Unlocking Efficiency in Brownfield Sites: A Guide to Visualisation and Data
PlantQuest
Transform your site operations with intelligent mapping. Locate and Track Assets.
Abstract
Mission-critical industries (Life Science & Pharmaceutical, Medical Device, Semiconductor, etc) stands at a crossroads where continuous digital transformation is essential for staying competitive, pushing boundaries, and meeting today's demands. Brownfield facilities, often burdened with legacy systems and outdated infrastructure, face particular challenges in adopting new technologies. This piece looks at practical approaches to integrating visualisation solutions into these existing facilities, highlighting the importance of choosing technologies that prioritise open architecture, standard data formats, cloud hosting, and the Unified Namespace (UNS) approach. By addressing the complexities posed by data silos and legacy systems and focusing on actionable implementation steps, we offer a comprehensive framework for manufacturers aiming to modernise their operations. Through improved operational efficiency, enhanced regulatory compliance, and the ability to scale in the future, brownfield facilities can achieve sustainable growth and maintain a competitive edge in an industry characterised by rapid innovation and stringent regulatory requirements.
1. Introduction
Digital transformation in mission-critical facilities is more than just updating technology; it's about shifting towards operational excellence, ensuring strict regulatory compliance, optimising processes, and sustaining growth. For brownfield facilities—existing plants with legacy systems and infrastructure—the path to modernisation brings unique challenges. This article looks into strategies for integrating advanced visualisation solutions into such facilities, emphasising the critical role of making informed technology choices. By focusing on open architecture, data collection in the field, standard data formats, cloud hosting, and adopting the Unified Namespace (UNS) approach, we show how these elements can form the backbone of a robust digital infrastructure. This infrastructure not only addresses current operational inefficiencies but also ensures long-term scalability and adaptability. Our aim is to equip stakeholders with a practical framework to digitally transform and visualise their brownfield operations, securing a competitive advantage in an industry driven by rapid innovation and regulatory demands.
2.0 The Promise of Digital
In today's rapidly evolving pharmaceutical, medical device and semiconductor sectors, technologies AI, IIoT, digital twins, and advanced data analytics are reshaping manufacturing processes. These technologies offer huge opportunities to revolutionise operations.
2.1 Artificial Intelligence and Machine Learning
AI algorithms can predict equipment failures before they happen, optimise production schedules, and enhance quality control. According to McKinsey & Company (2020), AI can reduce machine downtime by up to 50% and significantly increase forecasting accuracy. For example, machine learning models can analyse historical data to predict when a critical component is likely to fail, allowing for proactive maintenance and reducing unexpected downtime.
2.2 Industrial Internet of Things (IIoT)
IIoT connects devices and sensors across the manufacturing floor, providing real-time data for process optimisation. Deloitte (2019) found that IIoT implementation can lead to a 20% increase in production efficiency. Sensors can monitor parameters like temperature, humidity, and pressure, ensuring that manufacturing conditions remain within optimal ranges and complying with Good Manufacturing Practices (GMP).
2.3 Digital Twins and Augmented Reality
Digital twins create virtual replicas of physical systems, allowing simulation and testing without disrupting actual operations. Engineers can model process changes and foresee the impacts before implementation. Augmented Reality (AR) overlays digital information onto physical environments, assisting technicians in real-time during maintenance tasks (IEEE Spectrum, 2019).? These technologies promise a future where production processes are optimised, decision-making is data-driven, quality control is enhanced, and operational costs are reduced. However, while new facilities often integrate these technologies from the ground up, brownfield sites face significant hurdles due to existing infrastructures and systems.
3.0 Navigating the Unique Landscape of Brownfield Sites
Brownfield facilities present unique challenges when it comes to digital transformation. Many of these plants were built decades ago and have undergone multiple expansions and owners in their lifetime. This history has led to a myriad of equipment, systems, and data management practices, resulting in varying levels of data quality and accessibility.
3.1 Data Silos
Operational data is often trapped within disparate legacy systems, such as outdated databases, complex proprietary software, or even paper records. These silos hinder the integration and analysis of data across the organisation (ISA, 2018). For example, maintenance records might be stored separately from production data, making it difficult to correlate equipment performance with production outcomes.
3.2 Physical Constraints
The characteristics of layout of large, complex brownfield facilities often often leads to inconsistencies and gaps in engineering documentation like CAD, BIM and advanced networking equipment, required for digital initiatives. Retrofitting and remodelling? can be costly and disruptive (Pharmaceutical Manufacturing, 2021), for example installing IIoT devices in hazardous or hard-to-reach areas may require shutdowns or significant modifications. Given these challenges, a tailored approach is essential. This might involve adopting modular digital solutions that can integrate and leverage existing systems, focusing on incremental improvements, and planning for future expansions. By addressing specific pain points with targeted solutions, facilities can begin the transformation without overwhelming resources or personnel.
4.0 Unleashing Visualisation Opportunities
Visualisation technologies offer a bridge between legacy operations and digital innovation in brownfield facilities. Advanced visualisation methods, such as interactive mapping, 2D layouts, and 360° imagery capture, provide opportunities to enhance understanding, efficiency, and collaboration.
4.1 2D Mapping
Utilising existing layout drawings, 2D maps can be created that resemble familiar platforms like Google Maps. These maps provide an intuitive interface for navigating the facility, locating equipment, and visualising workflows. Typically the only requirement to create such maps are current layout drawings, which can be digitised and integrated into user-friendly platforms. This approach requires minimal investment and can be deployed quickly.
4.2 360-Degree Reality Capture
This involves capturing panoramic images or LIDAR scans of the facility using specialised cameras or scanners. The process can vary in quality, from basic images captured with consumer-grade equipment to high-resolution captures that meet Building Information Modelling (BIM) standards. These images allow stakeholders to virtually "walk through" the facility, aiding in remote inspections, training, and planning without the need for physical presence. These tools can be customised for brownfield facilities using lightweight, web-based applications that require minimal changes to existing infrastructure. This approach provides immediate benefits while setting the stage for broader digital initiatives.
5.0 The Imperative for Simplification
Complexity in pharmaceutical, medical device and semiconductor production processes among others can hinder efficiency and innovation, particularly in older facilities. Simplifying these processes is not just preferable but essential for operational excellence.
5.1 Decoding the Complexity: Barriers to Data Accessibility
Data silos and complex legacy systems lead to a fragmented approach to data management. Critical operational data is often locked away in outdated systems, making it inaccessible to modern digital tools that require comprehensive datasets. This fragmentation slows down information flow, hampers decision-making, and can lead to compliance risks if data is not accurately consolidated. For example, production data may be stored in one system, building management data in another, and maintenance logs in a third. Without integration, correlating this data to identify patterns or issues becomes a manual and time-consuming task.
5.2 Unifying the Digital Landscape
Creating a unified, visual interface that integrates data from various sources can transform how data is consumed and acted upon. Solutions that offer a single pane view of your operations can bring together fragmented data streams into a coherent, actionable overview. This unified approach helps manufacturers:
By simplifying data access and visualisation, facilities empower their workforce to make informed decisions swiftly.
6.0 System Considerations for Seamless Integration
Integrating advanced visualisation systems is a crucial step towards achieving operational excellence in manufacturing facilities. When selecting technology, it's important to consider budget, resolution, extensibility, and integrability to ensure the solution evolves with the facility's needs.
6.1 Budget Alignment: Balancing Cost and Value
Financial considerations are key in determining the scope of digital transformation initiatives. A thorough cost-benefit analysis is essential, weighing initial investments against potential long-term savings and efficiency gains. Tools that offer scalable pricing models or modular features allow facilities to start small and expand as needed.
6.2 Resolution Requirements: Ensuring Clarity and Precision
The level of detail provided by a visualisation system is determined by its resolution and available data. High-resolution systems like LiDAR scanning and 3D modelling offer detailed facility mapping but require significant investment and on-site data collection. While they provide comprehensive visualisation, they may deliver 20% of the value for 80% of the cost.In contrast, 2D maps created from existing layout drawings can be developed remotely and at a fraction of the cost. These maps can deliver 80% of the value for 20% of the cost, providing sufficient detail for most operational needs. Combining both approaches can offer full end-to-end visualisation, balancing detail and cost-effectiveness.
6.3 Extensibility: Preparing for Future Growth
Extensibility refers to the system's ability to adapt and expand over time. A platform designed with future growth in mind ensures that the system remains valuable throughout the facility's lifecycle. This includes the ability to add new modules, integrate additional data sources, and scale to accommodate more users or facilities. Choosing solutions that support plug-and-play components or open standards ensures that future technological advancements can be incorporated without overhauling the entire system.
6.4 Integrability: Ensuring Compatibility with Existing Systems
Compatibility with existing systems is crucial for seamless integration. Solutions should support standard data formats and offer robust Application Programming Interfaces (APIs) to communicate effectively with existing software and hardware. This includes integration with:
By ensuring integrability, facilities can create a cohesive ecosystem where data flows freely between systems, enhancing visibility and control.
7.0 The Value Proposition: Striking the Right Balance
Applying the 80/20 rule to visualisation systems highlights the potential to achieve substantial returns by focusing on solutions that deliver the most significant impact.
7.1 Embracing the 80/20 Rule in Visualisation Investments
A large portion of operational improvements can be realised through a strategic subset of features. Implementing an intuitive 2D mapping solution might provide 80% of the insights at just 20% of the cost of more sophisticated systems. This approach allows organisations to achieve quick wins and demonstrate value early in the transformation process. For example, a simple interactive map showing asset or alarm locations and statuses can significantly improve maintenance and alarm response times, helping to reduce downtime.
7.2 Prioritising Features for Maximum Impact
Identifying features that offer the most value involves assessing current operational challenges and strategic goals. Features that enable real-time monitoring, facilitate quick responses to issues, or provide clear data visualisations are often the most beneficial.
7.3 Key Features to Consider
By prioritising these features, facilities can enhance operational efficiency without overextending budgets.
8.0 The UNS: A Catalyst for Digital Transformation in the Brownfield
Identifying features that offer the most value involves assessing current operational challenges and strategic goals. Features that enable real-time monitoring, facilitate quick responses to issues, or provide clear data visualisations are often the most beneficial.
8.1 Core Benefits of the Unified Namespace
Seamless Integration: UNS acts as a central hub for all organisational data, facilitating the incorporation of legacy systems with new technologies (Walker Reynolds, 2020). It provides a single source of truth where all data is standardised and accessible.
Enhanced Accessibility: Centralising data ensures that vital information is readily available, enabling an informed workforce. Users can access the data they need without navigating multiple systems.
Interoperability: Standardising data formats and protocols promotes compatibility among diverse systems and technologies. This openness allows for flexibility in choosing vendors and solutions.
Accelerating Innovation: Streamlined data management allows for swift identification and action on process improvements, driving continuous advancement. By having all data in one place, analytics and machine learning applications can be more effectively applied.
8.2 Implementing UNS in Brownfield Facilities
Adopting a UNS approach helps address the challenge of leveraging existing infrastructure while embracing new technology. Implementation involves:
By ensuring data from legacy systems can be integrated and utilised effectively, the UNS enables a smoother transition to digital operations.
9.0 Practical Steps to Brownfield Digitisation
9.1 Step 1: Identify Critical Workflows and Processes
Begin by analysing current workflows to determine which areas would benefit most from enhanced visualisation. Engage with stakeholders across departments to understand pain points and opportunities for improvement.
9.2 Step 2: Understand Site Constraints
Assess the physical and technical limitations of the site, including:
9.3 Step 3: Define System Requirements
Establish technical specifications and operational needs, such as:
9.4 Step 4: Evaluate and Select Technology Solutions
With clear requirements, evaluate technology solutions that align with your needs. Prioritise options that support:
Consider conducting pilot programmes to test solutions before full-scale implementation.
9.5 Step 5: Ongoing Optimisation and Expansion
Treat implementation as an ongoing process. Continuously assess the system's performance and be prepared to adapt and expand as new technologies emerge and your facility's needs evolve. Establish feedback mechanisms to gather user input and monitor key performance indicators to measure success.
10.0 Conclusion
Embarking on digital transformation in mission-critical manufacturing, especially within brownfield facilities, requires a strategic and thoughtful approach. Integrating visualisation solutions and choosing technologies that support open architecture, standard data formats, and cloud hosting are essential steps. Implementing the Unified Namespace (UNS) approach is a pivotal part of this strategy, enabling seamless integration and enhanced data accessibility across different systems. By laying a solid foundation that meets current operational and compliance needs while allowing for future growth, manufacturers can navigate the complexities of digital transformation. This approach ensures continuous innovation and operational excellence across their brownfield portfolio, ultimately leading to sustainable growth and a competitive edge in the industry.
11.0 References