How do you balance the trade-offs between safety, security, and efficiency in industrial automation?

CUMPLIMIENTO. Es la única palabra válida cuando hablamos de seguridad. Cumplir con la normativa vigente y con las normas de buenas prácticas. Cualquier acción que vaya en contra de ese cumplimiento sea por la razón que sea no es justificable. La mayoría de la veces se realiza por intentar obtener un abaratamiento de los costes del proyecto. No cumplir también con las recomendaciones de los fabricantes e integradores puede poner en riesgo TODO: personas, medio ambiente y instalaciones. Nuestra misión como técnicos es velar con el cumplimiento de una ejecución correcta de los proyectos.

Ich habe die Erfahrung gemacht, dass Unternehmen unterschiedliche Ziele in der industriellen Automation verfolgen. Zumeist sollten die Ziele jedem bekannt sein. Die Erfahrung zeigte, dass der erste Fehler in der Zusammenstellung des Projektteams passiert. Es stellte sich in meinem Erfahrungsschatz als elementar wichtig dar, dass alle zust?ndigen Abteilungen (alle zust?ndigen Fachabteilung, IT, etc.) gemeinsam ein solches Thema angehen sollten um gemeinsam die Kompromisse festzulegen, damit Sicherheit und Effizienz in den Einklang gebracht werden kann.

I have experienced this trade-off between Safety and efficiency in many projects. As an example, during automation design, we often tend to prioritize safety by having a lot of interlocks, alarms and warnings whereas the client is more focused on efficiency by having plant operational for as much time as possible. A small safety interlock when active, can bring the entire process to a sudden halt. As a result, we have to optimize the design where we don't compromise on safety or efficiency. This is the reason alarm list is optimized in every project to avoid nuisance alarms and similarly false interlocks can be avoided by having some delay condition so that it will be activated only when its necessary.

Trade off...? What trade off...? To my understanding, there is no trade off between (functional) safety, security and efficiency.

Achieving the right balance between safety, security, and efficiency in production facilities is paramount. It involves a mix of rigorous risk assessments and integrating advanced cybersecurity measures. Prioritizing safety to avert accidents is non-negotiable, particularly in high-risk environments like chemical manufacturing. On the other hand, robust cybersecurity protocols are essential to shield against data breaches and malicious attacks. This balance is attained through continuous innovation, adopting state-of-the-art technologies, and fostering a safety and security awareness culture, ensuring both human and system resilience.

Security is another critical aspect of industrial automation which can have some impact on plant efficiency. As an example, if a critical action is required to be performed for process to move forward , we tend to add double confirmation prompts where operator will need additional approval from his supervisor to acknowledge the prompt. Although this might add some delay to the process, it is important considering the criticality of action and its overall impact on the remaining process. It should be noted that security and efficiency goes hand in hand.

Security in industrial automation involves safeguarding data and systems from unauthorized access, manipulation, or disruption, ensuring confidentiality, integrity, and availability. Secure network and communication channels with encryption, authentication, and firewalls. Implement security policies defining user roles, responsibilities, and access rights. Install and update security software and patches to prevent malware and viruses. Conduct security assessments and audits to identify vulnerabilities. Educate and train workers to recognize and report security incidents. These measures collectively fortify industrial automation against potential threats, ensuring robust protection of information and resources.

Some general tips for improve efficiency: Modular Design: Adopts a modular design approach to facilitate scalability and adaptability to future changes. Time is money here too. Technology Selection: Uses proven and reliable technologies to minimise downtime. That our equipment is not a broken bridge within the production line. Systems Integration: Ensure that automation systems are effectively integrated with existing systems (PLC, SCADA, etc.). Predictive Maintenance: Implement P.M. systems to prevent failures before they occur. Real-Time Monitoring: Use Real-Time systems to gain full visibility of automation and set allowable thresholds. Energy Optimisation: Implements technologies for optimising energy consumption.

Efficiency in industrial automation entails optimizing resources and processes to achieve desired outcomes with minimal waste and cost. Analyze machine and system performance using data and metrics to enhance productivity, quality, and profitability. Implement lean and agile principles to eliminate waste, reduce variation, and enhance flexibility. Utilize artificial intelligence, machine learning, and cloud computing to augment machine capabilities and intelligence. Innovate with new technologies and methods to solve problems and create value. Engage and empower workers in continuous improvement and collaboration to further enhance efficiency and drive success in industrial automation.

Balancing safety, security, and efficiency in industrial automation is crucial. For instance, in a chemical manufacturing plant, prioritizing safety is non-negotiable to prevent accidents. Simultaneously, implementing robust cybersecurity measures to safeguard against data breaches and malicious attacks is essential. Striking the right balance involves conducting thorough risk assessments, adopting advanced safety protocols, and utilizing intrusion detection systems. Ultimately, this equilibrium ensures smooth operations while safeguarding assets, employees, and sensitive data, setting the foundation for sustainable growth in the industrial automation sector.

??Safety First: Prioritize safety features like collision detection and emergency stops in the robot's programming. ??Security Integration: Implement secure communication protocols and access controls to protect the robot's programming from unauthorized access. ??Efficiency Optimization: Optimize programming for speed and productivity while maintaining safety and security standards. ??Training: Provide training to operators on safe and efficient use of the programmed robots.

we don't! safety, security and efficiency are three pillars of the design.no trade offs. efficiency is the justification of the business case. without it no automation project will happen. it is a core purpose. safety: same as before, one of the reason of deploying an automation is to replace human being in dangerous working environment. b) safety is critical for every incorporated system in this topic (HSE, RISK, Quality assurance, Employee welfare...) same for security: from data storage, archiving, patents, cybersecurity...it impacts the overall process. however, one can do iterative implementation of these concepts gradually

A last point... Feedback and Continuous Improvement: Establishes a constant feedback loop to identify areas for improvement and make adjustments. Continuous improvement can lead to sustainable increases in efficiency, with improvements of 5-10% per year. ????