Today’s process automation projects present unique challenges for project managers and their teams, who have found them more difficult to execute than other types of projects. Why is that? Let’s review some key factors based on my own years of experience as a project manager and conversations with my peers.

Real-world scenarios need to be taken into account when designing HMI. There should be no unnecessary functions that can potentially cause safety issues like they did for an airliner at Nashville International Airport in 2015.

Milk standardization systems have traditionally been stand-alone systems provided by original equipment manufacturers (OEMs).  Currently, many of these installed systems contain components which are obsolete or have reached their end-of-life, and need to be upgraded or replaced. These systems are proverbial “black boxes” and are islands of automation which are not integrated into a facility's main control system. Many of these existing systems have paths forward that are available from the OEM providers. In some cases, these upgrades range from new stand-alone control systems which may include new instrumentation and process equipment to entirely new replacement skids.

In 2015, an average U.S. dairy fluid milk plant processed 109.5 million pounds of milk. On average that same plant encountered an average product loss of 2.5%.

Product loss can happen throughout the entire process. Milk is left in the tanker or the lines during receiving. Losses occur during water-to-product and product-to-water interfaces during pasteurizing. Overfills contribute to produce lost in the filling area. Additional cost savings can be realized in wastewater reduction when this milk stops going down the drain. 

Sequential control programs can be an easier and more streamlined if the engineer ensures that the sequences have the same architectural model. Three tips are highlighted to make the process easier.

Manufacturing execution system (MES) solutions require a great deal of planning and testing to be successful. Everyone invloved must be on the same page.

Programming is a big portion of process control and following principles such as customer collaboration, responding to changes, and emphasizing individuals and interactions can help a great deal in creating a successful project.

Programming is a big portion of process control. Consider these four principles for effective and efficient program development:

Batch implementation projects are much more likely to be successful when a thorough front end engineering design (FEED) is performed and if several questions are addressed during the implementation process.

A batch (ANSI/ISA-88) implementation is appropriate for many types of process and industries. If it is appropriate for your project, there are many different choices and decisions that need to be made during the planning stages that can dramatically alter the complexity, cost, and final implementation utility. As with many projects, batch projects are much more likely to be successful when a thorough front end engineering design (FEED) is performed. There are several key questions that FEED should address during the project.