Today’s new world economy has manufacturers racing toward opportunities requiring growth through expansion and increased productivity while pricing remains flat. The increase in fuel, energy, raw materials and labor prices are offsetting scientific and technological advances applied to modern factory machinery, processes and the workforce.
Manufacturing automation technology solutions offer manufacturers monitoring and alerting applications improving plant manager oversight and response to quality, consistency and cost issues. While top 100 computer and software companies offer solutions in this space, finding a realistic positive ROI offering is daunting with many requiring huge investments in entire systems overhaul or replacement.
“More than any other sector, the chemicals industry is investing heavily in innovation to garner a competitive edge. Ninety-two percent of CEOs in this industry believe that innovation will lead to operational efficiencies and competitive advantage, 13 percent more than all CEOs surveyed.” By Tom Craren, PricewaterhouseCoopers, LLC. (See Figure)
Today’s IT systems are exorbitant purchases requiring a long-term commitment and a finite vision of volume and quality. Unfortunately these solution sets quickly become static when margins shrink and volumes must increase to continue operating in the red. Competitive solutions in this economic environment must show nearly immediate returns on investment by increasing output and improving quality. This requires a lighter and more powerful system that has the following traits.
- Unlimited scalability
- Seamless integration with current systems.
- Low cost fast deployment.
Plant managers and engineers should consider a lightweight approach to their efficiency shortfalls rather than the hefty out of the box system overhaul which may give a pretty picture but not the tailored in depth analysis and alerting needed.
Envision a real time layer over existing systems currently in place. A real time data engine that stands alone aggregating unlimited amounts of disparate data, analyzing it “on the fly” without a database and delivering it to any device in any format for real time machine-to-machine and human response.
The real time data engine would also have unlimited scalability creating an ever growing solutions platform using standard database querying language. The flexibility and power of this automation platform allows for continuous upgrading of machinery, flow process and simultaneously integrates dated systems and disparate devices from diverse manufacturers.
Practical benefits of a real time data engine will include the following:
- Real time big data processing and operational intelligence “on the fly”.
- Real time data enhancement “on the fly”.
- Real time historical comparatives and complex predictive analysis.
Real time operational decisions made in time by machines and humans will reduce downtime, improve quality and increase output.






