Consistent, high-quality automation project outcomes do not happen by accident. The system integrators behind them execute upon their own formalized, documented procedures and methodologies throughout a project’s progression.
System integrator selection insights
- There are three indicators of automation integration project’s success.
- A high-quality system integration project properly addresses the issues faced by manufacturers and is designed with future scalability in mind.
- It is critical that the system integrator and their customer mutually agree on what defines a project’s success.
Automation projects undertaken in today’s complex industrial manufacturing environment often carry significant risk. Manufacturers looking to implement new automation or update existing systems face a host of potential system integrators eager to bid on their projects.
However, identifying an integrator who can minimize project risks, consistently design and implement solutions that meet or exceed a client’s needs and deliver on time and within budget can be daunting. These three indicators of a project’s overall success — effective, well-designed functionality; timely completion; and remaining within budget — collectively measure the overall quality of the system integrator. Integrators who embed structured quality assurance processes into their workflow are inherently better equipped to reduce project risks and significantly improve the chances of delivering effective solutions to their clients.
Manufacturers might find identifying and selecting a skilled system integrator committed to delivering high-quality results to be a daunting task. But there are essential characteristics of a high-quality project that outlines the fundamental methodologies that effective system integrators embed into their workflows to ensure positive outcomes.
How to define a high-quality system integration project
At its core, a high-quality system integration project delivers the right functionality to fully address the original issues faced by the manufacturer and is strategically designed with future scalability in mind. It is delivered on budget and schedule.
Conversely, a poor-quality project fails to meet the above results. Instead, the manufacturer faces unmet promises. An inadequate solution won’t resolve the original problem or operate as expected, causing unexpected delays, which may impact production plans and add additional expense due to an expanding project timeline and scope. Code may also need to be rewritten to mitigate unresolved issues.
Manufacturers commonly prioritize a bidder’s overall cost when choosing a system integrator for a project, but it’s more expensive to fix a system that was poorly designed from the start than investing in an integrator equipped to deliver the right solution the first time.
Most manufacturers can identify the markers of a high-quality project delivery. However, identifying the traits of integrators who consistently achieve these results is more nuanced. Consistent, high-quality project outcomes don’t happen by accident. The integrators behind them execute upon their own formalized, documented procedures and methodologies throughout the entirety of a project’s progression. Because they recognize the value of their own quality management programs, these integrators will include verbiage pertaining to quality into their companies’ core values and mission statements.
How to choose a CSIA-certified system integrator
One overarching way a manufacturer can ascertain that they are working with a reputable integrator is to choose one who is CSIA-certified. The Control System Integrators Association (CSIA) is a nonprofit organization whose goal is to foster the continuous improvement of the standards of service within the control system integration industry.
While all CSIA system integrator members have access to their industry standard CSIA Best Practices and Benchmarks Manual, only those that obtain certification have gone through a rigorous third-party audit process to prove that all facets of their business meet CSIA’s standards for quality, reliability and performance. Auditors review the methodologies a system integrator has both documented and implemented that show the association’s best practices in action. Some of these best practices are outlined below.
Methodologies for consistent, high-quality results
There are methodologies used by system integrators who consistently obtain high-quality project outcomes. These are the most important methodologies a prospective client should consider when selecting a partner to complete a project. These include:
A consultative approach for the project’s definition
A skilled integrator will act as a partner and consultant to their clients by taking the time to understand the long-term, high-level plans for their operation. With this knowledge, the integrator can design a solution that can later be scaled to meet these future growth plans, maximizing the benefits.
For any project, it is important that both the system integrator and their customer mutually agree on the key markers that define its success. An integrator that is committed to a high-quality outcome will invest a significant amount of time collaborating with the client at a project’s outset to define and detail the functional requirements of the proposed solution. These metrics inform both parties of a project’s scope and ensure that the system designed by the integrator fully addresses the client’s needs.
However, a manufacturer may understand the problem or challenge they face, but they may not always know the full scope of the solution that best addresses it. An integrator who is committed to a high-quality outcome will employ a flexible approach to the management of this type of project. Rather than fixating on the limited project scope they may have been provided, they will ask further questions of the manufacturer to obtain a thorough understanding of their needs. The integrator may hold more frequent review and planning meetings with the client so that both parties agree on the project’s best steps forward.
Regular technical reviews
Each stage of a project’s progression should involve multifaceted reviews to ensure engineers progress towards the intended deliverable. The reviews should involve multiple people, including:
● Those with expertise in the actual systems under design
● Those with expertise in the process to which the control system is being applied
● The entire development team to ensure all aspects of the project remain streamlined and aligned with project goals
Additionally, it’s helpful to include someone in the review process who is not intimately involved in the project. This person is best suited to providing the bigger picture, which helps mitigate the potential issue of tunnel vision that can occur when only those embedded in the project are involved in its review.
Regular project audits
Alongside ongoing technical reviews, project managers need to regularly audit the project to ensure it remains on track with schedule and budget commitments.
System verification
Integrators who ensure a high-quality outcome have documentation outlining their verification methodology. This documentation will include the platforms and tools that will be used to verify that the project meets both internal standards and recognized industry standards established by relevant organizations including the International Society of Automation (ISA), the National Fire Protection Association (NFPA), the International Electrotechnical Commission (IEC), and more. They will also maintain checklists that allow them to ensure rigorous verification of the functionality at different phases of the project.
A skilled system integrator will use simulation tools to perform their own internal simulated factory acceptance test (FAT) that fully exercises the functionality of the code they developed, ensuring all aspects of the project’s specifications are met. Once the internal FAT is completed, the client is invited to verify the functionality themselves prior to installation. These steps ensure that once installation occurs onsite, there are few or no surprises. The client’s quality objectives and the specifications of the process are both met.
Consistent and open client communication
A project’s proposal will include formalized review meetings at specific milestones along its progression. For example, client-integrator review meetings may be scheduled for 30%, 60% and 90% completion. These meetings allow the client to remain fully informed about all facets of its progress, including the timeline, budget and ongoing technical development and challenges. For system integrators, they help ensure their client remains informed and is satisfied through every step of the process.
Furthermore, these integrators have structured their personnel such that there is always someone who can provide clear answers to any client questions or concerns.
Technical expertise and training
Reputable system integrators know that high-quality project outcomes require engineers and project managers with the skillsets and qualifications to implement the solution. They ensure their team has the technical expertise, qualifications, initiative and commitment to complete the work effectively.
Case studies highlighting the integrator’s process
An integrator focused on a high-quality outcome will have examples or case studies of previously completed successful work in addition to client references. The case studies will outline how the integrator’s methodologies effectively result in high-quality outcomes.
Dedication to continuous improvement
It’s important to note that a skilled integrator is committed to continuous improvement. They are always learning and adjusting their methodologies accordingly. When a project doesn’t go as planned, these integrators will conduct detailed reviews to understand why they fell short and how to prevent similar issues in the future, including methods to support established quality practices.
Choosing a system integrator for success
By selecting an integrator who consistently practices their own well-documented procedures — from thorough project definition and regular technical reviews to systematic functional verification — manufacturers set themselves up for reliably successful outcomes. The methodologies outlined above contribute to reducing risk, increasing transparency and ensuring a project’s functionality, timeliness and budgetary integrity.
Manufacturers benefit from partnering with system integrators who employ careful planning, expertise and continuous improvement to achieve high-quality automation outcomes that effectively address their operational needs and deliver real value.
Hargrove Controls & Automation is a Control System Integrators Association (CSIA)-certified system integrator.
Jody Poirier, PE, is an engineering leader with Hargrove Controls & Automation. Edited by Sheri Kasprzak, managing editor, Automation & Controls, WTWH Media.
