Asset Management Software to Address PLC Challenges
Programmable Logic Controllers (PLCs) play a critical role in industrial operations. These sophisticated industrial computers are designed to control and automate manufacturing, processing and safety critical applicationscapable of handling tasks such as monitoring sensors, and executing repetitive process operations. Essentially, they are robust and efficient process controllers following strict logic sequences to operateequipment (hence the term logic controllers) and can have a significant impact on efficiency, reliability and operational costs.
PLC Asset Management Challenges
PLC technology is the dominant controller type employed on manufacturing and processing for safety critical or repetitive operations. PLC software, based on ladder logic software has many reliability and resilience benefits compared to computing software but specific hallenges can arise in operations asset management. Understanding these challenges is crucial for maintaining the intended efficiency and reliability of your processing systems. So, what are the key challenges in PLC asset management?
Processing Drift. PLC programmers tend to focus on process control to avoid deviations from the intended operation becoming failures that pose risks to equipment, property or human life. PLC software accuracy relies on the accuracy of instrumentation inputs and machine process outputs. As instrument accuracy drifts and or processing components wear the PLC is not tracking deviation from the process blueprint. As the equipment ages, processing efficiency declines until the input or output errors hit setpoint limits.
PLC controllers process thousands of parameters, that is their strength compared to computing systems, but have very little onboard memory. History of the exact logic sequences are lost.
Data Security: Data security is a prevalent issue, with cyber attacks on the rise and becoming increasingly sophisticated. PLCs are regarded as soft targets and typically not connected to the internet. As PLC units control safety critical equipment and in that process process vast amounts of data they are goldmines of potentially available data. To access this datamine via the internet requires extensive cloud security measures must be used to protect sensitive information and avoid external bad actor attackers gaining control of the processing safety guard setpoints
Data Accessibility & Storage: Data accessibility and storage can also be a challenge since PLC software generates a vast amount of data but have no onboard method to store data. Remote (outside of a local area network) data access is limited on safety critical systems to telemetry, restricting the volume of data transmittal.
These challenges need to be addressed to get the most out of PLC systems. Asset management solutions can help with this and play a key role in enhancing operations management.
The Role of Asset Management Software
Asset management software is designed to help businesses in any industry, manage and optimise physical and digital assets throughout the lifecycle. Software usually comes with a range of features that enable this, including:
Maintenance scheduling: Automate and optimise maintenance schedules.
Data integration: Integrate data from various sources for data analytics projects.
Performance monitoring: Monitor equipment performance in real-time so that issues can be identified and addressed promptly.
Compliance and reporting: Ensure operations meet regulatory requirements and generate necessary reports.
Cost management: Track expenses related to industrial operations and maintenance, allowing for budget optimisation.
Lifecycle management: Manage the lifecycle of industrial equipment to ensure that assets are used effectively and cost efficiently.
PLC Asset Management Advances
Integrating asset management solutions with your PLC systems can bring a range of advantages for an industrial business and address the challenges mentioned above. However, you need to embed memory into the PLC network to capture, organize and store that data and to have cyber secure transmittal methods to access and combine asset islands into a system processing data set.
Improved Data Insight: Converting raw PLC data into actionable insights via asset management software allows decision-makers to optimise processes. Data analytics reveals trends and patterns that might have otherwise been missed, allowing for informed decision making that can improve efficiency.
Streamlined Operations: Asset management software can be integrated with PLC networks, allowing for real-time data that can be used to streamline business operations for higher levels of efficiency.
Long Term Monitoring: Long term tracking of operational parameters via predictive analytics enables the identification of patterns and trends and the planning of preventative maintenance activities. By anticipating issues before they become major problems, you can prevent downtime and extend the lifespan of your industrial equipment.
Real Time Data: This software allows for data to be captured and analysed in real time, which means that timely corrective action can be taken.
Cost Efficiency: Integrating this software with your industrial computers eliminates the need to invest in extra instrumentation, helping to lower costs. Additionally, uncovering previously hidden data could lead to further cost savings by optimising resource allocation and eliminating unnecessary costs.
Asset management software can significantly enhance operations management by providing a holistic view of operations and can assist with data handling, security and process optimization. By helping to overcome some of the challenges involved in PLC management, businesses can get the most out of their industrial computers to improve overall efficiency, detect issues early and minimise downtime.
Get in touch with the team today if you want to learn more about our embedded data, edge processing and cyber secure data transmittal solutions and how they can enhance operations management and overcome the key challenges associated with PLC software management.