Process automation, or adding automation into manufacturing process control systems, saves resources and boosts product quality. 

Even optimized process control systems may benefit from automation and continual improvement in today’s competitive, ever-changing regulatory environment. 

Here are four primary advantages to automating process control today:

  1. It boosts energy efficiency

    Manufacturing operations characteristically consume large amounts of energy, which can be expensive and not environmentally friendly. Process control systems empower plant managers to combine specific information—such as precisely how much electricity a piece of equipment uses over — with other production data to reveal what drives energy consumption in th

  2. It lowers costs and reduces waste

    Manufacturers that automate their operations spend less time manually inputting information, which lets them multi-task and saves time. Automation also enables manufacturers to monitor and analyze production materials, which gives them an opportunity to cut waste. It also lowers the risk for human error, which eradicates any wasted materials, returns and warranty payments.

  3. It heightens productivity and increases response time

    Automated systems can transfer data, run analyses and perform other functions much more quickly than can a human being. They also don’t need rest: With automated systems working around the clock, manufacturers have more time to process orders and analyze processes. With limited downtime, manufacturers can get orders out faster, which increases productivity and profits. It also makes processes more flexible, as operators can quickly analyze data to determine what changes they need to make.

  4. It improves quality

    Automation of process control can help manufacturers to boost quality. It makes in-process product easier, allowing operators to catch problems more quickly than with manual alternatives. Since automation lessens the chances for manual errors, manufacturers enjoy fewer mistakes and consistent results. They can also use process control systems to uncover opportunities for processes improvement, which can correlate directly to product quality.

Process control optimization across fields

Process control optimization can benefit manufacturers across a range of industries, including:

  • Pharmaceutical

    Pharmaceutical manufacturers must diligently comply with rigorous standards and requirements, which process automation can help with. Process control optimization and automation makes production and processing more exact. It also holds benefits for batch control, recipe management and automated reporting. The technology also boosts flexibility, reliability and response time. These features help connect production and quality assurance, which improves data integrity and product quality over time.

  • Automotive

    Optimizing process controls can enable automakers to produce vehicles and components more quickly. By getting a holistic view of their operations, they can improve quality in real time. They can also automate engineering, alarm management, and other features.

  • Food and beverage

    Food and beverage producers can use process control automation to reduce costs associated with energy use and line management. It can also help manufacturers to meet the field’s stringent quality requirements at a lower cost.