INTERACTIVE EXAMPLE · ILLUSTRATIVE SIGNALS
Reject conveyorPLC 01 · Software v1.0 · Contract C-001
● ViolationAPPROVED EXPECTATION
Reject arm active → conveyor stopped.
ConveyorRunTRUE
PusherExtendTRUE
Conveyor runs while the reject arm is extended.
The observed outputs violate the intended behavior approved in C-001.
View counterexample
Inputs captured with this behavior
- RunRequest
- TRUE
- RejectRequest
- TRUE
- PackagePresent
- TRUE
PLC behavior, across the engineering lifecycle
A consistent workflow.
An expanding ecosystem.
The core workflow connects behavior analysis, approved contracts, and runtime evidence. Engineering integrations and signal connectivity are scoped with each pilot.
Core workflow
Structured Text & Ladder
Analyze supported ST and LD logic, review possible behaviors, and establish the intended baseline for each version.
ST / LD
Coming soon
Beckhoff TwinCAT
Bring automated behavioral discovery and reproducible findings into TwinCAT-based PLC development.
TC
On the roadmap
CODESYS
Extend QualityHero's verification workflow to IEC 61131-3 projects built across the CODESYS ecosystem.
IEC
On the roadmap
Rockwell Studio 5000
Target the same behavior-first verification experience for Allen-Bradley control projects.
AB
Source import, runtime connectivity, and deployment workflows are confirmed for each pilot. Roadmap priorities may evolve with engineering access and pilot demand.
Why it's different
Carry engineering intent into production.
Engineering need
Before deployment
During operation
Understand behavior
Analyze code and review possible outcomes
Observe behavior through incoming PLC signals
Define the reference
Approve intent and baseline a software version
Compare against that version's approved contract
Investigate a finding
Inspect the analysis counterexample
Inspect the alarm, triggering inputs, and observed outputs
Review a code change
Review new behaviors and regression results
Use the newly approved baseline after deployment
Primary question
“Is this the behavior we intend?”
“Is the machine following that intent?”
Pilot QualityHero
Bring your PLC logic.
Define the behavior you intend.
Explore a pilot that connects behavioral verification, approved baseline contracts, and real-time monitoring. Start with a real PLC project and the machine behavior your team wants to understand.