How Plant Automation Works In Industries

Industrial revolution during the 18th century was characterized by wide use of human labor to operate machines. While this was not necessarily a problem, the cost of production was very high due to labor charges. Consequently, profit margins were also very low. On realizing the need to have a better solution, manufacturers had to look for alternative solutions, and automation won their hearts. Plant automation meant that fewer workers were needed to operate machines because things happened automatically.

Automated processes do not rely on human input. Sensors detect the state of the manufacturing process and respond accordingly. The number of supervisors or machine operators needed in these systems is quite low. Factories can also run non-stop 365 days a year, except when routine maintenance is needed.

The ultimate goal of any firm or industry is to maximize profits by minimizing labor costs through reduction of machine operators and supervisors. This is easily achieved through automation, or replacement of human labor with machines and sophisticated computer programs. This is beneficial in that it minimizes production costs. This can lead to increased wages for employees and more profits for shareholders.

Industries in Hudson, WI, can have their machines automated using PLCs (programmable logic controllers). PLCs are industry specific computers which can be programmed with special instructions like switching on and off of motors, solenoid valves and other actuators. These controllers vary in size, processing power and functionality, and this is what determines their possible applications.

Since PLCs are normally used in small plants, huge plants like vehicle factories need bigger controllers. SCADA, standing for supervisory control and data acquisition, is different in that there is a centrally located computer which controls all the machines in the process. It works through field modules which take-in inputs and give output signals. Huge plants like vehicle assembly lines and oil refineries need this type of system.

The capital investment that goes towards automating an industry can be huge, but it can be rewarding in the long run. This process normally entails acquiring equipment to use, installation of the controllers and computers, programming of PLCs and finally commissioning of the automated process. A few technicians and at least one engineer are needed to supervise the whole process. Once operational, the system becomes less prone to breakdowns.

Automating a process in a factory for its long term benefits is highly recommended. The old way of doing things should be avoided. Key industry players in manufacturing and processing, should adopt new technologies which are known to be very efficient and cost effective. These changes will make it possible for old factories to be transformed into modern assembly, processing or manufacturing plants. Examples of the available technologies include DCS, PLC and SCADA.

However much a manufacturer may want to transition into a new-age type of process, there are some cases where automating a system does not make sense financially. For instance, small plants only have a couple of essential personnel. If a PLC or SCADA is installed, the same number of workers may still be needed. Therefore, it will not make any sense to automate the process.

Read more about The Ins And Outs Of Plant Automation.

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