According to   Fortune Business Insights, the global industrial automation market, which was valued at $157 Billion USD in 2018, is expected to reach nearly $297 Billion USD by 2026. As   smart automation and digital solutions   take hold, the role of industrial automation system integrators becomes more important than ever. Systems are more connected and data sharing is critical for executing end-to-end process optimization.   Systems integration is not simple work. Connecting a diverse set of applications and systems in a way that business requirements for speed and profitability are met requires the skill of experienced experts. Good systems integration also allows end users to continue to focus on their core competency of plant production safety and efficiency instead of dealing with the distractions of systems malfunctions. Having a trusted partner to implement these complicated solutions helps ensure success, delivers solutions benefits faster, and reduces overall project risk.     In hybrid industries, like specialty chemicals, food & beverage, and pharmaceutical, where automation systems address both process and discrete manufacturing steps, there exists the unique need to bridge information from these varied automation applications. Success in achieving a seamless automation integration in such environments requires partnering with consulting organizations and technology providers who understand the nuances of hybrid industries. Steps to Selecting the Appropriate Hybrid Automation Partner When we at   Supertech, an automation systems integrator and certified Schneider Electric Master Alliance Partner and   EcoXpert, are asked to engage in industrial automation systems integration projects, we start by sharing the insights we have gained over the last 25 years. Those insights, developed when working with customers to minimize risk and accelerate ROI, can be summarized in these three points:   A turnkey systems integration approach saves time and money   – A capable systems integrator should be able to go beyond simply installing their automation system. The integration of ancillary components such as sensors, transmitters, on/off valves, control valves, erection material (cables, cable trays, junction boxes, tubing, steel and pipes for fabrication), with the automation system represents a critical success factor. Coordination between customer engineers and the systems integrator is needed to properly link the electrical, piping, mechanical, and civil engineering aspects of the project. An organization that has extensive experience in deploying hybrid systems, under strict time constraints, represents an important differentiator when selecting a partner. Such a partner is capable of assuming turnkey responsibility of the automation solution, which will avoid time delays, save money, and shift the project management burden to the trusted systems integrator.   A high degree of staff engineer technical competence is required   – As the complexity of automation systems deployments within hybrid industries increases, so does the required level of instrumentation and automation systems technical expertise. End users should determine solution provider competency levels by checking on the credentials of the engineers and by asking for references of jobs completed. A few of these references should be contacted and, if possible, visited to ascertain the quality of the engineering work. Look for teams of experts knowledgeable about the benefits surrounding the advanced level functions of batch, MES, and ERP integrations. In addition, every project has its challenges–timeline delays, payments delayed, frequent changes in system requirements, and technical complications to name a few. Find out how the solution provider has performed and supported the customer when these types of issues occur.   A systems integrator backed by a reputable global technology manufacturer lowers long-term risk   – The longevity of the industrial automation systems integrator can also impact the level of success the end user will experience when implementing their automation solution. Although end users may be familiar with a global solution provider, for example, they may not be as aware of the regional systems integrator. However, the integrator tends to be the end user’s lead interface over the long term. At the manufacturer level, regional management can change quite often (every 3 years on average), but the leadership at smaller regional integrators tends to remain in place from 15 to 20 years. Such long-term relationships signify an in-depth knowledge of the environment and of relevant end-user applications. Therefore, end users who work with knowledgeable, long-term industrial automation systems integrators are subjected to less risk, fewer implementation delays, and lower project change order-related expenses. Learn More about Automation Solutions Supertech Instrumentation Services Pvt Ltd.   is a   Master Alliance Partner with Schneider Electric for   Automation Systems: PLC, SCADA, DCS, Intelligent MCC, and Energy Management Systems. Supertech is one of 10 Master Level Alliance Partners for Schneider Electric and has received global awards for Technical Excellence for the last three consecutive years. See some of our   past projects here, read Supertech success stories on   Schneider Electric Exchange, view a   video interview   with Supertech, or contact   Chandrashekhar Limaye.   Originally posted on SE Blog ... View more

According to   Fortune Business Insights, the global industrial automation market, which was valued at $157 Billion USD in 2018, is expected to reach nearly $297 Billion USD by 2026. As   smart automation and digital solutions   take hold, the role of industrial automation system integrators becomes more important than ever. Systems are more connected and data sharing is critical for executing end-to-end process optimization.   Systems integration is not simple work. Connecting a diverse set of applications and systems in a way that business requirements for speed and profitability are met requires the skill of experienced experts. Good systems integration also allows end users to continue to focus on their core competency of plant production safety and efficiency instead of dealing with the distractions of systems malfunctions. Having a trusted partner to implement these complicated solutions helps ensure success, delivers solutions benefits faster, and reduces overall project risk.     In hybrid industries, like specialty chemicals, food & beverage, and pharmaceutical, where automation systems address both process and discrete manufacturing steps, there exists the unique need to bridge information from these varied automation applications. Success in achieving a seamless automation integration in such environments requires partnering with consulting organizations and technology providers who understand the nuances of hybrid industries. Steps to Selecting the Appropriate Hybrid Automation Partner When we at   Supertech, an automation systems integrator and certified Schneider Electric Master Alliance Partner and   EcoXpert, are asked to engage in industrial automation systems integration projects, we start by sharing the insights we have gained over the last 25 years. Those insights, developed when working with customers to minimize risk and accelerate ROI, can be summarized in these three points:   A turnkey systems integration approach saves time and money   – A capable systems integrator should be able to go beyond simply installing their automation system. The integration of ancillary components such as sensors, transmitters, on/off valves, control valves, erection material (cables, cable trays, junction boxes, tubing, steel and pipes for fabrication), with the automation system represents a critical success factor. Coordination between customer engineers and the systems integrator is needed to properly link the electrical, piping, mechanical, and civil engineering aspects of the project. An organization that has extensive experience in deploying hybrid systems, under strict time constraints, represents an important differentiator when selecting a partner. Such a partner is capable of assuming turnkey responsibility of the automation solution, which will avoid time delays, save money, and shift the project management burden to the trusted systems integrator.   A high degree of staff engineer technical competence is required   – As the complexity of automation systems deployments within hybrid industries increases, so does the required level of instrumentation and automation systems technical expertise. End users should determine solution provider competency levels by checking on the credentials of the engineers and by asking for references of jobs completed. A few of these references should be contacted and, if possible, visited to ascertain the quality of the engineering work. Look for teams of experts knowledgeable about the benefits surrounding the advanced level functions of batch, MES, and ERP integrations. In addition, every project has its challenges–timeline delays, payments delayed, frequent changes in system requirements, and technical complications to name a few. Find out how the solution provider has performed and supported the customer when these types of issues occur.   A systems integrator backed by a reputable global technology manufacturer lowers long-term risk   – The longevity of the industrial automation systems integrator can also impact the level of success the end user will experience when implementing their automation solution. Although end users may be familiar with a global solution provider, for example, they may not be as aware of the regional systems integrator. However, the integrator tends to be the end user’s lead interface over the long term. At the manufacturer level, regional management can change quite often (every 3 years on average), but the leadership at smaller regional integrators tends to remain in place from 15 to 20 years. Such long-term relationships signify an in-depth knowledge of the environment and of relevant end-user applications. Therefore, end users who work with knowledgeable, long-term industrial automation systems integrators are subjected to less risk, fewer implementation delays, and lower project change order-related expenses. Learn More about Automation Solutions Supertech Instrumentation Services Pvt Ltd.   is a   Master Alliance Partner with Schneider Electric for   Automation Systems: PLC, SCADA, DCS, Intelligent MCC, and Energy Management Systems. Supertech is one of 10 Master Level Alliance Partners for Schneider Electric and has received global awards for Technical Excellence for the last three consecutive years. See some of our   past projects here, read Supertech success stories on   Schneider Electric Exchange, view a   video interview   with Supertech, or contact   Chandrashekhar Limaye.   Originally posted on SE Blog ... View more

Emerging process industry segments such as small- to medium-sized manufacturers have a huge potential for growth and the right  industrial automation  systems can help fuel that growth. Take, for example, a paint manufacturer based in India who decided to invest in a new generation hybrid automation system (a system that addresses both the process and discrete steps of a manufacturing operation). Initially, the company was manually handling large quantities of raw materials. Barrels of liquid and bags of chemicals were delivered and dropped off on the plant production floor. These were then individually weighed on platform scales so that recipe quantities could be properly measured out. Then those ingredients were manually loaded into the mixers.       All of this changed when the company upgraded to an automation system specifically designed to meet the need of their hybrid processes. Now, the raw materials are stored in bulk in storage tanks. They are transferred by pumps to weighing tanks mounted on the load platforms. The raw materials are weighed in the weighing tank and transferred into the mixer according to the prescribed recipe. Bulk raw materials like oils, solvents, resins, and emulsions are directly transferred from storage tanks to the mixers, with quantities measured with mass flowmeters. Pneumatic conveying systems have been used for bulk powder raw materials, where quantities are measured by means of load cells on silos. This process automation has resulted in a drastic reduction in the requirement of manpower for material handling, safer handling of chemicals, faster batch cycle time, greater consistency in quality, and higher productivity.   Cutting Through Marketplace Automation Systems Confusion When we at   Supertech, an automation systems integrator and certified Schneider Electric   Alliance Partner   and   EcoXpert, meet with   customers   for the first time, they are often confused by the overwhelming amount of automation solution choices presented to them in the marketplace. Their dilemma is compounded by automation manufacturers who try to sell them traditional solutions that are not specifically designed to meet the needs of the hybrid segments.       Let me explain how this situation has evolved. Manufacturers can be broadly classified into three segments–discrete, process, and hybrid. The automation systems used in these segments are different from each other. In small discrete industries like machinery and electronics, logic and sequential control are based on PLCs and HMI / SCADA. These systems had the advantage of ease of use, openness, and flexibility. On the other hand, large continuous process industries such as oil & gas, power, and refining, have relied on traditional distributed control system (DCS) solutions. These high-speed, tightly integrated systems provide control and supervision, with high capacity for analog signal processing and computational capabilities. Traditional process applications (such as petrochemicals) and discrete applications (such as packaging) have worked separately, with little or no need for information-sharing. In hybrid segments like food & beverage, specialty chemicals, and pharmaceuticals, however, there exists the unique need to bridge islands of both process and discrete automation applications and to carry the information gleaned from these disparate systems across their plants.   Until now, in the absence of automation systems specifically designed for hybrid segments, manufacturers were forced to either use available PLC / SCADA systems (designed for machine automation) or DCS which are typically used by large, continuous process industries. However, these systems are not adequate to meet the requirements of hybrid segments because they lack the integrated connectivity to link data from both discrete   and   process applications. Users of these systems tried to overcome the shortcomings by developing customized software for each process. However, this was not very successful because the manufacturers became heavily reliant on the skills and availability of the software developers. Those who adopted the DCS option found that the systems were far too expensive to operate and maintain and did not have the desired features. This gap in the marketplace prompted the creation of a middle-level process automation platform designed specifically to meet the requirements of the hybrid segments.   Modern Solutions and Resources Help Support Hybrid Automation Projects New systems such as the Schneider Electric   Hybrid DCS   are designed to support hybrid industrial segments where engineering skills and manpower are in short supply. Such systems address the need of these industries for turnkey solutions that require a relatively small investment. By providing tight integration between control and supervision, and powerful diagnostics, these systems allow engineers and operators to work within an open, flexible, and easy-to-use environment. To learn more about how automation solutions can better serve hybrid segment manufacturing business requirements, review our   customer implementation projects   and find us on the   Schneider Electric Exchange   platform, a global network of experts and peers.   Learn More about Automation Solutions Supertech Instrumentation Services Pvt Ltd.   is an Alliance Partner and   EcoXpert Partner   with Schneider Electric for   Automation Systems: PLC, SCADA, DCS, Intelligent MCC, and Energy Management Systems. Supertech is one of 10 Master Level Alliance Partners for Schneider Electric and has received global awards for Technical Excellence for the last three consecutive years. See some of our   past projects   here,   Supertech success stories   on Exchange, a   video interview   with Supertech, or contact   Chandrashekhar Limaye.     Originally posted on SE Blog   ... View more

Emerging process industry segments such as small- to medium-sized manufacturers have a huge potential for growth and the right  industrial automation  systems can help fuel that growth. Take, for example, a paint manufacturer based in India who decided to invest in a new generation hybrid automation system (a system that addresses both the process and discrete steps of a manufacturing operation). Initially, the company was manually handling large quantities of raw materials. Barrels of liquid and bags of chemicals were delivered and dropped off on the plant production floor. These were then individually weighed on platform scales so that recipe quantities could be properly measured out. Then those ingredients were manually loaded into the mixers.     All of this changed when the company upgraded to an automation system specifically designed to meet the need of their hybrid processes. Now, the raw materials are stored in bulk in storage tanks. They are transferred by pumps to weighing tanks mounted on the load platforms. The raw materials are weighed in the weighing tank and transferred into the mixer according to the prescribed recipe. Bulk raw materials like oils, solvents, resins, and emulsions are directly transferred from storage tanks to the mixers, with quantities measured with mass flowmeters. Pneumatic conveying systems have been used for bulk powder raw materials, where quantities are measured by means of load cells on silos. This process automation has resulted in a drastic reduction in the requirement of manpower for material handling, safer handling of chemicals, faster batch cycle time, greater consistency in quality, and higher productivity.   Cutting Through Marketplace Automation Systems Confusion When we at   Supertech, an automation systems integrator and certified Schneider Electric   Alliance Partner   and   EcoXpert, meet with   customers   for the first time, they are often confused by the overwhelming amount of automation solution choices presented to them in the marketplace. Their dilemma is compounded by automation manufacturers who try to sell them traditional solutions that are not specifically designed to meet the needs of the hybrid segments.       Let me explain how this situation has evolved. Manufacturers can be broadly classified into three segments–discrete, process, and hybrid. The automation systems used in these segments are different from each other. In small discrete industries like machinery and electronics, logic and sequential control are based on PLCs and HMI / SCADA. These systems had the advantage of ease of use, openness, and flexibility. On the other hand, large continuous process industries such as oil & gas, power, and refining, have relied on traditional distributed control system (DCS) solutions. These high-speed, tightly integrated systems provide control and supervision, with high capacity for analog signal processing and computational capabilities. Traditional process applications (such as petrochemicals) and discrete applications (such as packaging) have worked separately, with little or no need for information-sharing. In hybrid segments like food & beverage, specialty chemicals, and pharmaceuticals, however, there exists the unique need to bridge islands of both process and discrete automation applications and to carry the information gleaned from these disparate systems across their plants.   Until now, in the absence of automation systems specifically designed for hybrid segments, manufacturers were forced to either use available PLC / SCADA systems (designed for machine automation) or DCS which are typically used by large, continuous process industries. However, these systems are not adequate to meet the requirements of hybrid segments because they lack the integrated connectivity to link data from both discrete   and   process applications. Users of these systems tried to overcome the shortcomings by developing customized software for each process. However, this was not very successful because the manufacturers became heavily reliant on the skills and availability of the software developers. Those who adopted the DCS option found that the systems were far too expensive to operate and maintain and did not have the desired features. This gap in the marketplace prompted the creation of a middle-level process automation platform designed specifically to meet the requirements of the hybrid segments.   Modern Solutions and Resources Help Support Hybrid Automation Projects New systems such as the Schneider Electric   Hybrid DCS   are designed to support hybrid industrial segments where engineering skills and manpower are in short supply. Such systems address the need of these industries for turnkey solutions that require a relatively small investment. By providing tight integration between control and supervision, and powerful diagnostics, these systems allow engineers and operators to work within an open, flexible, and easy-to-use environment. To learn more about how automation solutions can better serve hybrid segment manufacturing business requirements, review our   customer implementation projects   and find us on the   Schneider Electric Exchange   platform, a global network of experts and peers.   Learn More about Automation Solutions Supertech Instrumentation Services Pvt Ltd.   is an Alliance Partner and   EcoXpert Partner   with Schneider Electric for   Automation Systems: PLC, SCADA, DCS, Intelligent MCC, and Energy Management Systems. Supertech is one of 10 Master Level Alliance Partners for Schneider Electric and has received global awards for Technical Excellence for the last three consecutive years. See some of our   past projects   here,   Supertech success stories   on Exchange, a   video interview   with Supertech, or contact   Chandrashekhar Limaye.     Originally posted on SE Blog   ... View more