One of the most significant issues I encounter in automated plants is the absence of essential program documentation and drawings. These are crucial for repairs and modifications. However, many owners, managers and even maintenance personnel often undervalue electrical and mechanical schematics.
The lack of documentation can severely extend downtime during repairs. As a system integrator, the lack of proper documentation often forces us to reverse-engineer solutions, which is time-consuming and costly.
In many cases, the absence of documentation leads to a thorough process of manually tracing wires and drawing out system schematics. This scenario is especially challenging when dealing with long wire runs and complex systems. For example, equipment purchased from the used market often lacks proper documentation, creating hidden costs for future maintenance.
To address this challenge, I recommended maintaining a comprehensive inventory of all documentation to ensure it is consolidated and protected. Modern solutions include storing documentation in PDF form within human-machine interfaces (HMIs) and embedding descriptive documentation directly into programmable logic controllers (PLCs).
These solutions are not failproof and still require diligent backup practices. If you lose the program and don't have it stored elsewhere, you're facing significant downtime. That’s why proper documentation storage and regular backups are essential business practices.
My tip: Establish a rigorous documentation protocol. Ensure every automation project includes detailed schematics, wiring diagrams and program documentation. Regularly update these documents to reflect any changes or upgrades. Utilize digital documentation tools that allow easy access and updates, ensuring the most current information is always available.
Understanding the plant environment
Plant personnel may lack a thorough understanding of their operational environment, which includes factors such as temperature, humidity, moisture, particulates and corrosive chemicals. This knowledge gap can lead to improper equipment selection, installation issues and accelerated wear and tear on automation systems.
Heat is the biggest enemy of electronics. Some professionals think that for every 10 degrees above room temperature, the lifespan of industrial electronics is cut in half.
Dust, water and corrosive chemicals also pose significant threats. Lack of dust control is frequently caused by design flaws, while water ingress, especially in wash-down environments, can be disastrous for electronics.
To mitigate such risks, plant owners and engineers must ensure proper enclosure and cooling practices. Stainless steel enclosures, for instance, require careful consideration due to their poor heat dissipation properties. Another factor to consider is that modern enclosures must be resistant to the caustic cleaning solutions used in many hygienic environments.
Using proper gaskets and sealants and avoiding top penetrations in enclosures are essential practices. Conformal coatings on circuit boards, offered by leading PLC manufacturers, can also provide additional protection against corrosive environments.
My tip: Conduct a comprehensive environmental assessment before selecting and installing automation technologies. Use sensors and monitoring tools to gather real-time data on environmental conditions. Train plant personnel on the importance of these environmental factors and how they impact automation systems. Regularly review environmental data to anticipate and mitigate potential issues.
Connecting obsolescence with unplanned downtime
Many plant managers fail to recognize the link between obsolete equipment and unplanned downtime. As components age, their reliability decreases, leading to unexpected failures that can halt production. Proactive management of obsolescence is essential to maintaining continuous operations.
It's not uncommon to still see DOS-era technology on the plant floor, even though the office equipment has long since been updated. This disconnect can result in frequent breakdowns and a lack of compatibility with modern systems.
Modernizing plant technology is not just about updating equipment but also about adopting proactive maintenance practices. Advanced PLCs and HMIs offer improved functionality, better integration with existing systems and enhanced durability under harsh conditions.
It's crucial to communicate the benefits of modern technology to higher-level management. While initial costs may be high, the long-term benefits of reduced downtime and increased efficiency are substantial."
My tip: Implement a proactive obsolescence management plan. Regularly review the lifecycle status of all automation components and create a schedule for their replacement or upgrade. Utilize predictive maintenance tools that forecast equipment failures based on usage and wear patterns. Educate plant management on the costs of unplanned downtime versus the benefits of planned upgrades.
