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You're juggling multiple control systems updates. How do you prioritize competing priorities effectively?

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In control engineering, you're often faced with the challenge of updating multiple control systems simultaneously. These systems, which manage the behavior of dynamic machines and processes, are crucial to the efficiency and safety of operations. Prioritizing updates is essential, and it's a task that requires a keen understanding of each system's impact on your overall operation. Whether you're dealing with Programmable Logic Controllers (PLCs), Distributed Control Systems (DCS), or Supervisory Control and Data Acquisition (SCADA) systems, the key to effective prioritization lies in a strategic approach that balances risk, cost, and performance benefits.

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Jatin K.

I&C Engineer | ISA/IEC 62443 CFS
Er. SANDEEP WALUNJ

ADNOC-Passionate Sr. Instru & Control Specialist l Oil & Gas Detail Engineering ,BOSET,Out of box thinker, Voice over…
Shahin Abdulov

ICSS / Instrumentation Engineer

1 Assess Risks

When prioritizing control system updates, your first step is to assess the risks associated with each system. Consider the potential for system failure, the safety implications, and the likelihood of security breaches. High-risk systems, especially those that could lead to significant downtime or pose safety hazards, should be at the top of your list. By evaluating the risks, you can ensure that the most critical updates are addressed promptly, minimizing the chance of costly or dangerous outcomes.

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Jatin K.

I&C Engineer | ISA/IEC 62443 CFS
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Risk assessment and risk ranking to be done based on criticality and urgency requirements. Criticality: Evaluate which systems are critical to operations/production. Systems that impact safety, security, or core business functions/production should be prioritised. Urgency: Identify which updates are urgent, such as those fixing security vulnerabilities or compliance issues or components which are under end of life. Once risk is prioritised, Resource Availability, Cost-Benefit Analysis, budget approval and support from management play important role.

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Er. SANDEEP WALUNJ

ADNOC-Passionate Sr. Instru & Control Specialist l Oil & Gas Detail Engineering ,BOSET,Out of box thinker, Voice over artist,Youtuber, Ex Thermax-Ex Reliance ada- Ex Rolta- Ex Honeywell Int, Vadodara
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One thing i would like to add in risk assessment is, Cybersecurity Risk assessment while dealing with updates of multiple control systems. For major control system parts or devices, need to work on Threat sources, Threat action, Impacts, Consequences, Countermeasures and recommendations to be worked out.

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Shahin Abdulov

ICSS / Instrumentation Engineer
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- Utilize task management tools. - Develop a system for ranking priorities. - Set specific, clear goals. - Visualize your priorities. - Design a prioritization matrix. - Compile a comprehensive task list. - Modify timelines as needed. - Plan and allocate resources effectively. I believe this is the most effective method for setting priorities.

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Er. SANDEEP WALUNJ

ADNOC-Passionate Sr. Instru & Control Specialist l Oil & Gas Detail Engineering ,BOSET,Out of box thinker, Voice over artist,Youtuber, Ex Thermax-Ex Reliance ada- Ex Rolta- Ex Honeywell Int, Vadodara
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One thing i would like to add in risk assessment is, Cybersecurity Risk assessment while dealing with updates of multiple control systems. For major control system parts or devices, need to work on Threat sources, Threat action, Impacts, Consequences, Countermeasures and recommendations to be worked out.

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Chandramouli Rajagopalan

Senior Engineer - Instrumentation at TOPSOE | NITT ALUMNI | FINANCE ENTHUSIAST
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One way this can be tackled is checking if there are redundant units which are not in operation for which software update won’t update production.

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2 Evaluate Impact

Next, evaluate the impact of each control system on your operations. Systems that are integral to production or have a direct effect on product quality should be given priority. This evaluation should include an analysis of how an update will improve system performance and the potential return on investment. By focusing on updates that offer the most significant operational benefits, you can optimize your resources and ensure that your control systems contribute positively to your business goals.

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3 Consider Costs

Cost is a major factor in prioritizing updates. You must balance the expense of an update against its urgency and importance. Updates that can prevent costly breakdowns or reduce energy consumption might justify a higher upfront cost. Conversely, if budget constraints are tight, you may need to prioritize less expensive updates that still offer significant benefits or address critical vulnerabilities.

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4 Plan Strategically

Strategic planning is essential for managing multiple updates effectively. Develop a timeline that allows for the most critical updates to be implemented first while considering the interdependencies between systems. This plan should also account for potential disruptions to operations and include contingencies for unexpected issues. By having a well-thought-out strategy, you can ensure a smooth transition during updates and maintain operational continuity.

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5 Communicate Clearly

Clear communication with all stakeholders is crucial when updating control systems. Ensure that everyone involved understands the prioritization criteria, the schedule for updates, and their roles in the process. This includes not only your engineering team but also operations staff and management. Effective communication helps prevent misunderstandings and ensures that everyone is aligned with the update strategy.

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Carl Lee Tolbert, PhD, CMRP

Leading Voice in Industrial Systems & AI | AC Drive Performance & Reliability Expert | Published Research Scholar | Social Media Exponent | Lecturer
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For me, the prioritization is first-in-first-out with transparency to the end-users. Sales will always want mediation, but like cost, sometimes designs have a specific lead time with little to do with negotiation. The things that can shift this are resources and product avaibility based on factors outside your organization’s control. However, If you have a Pareto-customer with an agreement that they always get priority, this practice is acceptable. Still, the potential changes with the other projects must be made aware at the onset of project discussions that they will potentially get bumped. This adoption also goes for breakdowns or expedites. The reality is that transparency changes perception from equity to proportionality.

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6 Maintain Flexibility

Finally, while it's important to have a prioritization plan, you must also maintain flexibility. The dynamic nature of control systems and the environments they operate in means that new risks or opportunities can emerge unexpectedly. Be prepared to reassess and adjust your priorities as needed to respond to changing circumstances or new information. This adaptability is key to effective control system management.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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You're juggling multiple control systems updates. How do you prioritize competing priorities effectively?

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1 Assess Risks

2 Evaluate Impact

3 Consider Costs

4 Plan Strategically

5 Communicate Clearly

6 Maintain Flexibility

7 Here’s what else to consider

Control Engineering

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