Enhancing your business operations in Plant Operations using technology

This article was compiled based on my contributions to a collaborative article, which contain topics like Automation Upsurge, Data Analytics, IoT Integration, Advanced Robotics, Cloud Computing, Cybersecurity Focus and Roadmap to Digital Transformation.

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Automation Upsurge

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Automation is everywhere, from home appliance devices to cars and factories.

Automation is used to automate manual and repetitive tasks, but now it also automates cognitive and repetitive tasks.

You should not be afraid of it. You have to embrace it.

Plants heavily investing in these technologies are taking large benefits and becoming ahead of their competitors with significant returns on investment.

Most of the benefits are operating cost savings (e.g., raw materials, chemicals, energy), increasing stability and production, reducing unplanned shutdowns, better quality, making the process safer, retaining know-how, becoming more environmentally friendly, etc.

When buying a car in the 90s, the main attributes were horsepower and fuel consumption, which we can make an analogy for plants as production capacity and chemical/energy consumption. Now, on top of that, we want to know what level of automation and digitalization our future car will have. We want our car to control the speed on the highway, we want to have parking sensors and cameras, we want to connect our phone to the multimedia, we want to be advised when something is wrong, etc. The same applies to plants and technologies like Advanced Process Controls, Digital Twins, Asset Management, Data historians, Robotics, Computer Vision, and AI, which are key to an optimized plant.

Data Analytics

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AI is now more accessible than ever.

There are many available tools in the market and some key elements are crucial to use and take full advantage of:

• Time shifting: Data needs to be on the same time basis. Most industrial processes have transport time and without shifting the time, most tools are useless or will not have full potential.
• Cause and effect relationship: the ability to map and link it. Correlation is not a relationship!
• Domain know-how (e.g.: process, equipment, automation): If you want to solve a problem, you need to know what you are solving.
• Possibility to identify if the model requires retraining once the model drifts over time.
• Possibility to simulate scenarios: to test before using as an advisor or controlling the process.

IoT Integration

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Data is key for any IoT project.

If you want to use AI, you need access to data, such as process or sensors data.

One of the most challenging topics is data integration. It is not only about transmitting data but also about ensuring it will not fail and is secure.

With the more demand, the cyber risks are increasing. You need to ensure your connections are secure, and they will not put your control system at risk.

You also need to check if your control system is able to provide all the data. This is the most common constraint for IoT projects.

You should also consider integrating cameras. Computer Vision can transform the image into numeric values that can be used to advise and control the process.

Data architecture is key to success of the IoT integration, and you need to design it so that it can grow over time. You need to consider that the demand for data consumption will always increase and your architecture needs to reflect that.

Advanced Robotics

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For decades, robots were typically used in assembly lines, but they are now starting to be used for manual and repetitive tasks like inspection and field operations maneuvers.

One of the best examples in the pulp industry is cleaning the smelt spout in the Recovery Boiler, which includes precise movement, improvement of smell flow, and eliminating risks to operators. My expectation is that in 5-10 years, this will even become mandatory for every Recovery Boiler, with plants taking safety as a high priority, if not early. Front-runners are already using this technology.

As with any other equipment, robots require maintenance. You can hire qualified personnel to maintain them, or you can opt for a service agreement to keep them operating and updated.

Cloud Computing

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The future is with AI, and to run it, you need computing power, which is very difficult to have in a physical server inside the factory.

Cloud providers offer many out-of-the-box technologies that can accelerate your development, but to get the full benefits, you still need to combine them with domain know-how (process, equipment, automation, process control).

As these technologies are easier to use, it is tempting to make multiple PoCs to test the technologies. But there is still a long way to go between a prototype and an industrial product. Several extra precautions should be taken when you are using this technology to control the process.

You need to ensure there are safeguards to monitor the health of the model and decide when not to use the model from the cloud.

Cybersecurity Focus

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Cyber risks are real.

This is a complex topic.

It can impact your plant operators and damage your company’s reputation.

No one wants to be hacked, but even with modern tools, hackers are knocking on the doors of the plant on a daily basis.

There is even the chance you were already hacked your plant. It is like opening the door of your house, entering your bedroom, and not doing anything. They might wait until the best time to do it.

I highly recommend a third-party audit. One of the best tests is a penetration test, which will check whether you are exposed. It will not eliminate your issues, but it is certainly a good reality check.

Having continuous monitoring and a detailed plan for risk mitigation also helps to ensure your risks are under control.

Here’s what else to consider

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Roadmap for Digital Transformation

Your strategy needs to start with business objectives. I have seen many cases where people start with the technology's PoC and then try to justify the project by finding a problem to solve.

It is also typically a multi-year project, and you should carefully consider the investment x return and check the feasibility of the infrastructure.

It also requires a change management plan. Why?

Because Digital Transformation is new, it is a change, and people are usually afraid of change. Training your team is key to achieving success in the long term. You should also involved your team as early as possible, once this will increase their engagement’s .

You also need to implement the process of using and measuring the benefits and consider a strategy to maintain and expand them in the long term.

Experts can save you time and expand your benefits.

Example of a roadmap:

You might also be interested in the following articles

Optimizing your plant operations team for high performance

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Topics:

• Enhance training
• Empower Employees
• Utilize Technology
• Foster Teamwork
• Continuous Improvement
• Encourage Risk

What is the connection to this article?

To maximize the results with plant operations, you need a high-performance team.

Developing and communicating a clear vision and strategy for continuous improvement

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Topics:

• Identify your goals and objectives
• Analyze your data and processes
• Generate and evaluate ideas
• Plan and implement changes
• Monitor and review results
• Communicate your vision and strategy
• You need to define the strategy to sustain the benefits in the long-term.

What is the connection to this article?

The definition, communication and monitoring of your plan is key for the success of your project.

Thanks for reading!

I hope I can help you by sharing my comments.

Feel free to add your comments as well.