Journey of Industrial modernization to Digital Transformation

The thought came in my mind when I look todays technological progress & flash back of human development the dream started with the invention & use of electricity somewhere, I want to summarize the journey & capture the trend to live in future.

INDUSTRIAL PROCESS PLANTs: -

Systematic series involving chemical, physical, electrical or mechanical operation that?produce?or?manufacture?something, usually carried out on a very large scale. Industrial processes are the key components of heavy industry.

Industrial functioning involves technological management in the area can be categorized in

·????????Specific product technological consultancy

·????????Process technology

·????????Civil engineering

·????????Electrical engineering

·????????Mechanical engineering

ELECTRICS IN INDUSTRY (Door step to modernization): -

Electricity became important during the second Industrial revolution in the late 1800.Electric lights allowed factories to stay open longer and produce more goods.

It is the greatest?invention?in history and central to the ability of almost all modern societies to function.

Hospitals, air traffic control systems, street lights, modern sewage systems, most forms of communication, and the U.S. financial services industry are all dependent upon electricity.

POWER SYSTEM FLOW & DISTRIBUTIONs: -

Below are the snaps to demonstrate a general idea the flow of electricity from generation, transmission to distribution in various networks levels. Electricity utilization from various level of distribution like

·????????Trans regional distribution (60 KV): - used for large scale industries

·????????Regional distribution (20 KV & 10 KV): - used for medium scale industries & energy storage

·????????Local distribution network (440V & 220 V): - Used small industries & domestic, commercial utilities

INDUSTRIAL ELECTRICAL SCOPE INVOLVE: -

On electrical aspect in industrial application equipment & accessories can be categorized as below.

Based on application process requirement this all can be designed, engineered & altered to make best fit.

ELECTRICAL ENGINEERING FUNCTIONS: -

Electrical engineers?design, develop, test, and supervise the manufacture of electrical equipment, such as electric motors, radar and navigation systems, communications systems, or power generation equipment.

Electrical engineers also design the electrical systems of automobiles and aircraft.

INDUSTRIAL PROCESS MONITOR & NECESSITY: -

Two major tasks of process monitoring are?

Fault detection: - To detect process faults caused by improper operation, equipment malfunction, disturbances, and so on

Fault diagnosis. :-?Root cause analysis of cause of fault

Finally, to build a robust model which remove/ prevent occurrence of fault.

Also built a monitoring model to detect the fault in very early stages also diagnose new appearance of fault.

Process monitoring purpose to quickly detect abnormal variation, and fix it by finding the root cause.

Types of Monitoring: -

·????????Process monitoring

·????????Compliance monitoring

·????????Context monitoring.

·????????Beneficiary monitoring.

·????????Financial monitoring.

·????????Impact monitoring

·????????Organisational monitoring.

·????????Results monitoring.

INDUSTRIAL PROCESS CONTROL: -

To understand industrial process control we can understand

Process: - Set of interrelated or interacting activities that use inputs to deliver an intended result (can be validated) which might be input of other process as well. Process always planned & carried out under control condition (value addition). However Special processes are those where intended result can’t validate readily & economically.

Control: - The power to influence/restraint/regulate/ authority to manage /direct

·????????Machinery

·????????Systems,

·????????Processes

Control Plan: - It is living document that outlines the methods taken for quality control of critical inputs to deliver outputs?that meet customer requirements. It also provides a written description of the measurements, inspections, and checks put in place to control production parts and processes.

Control Methods: -

?

Various adopted to control like

?

·????????Verbal instruction

·????????Standard operating procedure (SOP’s)

·????????Mistake Proofing --Poka Yoke

·????????Visuals like colour coding, special identifications

·????????Statistical process control (SPC)

·????????Total productive maintenance (TPM) to equipment’s

HIRERCHY OF CONTROL ===> ENGINEERING CONTROL: -

PRINCIPLES & OBJECTIVES OF CONTROL:-

Elimination:- Elimination of possibility of error (Redesigning process)

Replacement?:- Substitute with more reliable process (Using Automation)

Engineering Control?:-Modification or replacement? (Engineering or automation)

Facilitation :- Making work easier to control (Color coding, combining step)

Detection:- Detecting error before further processing (Communication & Notification when wrong happened)

Mitigation:- Minimizing effect of error (Protection, insurance?)

IDEAS OF AUTOMATION: -

The term automation was coined in the?automobile industry?about 1946 use of automatic devices and controls in mechanized production lines

the origin of the word is attributed to D.S. Harder, an?engineering?manager at the?Ford Motor Company?at the time.

The term is used widely in a?manufacturing?context, but it is also applied outside manufacturing in connection with a variety of systems in which there is a significant substitution of mechanical, electrical, or computerized action for human effort and intelligence to reduce and avoid human error means possible error in human functioning

WHAT IS PROCESS AUTOMATION: -

It the technique of making an apparatus, a process or a system operate automatically.

It describes a wide range of technologies that reduce human intervention in processes.

Human intervention is reduced by predetermining decision criteria, subprocess relationships, and related actions — and embodying those predeterminations in machines.

Process automation involves?using sensors, actuators, computer technology, robotics, AI and software engineering?to help power plants and factories in industries as diverse as paper, mining and cement operate more efficiently and safely.

Automation adaption flow as follows:-

·????????Open loop (On/OFF) control

·????????PID Control [close loop (feedback) control]

·????????Sequential control and logical sequence control or system state control

·????????Computer control

BENEFITS OF AUTOMATION: -

It is already known to every industrialist the benefits of automation, though some of the notable points draw out

??Increases Productivity & efficiency by

o??Better planning.

o??Reducing manufacturing & operating cost,

o??Maximize labour by utilize employee time better

o??Easily manage decentralized teams in different time zones.

?

??Faster ROI (Return on investment)

??Enhances Quality by

o??Define business processes

o??Consistent and improved part production. ...

o??Reduced factory lead times

o??Ability to be more competitive

o??Easy integration

o??Optimal utilization of floor space

o??Increase system versatility

o??Eliminate the manipulation of paper documents

??Industrial Safety by improve worker safety.

??Make better projections.

??Accurate Results. ...

??Better Working Conditions and Value-Addition. ...

??Industrial Communication.

??Smaller environmental footprint

??Allow new business opportunities

?

DISADVANTAGES OF AUTOMATION: -

With benefits of automation it has disadvantages too which impact

·????????Individual

·????????Society

Like worker displacement, relocation, fear of losing jobs which also another source of stress.

Also automated equipment includes high capital expenditure required to invest in automation.

The potential risks that automation?technology?will ultimately subjugate rather than serve humankind. The risks include the possibility that workers will become slaves to automated machines, that the privacy of humans will be invaded by vast computer data networks, that human error in the management of technology will somehow endanger civilization, and that society will become dependent on automation for its economic well-being.

???????Loss of flexibility. Modify workflows; tasks and processes may involve certain rigidity.

Three types of automation in production can be distinguished:?(1) fixed automation, (2) programmable automation, and (3) flexible automation

EVOLUTION OF AUTOMATION & INDUSTRY 4.0: -

BASIC OF DIGITIZATION, DIGITALIZATION & DIGITAL TRANSFORMATION

DIGITAL FRAMEWORK:-