When properly programmed, I&C systems can be the brains of your operation. With the advent and affordability of new technology, this discipline is changing. These changes offer the potential for significant benefits, including increased efficiency and cost reductions.
There are numerous ways that I&C systems can now be customized to accommodate project specifications: size, mounting, environment, materials, accessories, ratings and more. No matter a project’s unique requirements, I&C systems can be designed, modified and tweaked to match them and deliver superior performance. This level of customization, paired with evolving technologies, allows for turnkey, precise solutions that enhance efficiency—lowering the potential for costly errors, improving production or operations and creating long-term cost-savings for owners and operators.
Making Real-Time Improvements
Most recently, I&C software and hardware have become more reliable, flexible and user-friendly, improving the connectivity between process equipment and instrumentation. These advancements help provide facility operators with the right information at the right time. In real time, operators are given control over multiple elements of their production process, such as personnel, machines and support services.
In Fullerton, California, for example, Alcoa Fastening Systems was able to take advantage of I&C system enhancements. Dealing with dated systems, the company upgraded its wastewater treatment plant to give operators complete control and monitoring capabilities from within the control room, alarm notification via dial out, and historical data necessary for identifying the source of process problems quickly. Making these improvements solved operational issues caused by burnt out lights, loose wires, lack of information in emergency situations, and no historical data collection. Alcoa’s operators are now empowered to act proactively when issues arise.
Taking Control of Costs
Tech-based enhancements have led to a variety of cost-related benefits for I&C-managed facilities:
Collaborating to Calibrate Success
Teamwork is a cornerstone to creating well-functioning I&C systems that realize savings such as those listed above. Synergy between engineers, technicians and programmers—particularly on design-build projects—from concept design through 100 percent completion and startup is key to achieving high-quality results. Project teams should work as an integrated unit as early as possible. Understanding the costs and benefits associated with all alternatives will help the team produce the right I&C design, fit for purpose and thoughtfully tailored to meet specifications. Through continuous interfacing and collaboration, I&C engineers are also able to react quickly to design and scope changes as they arise and adjust systems accordingly, improving ease of operability and reducing wasted resource hours.
Chris Aviña, Instrumentation and Controls Manager, DBIA, has more than 20 years of electrical and I&C experience. He has served as the I&C project manager, control panel designer and estimator for various I&C system projects for water and wastewater treatment facilities and industrial projects. His work experience includes projects in Arizona, Arkansas, California, Denver, Florida, Guam, Nevada, South Carolina, and Washington state.
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The intelligent use of process control technologies within the manufacturing process has beneficial effects far beyond the traditional aspects of dimensional quality assurance.
If your machines are overloaded then you may be facing a sizeable capital investment to make up the shortfall. Either that, or a large sub-contract bill. Or worse still, you might find yourself turning away profitable work.
But what if you could extract more throughput from the machinery you already have?
Are you reliant on skilled operators to keep your machines running, leading to high labour costs and a substantial overtime bill? Or perhaps your engineers are tied up with shop support rather than working on new processes.
What impact would lower direct labour and shop support costs have on your competitiveness?
Scrapping parts is always painful - it's a waste of time, effort and materials. Similarly, rework and concessions lead to late deliveries, fire-fighting and overtime.
If you could largely eliminate such quality costs, how would this help your responsiveness and profitability?
Customers are demanding ever more complex work, whilst regulations are driving greater traceability throughout the manufacturing process. Are your capabilities keeping pace with the needs of your market?
Do you need a cost-effective way to boost the capability of your machining and inspection processes?
Want more information on process control instruments? Feel free to contact us.