IT in Manufacturing


A portfolio approach to operations IT solutions management

May 2016 IT in Manufacturing

The business need for more automated and efficient operations has led end users in industrial plants to accumulate large and increasingly complex collections of operations-related information technology (IT) solutions. Each solution in itself can represent a combination of custom-configured software and hardware products.

As with the plant’s physical assets, these collections of IT solutions, plus any associated custom intellectual property, can represent a significant investment in time, money, and effort.

Operations and engineering organisations are accountable for these solutions and have specific responsibilities that cannot easily be delegated to the corporate IT group or external IT providers. The size and complexity of many collections require a portfolio-based approach to meet all associated challenges.

Operations IT solutions

Owner-operators face the constant need to improve operational effectiveness and efficiency to remain competitive. Changing business needs and expectations must be addressed with a flexible and evolving business strategy, which in turn requires integrating business processes with manufacturing and engineering operations. This leads to a gradual evolution of large and more complex collections of IT solutions to support these business processes. These collections may include solutions from a variety of suppliers and employ a broad range of information and communications technologies.

Solutions are created and implemented to solve specific business problems. As a result they must be consistent with current or planned business processes. The requirements and constraints of these processes provide the most significant drivers. Increased business efficiency and effectiveness require increased integration between solutions, often crossing traditional business process boundaries.

Solution management

Effectively managing large collections of solutions is a challenge not only because of the number of solutions but also because individual solutions are subject to rapid changes and improvements to the underlying systems and technology. In some cases, the business processes themselves may also change. Failure to manage these solutions increases susceptibility to security threats and exposes the organisation to a higher probability of complex failures.

While there are cases where the collection of solutions are from either a single source or supplier and/or built on a common architecture, it is much more common to have a collection of solutions from multiple sources. This requires acquiring and maintaining interfaces and other means of integration. It also means that decisions made with respect to one solution may impact others.

Effective management requires dedicated and skilled resources, not only in the IT function but also within the affected business processes. IT groups can support individual products, technologies and systems, but integrating and interconnecting these systems requires detailed knowledge of the business processes.

Responding to this combination of ­technical and process complexity can quickly become very resource intensive. Failure to meet the management requirements by taking steps such as freezing system versions or dropping support agreements can provide short-term relief, but eventually a price has to be paid.

A portfolio approach

Responding to the above challenges and complexities begins by adopting a 'portfolio approach' to solutions management.

The first step is to define the scope of the portfolio(s) to be managed. This scope can be expressed in any of several ways. In some situations, it may be possible to define the scope as including all solutions provided by a specific supplier. This is often not possible when dealing with collections of operations IT solutions, since they may be acquired from a variety of suppliers, supplemented by internally developed solutions or components. In these situations it is more effective to define the scope in terms of the affected business processes. Examples include production or maintenance operations management. These and similar processes are described in the ISA95 series of standards.

With the functional scope defined, it is essential to define accountability for each specific portfolio. Operations and engineering organisations within user companies are accountable for operations IT solutions and have specific responsibilities that cannot easily be delegated.

The next step is to identify all portfolio components. Each of these is in turn described or classified using attributes such as source, life cycle position, and degree of customisation or additional integration required. Understanding the degree of integration is necessary to identify cases where changes to one solution may have secondary effects on others in the portfolio.

Effective solutions management also requires a solid understanding of the life cycle concept. This concept can be applied from any of several perspectives (acquisition, development, implementation, support, etc.) as a basis for making decisions.

It is also important to understand the life cycle position of solutions with respect to development. Solutions that may have only recently become available can be expected to have frequent updates to add new functions or address problems. More mature solutions may change less frequently and obsolete functions may have no updates or improvements planned or available. Each of these situations presents specific challenges. Solutions that have been widely deployed generally present fewer problems because of this experience.

Tie to strategy

It is critical to maintain a clear tie to business strategy. While forces such as technology changes or new versions of specific solutions may drive specific changes to the portfolio, the full implications for the strategy and associated business processes must be understood before such changes are implemented.

Eric Cosman, a senior consultant at ARC Advisory Group, has over 35 years of experience developing and ­supporting operations information technology solutions in the process industries. During his career, his assignments and responsibilities have included process automation systems development, communications network design, functional and technical architecture design, and technology lifecycle management.

For more information contact Paul Miller, ARC Advisory Group, +1 781 471 1141, [email protected], www.arcweb.com





Share this article:
Share via emailShare via LinkedInPrint this page

Further reading:

Even in autonomous systems, human insight is important
Schneider Electric South Africa IT in Manufacturing
As AI, IIoT and digital twins reshape industrial operations, Schneider Electric’s Kobus Vermeulen and Bafana Msibi argue that the operator’s role is shifting from controlling equipment to interpreting intelligence, validating AI recommendations and making decisions that improve

Read more...
AI-based quality inspection scales across P&G operations
Siemens South Africa IT in Manufacturing
Siemens and Procter & Gamble are expanding an AI-based visual inspection system across P&G’s manufacturing operations worldwide, inspecting products in real time at full line speed, and reducing scrap rates by 10 to 20% depending on the product.

Read more...
How sustainability unlocks real business impact
Rockwell Automation IT in Manufacturing
Sustainability has moved from a compliance obligation to a strategic driver of resilience and value for manufacturers. Rockwell Automation explains how its Triple A framework and connected-data approach help producers cut energy, water and waste while improving productivity.

Read more...
Mining’s AI future will depend on people as well as technology
IT in Manufacturing
South Africa’s mining industry is embracing digitalisation and AI, but AvenirHoldings chief executive officer, Tshidi Mndzebele says the real test is whether the people behind the industry are equipped to move forward with it, and outlines five things mining needs to get right.

Read more...
How BIC overcame operational silos to integrate technology and people
Rockwell Automation IT in Manufacturing
Manufacturing giant BIC deployed Plex MES from Rockwell Automation at its Bizerte plant in Tunisia, replacing fragmented, partly in-house software with a single cloud-based execution system that broke operational silos and improved shop-floor visibility.

Read more...
AI in industry is an early warning system, not a guarantee
Schneider Electric South Africa IT in Manufacturing
Schneider Electric’s Paul Steyn argues that AI in industrial maintenance is only as good as the infrastructure and people behind it, and explains the three layers a facility needs before predictive maintenance can deliver on its promise.

Read more...
SA’s mining industry must put people at the heart of its digital future
IT in Manufacturing
South Africa’s mining industry employs around 470 000 people while its digital transition accelerates. Avenir’s chied executive officer, Tshidi Mndzebele argues that technology should enable and upskill the workforce rather than replace it, setting out five ways mining can make technology work for its people.

Read more...
Quality control supports efficient tissue production
Valmet South Africa IT in Manufacturing
Valmet’s advanced quality control technology is helping tissue producers improve product consistency while reducing energy and raw material consumption. Its latest installation at KORO Paper in Vietnam combines real-time measurement, process optimisation and non-contact, nuclear-free quality control.

Read more...
Patented algorithm maximises operator efficiency
Rockwell Automation IT in Manufacturing
Rockwell Automation piloted a patented anomaly detection algorithm and FactoryTalk DataMosaix at its Twinsburg electronics plant, giving operators 30 to 60 days’ advance warning of stencil failure, improving fail rates by 22% and achieving a 200% return on investment.

Read more...
Cybersecurity must become part of the next era of industrial automation
Adroit Technologies IT in Manufacturing
The EU’s Cyber Resilience Act is setting a global benchmark for connected products, making cybersecurity a core engineering requirement in industrial automation. Adroit Technologies and Mitsubishi Electric explain how building security into controllers, PLCs and drives from the outset helps South African manufacturers protect production and meet international expectations.

Read more...









While every effort has been made to ensure the accuracy of the information contained herein, the publisher and its agents cannot be held responsible for any errors contained, or any loss incurred as a result. Articles published do not necessarily reflect the views of the publishers. The editor reserves the right to alter or cut copy. Articles submitted are deemed to have been cleared for publication. Advertisements and company contact details are published as provided by the advertiser. Technews Publishing (Pty) Ltd cannot be held responsible for the accuracy or veracity of supplied material.




© Technews Publishing (Pty) Ltd | All Rights Reserved