What mistakes should you avoid when implementing plant automation?

- Poor Management Decision - Insufficient Planning - Overlooking Scalability - Lack of Flexibility - Focusing Solely on Cost Reduction - Failure to Monitor Performance

Automation ... or Autonomation? First of all , before putting any money in a system, use the power of Lean. Identify the True North, identify the Process and start building a system including People to reach targets without Waste. True North means True customers! Outside and Inside the company! A successful project includes them at each relevant steps of the project. Not so Easy? Amazing is the power of such a way of working! To make Money, Make it Easy for everybody!

Walk before you run! For high mix and low or medium volume products (100 to 5,000 units per year) the 80/20 rule applies: Gain 80% of the benefit by automating the mundane, repetitive tasks of manual testing without any robotic actuation. The automation system can still configure the product, test conditions, test setup, prompt the technician's actions, perform the data acquisition, evaluate pass/fail results, generate a test record, and update a data base. Plan for increased throughput compared with manual testing, while reducing the potential for human errors.

Clear objectives need to include studying the best practices, regulatory requirements, talent identification with in the organization and suppliers.

Failing to communicate and collaborate well with all involved parties is a common mistake in plant automation. This includes your employees, suppliers, customers, and even competitors. It's important to share your automation plans with them, seek their opinions, and make sure your new systems work well with your current ones. Bad communication can cause confusion, conflicts, mistakes, and delays.

1.Clear Channels: Establish effective communication methods. 2.Roles Defined: Clearly outline team roles and responsibilities. 3.Regular Updates: Hold frequent progress update meetings. 4.Collaborative Culture: Foster an open culture of collaboration. 5.Conflict Resolution: Address conflicts promptly, implement feedback mechanisms.

Any project that fails to communicate effectively & efficiently will result many mistakes especially 'buy-in' from key customers and colleagues. Lack of engagement too. Poor communication drives frustrations and confusion. RGO (role, goal, objective) is a good approach to take.

Communication is an important key during automation of any process. All stakeholders must align on comman goals. It happens often that one user get more than what they required and another one is chasing for simple reports. Before execution an through planning cycle is very essential with all concern stockholders for understanding final outcome for each of them.

Normally in automation the expectations and deliverables have a wide gap . Success lies in bridging the two . So communication becomes important .

Your automation is only as good as your training. Your operators need to be fully trained before implementation. We used a mock training station to get everyone used to the page set ups.

Understanding the end users level of maintenance support is crucial when implementing automation. Smart components are available (at a cost) to help customers manage their new system. From VPN connections to live camera feeds, options are out there to help in troubleshooting to maximize productivity.

1.Comprehensive Training: Ensure employees receive comprehensive training on automation system operations. 2.Establish Support Systems: Create support mechanisms, including technical assistance and issue resolution channels. 3.Ongoing Training Plans: Develop continuous training plans to keep up with technological updates and train new employees. 4.Resource Sharing Platform: Establish a platform for sharing resources, allowing employees to exchange experiences and solutions. 5.Regular Training Assessments: Periodically assess training programs to ensure they meet employee needs and enhance efficiency.

Qualify the team by proper training and operation and do and donuts . Must have risk assessment during training and solutions for any unwanted situations . Qualified support team need to build up for failure of softwares / valves etc

Effective automation is a system of individual automations and human interaction working together to improve the value chain. Too often we focus on one application alone delivering limited value as an island of automation. In this case the sum of it’s parts is worth less than a well thought out collaborative automation design.

Understanding the terminology used when explaining processes. Clear and concise explanations provide for smoother transition and training.

Insufficient data and testing: Don't rush into full-scale automation. Pilot test new systems on a small scale first and gather data to ensure they function as expected. Inadequate change management: Implementing automation can be disruptive to existing workflows. Develop a clear change management plan to communicate effectively with employees and address their concerns. Skilling the workforce: Ensure workforce has the skills and knowledge to operate and maintain automated systems. Provide proper training programs to bridge any skill gaps.

Automation systems should be flexible enough to adapt to changes in market demand, product specifications, and regulatory requirements. Failing to consider these factors can result in lost opportunities and decreased competitiveness and Inflexible automation systems may require specialized training for operators and maintenance personnel. Failing to provide adequate training can lead to errors, inefficiencies, and safety hazards.

Commented parameter tables and log books, really helps out in future when modifying/shirnking or expanding your system. Dont do it in full scale at once, implement&test it piece by piece and make alot of comments and examples in comments.

The automation process is evolving rapidly from IIoT to ML and AI. Covering our bases with related regulatory compliance will enhance the capabilities of the organisations to be better equipped with the threats associated with the new technologies. For connected machines (IoT), one may consider ISO/IEC 27001 (information security management systems) compliance. ML and AI will soon make a promising entry into smart production, products and services, business operations and management, supply chain, and business model decision-making. It is good idea to incorporate the following for better planning and execution. ISO/IEC 42001 AI management systems ISO/IEC 23894 AI – Guidance on risk management ISO/IEC 23053 Framework for AI Systems Using ML

Avoid unauthorised access Real time monitoring system Escalation matrix. Avoid complex logic Right person right place Minimise the human intervention

Proper security compliance require to apply so proper authorities provided to qualified operators . Not by pass mechanism is applicable by any one . All data is captured and can not be modified by any one even support team or Administration .

Neglecting security and compliance in plant automation can have serious consequences. Automation systems often handle sensitive data and control critical processes, making them targets for cyberattacks. A lack of security measures can lead to data breaches, operational disruptions, and loss of reputation. Additionally, failing to comply with industry regulations and standards can result in legal penalties and fines. It's essential to prioritize cybersecurity and ensure that automation systems adhere to relevant compliance requirements. Implementing robust security protocols and staying updated with regulatory changes are crucial steps in protecting the organization and maintaining trust with stakeholders.

Sem duvidas a “cyber security” nao eh uma opção e sim uma obrigação, portanto toda implementação de automação deve vir junto o pacote de segurança. blindar a empresa eh primordial

One critical mistake to avoid when implementing plant automation in manufacturing industries is the lack of clarity and planning. Without a clear understanding of the objectives, scope, and integration points of the automation project, companies risk misaligning technology with their actual needs. Inadequate planning can lead to overspending, prolonged timelines, and technology that doesn't effectively address the operational challenges or enhance productivity. Proper planning involves detailed requirements gathering, realistic goal setting, and a comprehensive strategy that aligns with the company's long-term objectives.

Uma vez que qualquer sistema automatizado faz o que é mandado fazer, é de suma importância que as instruções sejam fornecidas por especialistas e validadas por usuários. Em meus anos de trabalho vi diversas vezes o executor dissociado do mentor e este tentando criar sistemas complexos e nada práticos, não atende do os usuários. Se você tem duvida tente comprar uma linha de celular adicional em sua operadora. O mentor tem que entender as necessidades, entender o que pode ser feito em termos de automação e deixar que os usuários a validem sem interferir.

Focus automation initiatives on value-added work. Engineers and automation firms will develop creative automation solutions to almost anything you point them to. Operations must focus them on tasks and work that cannot be eliminated or simplified with work station redesign, training, etc.

Have a clear understanding of your process before automation. Understand clearly why your automating your line and what changes could come in the future. Many firms strand their automation when product/process or business needs change and don't realize the savings as a result.

Automation system has some kind of specific jigs / wear part / spare part , we should always maintaining some buffer stock , because failure of this minor parts results affect the production… Contingency plan to be prepared incase of this kind of automation system in BD Conditions. Another important aspect is safety, machine layout to be consider with man approachability for parts change.