What do you do if your plant engineering processes could benefit from automation?

No meu trabalho, sempre que o processo impede de serem implementados novos melhoramentos devidos aos custos (tempo), avalio a necessidade de transformar a rotina manual em algo mais autônomo. Isso diminui tempos de análise e abre espaço para evoluir.

Automating plant engineering processes can lead to increased efficiency, reduced errors, and cost savings. Here's a general roadmap to follow: Assessment: Start by identifying which processes can benefit most from automation. Look for repetitive tasks, manual data entry, or processes prone to human error. Set Goals: Define clear objectives for automation. These could include reducing cycle times, improving accuracy, or enhancing scalability. Technology Selection: Research and select appropriate automation technologies. This could involve robotic process automation (RPA), industrial IoT (IIoT) devices, machine learning algorithms, or a combination of these.

Finding and evaluating opportunities in your operation is definitely the first step. These opportunities don’t just appear. Finding these opportunities requires an innovative mindset. Outside automation suppliers are often willing to evaluate your operations to spot potential opportunities. A fee is usually involved. Automation should always pay for itself with savings from efficiencies, quality improvement, and/or material savings. All opportunities for automation should be evaluated using a return on investment model.

Esto se puede ver desde el punto de vista de automatización de procesos industriales y/o administrativos, en ambos es crucial una evaluacion previa del proceso a automatizar pues lo unico peor que un proceso mal definido, es un proceso mal definido automatizado.

Conduct a comprehensive analysis of your plant engineering processes to identify tasks and workflows that can be automated. Look for repetitive tasks, manual data entry, and processes with a high potential for error or inefficiency.

If your plant engineering processes could benefit from automation, explore solutions like: Digital tools for design and simulation. Automation of repetitive tasks (data entry, calculations). SCADA/HMI systems for monitoring and control.

Sempre importante uma avaliação prévia, para identificar possíveis pontos a se melhorar, mas também possíveis falhas ou deficiência que possa ocorrer. Mas acima de tudo, sempre será uma ferramenta de aumento na eficiente e produtividade, além de diminuição de falhas e acidentes.

Understanding the need for automation is cardinal. So, identifying the problem first, knowing what system of automation that would work for/ and with your running system including human resource, weighing cost effective system to employ and then organise your resources for implementation

Pros of Automation: 1. Increased Efficiency 2. Cost Savings 3. Enhanced Capabilities 4. Focus on Strategic Work Cons of Automation: 1. Initial Cost 2. Job Displacement 3. Complexity in Implementation 4. Overdependence

Automation is a multifaceted issue. If you simplify the thought to something like a residential sprinkler system the concepts are all there. You no longer need to deal with many simple task and time of day becomes irrelevant. So now while you sleep 4 zones are watered for different times. The flip side is what if a sprinkler is broken or a zone over or under waters an area. You may not realize until a neighbor calls to tell you of a flood or an area starts to turn brown. Automation in it's widest realm is obvious that it can do things faster, longer, more efficiently and more accurately than humans. It also suffers from maladys like a sick days or disability. What happens when a sensor fails or an actuator burns out?

Bring in multiple automation vendors and have them provide detailed quotations. This will be very useful even if you end up building the automation yourself. There’s always more than one way to automate any process. Drilling down to the best way for you is critical at this point. Consider not only initial cost, but installation costs, complexity, maintenance costs, utility costs, and labor. Some automation can be used as standalone improvements. For us it is our tapping machine is a great example. This machine is faster and it makes every taped hole perfectly perpendicular! Paid for itself quickly and we have enjoyed the benefits for decades now. Invest in machines that have a good ROI and can be relevant for a long time.

Concerteza vai muito além da implantação da automação, necessário mão de obra qualificada e acompanhamento quando necessário.

Research and evaluate automation technologies that align with your objectives and requirements. This could include robotics, machine learning, artificial intelligence, industrial IoT (Internet of Things), and automation software platforms.

Selecting the right automation technology is crucial as it ensures compatibility with existing systems, scalability for future growth, and strong vendor support, all of which are essential for long-term success and adaptability.

If your plant engineering processes could benefit from automation, you should assess current workflows, research relevant technologies, develop a strategy for implementation, start with small-scale pilots, collaborate with experts, train personnel, monitor performance, ensure cybersecurity, and stay agile to adapt to changing needs and advancements in automation.

One thing I have found useful is Training. It is really essential to prepare your workforce for the new challenges realization that the automated new machinery and process system is required and very rewarding , but with out skills and the ability to troublshoot the new systems it may make it worse.

Provide comprehensive training and upskilling programs for employees to familiarize them with automation technologies and processes. Encourage a culture of innovation and continuous learning to support the adoption of automation.

Start with the basics, the workforce needs to understand why we are moving this way, in what way it benefits everyone and what added value will they give to the company in the future following this path. After explaining the value of this step, its time to demonstrate and engage the workforce and for that, a good guided training on all new software and hardware is necessary, as also a good follow up to create a good understanding and a solid structure for long term stability and garantee of the process and its future success. Making sure the company has the right human capital on track for teaching is required, as also a sharp and clear understanding of its impact, in order to pass all the knowledge to the team and make it successful.

Continuously iterate and improve your automation strategies based on feedback and performance data. Be open to adjusting processes, adopting new technologies, and scaling automation initiatives as your plant engineering evolves.

Implement monitoring and performance tracking mechanisms to evaluate the effectiveness of automation initiatives. Collect data on key performance indicators (KPIs) such as productivity, efficiency, error rates, and cost savings to measure the impact of automation.

Maintain flexibility and agility in your approach to automation to adapt to changing business needs, technological advancements, and market dynamics. Embrace a culture of innovation and adaptability to maximize the benefits of automation over time.