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What are the most effective methods for ensuring the scalability of your process automation design system?

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Process automation design is a key aspect of manufacturing engineering that involves creating and implementing systems that can perform repetitive tasks without human intervention. Process automation can improve productivity, quality, safety, and efficiency in various manufacturing sectors. However, to achieve these benefits, you need to ensure that your process automation design system is scalable, meaning that it can adapt to changing demands, requirements, and environments without compromising performance or functionality. In this article, you will learn about some of the most effective methods for ensuring the scalability of your process automation design system.

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Jeremy Huff

1 Define your scalability goals

Before you start designing your process automation system, you need to define your scalability goals and metrics. This means that you need to identify what aspects of your system you want to scale, such as throughput, capacity, reliability, or complexity. You also need to determine how you will measure the scalability of your system, such as by using key performance indicators (KPIs), benchmarks, or tests. Defining your scalability goals and metrics will help you to align your design decisions with your desired outcomes and to evaluate the effectiveness of your system.

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Aris Sena

Senior Test Engineer II at Microchip Technology Inc.
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Of course you start NPD projects to get released safely on a lower site count with the intention of scaling it in the future when project volume improves.

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Graziéle L. Scienza

Customer Experience I Atendimento ao cliente I Melhoria Contínua I Projetos I NPS I CSAT
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Imagine a escalabilidade do seu sistema de automa??o como um jogo de blocos LEGO. Escolha pe?as modulares (tecnologias escaláveis) e monte seu projeto. à medida que cresce, adicione novos blocos (módulos de automa??o) para expandir de maneira flexível e eficaz. Pense no seu sistema como uma constru??o em constante evolu??o, mantendo a adaptabilidade para lidar com desafios futuros.

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Ross Jordan MBA, CGBP

Vice President of Business Development, Chief Nerd Herder, Resource Wrangler, AI Sherpa, vCAIO, Pragmatic Optimist
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Having worked in some very process driven organizations, I would suggest there is more to it than just a process. Where I have seen success is where organizations build "systems" around the processes. Think of it as an over arching "what if" insurance policy. "What if the process doesn't work?" "What happens if the need exceeds the processes ability or talent?" Organizations that I have seen success in, deliver on actionable deliverable for the "What if?". If a process is the sole solutions for a workflow, and it does not serve the process exactly, what do you do? Deliver the outcome...not the process. Process is a tool. Systems deliver solutions/outcomes.

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2 Use modular and flexible components

One of the most effective methods for ensuring the scalability of your process automation design system is to use modular and flexible components. Modular components are those that can be easily added, removed, or replaced without affecting the rest of the system. Flexible components are those that can be configured or customized to suit different scenarios or conditions. Using modular and flexible components will allow you to adjust your system to changing needs, demands, or environments without requiring major redesigns or overhauls.

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Aris Sena

Senior Test Engineer II at Microchip Technology Inc.
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I worked with a company that used to automate the measuring instrument which is cheaper than a tester. Aside from the test getting cheaper, you can design it with scalability in mind.

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Aris Sena

Senior Test Engineer II at Microchip Technology Inc.
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Work with your vendor! Ask if there are newer options that may have higher channel count that will help you with scalability.

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3 Adopt standard and open protocols

Another effective method for ensuring the scalability of your process automation design system is to adopt standard and open protocols. Standard protocols are those that are widely accepted and used by the industry or the market. Open protocols are those that are publicly available and interoperable with other systems or devices. Adopting standard and open protocols will enable you to integrate your system with existing or future technologies, platforms, or networks without facing compatibility or communication issues.

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4 Implement feedback and control loops

A feedback and control loop is a mechanism that allows your process automation design system to monitor its own performance, detect any errors or deviations, and adjust its actions accordingly. Implementing feedback and control loops will enhance the scalability of your process automation design system by ensuring that it can maintain or improve its quality, efficiency, or safety in response to changing inputs, outputs, or conditions. Feedback and control loops can be implemented using sensors, actuators, controllers, or software.

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5 Test and validate your system

The final method for ensuring the scalability of your process automation design system is to test and validate your system. Testing and validating your system means that you need to verify that your system meets your scalability goals and metrics, as well as your functional and operational requirements. Testing and validating your system will help you to identify and resolve any issues, errors, or gaps in your design, as well as to optimize and improve your system. Testing and validating your system can be done using simulations, experiments, or trials.

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Jeremy Huff
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While using loopback logic and automated simulation loops help test the system as is, there are further steps to ensure scalability. A well designed control system should allow for the easy addition or subtraction of devices with little to no programming interaction. When we test, we will often add devices not in the current design, confirm operation, remove those devices, confirm operation. This is one of the most difficult aspects for new programmers/designers to learn and our testing gives them a real world example of why it's important.

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6 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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Aris Sena

Senior Test Engineer II at Microchip Technology Inc.
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Also, not everything is about scaling up. Since business cannot retire lower scale test equipment immediately or buy high scale test equipment outright. Otherwise, your production floor will have a bottleneck on few equipments and some equipments are under utilized. Always have balance in mind.

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What are the most effective methods for ensuring the scalability of your process automation design system?

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3

4

5

6

1 Define your scalability goals

2 Use modular and flexible components

3 Adopt standard and open protocols

4 Implement feedback and control loops

5 Test and validate your system

6 Here’s what else to consider

Manufacturing Engineering

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What are the most effective methods for ensuring the scalability of your process automation design system?

1

2

3

4

5

6

1 Define your scalability goals

2 Use modular and flexible components

3 Adopt standard and open protocols

4 Implement feedback and control loops

5 Test and validate your system

6 Here’s what else to consider

Manufacturing Engineering

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