It takes a focused effort and dedicated resources to keep your continuous or batch process operation up and running. You spend considerable time and money annually for plant maintenance, repairs and system modifications. Many process operations are running at 100% of capacity, squeezing everything you can out of every production run and pushing legacy systems to their limit. Key process industry workers with specialized knowledge on aging systems help keep plants operating.
Now manufacturers are dealing with a severely stressed supply chain and scarcity of skilled workers. Process facilities are under pressure to decarbonize, meet tightening regulations and make progress on aggressive corporate sustainability goals.
And with consumer demand trends shifting constantly, you must be able to turn on a dime to stay competitive. All this while keeping the workforce safe from harm and happy enough so they stay with the company.
No wonder many manufacturers are hard-pressed to explore the possibilities that modernization can bring them.
The wonders of digital transformation (DX) might sound enticing, but for plant managers, getting a large-scale distributed control system (DCS) project funded and supported is often challenging. They also know a project of this magnitude isn’t without operational risk as they deal with the reality of daily production, quality and profitability requirements.
Many process manufacturers ask, “Why should I ‘digitally transform’ my operation at all? It’s running fine just like it is.”
Problems and Pressures
Empirically, you might know you really need to modernize. After all, most operations are facing well-known legacy system risks, such as:
- Lack of flexibility/agility. Aging systems can’t adapt quickly enough to changing production needs nor easily interface with modern software applications.
- Unplanned downtime. When a continuous process breaks down, the cost to diagnose, repair and bring it back online is high. A single equipment failure could cost tens of thousands of dollars — and the repair doesn’t even improve performance. When unplanned downtime involves a safety issue, the cost can be much higher.
- Skilled resource scarcity. With a lack of incoming resources who know your old system — or even want to work on it — sticking with equipment several generations old can jeopardize future operations.
- Cybersecurity vulnerability. Staying hyper-vigilant against cyber threats and protecting intellectual property (IP) is a challenge for even the most modern facilities. On older systems, even installing the latest patches is problematic at best.
- Sustainability and compliance. Reacting to changing industry regulations and standards is more difficult using obsolete or older systems. Achieving sustainability goals, such as decarbonization, is more costly and challenging.
All these things are inconvenient, to be sure. And they cost money. Opportunity loss may be the highest cost of all.
Saving money to boost the bottom line is important, but transitioning to a new process automation system also can impact revenue streams. Automation systems that don’t evolve, just like people, show their age. Unless there is a life-cycle support process in place to keep the system fresh and vital, plant performance will inevitably drop over time.
DX is Here — So What?
Let’s review some of the positive outcomes that DX can bring.
Improved Productivity. This benefits the bottom line. Increasing productivity is one of the most valued reasons to modernize. Modern process automation solutions using a state-of-the-art DCS to improve production and facilitate faster time to market for new products, for several reasons.
These systems are scalable to allow for fluctuation in production levels or product type. Asset utilization is improved, and predictive maintenance programs anticipate failure points. Also, innovations such as integrating the process and power platforms improves diagnostics and consolidates networks, technology and maintenance.
Unlocks the Power of Process Data. DX is more than just a fancy dashboard or extra data storage. It extracts the huge amount of data hiding in your control system and converts it to vital information for better asset utilization, waste reduction, inventory control and resource management. Real-time reports take the place of paper-based manual processes.
Production data is displayed in real time on high-performance human-machine interface (HMI) graphics to enhance operator awareness, provide faster visibility of the operation and better control of process parameters and I/O. Improved process safety measures help keep workers safe.
And that’s just the tip of the DX iceberg.
Strengthened Cybersecurity. With millions of threats against process industry infrastructureevery year, hardening critical manufacturing assets and bringing the facility into compliance with IEC 62443 provides protection for your IP and operations. Patches and updates can upload automatically and be done remotely.
Enhanced Sustainability for Humanity and Business. Decarbonization, zero net impact and similar catchphrases are becoming a mandate for process manufacturers. Modern process control systems provide enterprise-wide holistic views into the company’s environmental impact, and insights into the health of the business.
Automated reporting and alarms can support regulatory compliance and reduce risk. Sustainability is not insurmountable. Modern control systems can provide the right information to the right people at the right time to help achieve it.
Workforce Ease. The specialized knowledge that kept the old system online is captured and ported into the new control system, reducing dependence on a few key employees. Operators are trained, informed and empowered. They are safer. Your modernized facility is a much stronger employment draw for recent graduates and early career engineers. Continuous process operation also is easier with the convenience of remote management, remote access and 24/7 support.
Ancillary Benefits. Other positive outcomes from DX can include:
- A well-documented operating system.
- Increased computing power.
- Better connectivity.
- Interoperability between systems.
- Software simulation and digital twins.
- Benefits specific to your industry, operational needs and future expansion plans.
So this explains the value and, in fact, the necessity of modernization. How do we begin?
Tips for Developing a Plan
Upfront planning, pre-engineering and working with experts who know how to bring you the best return on investment (ROI) are the keys to a successful modernization project. Here are three tips for developing a solid plan.
1. Gather Internal Stakeholders and Start the Conversation. Make a list of interested people from all areas of your company. Collect critical viewpoints, expertise and insights.
2. Talk to Third-Party Modernization Experts. Open a dialogue with professionals from an automation solutions supplier that has the right knowledge and experience. If they don’t know your industry, they can’t help you.
3. Plan, Plan, Plan. Work with your automation solutions provider on a front-end loading (FEL) process, which includes planning, budgeting, justification and system-design parameters.
Once you begin, you’ll discover an exciting world of maximized performance, flexibility and sustainability. A world that sets you up for success now and gives you a competitive edge for years to come.
