OT Assessment for Automation
Published on : Wednesday 07-08-2024
Darshana Thakkar offers a few practical tips for MSMEs embarking on their automation journey.
In the contemporary global industrial scenario, factory automation is essential for maintaining and enhancing a company’s competitive edge. By improving productivity, reducing costs, enhancing quality and providing flexibility, automation enables manufacturers to respond more effectively to market demands and challenges. Furthermore, collecting and analysing data in real time allows for continuous improvement and innovation, ensuring long-term success and sustainability.
Implementing factory automation is not just about keeping pace with competitors; it is about positioning the company for future growth and leadership in the industry.
Factory automation is the cornerstone of Industry 4.0, integrating cyber-physical systems, IoT, and AI to create smart factories.
However, for the traditional manufacturing plant, where almost all the processes are done with conventional machinery and systems, a few key questions spike in the mind of the factory owner, such as:
· Is automation a simple process?
· Can a factory owner do it autonomously?
· What are the strategies for effective transformation?
· Is there any pre-requisite?
· How to prepare one’s factory for automation?
· What are the stages of implementation?
As per the Ministry of Statistics report and program implementation, the contribution of the MSME sector to GDP is about 29%, exports are about 48%, and the manufacturing output of the MSME sector is about 36%.
With such a high manufacturing contribution, the MSME sector needs sustainable manufacturing practices to stay competitive in the global market.
As I am closely connected with many MSME organisations and am part of an Indian MSME ecosystem, I always try to contribute in the best possible way to improve the business practices of the MSME sector.
Considering the need for awareness about automation processes and requirements in the sector, I am sharing crucial details to start with the automation. MSME business owners need to be a little aware even when they plan to hire a third-party automation expert.
If a company wants to start automation in their plant, primarily, they should opt for automation by using a control system – DCS, PLC, or SCADA. However, before deciding, the company must analyse its operation and technology to integrate the process with the control system.
The company needs to arrange an OT (Operational Technology) assessment for a plant as a first step. The company should have a detailed report about the following points to determine investment planning and decision-making:
· Current operational technology
· Availability of data and data connectivity
· Availability of internet connectivity
· Digital readiness of the people, and
· Availability of skilled workforce.
So, the company needs to understand what is available and required. Based on that report, the company can proceed with Requirement planning and create a Request for a Quote for the concern.
The first step in the automation journey is Plant Assessment. When conducting an Operational Technology (OT) assessment to initiate automation for a plant, it is essential to ensure that prerequisites are met and a comprehensive checklist is ready to ensure the evaluation is thorough and effective. Below are some critical prerequisites to consider:
Pre-requisites
1. Define Objectives and Scope
• Determine the specific goals for the automation project, such as improving efficiency, reducing costs, or enhancing data accuracy.
• Define the boundaries of the project. What operations and technologies will be assessed? What are the limitations?
2. Stakeholder Engagement
• Identify and engage critical stakeholders (Management, engineers, operators).
• Prepare a few groups of people comprising management, engineering, and operator-level staff.
• Conduct interviews and surveys with employees and other stakeholders to gather insights and identify pain points.
• If necessary, include experts from various domains such as operations, IT, control systems, and external consultants.
• Clearly define the roles and responsibilities of each team member.
3. Documentation
• List of equipment and instruments with specifications installed in every area of the plant
• Gather existing plant documentation, including process flow diagrams, control system architecture, network diagrams, and equipment specifications.
• Collect past assessment reports, incident logs, and maintenance records.
4. Current System Evaluation
• Evaluate the current state of OT systems (SCADA, PLC, DCS, HMI).
• Compile a list of existing technologies, including hardware, software, and control systems.
• Assess existing levels of automation and control systems.
• Gather data on current processes, workflows, and performance metrics.
• Compile a list of existing technologies, including hardware, software, and control systems.
• Create detailed maps of current processes to understand workflow and dependencies.
• Evaluate the capabilities and limitations of existing technologies. Assess compatibility with potential control systems.
• Identify gaps between current operations and the desired state post-automation.
5. Network Infrastructure
• Review the current network infrastructure and topology.
• Check for network segmentation, firewall configurations, and VLANs.
• Assess the plant network and system integration with the office and management systems.
• Assess current cybersecurity measures in place.
• Review policies for access control, data encryption, and incident response.
• Check the history to see if any fraud or security breach has happened.
7. Compliance and Standards
• Identify relevant industry standards and regulatory requirements.For Example:
i. IEC 62443 focuses on cyber security for industrial automation and control systems.
ii. NIST for Cyber Security Framework
iii ISO 27001 information security framework
• Ensure compliance with local, national, and international regulations.
8. Resource Availability
• Ensure the availability of skilled personnel for the assessment.
• Allocate necessary resources like time, budget, and tools for the assessment
9. Risk Management
• Conduct a preliminary risk assessment.
• Identify potential hazards and mitigation strategies.
After preparing for the prerequisites as per the checklist, as mentioned earlier, for automation the company needs to prepare a checklist before proceeding further. I have given herewith a comprehensive checklist for primary understanding and preparation.
Checklist Parameters
1. Physical Infrastructure
-Inventory of OT hardware like controllers, sensors, and actuators.
-Condition assessment of physical infrastructure.
2. System Integration
-Check for interoperability of existing systems.
-Evaluate integration points between OT and IT systems.
3. Data Flow Analysis
-Map out data flow between devices and systems.
-Identify critical data paths and potential bottlenecks.
4. Performance Metrics
-Collect baseline performance metrics such as latency, throughput, and error rates.
-Establish key performance indicators (KPIs) for assessment.
5. Redundancy and Reliability
-Assess system redundancy, such as backup systems and failover mechanisms.
-Evaluate system reliability and uptime history.
6. Security Assessment
-Conduct vulnerability scans and penetration testing.
-Review access control mechanisms that include user authentication and role-based access
7. Compliance Check
-Verify adherence to industry standards and best practices.
-Review documentation for regulatory compliance.
8. Operational Procedures
-Evaluate existing operational procedures and protocols.
-Identify areas for improvement and automation potential.
9. Training and Awareness
-Assess current training programs for staff.
-Identify gaps in knowledge and propose training initiatives.
10. Change Management
-Review change management processes.
-Ensure proper documentation and approval workflows are in place.
11. Disaster Recovery and Business Continuity
-Assess disaster recovery plans and business continuity strategies.
-Test backup and recovery procedures.
12. Future Scalability
-Evaluate the scalability of current systems for future expansion.
-Plan for future technology upgrades and integrations.
After preparing the above check, the following are the steps for conducting the OT Assessment.
· Define the scope and objectives of the assessment.
· Develop a detailed assessment plan with timelines and responsibilities.
· Conduct site visits and interviews with key personnel.
· Collect data through observations, surveys, and automated tools.
· Analyse collected data against established benchmarks and standards.
· Identify gaps, risks, and opportunities for improvement.
· Prepare a comprehensive report detailing findings, conclusions, and recommendations.
· Present the report to stakeholders and discuss the next steps.
· Develop an action plan to address identified issues and implement recommendations.
· Prioritise actions based on risk, impact, and feasibility.
· Implement the action plan with regular monitoring and updates.
· Establish ongoing assessment and continuous improvement processes.
By following this checklist and meeting the prerequisites, you can ensure a thorough and effective OT assessment to initiate automation for a plant.
Tools and technologies to consider
· Process Mapping Tools: Visio, Lucidchart
· Data Collection Tools: Excel, SQL databases, specialised data collection software
· Risk Management Tools: Risk matrices, risk management software
· Project Management Tools: Asana, Trello, Microsoft Project, and
· Monitoring Tools: SCADA systems, performance monitoring software.
By following these steps, a company can systematically assess and analyse its operations and technology, leading to a successful integration with a control system.
Darshana Thakkar is an MSME Transformation specialist and Founder of Transformation – The Strategy HUB. With an Electrical engineering and MBA in business operations background, she has 28 years of hardcore industrial experience in transforming Small businesses. She helps MSMEs define growth paths, derive marketing strategies, improve business operations, adopt digital Transformation, and increase profitability.Darshana Thakkar is an author,speaker, and TV panelist. Her achievements, journey, and interviews have been featured in several newspapers, Premium business magazines, and TV.
She has won several regional, national, and international awards and is famous as an MSME activist and women's business leader. Her consulting venture, Transformation, was listed among the most trusted consulting companies in 2022 and among the top 50 consulting companies for MSME in 2023. She holds a few honorary positions in industry associations.
Major achievements:
· Winner of Global Women Leader -2023 by Global Women Leadership Award
· MSME Honor award-2022 -Champion of Cause by Tally Solutions
· Winner of Gujarat Women's Leader Award – 2021
She is associated with a few other premier institutes as
· Certified Women Director & Independent Director by IICA, MCA, GoI.
· Member of the Board of Management at Makarpura GIDC Industrial Estate Cooperative Bank Ltd.
· National President: WICCI-Entrepreneurship Development Council
· Trainer, Startup mentor, & Jury member at CED, Government of Gujarat.
https://www.linkedin.com/in/darshanamthakkar/
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