Which industrial automation tools provide real-time monitoring and analytics for process optimization?

Supervisory Control and Data Acquisition is a process control system architecture that uses computers, networked data communications, and graphical Human Machine Interfaces (HMIs) to enable high-level process supervisory management and control. SCADA systems are used to monitor and automate the control processes of industrial automation

PLCs are like the bosses of machines. They watch over them and make sure they work right. You can teach them what to do. And with special computer help, they can find problems and make things work better. They're great at getting information fast to keep everything running smoothly.

SCADA and DCS systems are traditionally used for real-time monitoring and basic analytics, whereas MES, IoT platforms, and AI integration provide more advanced analytics and optimization capabilities. The choice of tools depends on the specific needs and complexity of the operations, as well as considerations such as scalability, interoperability, and cybersecurity.

Na minha experiência o uso dos controladores lógicos programáveis, além de infinitos recursos, nos possibilitam materializar ideias/soluções nos eixos de segurança, produtividade, eficiência operacional, entre outras necessidades específicas dentro cada processo produtivo. Hoje evoluímos muito tecnologicamente, as ferramentas, softwares e recursos se tornam cada vez mais robustas, possibilitando cada vez mais integrações com sistemas adjacentes, otimizando cada vez mais nossos processos.

I actually agree with the fact that PLCs provide real-time control and monitoring of machinery and production. They are reliable compared to it's predecessor (Relay Logic Control). I have used PLC to implement a great deal of plant control and it's very efficient.

The beauty of SCADA systems is the scalability. SCADA can be applied to a small factory floor setup employing a few PLCs and their field devices. SCADA can also be expanded to cover a Wide area network encompassing several facilities spread over large distances. These facilities can be linked to a central supervisory control station via the internet or radio communications.

I totally agree, SCADA systems provide a more organized and comprehensive control and monitoring approach. From remote access of a far away process to efficiency calculation of the process SCADA provides an organization a better viewpoint. Real time graphics give a better visualization of the whole process or integrated processes at a single platform.

Na minha experiência, os sistemas SCADA desempenham um papel crucial na operação, sendo uma ferramenta chave na segurança operacional. Materializa o cenário real da área para um ambiente remoto em cabines de operação e salas de controle. A interface dos dados nos possibilitam diagnósticos mais eficientes e assertivos, acompanhando tendências de falha dos equipamentos, minimizando o tempo para uma tomada de decisão, gerando logs de eventos, e interface de alarmes para equipe operacional e de manutenção. Ferramenta que sempre pode ser aprimorada com as implementações de projeto ao decorrer dos anos, tornando a experiência cada vez mais otimizada e efetiva.

I believe in my own views SCADA is one of the most important thing to consider in becoming an control expert and key attention will be needed to carry out this part of automation software that most play out in one becoming a PLC engineer is very important to that you well understand SCADA becoming building your ladder logic in order to avoid and problems that cannot to easily trace and deal with. One must be good in detail-oriented Electrical Engineer that have supervision knowledge to work with SCADA

SCADA is a sophisticated system designed to monitor, control and collect data from industrial operations. Through driver management you can collect data from different sources without depending on an exclusive manufacturer, making the system more inclusive.

In my experience process plant typically utilise multiple DCS and PLC systems. Integrating multiple systems on a single platform with cross communication is very important, as at times it gets hectic for operators to monitor multiple screens of multiple platforms. This should also be kept in mind during both front end and back end upgradation. Also, with new age AI based historian provided by various solution providers, maintenance planning has become more efficient and cost effective.

In the realm of operations or processes with significant scale, the implementation of a well-designed Distributed Control System (DCS) becomes imperative. This sophisticated infrastructure stands as an invaluable asset for technicians, operators, and plant managers. By consolidating control mechanisms, supervisory functions, and alarm systems, the DCS facilitates streamlined access to crucial data from any corner of the plant, enhancing operational efficiency and responsiveness.

I believe its up to the Electrical Engineer and the company in particular that the DCS work effectively why did I say so because if a company wants the best in having their mechanics running smoothly and effectively they go for the best in terms of discipline and detail oriented for their company to have zero or no problem at all. For electrical engineer you must be sure you know how to operate and create a ladder logic that suits the requirements of the mechanics so that your DCS will not find it a problem working with the entire program that it need to carry.

Atualmente entregamos soluções que tem com base vários sistemas distribuídos, integrações, capacidades avançadas de controle, uma interface amigável e capacidade de diagnósticos. Com isso os clientes obtêm uma análise em tempo real e imediato dos resultados das suas operações.

Na minha opinião, os Sistemas de Controle Distribuído (DCS) são extremamente úteis em processos complexos, onde até pequenas variações podem afetar significativamente as malhas de controle e a interação entre elas para o resultado final. Na minha empresa utilizamos para o controle dos fornos de reaquecimento, onde qualquer desvio poderia impactar na eficiência energética, otimização do processo, consequentemente nos KPIs do processo.

This integration allows you to track KPIs, monitor production progress in real-time, and identify areas for improvement. It's a standard for manufacturing companies. Plus, many MES platforms offer advanced analytics and reporting capabilities, giving you valuable insights to optimize your operations.

Na minha opinião, a integração do Sistema de Execução de Manufatura (MES) conecta o monitoramento em tempo real das atividades da planta, com o planejamento da alta gestão, proporcionando uma perspectiva completa das operações. Isso permite otimizar processos, reduzir desperdícios e responder rapidamente às mudanças de cenário, tornando o processo cada vez mais competitivo no mercado.

This helps you know if you're making progress or not in my own opinion is the analytical aspect that is more important for the manufacturing company have quality important to their desk in order to identify where needs improvement and we need critical improvement so giving it a good amount of time and attention worth the effort.

MES can dive directly to the bottleneck for the Production line, giving the line teams the data they need to improve OEE and tackle the correct issues although sometimes waiting times can be missed as they are not included in the bottleneck calculations

IoT devices and platforms exhibit unparalleled potential compared to PLCs and SCADA systems, provided they communicate via secure channels and protocols. For critical operations and monitoring, PLCs and SCADA systems remain prevalent due to the robust system-level security they offer. If IoT devices are to be used for critical operations and monitoring, implementing robust encryption and authentication mechanisms is paramount.

A Internet das Coisas (IoT) trouxe uma verdadeira revolução à automação industrial, permitindo a integração de dispositivos de diferentes fabricantes em uma rede de gerenciamento central, possibilitando ter dados acessíveis em qualquer dispositivo, e a qualquer hora. Otimizando os processos, melhorando a eficiência, compartilhando as informações de forma confiável e instantânea. A implementação/integração das plataformas IoT em plantas com controladores obsoletos, redes proprietárias de protocolo fechado, ainda é um grande desafio para quem quer melhorar a eficiência dos seus processos, até uma futura atualização tecnológica.

Hoje a integração de outras plataformas, entregam resultados muito resumidos e assertivos. Com a possibilidade de uso instantâneo dos dados e atualização em tempo real.

The many advantages of using IoT: IoT generates vast amounts of data, which can be analyzed for valuable insights. A peek into the heart of your operation’s health and efficiency. Connects devices with ease and with seemingly instant data exchanges. For example … IoT, if programmed to do so, can locate a weak point in your process and utilize all collected data from various locations in the process to find a way to achieve the maximum efficiency and safely implement a fix. The luxury of its effortless remote access and monitoring has a huge advantage over any other system. It can also utilize edge computing, reducing latency and increasing data speed. Also easily aiding in predictive maintenance and process optimization

Believe it or not this is where most electrical technician or engineers miss out because this is what quality your ladder logic and you so be good and understanding this because loT is not good is very very important for the company to know their business objectives and success.

Disagree: While AI sounds cool, using it for process control isn't always easy. Imagine if you have a robot helper at home. Sometimes it might misunderstand what you want, or it could make mistakes. In a factory, AI might not always understand all the data, or it could suggest changes that don't work well. For instance, in a chemical processing plant, AI might misinterpret sensor readings and make adjustments that lead to product defects or safety hazards. Plus, it can be expensive to set up and train AI systems, which can be tough for smaller businesses.

A big problem for most AI integrations is that it can't read the business unstructured data. This is why Prompt Privacy made a Cognitive Engine that can organize and structure petabytes of data, allowing it to be used in Intelligent Process Automation. This allows AI to utilize multiple integrations for analyzation and execute frame worked processes.

The IBA (Integrated Business Architecture) system in a plant is responsible for the overall management and control of the plant. It collects data from various sources, including PLCs (Programmable Logic Controllers), and uses that data to make decisions and control the plant. The IBA system plays a critical role in monitoring the production process, quality control, and safety of the plant. The IBA system enables real-time monitoring of the production process and provides essential data to improve efficiency and optimize production processes. The system can also identify potential issues before they occur, which reduces the likelihood of unplanned downtime and equipment failure.