Industrial automation for large companies

What is industrial automation? 

Industrial automation refers to the application of technologies and systems to control and operate industrial processes with minimal or no human involvement.

It involves the use of machines, sensors, computers e advanced to monitor, control and optimize production and other operations in a factory or industrial environment.

The heart of industrial automation is the ability to program devices to perform tasks consistently and precisely, often in real time. 

These systems are designed to monitor conditions, collect data, make decisions based on defined parameters and carry out actions without the need for direct human intervention.

What are the benefits of industrial automation?

Industrial automation offers a number of significant advantages for companies that adopt it.

O increased efficiency is one of the main benefits, as this approach allows complex tasks to be carried out more quickly and accurately than manual processes, resulting in more efficient production and reduced downtime.

In addition, automation contributes to higher product qualityby eliminating variations caused by human error and ensuring compliance with specific standards.

The gains in terms of cost reduction are also notable, as the use of automated systems can reduce operating costs in the long term, requiring fewer human resources to operate the machines.

A mproving safety is a crucial aspect, since dangerous or repetitive processes can be carried out by machines, minimizing the risk of accidents at work and improving employee safety. Another important point that automation systems make possible is constant monitoring of operations, allowing problems to be identified quickly and corrective measures to be taken before they cause major disruptions.

A flexibility e adaptability are other strengths of industrial automation. Automated systems can be reprogrammed and reconfigured to suit different products and processes, making production more agile and flexible.

Another positive point is that the generation of data enables decision-making based on solid information, contributing to more informed and strategic choices.

Automation can also offer increased production capacity without the need to significantly increase the workforce. This results in more efficient and faster production, making companies more competitive on the market.

Last but not least, automation can be designed with a view to sustainabilityoptimizing energy and resource consumption, which contributes to more responsible and environmentally friendly practices.

These are just some of the benefits that industrial automation can bring to large companies. 

 

What are the main industrial automation technologies?

In the modern industrial landscape industrial automation is the main catalyst for operational efficiency, improved quality e productivity.

This technological advance has revolutionized the way companies conduct their operations, allowing complex processes to be carried out accurately, consistently and effectively. 

The key to this progress lies in the synergy between a variety of technologies, each playing a crucial role in the automation ecosystem. 

Sensors and actuators

The sensors are devices that capture data from the environment around them and convert it into information via electrical or digital signals. They can measure various parameters, such as temperature, pressure, humidity, level, speed, presence and much more.

This data is essential for the precise control of industrial processes. Intelligent sensors can send real-time data to control systems, allowing immediate adjustments when necessary.

The actuatorsare devices that respond to the signals sent by the control system by performing physical actions. They can be used to move equipment, open or close valves, drive motors, among other actions. Electric, pneumatic and hydraulic actuators are common in different industrial scenarios, allowing complex movements to be automated.

The combination of sensors e actuators enables a feedback loop in which the data collected by the sensors is processed by the control system, which makes decisions and sends commands to the actuators. This allows processes to automatically adjust to changes in environmental conditions, ensuring more precise and efficient operations.

Programmable logic controllers (PLCs)

Programmable Programmable Logic ControllersProgrammable Logic Controllers, known as PLCs, are crucial electronic devices in industrial automation, responsible for control e monitoring of complex processes.

PLCs are designed to automate sequences of operations. They operate by following programmed instructions, processing sensor inputs and making logic-based decisions to trigger outputs such as actuators, relays or other control devices.

PLCs have a modular structure consisting of inputs, processing units, memory and outputs. They can be programmed using specific programming languages, such as ladder language, FBD (Function Block Diagram), or other logic-based languages.

 

Supervisory systems

Supervisory supervisory systems play a crucial role in industrial automationallowing monitoring e control control of complex processes.

Supervisory systems, also known as SCADA (Supervisory Control and Data Acquisition)are software programs that provide a visual interface for monitoring, controlling and interacting with industrial processes in real time.

These systems allow operators to monitor the status of machines, processes, production flows and other relevant parameters.

Industrial networks

Industrial industrial networks play an essential role in the efficient communication between devices and automated systems in an industrial environment.

They allow quick change e reliable between sensors, actuators, PLCs, supervisory systems and other automation components. This is crucial for maintaining synchronization and coordination of operations in a complex industrial environment.

 

How to implement industrial automation in your company

The successful implementation of industrial automation in a company requires careful strategic planning and a systematic approach. 

We've listed the key steps to guide the process of a successful implementation.

Make a diagnosis of the current situation

Before starting any process of implementing industrial automation, it is essential to fully understand the current operating situation. This involves evaluating existing processes, identifying problem areas e setting clear goals for automation.

Map out current processes, documenting them in detail, from production to quality control and even logistics. This helps to identify points of inefficiency and bottlenecks.

Identify the main challenges facing the industrial operation, such as production delays, quality errors, high costs or the need to increase production. Use historical data, performance metrics and reports to understand where the greatest inefficiencies are occurring and which processes need improvement.

 

Define automation objectives and indicators

Defining clear objectives is crucial to the successful implementation of industrial automation. Objectives provide a clear direction for the automation process and help measure progress. In addition, establishing performance indicators (KPIs) will make it possible to monitor the impact of changes and evaluate the achievement of goals.

Also make sure that the objectives are measurable and quantifiable. For example, instead of simply aiming to "increase efficiency", set a specific target, such as "increase productivity by 20% over the next 12 months".

Another extremely important point is to ensure that the automation objectives are aligned with the company's overall strategy. Automation should be seen as a way of achieving the organization's overall goals.

 

Choose the right partners and suppliers

The choice of partners e suppliers plays a key role in the success of implementation of industrial automation.

Reliable partners and quality suppliers can contribute significantly to the development and successful execution of the project.

Carry out detailed research to identify partners and suppliers who offer the automation solutions you need. Assess their reputation, track record of successful projects and the quality of their products.

Choose partners and suppliers who have proven experience in the industry and the relevant technologies. An experienced team can guide you through best practices and avoid common pitfalls.

Ask for references or recommendations from other companies that have worked with the same partner or supplier. This can provide valuable information about the quality of the service provided.

Train and empower employees

The implementation of industrial automation is not just about technology, but also about empowering your staff to deal with the changes and effectively operate the new systems. Proper training is crucial to ensure that everyone understands how to use automation technologies effectively and maximize the benefits.

Some factors to consider are assessing the current skills of the team and identifying the knowledge gaps that need to be filled in order to operate and maintain the automation systems.

Create customized training programs that address the specific needs of the team. This can include technical training on automation technologies as well as practical training on day-to-day operations.

Combine theoretical training with practical training to ensure that employees understand both the concepts and the actual application of the technologies.

Include staff in the training process, encouraging participation and knowledge-sharing among employees, and offer support after training, allowing employees to ask questions and receive guidance as they apply what they have learned.

Monitor and evaluate results

After the implementation of industrial automationit is essential to monitor e evaluate results continuously to ensure that the objectives set are being achieved.

Constant monitoring helps to identify opportunities for improvement and to adjust strategies as necessary.

Remember the performance indicators (KPIs) and start collecting relevant data for each of them.

If you have implemented supervisory systems and industrial networks, use them to collect real-time data on the automated processes and regularly compare the data collected with the objectives set. This helps determine whether the automation is achieving its intended goals.

Identify any deviations between the current results and the objectives. This helps to find areas that need adjustment or improvement. If the results are not in line with expectations, carry out detailed analyses to identify the root causes of the problems.

Based on the analysis, implement improvements and adjustments to the automated processes. This may involve changes to configurations, optimizations to algorithms or adjustments to operation.

 

Conclusion

Industrial automation has emerged as a powerful catalyst for efficiency, productivity and innovation in today's companies. Throughout this article, we explore the key technologies driving this quiet but powerful revolution.

Let's remember that industrial automation is not just about machines and systems; it's about enabling companies to achieve their goals in a more effective, sustainable and competitive way.

We at Cast group believe in the power of Industrial Automation to transform different types of business, impacting on the evolution of Industry as a whole. 

That said, in 2023, we will become a systems integrator Rockwell Automation through the PartnerNetwork™the multinational's partnership program, and we are now a Rockwell service provider

Are you faced with the challenge of automating your factory? 

Become our client and join big names such as Anglo American, VALE, FIAT, Cemig, Copasa and Banco do Brasil, which already have our solutions.