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The relentless pursuit of quality and reliability is at the core of all manufacturing operations. As control systems become more complex and interconnected, new challenges and opportunities emerge for quality professionals. Staying ahead of these changes is essential to ensuring operational excellence, regulatory compliance, and system integrity. This article explores three pivotal trends shaping modern control systems.

1: The Push for Safety PLCs to Meet Rigorous ISO Standards

A significant trend impacting manufacturing quality is the increasing adoption of safety PLCs. This is a direct response to the growing global emphasis on meeting rigorous ISO standards. While risk assessments have always been a part of the process, companies now have a heightened emphasis on achieving specific, quantifiable benchmarks like Performance Level (PL) or Safety Integrity Level (SIL) classifications.

For quality professionals, this means designing and validating systems to achieve specific ratings, not just general safety measures. The process begins with a risk assessment, but it continues by using safety PLCs with advanced features and appropriate hardware to build a control system that can demonstrably achieve the required performance levels. This shift to a certified, standards-based approach provides a more robust and verifiable safety framework, directly improving the quality and safety of manufacturing operations.

2: AI Enhances Digital Twin Technology

Artificial intelligence (AI) is making digital twin technology a more powerful and accessible tool for process simulation and optimization. By improving the link between virtual models and physical machines, AI-enhanced digital twins can more accurately replicate real-world decision-making. This advancement is a significant opportunity for quality professionals to boost operational efficiency, accelerate development, and reduce downtime.

During the design phase, digital twins enable rapid prototyping and more accurate testing of new configurations in a virtual environment. This allows for cost-efficient remote commissioning and helps identify potential issues early on. Tools are also making it easier to update digital twins as new equipment is introduced. For example, machine manufacturers are starting to provide digital twin schematics that can be uploaded directly into a plant’s virtual model, allowing teams to quickly simulate new equipment before it’s even on the factory floor. This level of virtual integration streamlines the entire process and minimizes errors that could compromise quality.

3: Addressing Evolving Cybersecurity Threats

As manufacturing systems become more interconnected, they face a growing threat from cyberattacks. A particularly concerning threat involves attackers gaining remote or even onsite access to a network to hack into the local PLC network. A hacker who gains control of a local PLC network could manipulate settings, disrupt operations, or even compromise safety by taking control of critical equipment.

The first line of defense is to harden physical access to the plant, but the next critical step is to implement a Defense-in-Depth (DID) approach to cybersecurity. This involves embedding security directly into the PLC network. For many legacy systems, installing DID switches in PLC panels is an effective solution. These switches can be configured to allow access only via specific, pre-authorized ports and communication partners, effectively isolating the PLC network from other building systems. By adopting this strategy, quality professionals can proactively protect control systems, safeguard operations, and maintain the highest standards of safety and integrity.

Ensuring Operational Excellence with Innovation

These trends highlight the continuous advancements that are enhancing the efficiency, safety, and security of control systems. For quality professionals, adapting to these new technologies is vital for ensuring that manufacturing operations remain optimized, resilient, and compliant. By championing innovation, leveraging powerful tools like AI, and implementing robust cybersecurity, you can maintain the highest standards of safety, security, and performance.