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5 Ways to Achieve Highly-Efficient Operations and Drive Savings and Productivity

June 15, 2022
Businesses are always looking for ways to elevate the level of efficiency and productivity in every step of their processes. They understand that real improvements to their profitability can be done through optimizing complex industrial processes at the source. This has led many companies to turn to programmable automation controls and optimization software.

While these traditional tools, such as Programmable Logic Controllers (PLCs) and Programmable Automation Controllers (PACs), are more commonly used in the market, the growing industrial internet era is creating space for analytics tools to evolve, supporting the increasing need for flexibility when optimizing processes.

Check out these five ways to achieve operational efficiency and drive savings and productivity with the help of data analytics:

Improve device and equipment integrations
Data and analytics can help tie equipment to business objectives and performance. The successful integration of devices and equipment with business automation tools makes it easier to develop condition-based maintenance strategies and, in turn, improve Overall Equipment Effectiveness, or OEE.

There is also merit in making use of condition-based maintenance versus the usual scheduled or calendar type of maintenance. This works on many types of equipment, especially those that perform a consistent task, such as a pump, motor, compressor, or fan.

Take advantage of high-performance computing at the Edge
Advancements in processor technology are increasing the performance of industrial devices, leading to an expanded and often multi-purpose role for edge controllers. One way to maximize the power of this new generation of outcome-optimizing devices is by virtualizing programmable automation control systems.

These hardware visualization techniques provide a new approach to the optimization of control processes, optimizing them by allowing analytics and optimization applications to run at the machine level without directly impacting or hindering deterministic, real-time control.

Harness the power of real-time data
New generation programmable automation control systems provide enhanced productivity, efficiency, and security to any operation through capturing and analyzing data and using said data in real time to adapt to a wide range of variables.

Edge technology also has an important role in real-time data processing: addressing latency issues, which is crucial for applications where even a split-second delay in sending and processing data can hinder an operation.

Use local web-based HMIs
Human-machine interfaces (HMIs) can access data using a web browser or mobile device, giving HMIs the ability to access them anywhere. This can reduce a facility’s device footprint and support a new generation of workers who usually spend most of their work hours physically present in the plant. Facilities can also develop a web-based application which can further cut costs and save time during development and troubleshooting.

Monitor and diagnose remotely
Keeping track of the state and health of different systems can be challenging for OEMs, especially when their scope involves large fleets or numerous remote assets. With the help of connectivity, OEMs need not physically check on their systems unless necessary. They can maximize the use of real-time information to gain insights on their operations remotely. This way, OEMs can be proactive at servicing equipment when early signs of failure are seen, rather than when the equipment has already failed. This asset reliability service can also be managed by NECI.

NECI can help you harness the power of data analytics to achieve operational excellence. Click here to learn more about our Digital Transformation solutions.