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How modernizing control systems can reduce business risk and deliver profit improvement

Process control systems, power monitoring and control systems, security instrumented systems are the heartbeat of any industrial manufacturing asset.  The efficiency of those systems straight impacts the profitability, sustainability, effectivity, and operational resilience of every asset.

Traditionally these systems are thought-about in isolation, but all endure the identical challenges – getting older, restricted system efficiency, lack of experience and data, opposing hostile cybersecurity threats, assembly demanding requirements and directives, rising assist prices, unplanned downtime, – the challenges are many – however all come down to 1 factor – they current a business risk.  The mixture of getting older tools, diminishing budgets and lack of area experience has made this example all too widespread lately.

How will we mitigate the business risk and deliver a successful Return on Investment?

Doing a “replacement in kind” of getting older automation or electrical systems to mitigate the business risk offers little or no profit. There must be extra worth created for the business or else why upset the established order?

One confirmed strategy is to contemplate the “sum of the systems”, for instance, combining energy and course of data collectively to unlock new efficiency and create a successful Return on Investment.

Increased Profit = S Process Automation + Electrical Automation + Expertise

This strategy has proven to deliver better operational effectivity with improved course of power utilization as much as 10%, lowered downtime by as a lot as 15% and improved profitability by as a lot as 3% factors.

What’s one of the best ways to strategy the funding request?

The justification for a system improve is seldom based mostly on a single issue. Many concerns mix to in the end construct a profitable ROI case for modernization. But, should you take a risk-based strategy to handle the business risk, then it offers the context behind the choice to hunt funding.

Reduce Unplanned Outages

When the plant is experiencing a number of surprising outages or journeys in a 12 months the justification must be straightforward… nevertheless, simply because it hasn’t failed but doesn’t imply that it received’t fail. It’s all a query of likelihood / chance, or “When, not if.”

If you wait till one thing fails, it then turns into pressing, and important sources should be diverted from current tasks or budgets to resolve the problem as mentioned in our final weblog. This typically ends in larger general prices ensuing from a compressed substitute schedule, paying a premium to expedite spares / repairs, and acquiring the data and experience required at a second’s discover.

The greatest affect of any unplanned outage is the affect of business interruption. The whole manufacturing planning and scheduling can be thrown off stability, provide contract commitments can be positioned in jeopardy, off-specification product could also be produced that must be written off, manufacturing targets can be missed, and the record continues.

Show the business risk utilizing a risk matrix  

Providing a easy visible of the various components related to modernizing any system can be vastly impactful. The Risk Matrix is a typical denominator throughout most working corporations (though many use totally different sizes, 4×4, 5×5, 8×8) however it’s recognized and perceive. So, should you ignore the mathematics behind the matrix (it’s exhausting to calculate the chance, however the penalties stay the identical), then the risk matrix offers a easy, straightforward to grasp, widespread view round which to have the dialogue.

Another strategy is to justify the improve when it comes to Risk Reduction achieved per $1 spent:

It could also be value factoring in “What if” situations into the ROI calculation to reveal the business consequence.  If such an occasion has occurred, then actual numbers can be ascertained and used to assist the ROI. If not, then some “What if” situations could show helpful in elevating consciousness and displaying the cascading impact it has on the enterprise and shareholder affect.  Anything that has the potential to affect the underside line typically will get precedence!

What components must you contemplate in your risk matrix?


Typical components for consideration embrace:

Explore some great benefits of mixed energy and course of data

In addition to mitigating risk, an improve can additionally deliver added effectivity and sustainability. Schneider Electric has launched EcoStruxure Power and Process to carry each low voltage and medium voltage data into the EcoStruxure Foxboro DCS to create a single window for visibility that enables operators to:

  1. Quickly diagnose occasions
  • Combined electrical and course of SOE for quicker journey investigation
  • Determine if electrical glitch, course of control drawback or tools failure

= Recover misplaced manufacturing income quicker

  1. Manage the state of affairs
  • Know course of and electrical limits
  • Respond to altering course of and electrical circumstances
  • Operate inside constraints

   = Maintain manufacturing

  1. Identify power financial savings
  • Easily perceive energy utilization
  • Track and development energy consumption
  • Explore power saving alternatives

= Make power environment friendly selections

Once you may have made the case for an improve, it’s time to plan a path to lengthen the working lifetime of the control system.  Upgrades are sometimes “gradual,” and elements of the system are upgraded as / when the time or alternative presents itself. Key to the success of this strategy is to make sure the interoperability of the totally different variations of the systems. As systems are upgraded, this strategy creates “spares” that can be used to assist the opposite legacy systems till they can be upgraded.

We will assist you construct a technique with the proper instruments, reliable know-how, and area experience that can assist empower you to fulfill the challenges confronted in right now’s market. Leveraging one of the best of Power, Process and Digital, our power administration and automation options, mixed with AVEVA’s built-in information platform and modern industrial software program, allow your improve tasks to attenuate risk, whereas empowering your folks by way of related capabilities and applied sciences.

In our subsequent weblog we are going to have a look at one of the best ways to modernize course of control systems and  power monitoring and control systems. In the imply time, discover extra about our modernization companies right here and particular data on distributed control systems right here.

If you may have questions on EcoStruxure Power and Process, be happy to achieve out on to me, at

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