Choosing the Right Maintenance Strategy

How do you choose the right maintenance strategy for your organization? Someone from the outside looking in might think the notion of choosing a maintenance strategy is as simple as choosing between ‘repair it’ or ‘replace it’, and that’s not entirely inaccurate. Beyond the surface, though, there are a number of different considerations that can have a long-term impact on a company’s bottom line and ultimate viability. Particularly when working with numerous or expensive essential assets that are subject to the continual wear-and-tear and eventual breakdown that plagues all machines, maintenance costs can take enormous bites out of revenue.

Fortunately, numerous maintenance strategies have evolved over the years, and technology allows us to apply new techniques using new models that were previously unheard of. Let’s review some of the more popular maintenance strategies:

Reactive Maintenance
This is the simplest strategy, sometimes referred to as ‘breakdown maintenance’. The premise is simple: Use something until it can no longer be used. Then, do what needs to be to repair it and get it back in action. If it can’t be repaired, replace it. There are some benefits when compared to other strategies, such as lower initial costs and reduced staff, as well as eliminating the need to plan. Of course, these benefits are usually negated in the long term by unplanned downtime, shortened life expectancy of assets, and a complete inability to predict breakdowns and maintenance needs. The only real viable reason for employing this strategy is an inability to afford the initial costs of any other strategy.

Preventative Maintenance
Preventative maintenance is performed while an asset is still operational in order to decrease the likelihood of failure. In this strategy, maintenance is performed according to a particular time or usage schedule. For instance, regular maintenance will be performed when this particular machine reaches 5,000 hours of uptime since the last maintenance. Predictive maintenance will typically keep equipment operating with greater efficiency and extend the lifetime of the asset compared to reactive maintenance, while also preventing unnecessary downtime. It does, however, require greater planning and man-power. Preventative maintenance is not a good choice for assets like circuit boards that can fail randomly regardless of maintenance. It is also not ideal for assets that do not serve a critical function and will not cause downtime in the event of a failure.

 

Predictive Maintenance
The purpose of predictive maintenance is to predict an imminent failure and perform maintenance before it occurs. This strategy requires some specific condition monitoring and will typically have a higher upfront cost due to the need to add sensors or other hardware, and will also require skilled personnel capable of anticipating failures based on the data points being monitored. Benefits include: the ability to prevent unnecessary downtime, and minimal time spent performing maintenance as it is only done when failure is imminent. Predictive maintenance is usually not a good option for assets that do not serve a critical function, or assets that do not have a predictable failure mode.

Condition-Based Maintenance
Condition-based maintenance is similar to predictive maintenance in that it involves continually monitoring specific conditions to determine when maintenance should be performed. Typically, however, condition-based maintenance is not just performed to prevent failure, but also to ensure optimum efficiency, which can not only improve productivity but extend the life of the asset as well. Because condition monitoring equipment and expertise can be expensive, initial costs can be quite high – prohibitive in some cases. In the long term, however, condition-based maintenance may be the most cost-effective strategy for ensuring optimal productivity and extended asset lifecycles. Condition-based maintenance is usually not a good choice for non-critical assets or older assets that may be difficult to retrofit with sensors.

When choosing a maintenance strategy, think about your goals: both long-term and short-term. Determine which of your assets are critical and which are not. Calculate the cost of downtime (per minute, per hour, etc.). Take into account whatever data may already be available for you to monitor. Determine the cost and viability of adding sensors to monitor things like temperature, vibration, electric currents, subsurface defects (ultrasonic sensing), or vacuum leaks (acoustic sensing). Estimate the costs of maintenance personnel in different scenarios. Estimate the difference in costs between each of the different strategies.

You may determine that a condition-based maintenance program would provide the greatest value, but you lack the resources to implement it right away. Can you deploy a simple predictive maintenance program in the meantime, while positioning yourself to make the leap to CBM in the future?

There is not going to be any one-size-fits-all “best” strategy, and not much drains a bank account faster than over-maintaining your equipment (yes, there is such a thing). Consider your circumstances and your goals, and choose wisely. It’s one of the most important business decisions you will make.

*B-Scada software provides data analysis, task automation, and real-time visualization for enterprises looking to implement a CBM program. Learn more at www.scada.com.

To Each His Own: Creating Custom Dashboards for Operators and Analysts

manyFaces

It’s always very annoying when I try to perform what seems like it would be fairly routine maintenance on a home appliance or worse – my car – only to find out that this seemingly simple thing I would like to do is actually quite difficult with the tools at my disposal. A little bit of research usually reveals that it actually is quite simple; I just have to buy this proprietary tool from the manufacturer for what seems like a ridiculous price, and then I can proceed.

Of course, it’s easy to understand why the manufacturer doesn’t want to make it easy for end users to service their product. They want you to buy a new one, or at the very least buy this overpriced tool from them so they can scrape every morsel of profit afforded by their built-in obsolescence.

It really makes me appreciate the simplicity and widespread application of some of our more traditional tools. Take a hammer, for instance. If you need to drive a nail into wood, it doesn’t matter if it’s a big nail, a little nail, a long nail, or a short nail. It doesn’t matter who manufactured it or when. All that matters is that it’s a nail. Just get a hammer; you’ll be fine.

This got me thinking. What if we had a hammer for every type of nail available? What if each hammer was perfectly sized, shaped, weighted and balanced for each particular nail? And what if that perfect hammer was always available to you every time you needed it. This isn’t realistic, obviously, but it reminds me of some of the things I hear from our customers.

One of the great benefits cited by our end users is the ability to create custom dashboards for the different work responsibilities in their organizations. The same system is used to create maintenance dashboards for technicians, control panels for operators, system overviews for managers, reports for analysts, and even special dashboards for contractors and vendors. By providing every member of the team with a real-time view of exactly the information they need to do their jobs and nothing more, each person is empowered to do their jobs with the utmost efficiency – improving the speed and accuracy of decision-making as well as increasing the capacity for planning.

In the past, so much of our data visualization was tied to the device from which the data was drawn. If you wanted to know something about a particular machine, you had to look at the same picture as everyone else, regardless of what you needed to see.

Some modern software platforms like B-Scada’s Status products eliminate this need to tie visualizations to the device from which the data is drawn. It is now possible to visualize data from multiple devices at multiple locations through the same interface. This allows for a new concept in user interface design: rather than displaying all available information about this particular thing, you can now display all information relevant to a particular task or set of tasks.

It’s not quite “a hammer for every nail”; it’s more like a complete tool set tailored to every job, containing exactly the tools you need and nothing more. It’s really been a transformative development for many organizations.

B-Scada recently released a case study detailing how one prominent North American electric utility used Status to create a system of customized views for their operators, managers, and analysts, providing specific insights into the real-time status of their generation resources:

Read It Now

 

Oh, The Possibilities … When the IoT Grows Up

5Ways.jpg


The Internet of Things is something like a gangly, acne-covered adolescent with knobby knees and a clumsy gait.
We can see the bright eyes, the long legs and strong hands, and we know it is chock full of “potential”, but it sure is awkward right now.

Notwithstanding all of this awkwardness, however, this clumsy youngster has already made a tremendous difference in the world. The very thought of its possibilities has sent a tremor to the core of our civilization, touching every aspect of our material and intellectual lives. Just consider the fact that the sentence you just read – as blustery and over-the-top as it may seem – is not even inaccurate. Sure, a person can still live a simple life without all of the trappings of modern technology or communication media (I assume?), living only from sustenance won by his or her bare hands directly from the natural world, never interacting with another living soul. I suppose this is possible, and maybe this person could make a strong case that his/her life remains untouched in any way by the Internet of Things. This person, however, will not be reading this and need not be a part of the conversation.

So, to reiterate: the Internet of Things – or at least the thought of it – is influencing every component of our world today. This is because it is not simply an evolution of technology; it the sort of technological/philosophical movement that transforms civilizations. On the order of agriculture, kingship, or industrialization.

Yes, it is that significant.

That is to say, the technological/ philosophical movement started by the Internet itself is that significant. After all, the words, images, videos, and applications that inhabit the regular old Internet are themselves ‘things’. The concept behind what we call the Internet of Things is simply the dawning of the realization that the Internet is not just about people communicating with people; it’s about everything communicating with everything.

Consider what we already see happening to:

 

Cities

In Oskarshamm, Sweden smart building technology has helped reduce the city’s power consumption by 350 MWh, reducing their carbon footprint by 80 tons of CO2. Houston, Texas has used new sensing technology to retrofit 40 municipal buildings for energy efficiency, delivering $3 million in yearly energy and water savings.

Entire cities are changing the way they govern their populations, the way they distribute resources, the way they police themselves. Cities are changing the way they transport goods and people, the way they measure and control their impact on their environments. Everything that defines what a city is and does is being transformed by not just new technologies, but the new ideas inspired the Internet of Things.

 

Agriculture

One of the foundational elements of civilization, a technological/philosophical movement that predates history itself, is being profoundly influenced by the Internet of Things. Farmers large and small are using networked data to maximize the already-known benefits of established practices (knowing what types of crops to plant when, knowing when and how much to water, etc.). Farmers have also had success safely and naturally controlling pests through the intelligent release of pheromones. Decreased resource consumption and increased yield are very tangible benefits that have the potential to solve some very serious problems related to food shortages and ever-increasing populations, while simultaneously reducing the environmental impact of farming and bringing the family-owned farm back into the global marketplace.

 

Industry

This is the realm of autonomous factories and self-healing machines. Through the convergent development of advanced computing power, sophisticated network technology, sensors, robotics, and analytic techniques, we are seeing the integration of industrial systems both vertically and horizontally. Machines to Machine communication, predictive maintenance, and continuous improvement programs are completely reinventing manufacturing.

Companies like Honda and ABB are using IoT technology to consolidate and organize their manufacturing and maintenance operations through systems of real-time communication and process automation. Companies are using advanced analytics to discover unknown opportunities for improved efficiency. Consider how Kennametal reduced their production cycle time by as much as %40 by simple modifications to their processes like changing the angle of a cut in a particular machining operation.

Real-time consumer data is helping companies be more responsive to the needs and expectations of their customers, and eliminating gaps between supply and demand. Predictive analysis is helping to reduce maintenance costs and incrementally improve production processes through systems of continual improvement. A unique quality of the impact the Internet of Things is having on Industry is its benefits extend beyond the marketplace. Whereas previously profit increases were sought by increasing the scale or speed of production, the new paradigm focuses on increasing efficiency, reducing resource consumption and eliminating waste. The new industrial landscape of smart, connected devices will incidentally lead to a cleaner, safer, more sustainable planet, which leads to the next item…

 

Environment

It is certainly possible to see new technologies as a double-edged sword in this arena. Historically, what humankind has deemed to be good for itself has quite often seemed to be detrimental to our environment. As the Internet of Things makes it easier for us feed and accommodate larger populations, and populations continue to grow, it is not difficult to see how this could negatively impact the environment. An interesting quality of the philosophical thrust behind most Internet of Things initiatives, though, is the tendency toward reduction and conservation.  Use fewer resources. Create less waste. Do as much as possible with what is available to us. In a way that may be unprecedented, this worldwide technological evolution may actually improve our relationship with the natural world.

 

Yes, the Internet of Things is a gangly, awkward, stumbling bunch of possibilities right now, but it is already changing our world. And while we may not have reached that tipping point yet – the point where what is possible becomes what is necessary, and a movement truly transforms our civilization – I think most of us can feel the axis tilting.

There will inevitably come a time when what is happening becomes what has happened, and we will only recognize the revolutionary quality of it when we look back at it in retrospect. In the case of the Internet of Things, I think we have reason to be optimistic.

(Originally published on the B-Scada, Inc. blog.)

3 Keys to Effective Real-Time Data Visualization

Everybody appreciates the value of a good picture. Each one says a thousand words, after all, or so the saying goes. If we really dig in to this metaphor, we’d probably admit that some pictures say substantially more than that – while others probably come in well under a dozen (just look at a random Facebook wall for some examples).

Ours has become a very visual culture, and one occupying a place in time defined by an overwhelming abundance of information all around us. Considering these two facts, it is not at all surprising that we see such an increased interest in data visualization – that is to say the process of placing a particular, specific set of data points in a highly visual context that allows it to be quickly consumed and analyzed.

It’s not a new concept; data has been visualized in pictures for centuries. A map is a type of data visualization, for instance, as are the many charts and graphs that have been used since the end of the 18th Century. What is new is the massive quantity of data available to nearly everyone, and the wide array of tools that can be used to create compelling visualizations. Think about the cool infographic you saw the other day. Was it created painstakingly over several days of carefully reviewing ethnographic data compiled by a dogged scientist over the course of his career? Maybe, but probably not. It was more likely created by some marketing department somewhere (not that there’s anything wrong with that) using somebody else’s data and somebody else’s visualization tools.

The purpose of this post, though, is not to discuss the merits of data visualization in general, but rather the specific subset of data visualization that deals with real-time data. This is a completely separate species of data visualization and should be treated as such.

Real-time data visualization refers to visualization of data that is continuously updated as new data is generated by connected devices or people. This is the type of data that is used to make real-time decisions and, when done correctly, can truly transform business processes.

There are a number of important factors to consider when attempting to visualize data in real time, but we will focus on three simple and obvious keys: clarity, consistency, and feedback.

 

Clarity

Real-Time graphics should emphasize pertinent information and use design principles that promote ease-of-use and accessibility above aesthetics. Things like size, color and brightness can be used to distinguish primary details from secondary and tertiary details. Special graphics can be created to emphasize different information under different conditions (i.e. a special set of graphics to be used when a certain alarm is triggered).

 

Hierarchical Data
Hierarchical Data Makes its Relevance Obvious

Clear visualizations provide actionable information at a glance, and clearly show the current process state and conditions. Alarms and indicators of abnormal conditions are prominent and impossible to ignore.

Clarity encompasses both content and context.

dataVis3.png
Contextual Controls Allow You to Assess Current Conditions at a Glance

 

Consistency

Consistent visualizations are standardized and consistently formatted. Interaction requires a minimum of keystrokes or pointer manipulations.

Shapes, colors, and layouts should be used consistently through all screens. If the color red is used in one place to designate an abnormally high value on one screen, that same color red should be used to indicate all abnormally high values of the same type on all screens. If navigation buttons are on the left side of one screen, they should be on the left side of all screens. A consistent visualization system is arranged in a logical, hierarchical manner, allowing operators to visualize both a general overview of the system as well as more detailed information on different components as needed. Navigation and interaction of any type should be as easy and intuitive as possible.

Consistency is closely related to clarity.

dataVis4.png
Color is a Great Way to Distinguish One Property from Another, As Long As it Is Consistently Applied.

 

Feedback

An operator should be fully confident that the choices they make are having the desired effect. Screens should be designed in a way that provides information, putting relevant data in the proper context. Also, important actions that carry significant consequences should have confirmation mechanisms to ensure that they are not activated inadvertently.

Controls will function consistently in all situations. If something is not working as it should, that fact should be immediately obvious and undeniable. In a well-designed system, design principles are employed to reduce user fatigue.

There are obviously many other important factors to consider when real developing a real-time visualization system. Anyone who wants to dig deeper is encouraged to read this free whitepaper on the subject:

Click here to read it

3 Reasons You Should Consider Giving Your Process Operators Mobile Devices

eim_image-fw

That’s right. It’s time to own up to the fact that the majority of us are using phones and tablets to do business everyday. We buy, sell, trade, learn, teach, and all manner of horrible and wonderful things that we have always done (no, not everyone does horrible things, but don’t act like the things you do are always so wonderful either) all with the aid of portable devices that allow us to move freely about our lives without being tethered to a desk chair.

Why, then, is it so difficult for some people to recognize that our industrial process operators and technicians – who are so often stuck behind a stationary HMI or calling from the field to speak with someone who is – would be far better equipped to do their jobs if only they were afforded the same conveniences they afford themselves in their lives outside of work.

I know there are concerns about security – about opening some digital wormhole through which all sorts of nefarious activity could be invited. There are concerns about ill-intentioned deviants having potential access to sensitive process data – which is not only proprietary, but often essential to our infrastrucure – as well there should be. But it’s not like these potential problems didn’t exist before mobile devices, and while some concerns are certainly valid, mobile devices provide a number of key benefits and opportunities that cannot be ignored:

 

  • For Remote Management of Disparate Assets
    This one seems pretty obvious, but imagine the amount of time that could be saved by not having to manually inspect field equipment or call back to the control station every time there is a simple question.
  • For Constant Access to a Portable Media Viewer
    How can you ensure that operators and techs always have access to the latest work masters, training videos, etc.? Upload or edit a document and make your changes instantly available to all relevant perties – regradless of where they are or what they’re doing.
  • For Instant access to Forms and Form Data
    Create Purchase Orders or close Work Requests from anywhere. Assign new owners or upload a picture you just snapped and attach it to a Job. The possibilities are nearly unlimited.

 

Sure, there are only three benfits listed here, but without much thought I’m sure you could think of a few more. Let me know in the comments below.

And for some additional food for for thought, check out this white paper on “The Benefits of Mobile HMIs” and tell me I’m not absolutely right about this:

Download White Paper

How To Improve Any Business Process

mobile_automation

If you are responsible for managing a business or organization of any type, you have undoubtedly sought out opportunities to make things run more smoothly and efficiently. It’s only natural. This means that responsible owners and managers are continually looking for opportunites to optimize their business processes.

How about some free advice?

First of all, let’s be clear about what it is we’re referring to when we use the term ‘business process’. In short, a business process is defined as a collection of linked tasks which can find their end in the delivery of a service or product to a client. It has also been defined as a set of activities and tasks that – once completed – will accomplish an organizational goal.

Any business (regardless of how poorly it may be run) employs some type of business process. Some are clearly better than others.

What we refer to as Business Process Management (BPM) can be defined as the set of techniques employed to map the flow of information and communication between various business assets and departments, identify opportunities for improvement, and establish and enforce rules to optimize the process moving forward. These techniques can (and should) be employed continually.

A BPM system can provide any company with several measurable benefits:

  • The ability to identify otherwise unknown inefficiencies
  • Reduced downtime and cost associated with wasted time and material
  • The ability to connect processes over multiple facilities and or operations
  • Automation of repeated and/or predictable tasks
  • Establishment of a program for continual improvement

These benefits are very attainable. Provided you use the right tools and follow a simple procedure, anyone can realize the improved efficiency and reduced waste that BPM systems provide. And what is the correct procedure? In very simple terms:

  1. Analyze Current Processes
    Create a business process map to paint a clear picture of the current flow of information between different business assets. Use this map to uncover inefficiencies and establish a preferred methodology.
  2. Establish and Enforce New Rules
    Define rules for how you would like information to flow, and create workflow tasks to automate tasks or send automatic notifications to people that need to be involved in enforcing the new rules.
  3. Implement, Train, Rinse and Repeat
    Once the new process is clearly defined and automated, ensure that all parties are fully trained and equipped to adhere to these new rules moving forward. You can create custom dashboards to track real-time data, create a centralized knowledge base that is shared and continually updated, and use automated real-time notifications to be sure that everyone is always aware of the current state of the process. Finally, ensure that your new process is fully repeatable and scalable to allow for continual evaluation and improvement.

Seems pretty simple, right? It can be when you combine your innate understanding of your business process with the right tools.

 

**Learn more about some of the data acquisition and visualization technology the empowers Business Process Management at http://scada.com

Object Virtualization: Digitizing the World

Object virtualization is the enabling technology behind the IoT (Internet of Things)

We are changing our world. With the advent of new sensing and communication technologies, we are finding ways of making everyday objects more intelligent and connected. As we connect more and more things to one another, however, we are finding a need to democratize the process. We have to make different things the same, or at least equal. We are still trying to answer the Mad Hatter’s famous riddle: How is a raven like a writing desk?

Though Alice’s time in Wonderland may have come and gone, ours is just beginning. While we may not be connecting ravens to writing desks (though nothing would surprise me at this point), we do have a need to connect seemingly unrelated objects in new ways.

One solution to this dilemma is the process of object virtualization. By creating virtual models, or representations, of the things you want to monitor and manage, you are putting ‘things’ on equal footing, creating new opportunities for analysis and task automation.

To understand object virtualization, consider the contact list in your phone. A contact can be thought of as a virtual model of an actual person. It is something like a digital identity. Imagine you have a contact named Mary Smith. Mary has a name, a phone number (or two), an email address, maybe a photo. Mary can have a Facebook profile, a Twitter alias – you can even assign Mary a special ringtone. All of these things combine to create a virtual model of Mary stored in your phone.

Now, to make your model of Mary a bit more intelligent and useful, you could add her date of birth, her hair color, her favorite book, her pet cat’s name, or any number of different properties of Mary. If we slapped a bunch of sensors on Mary, we may know things like her current location, current body temperature, her heart rate, her blood pressure. If this information is communicated to your model in real time, you have an active, living representation of Mary that tells you more about her than she may know herself.

Imagine applying this same process to your house, your car, your toaster, or your favorite pair of socks. Now, maybe you can’t think of a good reason for your socks to talk to your toaster, but they may have a thing or two to share with your washing machine. And maybe your house and your toaster can have a nice conversation about lowering your electric bill. Of course, your things aren’t just talking to your other things. They can talk to other things anywhere. Do you think it might be helpful for your air conditioning system to know something about today’s weather forecast? Or for your car to know about that new road construction on your way to work?

Your virtualized house doesn’t care that it’s a house. It may as well be an elephant or a water balloon. The same is true of your car, your refrigerator, or your lawn sprinklers. Virtual models can share information with other virtual models without regard for where the data is coming from or how it got there. Virtualization can make every “thing” accessible to every other “thing”, and ultimately to you.

**B-Scada’s VoT (Virtualization of Things) Platform allows you to create virtual models using data from multiple and disparate sources, providing a simple platform for creating powerful and intelligent IoT (Internet of Things) applications. Learn more at http://votplatform.com.

Information Modeling as a Tool for Collaboration

In the spirit of the upcoming holiday season, let’s take a moment to examine one of the greatest and most appreciable qualities of a healthy organization: collaboration. In a world so full of information, where we are all so busy and so pressed for time, it seems collaboration has become something done more out of necessity than out of a desire for quality and efficiency.

Some of this reality may be due to the fact that there simply are no good tools for collaboration in the modern workplace. Sure, we have email and teleconferencing, web meetings and text messages – but for all of our technology, our endless need to compartmentalize and segment our business processes has left us no closer to a model of organic collaboration than we were in the past.

With relevant information stored in separate silos, decision-makers are still forced to rely on reports and statistics compiled from historical data and interpreted to support a specific agenda. There has really been no truly organic means analyzing real-time data alongside the historical data. Likewise, the available tools for integrating data from separate systems are limited in terms of their ability to create a real-time context and to display the appropriate data to decision-makers at the speed with which decisions must often be made.

While these tools may be useful for looking back and analyzing what has happened, it is another matter altogether when trying to look forward to make plans or predict outcomes.

Information Modeling

One of the ways this challenge can be overcome is by using an information model to organize and structure your organization’s data in a way that provides context and clarity in real time. Information modeling allows assets to be associated with all relevant information – regardless of where that information may reside.

For instance, a motor on your plant floor can have live data related to its RPM, temperature, throughput, or other process data – as well as a commission date, a maintenance schedule, troubleshooting documents and training videos. Properties of this motor can also include OEE (Overall Equipment Efficiency), Net Asset Value, or other performance and resource planning metrics. Some of this data may be coming from PLCs, some from databases like SQL Server, some from user input, and other data is coming from programmed calculations. In this situation, it is not important how this data is generated or where it is stored. What is important is that this data can be visualized at any time in whatever way suits your collaborative needs.

There are a number of different tools that can be used to create an information model for your organization. A few things to consider when choosing an information modeling tool:

  • Does the modeling software take into account both real-time AND historical data?
  • Does the modeling software allow you to include ALL relevant information from every source?
  • Is your modeled data logged in a relational database like SQL Server so it can be queried if additional information is needed?
  • Does your modeling software provide the tools you need to visualize your data in a useful way that supports decision-making?
Before you jump into a new software product and a new data management system, do some homework. As with everything there are pros and cons to the different products available.

The Integrated Enterprise – Are We Ready?

13451387_m

There are many barriers to change in a commercial enterprise, and most of them start with a dollar sign. You are comfortable with what you’re doing. Your staff is comfortable. Sure, there may be some missed opportunities, but perfection is unrealistic. To implement enterprise-wide changes to something like your data management strategy would require cooperation across multiple departments, absorb numerous man-hours in implementation, and who can say how long it will take for all parties to get used to the new strategy and work with a level of comfort they already feel today? Is it worth it? How long will it take to recover the investment?

There are many legitimate questions to ask when considering whether or not to move toward an integrated data management strategy. How do we calculate the true cost of making such a change? A question that is very rarely asked is: What is the true cost of not making such a change?

First, let’s consider some of the reasons in favor of data integration.

Inconsistent data

One of the problems addressed by data integration is inconsistency between data on the plant floor and the business data further upstairs. Depending on the type of business, different departments typically have different goals and criteria for success. The plant floor supervisor wants to know where his products are; the executive upstairs wants to know how much his products are worth. Here is a case where we have different people querying for different bits of information about the same asset. Over time, the different goals and process definitions have led to departments using the same terms to describe different things, and different terms to describe the same things. This barrier to departmental collaboration in the manufacturing industry, for example, has led to the development of standards like ISA 95 to help facilitate the integration of manufacturing systems with business systems.

Redundant data

Another common condition is the tendency for different departments or divisions to have different ways of recording information about the same things. It is not at all unusual for large organizations to have multiple records of the same asset. For instance, if we imagine a particular production unit from the perspective of the plant floor operator, he will need to have information about where it is in the production process, its quality, the personnel involved in its production and testing, and when it will be shipping. At the same time, a manager will want to have information about how much it cost to produce this unit, how many units will be produced today, and how much we will get for it. We now have a situation where we are capturing and recording separate sets of data about the same thing.

Fewer Human Resources

This one seems obvious, but it a significant difference-maker when you analyze your bottom line. Making it easier to find needed data will allow personnel to spend more time focusing on other aspects of their jobs. It will allow for faster decisions and more immediate response to abnormal conditions. Your plant floor supervisor won’t have to make that call upstairs to find out why today’s production schedule has changed, or log in to a separate system to find out when a piece of equipment was last inspected. And the manager upstairs won’t have to call downstairs to find out why we are behind schedule today, or what happened to that shipment that was supposed to go out. Having the ability to quickly assess a situation leads to better-informed decisions made more quickly and with more immediate results.

Reduced Risk

While we are on the topic of making informed decisions more quickly, this is a good time to consider the way that decisions are currently made in many enterprises. When a decision needs to be made quickly, and the data that could support that decision is not available as quickly as the decision is needed, owners and executives are left to make decisions based on intuition. Studies have suggested that about 80% of decisions are made this way. It may work and it may not. Having the right information when and where it is needed can significantly reduce the risk involved in the decision-making process.

There are many additional benefits that can be attributed to data integration. New business opportunities can be revealed. New calculations can be used to improve efficiency and coordinate processes. Improve inventory management, energy consumption, supply chain scheduling, etc. Whether you choose to use a system of data virtualization to integrate key data from different divisions, a system of data federation to consolidate all enterprise data, or opt for a complete data integration solution that re-engineers your entire data system, the benefits are very real and yes, so is the cost. The cost, however, is a short-term loss for a long-term gain; a temporary pain for permanent growth.

So, to revisit the topic of this article: Are we ready for the integrated enterprise? The answer is irrelevant. Those who are ready will continue to prosper. Those who are not will lose the ability to compete, and will ultimately have to get ready or get out of the way.

For more information on how you can integrate and visualize your business’s data, visit: www.scada.com