INTRODUCTION
Everything has changed. Everything is changing still.
The rate of change is now becoming radical.
There is simply no option but to modernize automation systems and the environment they are managed in. You need an ongoing protocol to stay adapted to what the environment demands.
If you don't get on-board your system will slowly become useless.
You need to be guided through this. It's not necessarily because you don't know what to do. Very likely you do. What you need is help thinking through the issues, coming up with creative options.
Follow these 12 steps that will get you to where you need to be. It's ok if this is a 3 year plan. One would be better but 3 is infinitely better than zero.
These 12 steps are designed to be a comprehensive framework to ensure your green or brownfield system operates with maximum ability, output, reliability and security.
Over the coming days you will see them come through, stay tuned and leave your comments to help get more perspectives on this!
STEP 1 - DOCUMENT WHAT YOU HAVE
I have watched for years as poorly cared for automation systems delve into disarray.
It happens because people change out and there are many details to deal with in the right way.
Now, a virus has surprised us all and created a demand to make it easier to keep them running safely, securely and with high performance.
It has also created a demand to reconfigure manufacturing and process systems quickly, even remotely if possible.
Getting to the place where this is possible is not always technically hard. I believe often it is simply a matter of knowing how to build in the right techniques and disciplines.
STEP #1 (of 12) - Document What You Have
You must know what makes up your system. Every controller, computer, PLC, remote I/O, network, HMI, actuator, sensor, etc.
How can you manage, protect, secure, update and reconfigure what you don't even know you have?
(...to be continued to STEP 2)
What do you think…what can you add…what would you do?
STEP 2 - SETUP YOUR DEVOPS INFRASTRUCTURE
The next step after documenting your system is to be able to modify it.
In the times past, making changes to PLC code and HMI configurations was very static. In many factories and systems, it's still this way.
Today, that is unnecessary.
The IT world created this concept of DEVOPS. That's development and operations combined. It carries the idea that you make changes as the systems are being used.
This can be applied to automation development infrastructure. It takes setting up a few things to do it well though.
The goal is to be able to make changes to every part of the system from designated workstation(s). Files, licenses, network access and controller locations needs to be pre-mapped. This was done in STEP 1.
STEP #2 (of 12) - Setup Your DEVOPS Infrastructure
One of the added benefits is this is a key prerequisite for continuous improvement. Another benefit is the support of high uptime, enabled by rapid response to issues.
Be careful though. Ensure only qualified people have the ability to make changes. Later we will talk about having a change process to keep control of the modifications.
(...to be continued)
What do you think…what can you add…what would you do?
STEP 3 - SETUP YOUR FILE REPOSITORY
The files, oh the files it takes to manage an automation system. Code, configuration, drawings, spreadsheets, photos, software….on and on.
They must be organized, which is painful, just painful. Especially when you come into someone else's mess. Shoot, even if it is your mess.
It is worth the effort to get them organized, into a system and then kept that way. It really is worth it.
STEP #3 (of 12) - Setup Your File Repository
One popular option is Subversion, but there are others, including simple file management.
This step is worth the trouble to figure out. Keeping files organized and under control is simply necessary.
(...to be continued)
What do you think…what can you add…what would you do?
STEP 4 - UPLOAD AND MERGE ALL CODE
This is the next thing I think needs to be addressed in the process of getting an automation system under control.
It's easy to forget about the code that runs a system after it's installed.
But that is a mistake. You absolutely will have trouble. This step makes you ready.
STEP #4 (of 12) - Upload and Merge All Code
It is a real pain to keep this going. It is a bigger pain to not have code to reload after a failure.
It's also a big pain to modify the wrong code for an upgrade or expansion.
(...to be continued)
What do you think…what can you add…what would you do?
STEP 5 - CREATE THE CHANGE PROCESS
Of all the things we struggle with, keeping up with change is one of the most difficult.
The reason is because different kinds of change require different kinds of reactions.
A simple change might require modifications in one or two different areas. A complex change might require twenty or more. Knowing what to change is a matter of careful thought that is difficult in fast moving and noisy environments
STEP #5 (of 12) - Create the Change Process
The way of change can be pre-thought and laid out.
When the work needs to be done, the created checklist is consulted, the work done….and you move on. But you don't move on until the tasks are completed.
(...to be continued)
What do you think…what can you add…what would you do?
STEP 6 - INJECT CYBERSEC FUNDEMENTALS
Cybersecurity is a huge subject area. That might be why it is often being ignored.
There are a small set of fundamentals, that if done, will eliminate many of the likely potential issues.
People argue like crazy about how to get this right. Those arguments are good for sorting through a complex and dangerous area.
STEP #6 (of 12) - Inject Cyber Security Fundementals
Baby steps is the key with anything overwhelming.
(...to be continued)
What do you think…what can you add…what would you do?
STEP 7 - VISUALIZATION EXPANSION
Today there are HMI and SCADA system everywhere. Many are horrible; they are ugly and under developed. Others are over engineered and complicated. Then there are some that are works of art.
These systems are your view into the inner world of the control systems. It is also of course how things are controlled.
The appetite for data has hit the roof. Time to raise the roof.
STEP #7 (of 12) - Visualization Expansion
The improvements in this are supported by prerequisites setup in Step #2.
The key here is to setup for continuous improvement. The people and system are the key here.
(...to be continued)
What do you think…what can you add…what would you do?
STEP 8 - ANALYTICS EXPANSION
Understanding what has happened, is happening and will happen is the name of the game today.
There is a lot of talk about big data and data in general. We are now overwhelmed with that.
Every area has basics. When stuck, this is where you start and stay until you get momentum.
STEP #8 (of 12) - Analytics Expansion
Don't start with the bigness, start with something…anything that has value to know and understand better.
(...to be continued)
What do you think…what can you add…what would you do?
STEP 9 - IMPROVEMENT AND 4.0 TRANSITION
15 years ago, things were fairly static. Systems were built and left for years at a time.
Now things can change overnight and we MUST constantly improve and become more adaptable, ready for a certainly uncertain future.
Continuous Improvement and Industry 4.0 are very complimentary. Doing both will help you be ready and constantly becoming more ready.
STEP #9 (of 12) - Continuous Improvement and Industry 4.0 Transition
Again, the basics and small is where to start if this seems impossible. You need to know that much of the marketing aimed at you is going to be confusing. Learn to think small enough to start.
You may have tried this before and failed. That has nothing to do with using a new mindset and/or tactics to succeed now.
(...to be continued)
What do you think…what can you add…what would you do?
STEP 10 - CABINETS CLEAN AND SECURING
Sometimes the little things are what matter most.
If there is anything that is ignored more that anything else it's the electrical cabinets.
These are the core of the system…do not:
1. Store hardware in them
2. Store drawings in them (that is a fire hazard)
3. Leave wires hanging
4. Make changes and not correct wire labeling
5. Leave wires hanging and unterminated
STEP #10 (of 12) - Cabinets Clean and Securing
The insides need to be free of dirt, dust and junk. Make sure the hinges and locks work. Replace disconnects that don't align right and prevent to door from shutting correctly.
Things degrade. Don't let this happen without a fight.
(...to be continued)
What do you think…what can you add…what would you do?
STEP 11 - INFORMATION SYSTEM CREATE
Information must be controlled today. This isn't easy because the amount of information and the rate that it changes is a huge issue.
It can be ignored, but things will deteriorate if only the information related to fires is managed on paper and simple apps.
STEP #11 (of 12) - Information System Create
Excel is a great starting point. Even after multiple decades as a staple, it's still very useful. However, it has limitations; it's not designed to share and manage information the way it is done today.
There are multiple perspectives to manage information from. It starts with your perspective up to the systems you are given that push information up into the organization you work within.
(...to be continued)
What do you think…what can you add…what would you do?
STEP 12 - EXPAND W EXCEPTIONAL SPEED AND PERFORMANCE
This is where the excitement is!
This is where to be a professional!
All the previous steps lead to this!
STEP #12 (of 12) - Expand with Exceptional Speed and Performance
This is the holy grail…few attain this…can you?
(...to be continued)
What do you think…what can you add…what would you do?
SUMMARY
We went through the steps we think you must do to get and keep control of your systems.
Your automation system is a tool. It's a tool the organization you work for uses to provide valuable products to it's customers.
The country and world need what comes from these systems. You are the front line of getting this to happen reliably.
It is critical that you have the ability to marshal the ideas, strategy, tactics and actions needed to make a high performing system a reality.
The other side of the technical realm is a mental one. I will cover that in other articles.
What do you think…what can you add…what would you do?
I push a lot of content here. If you want emails with this content, sign up here…
#automation #manuafacturing #energy #automationsystems #processautomation #logistics