People have been saying for quite some time now that the future is just around the corner. Well, it’s safe to say that it has indeed arrived. In factories, technology now makes it possible to digitize a large portion of operations, and it’s even possible to resolve production issues remotely, in real time. Industrial control systems, such as SCADA, are proof of this.
Whether you’re a project manager, maintenance manager, supervisor, production manager, process manager, or the director or owner of a manufacturing company, this article is for you.
My name is Julien Cyr, president of Cyr Automation. From a very young age, I was fascinated by the world of electronics, spending my time playing with remote-controlled cars. Even back then, I was building up the technical knowledge that would soon shape my career. With a degree in electromechanics and certified as an electrician, I continued my training with a major contractor in the field, where I was quickly entrusted with projects in the control division and became a shareholder in the company. Through this document, I offer you the benefit of my many years of experience in industrial automation, programming, and integration.
Find out how you can access your factory’s production data and reports in real time, and how you can influence production activities even when working remotely. You’ll be able to monitor operations, receive diagnostics, and take action more quickly—among other benefits—to schedule maintenance and address machine downtime.
You’re probably asking yourself the following questions: Sure, but how? That all sounds great, but at what cost? Will I get a satisfactory return on investment? Here’s exactly what you need to know about SCADA, its applications, benefits, and limitations.
What are the main questions asked by customers considering a SCADA system?
In most cases, business owners who come to us to learn about real-time data acquisition and monitoring systems already have equipment that allows them to collect data from specific machines independently, for a specific purpose. They are looking for a way to gain better control over their operations and improve coordination between machines, and they need to obtain a comprehensive overview of their facilities.
During our discussions, the client wants to know right away how they can monitor their factory. Will they have only local access, or will they be able to intervene remotely via a web interface? As a manager, in addition to wanting to monitor the various stages of the manufacturing process, it can be very helpful to obtain information on how operators are managing the production line.
The SCADA system allows users to manually control the various machines in a factory, as well as to set up automatic sequences based on predefined criteria or parameters. Customers will also have questions regarding the various alarms that can be integrated into the system to prevent machine breakdowns, production stoppages, or worker injuries.
For example, the manager could be notified of a malfunctioning valve or an overheating motor. These alarms can be configured based on the normal operating parameters of the various machines, as well as production history. Alarms can also be set up to trigger when there are drops in production, allowing the manager to investigate why operations were affected at a specific time. A comprehensive report can then be generated to obtain answers quickly.
SCADA provides a virtually inexhaustible source of real-time data, enabling precise analysis of the various components of the production line so that less efficient areas can be easily identified and the necessary adjustments made.
What are the concerns regarding the SCADA acquisition?
IT System Reliability
One of the customer’s main concerns is the reliability of the IT system on which the control system is based. Could a breakdown or malfunction disrupt production operations or, worse still, bring the plant to a complete standstill? That would be a nightmare scenario that must be avoided at all costs.
To prevent IT issues from affecting the machinery, the various data acquisition sequences are managed by external PLCs, and the SCADA system is deployed on rugged industrial computers that have a reliability rate far superior to that of consumer-grade devices. The system is also integrated to ensure it does not interfere with the manufacturing process. The only issue related to malfunctions is the interruption of data logging.
To ensure that data collection continues as much as possible, two SCADA systems are often used in a redundant configuration; this means that if one system fails due to a Windows malfunction or a hardware failure, the second system takes over.
Return on Investment
Control systems offer a wide range of possibilities, but they represent a significant investment. Many customers have legitimate concerns about the potential return on investment. After discussion, we sometimes conclude that, despite all the benefits of SCADA, it is not the right fit for a particular company.
More often, however, we will reduce the acquisition cost by, among other things, eliminating redundancy or removing options that enable 3D visualization of plant components. This allows for a faster return on investment, and these options can be added in a second phase.
Risk of hacking
Many companies fear becoming victims of cyberattacks. They worry that malicious hackers might gain access to their data or, worse still, disrupt the operation of their factory equipment.
This concern is entirely legitimate, as there have been documented cases of control system hacking. There are two effective safeguards against hacking. The first is the use of a highly advanced industrial firewall that strictly limits what can enter the system. The second is to run the SCADA system within a local network. The data is then duplicated and made available in a read-only cloud. This ensures that it is impossible for a hacker to interfere with the customer’s network.
Resistance to change
In some organizations, resistance to change among frontline workers can become a cause for concern. Some believe that a monitoring system gives their boss access to far too much data about the quality of the final product—and, by extension, about their work. The shift to more advanced technology can also be daunting for older workers who are reluctant to learn a new way of doing things.
It’s important to note that you don’t need a degree in programming to operate the SCADA system; knowing how to use a computer is enough. But for some people, this can still be a challenge and a source of stress.
To address this concern, the addition of highly realistic 3D renderings of the factory makes it easier for everyone—including new employees—to find their way around. We cannot stress enough how important it is to plan for this major change by involving your employees closely in the process to ensure their understanding and buy-in.
End of service
What would happen if Cyr Automation were to go out of business? Would the investment become worthless? Would it still be possible to receive support for system operation and updates?
We use a recognized programming platform to implement the SCADA system and, if necessary, provide the client with a list of source code so that they can hire a programmer of their choice to address any issues that may arise. It is important to note, however, that once the software is fully implemented, it requires very little maintenance.
We can even provide training to the company’s employees so they can make certain adjustments or even add new equipment to the SCADA system during an acquisition. This ensures greater autonomy.
How does it work?
SCADA (Supervisory Control and Data Acquisition) is software that is custom-developed to meet the specific needs of the company that purchases it. It includes a schematic representation of the plant, along with models of various pieces of equipment and the flow of production activities.
A real-time data acquisition and control system is a large-scale remote management system capable of processing a large number of telemetry readings in real time and remotely controlling technical installations. It is an industrial technology that includes hardware, controllers, networks and communications, a database, I/O management software, and a human-machine interface.
Field data from the SCADA system is centralized on a central processing unit. This unit enables remote operation and data collection. Field control is carried out by automatic measurement and control instruments or by programmable logic controllers. The information is then transmitted locally or made accessible via the Web. It can then be viewed in real time using an external computer or a mobile device.
The software used by Cyr Automatisation is a Phoenix interface to which programming elements are added as needed.
What customization options are available?
The SCADA software is custom-developed to fit the company’s physical layout and specific operational needs. Control panels are installed (or utilized if already in place) at each machine in the facility, and operational data is collected and sent to a customized database with secure access.
Every project is unique!
Who is SCADA designed for (and who is it not designed for)?
SCADA is primarily suited for companies of a certain size that often have measurement instruments installed on some of their equipment. These companies seek to take their facility automation processes to the next level and gain a comprehensive overview of their production line. They are customers who want to obtain detailed data that will enable them to make the necessary adjustments to optimize their production operations.
Conversely, the control system is less suitable for small businesses that have limited machinery and can already obtain a fair amount of useful information using one or two control panels. In such cases, it would be more difficult to justify the implementation of the IT infrastructure, as well as the minimum investment required to implement a SCADA system (estimated at at least $60,000). In these cases, it is possible to obtain an overview of the plant’s operations without having to connect everything together.
Another option
For such companies, it might make sense to install a touchscreen that compiles the data rather than opting for a large-scale system. This solution offers fewer options—it does not include a 3D environment and does not go as far in data collection, for example—but it is much less expensive and allows most monitoring objectives to be met.
What are the pros (and cons)?
Benefits
Here is a list of the various benefits associated with implementing an effective monitoring system within a company:
- Saves time (a lot of time);
- Remote, real-time monitoring of plant operations (production tracking, alarm management, monitoring of equipment shutdowns and startups, etc.);
- Helps new employees understand and adapt to their new roles;
- Makes problem-solving easier;
- Provides an overview of the company’s activities;
- Attracts younger professionals interested in the IT field;
- Enables easy access to data and the generation of detailed reports;
- Allows you to compare data over time to quickly assess increases and decreases in performance (historical data);
- etc.
Disadvantages
Here is a list of potential drawbacks that may arise when implementing a SCADA system:
- It represents a fairly costly initial investment, which is not suitable for all businesses;
- Requires a significant amount of time for design, delivery, and installation (usually about 2 to 3 months);
- It also requires a labor investment on the part of the client;
- May be met with resistance to change from long-time employees who are reluctant to alter their established ways of doing things;
- Requires the implementation of a large-scale infrastructure, which entails training costs, learning curves, and additional administrative work. Plans must be made to update production systems;
- etc.
Are there any alternative technologies or systems to SCADA?
There are indeed ways to help businesses gain some control over their facilities through systems with a more limited scope, such as installing a touchscreen (as suggested earlier). While this solution may be effective for smaller businesses, it deprives customers of certain data management options that can be particularly useful.
These systems often do not support 3D visualization (or only to a very limited extent), collect less comprehensive data, and may not offer remote control capabilities. This solution is often a temporary measure while the company is growing. The investment can quickly become redundant (a waste of money) if the customer decides, after a few years, to implement a SCADA system at its facilities.
It is also possible to implement large-scale SCADA systems that require investments of several hundred thousand dollars, including additional features. This solution is generally reserved for large companies.
Some SCADA systems operate entirely in the cloud, which entails recurring maintenance costs. Others offer enhanced aesthetics and charge higher prices accordingly.
Important: Don’t fall into the trap of entrusting the implementation of your system to a firm with only one or two programming staff members. The code included in your SCADA system must be simple, proven, and thoroughly tested to prevent errors or certain actions from compromising your operations or data collection over the long term. Be wary of programmers with little experience or who work alone. If they are no longer able to support your system for any reason, you will find yourself in trouble, lacking the expertise needed for your SCADA system.
Since there are many technologies on the market that may appear similar but offer very different options and performance levels, it is essential to conduct a thorough analysis of the situation in order to choose the solution that best suits your needs—not only in the short term, but also in the medium and long term. We cannot stress enough how important it is to choose a specialist who is familiar with the various technologies available and who can offer you a solution that effectively meets your current and future needs.
What factors influence costs?
Implementing a SCADA system in a company requires a minimum investment of $60,000. There is a basic cost associated with setting up the infrastructure: purchasing the computer, initial programming, etc.
The price will then fluctuate depending on:
- The number of pieces of equipment to be inspected;
- What the customer wants in terms of features (alarm setup, types of data to be collected for reports, complexity of the sequences to be programmed, complexity of interactions between devices);
- Quality and level of detail of the visuals to be included;
- Regarding the cost of the SCADA license. At Cyr Automatisation, the license is included in the package, but some competitors opt for an annually renewable license.
Other cost considerations:
- Delivery and installation costs: Installing new equipment (machines and control panels) at the same time as the SCADA system can result in additional costs and a longer timeline.
- System maintenance and update costs: Annual maintenance costs are minimal. However, you should factor in the cost of migrating to PC software (Windows), regular updates to the operating system, and certain costs associated with IT security.
- Training costs: Depending on the size of the system being implemented, training for the team should be scheduled to last anywhere from a few hours to a few days.
- Warranty: Cyr Système offers a one-year warranty covering parts and labor for any issues not attributable to normal wear and tear of the infrastructure.
- Resale value / product depreciation: Once installed, the SCADA system can operate for many years. All that is required is to update it regularly and replace the computer on which it is installed as needed.
- Spare parts: No spare parts are required for the system itself, provided that the SCADA system is configured with redundancy. However, spare parts may be needed for repairs to the control panels.
Automation and the shift toward Industry 4.0 are essential steps for the vast majority of manufacturing companies in the short and medium term. To remain competitive in the face of a labor shortage, it is more critical than ever to maintain optimal control over operations in order to gather actionable data that enables precise adjustments to various elements of the production chain.
Implementing a SCADA system is a significant investment, but you can expect an excellent return on investment. It will give you real-time access to your production data and provide reports that allow you to compare your current results with past ones. You’ll also be able to remotely control your equipment to prevent breakdowns or set up alerts to avoid machine downtime.
In short, the possibilities are endless, and you’ll see a significant boost in productivity. You’ll be able to accomplish more with the same number of employees.
While the control system offers a world of possibilities, it can also be difficult to navigate. Which options are right for my business? Do I need 3D modeling or detailed reports? Is my friend’s son, who’s a programmer, capable of effectively implementing such a system?
To gain a clearer understanding, we recommend consulting with a team that has advanced expertise in robotics, computer science, and industrial programming. They will be able to provide you with expert guidance throughout your automation project. Work with a full team of programmers who will manage your control system from design through programming.
If you’d like advice, assistance, information, or a quote, come visit us at 24 Beauchesne Street in Warwick, call us at 1-844-358-6035, or email us at info@cyrsysteme.com.
Example of a SCADA industrial control system used to manage batching operations in a polymer plant.
An example of a SCADA industrial control system used to manage a process in a petrochemical or water treatment plant.