Many plants have yet to hire new employees to meet the growing demand. Efficiency is more important than ever, and plant managers are looking for ways to streamline manufacturing processes.
Thanks to lower-cost control systems and advances in software, I/O and Ethernet infrastructure, control engineers are better able to use industrial automation for its core purpose - to increase production flexibility and reduce the cost of ownership of a manufacturing or process facility.
Programmable controllers are at the heart of control systems. Whether it's a simple nano-programmable logic controller (PLC) or a full-size industrial PC, today's control platforms are much less expensive than similar models of just a few years ago. It's also easier than ever to closely match the processing performance of the control platform to the requirements of the machine. There is no need to purchase more controller functionality than the system requires.
In the past, smaller machines were a particular problem. It was difficult to find cost-effective controllers with built-in Ethernet connectivity. However, inexpensive nanoscale PLCs can now control small to medium-sized machines.
High-end PC control systems are at the other end of the spectrum. Plant managers need easy-to-program software with fast, comprehensive commissioning and seamless integration into human-machine interface (HMI) packages.
Ideally, a single vendor can provide a turnkey hardware/software solution. The benefits of a "one-stop shop" include faster programming and machine startup, simpler machine design, less troubleshooting, and reduced risk of downtime and lost production. In practice, however, single-vendor solutions are not always feasible, especially in larger, more complex automation systems.
Thanks to the standardization of fieldbus protocols, it is now possible to "mix and match" fieldbus products from different suppliers in a machine or system. In addition, the automation industry has standardized on Ethernet as the physical layer for reading and writing data to devices.
While commercial-grade Ethernet components may initially cost less, they cannot withstand the extreme conditions typical on the factory floor and in the field. Choosing industrial-grade Ethernet switches, Power over Ethernet and wireless products will save money in the long run.
Unmanaged switches are a more cost-effective choice for small, isolated networks. They do not need to be configured and transmit the required data to the intended receiving ports.
More complex networks require managed switches. With managed switches, you can add network configuration capabilities, remote monitoring and diagnostics, and basic IT-compatible network redundancy.
Managed switches have IT-friendly features such as simple network management protocols and Web-based management through a standard Web browser. If an application needs fast, self-healing connectivity between the corporate network and the plant floor, look for managed switches with higher-level features such as Fast Spanning Tree Protocol or Fast Ring High-Speed Redundancy, IGMP snooping and querying, VLANs, and port security.
In recent years, wireless technology has become more reliable and secure, making it an attractive option in situations where physical wiring is too costly or even impossible. In many cases, wireless can even salvage stranded data that was previously inaccessible.
By combining modern controllers with innovations in software, Ethernet infrastructure, and I/O, control engineers can build more flexible, powerful, and affordable automation systems.
Over the past three decades, automation has revolutionized manufacturing processes and transportation systems, reducing costs and increasing efficiency. Companies and organizations in the manufacturing, process control, and transportation industries face similar challenges as they strive to build on these gains and compete effectively in a global economic environment. These challenges include:
- Make strategic business decisions supported by accurate, real-time operational information
- Minimize operational, supply chain and service fulfillment risks
- Reduce excess inventory by improving visibility into production performance and demand information
- Consistently deliver high quality products and services
- Ensure on-time delivery and service performance
- Improve asset lifecycle management by processing more data from equipment and processes
- Reduce support costs for automation, equipment and industrial networks
- Deliver repeatable customer experiences with high levels of satisfaction
- Enhance the company's ability to compete effectively in a global business environment.
Where can organizations in the manufacturing, process control and transportation industries look for solutions? The answer lies in "industrial intelligence," which simply means enabling organizations to manage global industrial operations more intelligently and responsively. Traditional industrial automation tools, including factory systems running Programmable Logic Controllers (PLCs) and Supervisory Control and Data Acquisition (SCADA) systems, are only part of the picture of industrial intelligence.
Manufacturing and supply chain management organizations can reduce operational costs and increase manufacturing flexibility and agility by providing greater visibility into real-time production information through real-time business and economic context.
Chemical manufacturers, upstream and downstream oil and gas operations, and process manufacturers in the pharmaceutical, mining, metals, materials, food and beverage, and water and wastewater industries can implement industrial intelligence to improve operational performance.
Industrial Intelligence works with transportation systems to enable real-time video surveillance, real-time signage, IP-enabled traffic controllers and IP sensors.
Today, Industrial Intelligence goes beyond operations to connect the production environment to the rest of the business.