Optimize next-level automation installations, 2024 and beyond, Part 1: Automation needs and opportunities

Automation insights

• In a January 11, 2024, webcast, “Automation: Optimize next-level automation installations, 2024 and beyond,” Michael DeBoer, director of automation at Interstates, Eric Smith, President at APCO, and Scott Richards, senior project manager at Polytron discussed automation needs and opportunities, as well as providing best practice for implementation.
• In Part 1, DeBoer discusses automation needs and opportunities.

In the pursuit of enhanced operational efficiency and productivity within industrial facilities, the push towards greater automation is increasingly evident. The question then arises: where does one commence this complex journey? The identification of bottlenecks presents a fundamental starting point, suggesting that the integration of advanced sensors, logic devices, actuators and analytics, coupled with enhanced visibility, could significantly aid in making more informed decisions. The dilemma extends to whether the focus should be on upgrading existing systems or the procurement of entirely new ones. Furthermore, it is crucial to remain cognizant of the latest standards and regulatory requirements that govern such technological advancements.

In a January 11 Control Engineering webcast, “Automation: Optimize next-level automation installations, 2024 and beyond,” award-winning system integration shared their advice on advancing to the next level of automation applications. The featured webcast instructors were:

• Michael DeBoer, direction of automation at Interstates

• Eric Smith, President at APCO

• Scott Richards, senior product manager at Polytron.

The transcript of their presentation has been provided with minor edits and adaptations.

Assessing automation needs

Michael DeBoer: Let’s begin by discussing the assessment of needs. This stage presents a crucial opportunity for systems integrators to gain a comprehensive understanding of their customers. Identifying the stakeholders is a critical step—these may include individuals from production, operations, and possibly the business office, particularly if there is an emphasis on continuous improvement. This phase allows you to understand the variety of personalities and stakeholders within the organization. It is essential to document the objectives, priorities, and high-level goals of these different groups. As an integrator, you have the unique opportunity to unify these diverse units within a company, offering them a more holistic solution or merely a clearer understanding of the available possibilities.

During this assessment, gaining insight into the customer’s budget is imperative. Understanding how they plan to allocate their resources, their priorities, and whether they are focusing on a long-term, multi-year project or seeking to address an immediate need is crucial. This understanding will significantly influence the scope of your objectives. Furthermore, customers may not be fully aware of their own assets and capabilities. Therefore, conducting upfront engineering assessments or evaluations of their current facilities and processes can provide valuable information that aids in crafting a comprehensive solution.

Understanding stakeholder requirements

It’s also vital to grasp all the requirements and objectives of the various stakeholders. Whether they are focused on improving quality, production efficiencies, or reducing shrinkage, understanding their goals and the system requirements they aim to fulfill is essential.

Defining opportunities

Moving on to defining opportunities, it’s important to transform this process into a journey for the customer. By comprehensively understanding the needs and aspirations of the different stakeholders and the company’s direction, you position yourself to offer sustained, multi-project lifecycle support. This approach involves looking beyond immediate needs to outline a path for continued growth and problem-solving within the organization. Identifying where opportunities lie—be it in enhancing production, addressing turnover issues, or tackling change management—is crucial. It’s about defining these opportunities and laying out a strategy to address these challenges.

Solution development and quantifying costs

Once the needs are clearly defined, the next step involves developing solutions. This stage is about determining the necessary steps and projects that could or should be undertaken to help the customer achieve their ultimate goals. It entails documenting the scope, detailing the projects, and ensuring that the proposed solutions align with the stakeholders’ needs and expectations.

Quantifying costs is also a critical component of this process. After establishing the budget and continuing to review various projects, it’s essential to prioritize them based on the customer’s main goals. This prioritization helps in ensuring that the projects not only align with the customer’s objectives but also fit within their financial constraints.

Establishing priorities and understanding costs

The initial step in this phase involves determining the sequence of achievements: what can be accomplished first, second, and third? Identifying the primary priorities is crucial. To ensure success in all their projects, it’s vital to understand what needs to be in place. Offering options and pricing, even at a budgetary level, is essential to ensure that all parties understand the financial implications throughout the project’s duration. Engaging various stakeholders throughout this process is likely to foster greater buy-in. Often, securing additional support from stakeholders, especially those in continuous improvement or operations, can reveal opportunities to expand the budget. This expansion is due to the identification of more needs and the recognition of long-term benefits that the project will deliver. It’s important to clarify the stage of pricing being discussed: whether it’s budgetary pricing for leadership review and funding acquisition, or specific project costs that require precise estimation, within a range of 5% to 10%.

Quantifying and mitigating risks

As the process unfolds, identifying potential risks becomes a critical component. These risks may include budget constraints or challenges related to change management. Documenting these risks from both your perspective and the customer’s allows for a comprehensive risk assessment. Highlighting these risks throughout the project roadmap can influence project prioritization and funding as stakeholders become aware of potential challenges. Engaging the client in this risk mitigation process encourages their active participation, potentially leading to a reassessment of project priorities and enhancing their overall engagement.

Furthermore, it’s crucial to consider the risks associated with inaction. Customers may hesitate, but highlighting the dangers of not upgrading legacy systems, addressing quality issues, or meeting compliance requirements is essential. This aspect of risk management emphasizes the importance of proactive planning and mitigation strategies.

Stakeholder engagement and transition

The overarching theme of this process is the engagement of diverse personalities and stakeholders within the client organization. Maximizing engagement during the assessment of needs, budgeting, and risk management phases can significantly increase buy-in, enhancing the project’s success rate. This comprehensive approach positions your company as a valuable long-term partner for the client.

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