In an August 15, 2023 webcast, "SCADA series: New SCADA features and functions," Avanceon’s Matt Ruth joined Control Engineering to discuss obsolescence and SCADA system upgrades. Read part 1 of the edited transcript below.
SCADA insights
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In an August 15, 2023 webcast, “SCADA series: New SCADA features and functions,” Avanceon’s Matt Ruth and Nicholas Imfeld joined Control Engineering to discuss the key innovations in SCADA software packages that can improve efficiency and outcomes for end-users.
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In Part 1, Matt Ruth, President at Avanceon, discusses common drivers of SCADA system upgrades, including obsolesce, labor and skills shortages, and more.
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Read Part 2 for more information on the key SCADA features that can make an upgrade worth the investment, Part 3 for a SCADA upgrade case study, and Part 4 for information covered during the webcast’s live question and answer session.
Software for supervisory control and data acquisition (SCADA) has advanced to provide greater capabilities with less programming. What are key traits of SCADA software packages that make an upgrade worth the investment? Advantages include integration of certain standards; built-in communications and connections to other devices, software and systems; extensive libraries of code; integration with cloud capabilities; easier porting to mobile clients; and analytics. In an August 15, 2023 webcast, “SCADA series: New SCADA features and functions,” subject matter experts joined Control Engineering to discuss these topics and more. The featured webcast instructors were:
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Matt Ruth, President, Avanceon
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Nicholas Imfeld, Operations Manager, Avanceon
Below, the transcript of their presentations has been provided with minor edits and adaptations.
Reckoning with obsolescence
Matt Ruth: I would like to begin by stating that obsolescence is a widespread phenomenon. Reflect on how technology has evolved in your life over the past two decades. The methods of making phone calls, waking up to alarm clocks, typing and developing documents, performing calculations, saving files, taking pictures, and listening to music have all dramatically changed.
Control systems and automation are no different. Many facilities contain legacy systems that have become obsolete. In our field, it’s common to encounter outdated systems, sometimes identifiable by their tangled webs of wires, characteristic of legacy systems from 20 or 30 years ago. SCADA systems are not exempt from this trend. The images below, showing systems from the ’80s and ’90s, are still commonly found in manufacturing facilities today.
Modern SCADA and labor/skills shortages
When considering the obsolescence of SCADA systems, it’s not just about technology. Many leaders in manufacturing face limitations in their operations and workforce. They express frustration over not having clear visibility into their systems’ status, lacking the necessary dashboards or insights to make efficient and effective decisions.
Another issue is the dependency on a limited number of individuals who understand the intricacies of older technology. This reliance on a few knowledgeable personnel for troubleshooting and maintenance poses significant risks.
Additionally, there’s a challenge in integrating new employees into these older systems. The aging workforce in manufacturing means new staff are often more familiar with contemporary technology, like smartphones and gaming systems. Introducing them to outdated systems can lead to a lack of acceptance and understanding.
Achieving ROI
Unfortunately, there are barriers to upgrading SCADA systems. The first is the difficulty in justifying the return on investment (ROI). It’s challenging to quantify the benefits of upgrading or modifying SCADA systems. The current economic climate, exacerbated by COVID, has reduced the availability of downtime needed for implementing new systems. Production facilities are operating at maximum capacity, leaving little time for enhancements or upgrades. Additionally, there’s a belief that software upgrades don’t add substantial value compared to physical equipment, making it hard to translate the benefits into a tangible ROI.
How to justify a SCADA upgrade
The final point to consider is the old adage, ‘If it isn’t broken, don’t fix it.’ One might ask, ‘Why should I intervene or make changes?’ Choosing not to act is, in itself, a decision, and it comes with its own costs. One significant cost is the loss of expertise. Every day, facilities lose a substantial portion of their operational knowledge and understanding when their employees leave for the day. That issue will exacerbated when, soon, Baby Boomers and even Generation Xers walk out the door for the last time.
In contrast, new employees who replace these veterans often face a slow start. They must adapt to systems and interfaces that are unfamiliar, compared to what they encounter in other areas of life. This leads to a gradual adoption and understanding of these new tools. Moreover, despite the abundance of data available, there isn’t much actionable information to enhance productivity and understand inefficiencies.
From the perspective of the costs of inaction, consider the challenges faced. How can one justify the consideration of upgrading SCADA systems or implementing new technology? Many are conducting software investigation studies to explore the potential return on investment (ROI). These studies examine the current efficiency in using existing technology, the difficulties encountered, and the consequences of not upgrading.
To understand the impact and ROI of a SCADA upgrade, consider the following. Imagine initiating such a project. Based on our experience, the first aspect to address in a new SCADA project is change management, focusing on the human element. Many of these systems have been operational for 20 to 30 years, creating comfort and habitual use among older operators, but not for newer staff. Achieving a balance in change management is crucial. We recommend a gradual approach, involving both existing and new staff throughout the project. Applying agile methodologies for iterative design and development can effectively address these change management challenges.
Another key element is simplifying and streamlining information presentation. With the overwhelming amount of data available, and even more so with new SCADA systems, it’s essential to present information in a clear, simple manner.
Further considerations include ensuring accessibility for everyone, anywhere. This involves creating an open, inclusive system that’s easy to use and navigate. Transform data into meaningful knowledge, allowing operators to analyze and understand it, rather than just managing basic data. This broader perspective on information aids in making informed decisions. Additionally, system reliability and redundancy are vital. It may seem obvious, but ensuring operational continuity in any situation is crucial. Lastly, plan for future expansion, acknowledging that technological advancements are inevitable.”
– Edited by David Miller, Content Manager, Control Engineering, CFE Media and Technology, [email protected].
