Electricity and Control May 2023

COMMENT

INDUSTRY 4.0 + IIOT

energy + information in industry

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Automating the right processes – and the best

I note the resilience that so many folk show as we navigate ourselves away from the edge of the precipice. In a meeting the other day a clear call was made for better automation of specific processes. The point being made was that repeatability and reliability are both improved by automation. Naturally, the next logical intervention is to decide whether the automated process would be improved by adding a level of control. Although we always assume that we fully appreciate the role of automation and control, we do tend to forget some fundamental elements. For instance, we can automate pretty much any process – but the most critical element is to be certain that we are automating the right thing! What do we mean? There are many instances where poorly thought-through or inefficient processes have been automated. The key to automation is therefore first to optimise the process, and then to automate that. Many organisations suffer the consequences of having automated very bad processes. But the process is automated – so everyone feigns happiness. Then we can consider control – the ability to measure and compare and modify the process on the fly to ensure that the output is the desired one. Control therefore requires feedback and the ability to ensure that the final output meets the set input. Automated systems may or may not do that for us. Control also means we can set different requirements,

and the process can be adapted to meet these. There is much one can say about automation and control – but for now I think it pertinent to emphasise the first point I made: that is the importance of automating the best process – a process already designed and optimised to deliver the best results. I recall not long ago (oddly, at a time when Eskom was strongly promoting energy efficiency …) when wastage of material and energy was not really carefully considered in so many situations. I also recall an automated system stamping steel – where some gentle nudging (repositioning where the next stamp was made) resulted in significant material saving. And with that, of course, come the obvious benefits of energy saving and cost saving – and the manufacturer gets more bang for its buck – so to speak. So, in these challenging times, perhaps we should start by reviewing what we can automate – and once we’ve identified that, the first step must be to consider carefully how we can optimise the process before progressing to automate it. And when we do, we must be sure to select the best systems and components to suit the respective plant operations, the most appropriate software, hardware and communications connections, and thus develop an optimum integrated automation system.

Editor: Leigh Darroll Design & Layout: Darryl James Advertising Manager: Heidi Jandrell Circulation: Karen Smith Editorial Technical Director: Ian Jandrell Publisher: Karen Grant Deputy Publisher: Wilhelm du Plessis

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Electricity+Control is supported by

Ian Jandrell PrEng IntPE(SA), BSc(Eng) GDE PhD, FSAAE FSAIEE SMIEEE

The views expressed in this publication are not necessarily those of the publisher, the editor, SAAEs, SAEE, CESA or the Copper Development Association Africa

MAY 2023 Electricity + Control

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