How to enhance facility performance through strategic systems integration

Although the idea of systems integration (SI) has existed since the 1970s, its meaning and application have continuously evolved. Technological advances have increased the complexities of many products and processes, including advanced manufacturing and research and development (R&D).

That’s why it’s essential to understand how the integration of test equipment and facilities can lead to faster and better data and improved decision-making, all at a lower cost. Integration is fundamentally understanding the necessary interactions between systems and technologies required to create the desired big-picture output or outcome. Data and control technology advancements have allowed for a significant increase in simultaneous measurements and better simulations by way of this added data.

From this, SI can connect data/output and real/testing environments more effectively than ever. Understanding this evolution shows that a well-planned integration strategy and a skilled team with the expertise to make it happen will bring these complex projects to fruition.

Integration of state-of-the-art software and data acquisition (DAQ) systems enhances cybersecurity and prevents potential attacks. Courtesy: ACS

The history of systems integration

The traditional approach to the design and build of a high-tech manufacturing or  R&D test facility operated more like linear project management. It involved the client acting as the primary interface between process and test equipment vendors, the facility design firm  and the installation or construction contractors.

The late 1990s and early 2000s saw a dramatic increase in technological complexity across widespread industries, especially engineering    design and manufacturing. The rise of smart devices, control valves  and advanced process technologies added layers of intricacy to industrial equipment and processes, thereby increasing the importance of well-considered SI. The need to simulate, test  and model components in virtual environments became more pronounced as costs, complexity  and demand increased. The traditional, front line product engineer-led integration transitioned to a more sophisticated approach that required digital tools to manage and optimize process or asset performance.

This marked a significant evolution in the role of integrators from mere contractors implementing complex designs to vertically integrated turnkey partners. These partners began to offer comprehensive solutions that encompassed not only facilities and equipment but also deep process and application expertise.

As industries advanced, the expertise initially developed by original equipment manufacturers (OEMs) started to resonate across a broader market, including light-duty/passenger car manufacturing, aerospace   and other areas. Both OEMs and tier suppliers increasingly recognized the need for integrators who could bring together complex systems to optimize performance and efficiency. This evolution in systems integration was more than a response to market demands. It also reflected a growing commitment to innovation by many companies and increasing excellence in the integration process.

A holistic approach to the integration of equipment, facility, and control systems is foundational to scalability and flexibility. Courtesy: ACS

The journey from basic systems integration to a more sophisticated, vertically integrated approach mirrors broader trends in industrial practices. The ability of systems integrators to adapt and evolve with the changing needs of various industries has driven their growth and shaped the future of systems integration. This evolution underscores the importance of integrators who can respond to current demands and anticipate and drive the next generation of solutions across multiple industries.

Today, the role of SI is more crucial than ever. Effective SI involves understanding and managing the interactions between various systems and technologies. It also necessitates a well-coordinated team capable of translating and communicating needs across all stakeholders.

Trends and challenges shaping a need for a dedicated approach to SI

As technology rapidly advances across all industries, the landscape for industrial plants is becoming increasingly complex and competitive. Driven by several key trends and challenges, the future of industrial plants highlights the need for a dedicated approach to SI.

The pace of technological innovation, particularly in data acquisition and control, shows no signs of slowing down. New and emerging technologies such as the industrial internet of things (IIoT), artificial intelligence (AI )  and advanced data analytics offer opportunities for significant gains in efficiency, scalability  and flexibility.

Consider the push for modern manufacturers to adopt improved sensing and monitoring technologies and the rising capabilities of AI vision systems for widespread visibility. There’s also an increase in standardized data communication protocols, software interoperability  and a drive for universal connectivity, including IIoT readiness.

It’s imperative for industrial plants to stay abreast of these advancements while ensuring  new technologies can also integrate seamlessly with legacy systems that innovate and transform at a slower pace. This requires a sophisticated understanding of both the technologies and the integration processes.

The strategic integration of diverse systems ensures optimal performance and system synchronization. Courtesy: ACS

Complex and specialized demands characterize modern industrial plants. As products and customer expectations become more sophisticated, the systems and processes required to support them become more intricate. Failure to do so can lead to inefficiencies, compliance issues  and increased vulnerability to cybersecurity risks.

According to the IBM X-Force Threat Intelligence Index 2024, manufacturing was identified as the most vulnerable industry to data breaches for the third year in a row, especially with the increasing complexity of IIoT and global supply chains. A cybersecurity breach in a manufacturing setting could have devastating consequences, ranging from sensitive data leaks to production shutdowns or safety hazards. Stringent standards for regulation and compliance further compound this complexity to ensure safe practices. Each of these factors introduces additional layers of difficulty that must be managed through effective SI.

Engineers, facility managers  and leadership teams often possess specialized expertise , such as product development or operations. This specialization can sometimes lead to a narrow focus that overlooks the broader requirements of the entire industrial facility.

For instance, while a product development team might excel in creating cutting-edge technology, it may not have the expertise to address the specific integration needs of an industrial facility. This divergence necessitates a dedicated systems integrator who can bridge these gaps and ensure that all aspects of the facility are harmoniously aligned.

The rise of automated processes and increased access to data transform how industrial plants operate. This evolution is only projected to increase as automated technologies adapt and grow. The size of the global industrial automation market  was valued at $169 billion in 2019 and is expected to nearly double in upcoming years, increasing to $297 billion by 2026. Automation has greatly enhanced operational efficiency to meet heightened demands and introduces new SI complexities.

Data-driven insights can optimize performance only if the data is accurately captured, integrated  and analyzed. Automation also drives substantial growth and innovation in the warehouse software market to handle widespread adaptation to automated processes. The warehouse software market reached $7.2 billion in 2023 and is anticipated to grow to $16.6 billion by 2030. A skilled systems integrator can effectively manage and utilize data across diverse systems, software  and platforms.

Industrial plants are increasingly required to integrate diverse systems and technologies to ensure smooth and continuous operation. Modern SI is an ongoing, committed process, unlike simple or one-time integration projects. It involves continuous monitoring, updating and optimization to adapt to evolving technologies and operational requirements. This is easier said than done. A proactive and dedicated approach to SI, rather than a reactive or ad-hoc strategy, is essential. The potential for challenges increases as industrial plants become more interconnected and data-driven.

Addressing the evolving needs of industrial plants with a five-step  SI approach

A comprehensive SI approach starts at the project’s onset and involves defining clear project objectives, collaborating with diverse expertise, enabling predictive maintenance  and adapting to future trends. By following these five strategies, industrial plants can effectively manage complexity, enhance operational efficiency  and maintain a competitive edge in an ever-changing marketplace.

1. Commence with a clear definition of requirements and objectives. 

This begins with a comprehensive kickoff meeting involving all key stakeholders, such as engineers, facility managers  and organizational leadership. The goal is to establish a unified vision for the project, detailing objectives, success criteria  and functional and technical requirements with a high-level view of how various components will interact. Clearly defined metrics and key performance indicators will help track progress and measure success, but this demands upfront conversations about capabilities and resources from an expert’s point of view. Engaging industry experts early in the process ensures that the project aligns with best practices and emerging trends. Additionally, benchmarking against industry standards helps make sure the integration approach is competitive and compliant.

2. Collaborate with the right experts  at the right time. 

A key step is assembling a cross-functional team that includes cross-industry experts, niche specialists  and engineers. It’s crucial for each team member’s roles and responsibilities to be clearly defined to make the most of their expertise. During the design phase, involve subject-matter experts who can provide insights into specific technologies and processes to refine the integration strategy. Include end-users during the testing phase to ensure that the system meets practical needs and is user-friendly. To maintain effective collaboration, schedule regular review meetings to address issues and adjust plans as needed.

3. Commit to ongoing predictive maintenance and asset optimization. 

This is increasingly vital for maintaining a competitive edge in industrial operations. Implementing predictive analytics involves equipping critical assets with solutions to collect real-time performance data, essential for forecasting maintenance needs. Advanced analytics tools can then predict maintenance requirements, optimize asset performance, minimize downtime  and extend asset lifespan.

4. Stay adaptable to ongoing and fast-paced evolution.

Future trends and technologies will continue to drive the need for increased flexibility and scalability. Deloitte reported that industry priorities include digital twinning and modeling technologies, reduced carbon emissions, supply chain resilience  and smart factory solutions. Heightened specialization across industries will also continue, further diversifying technologies and processes. It’s predicted that more than 75%  of manufacturers plan to adopt big data, cloud computing and AI within the next five years, while 86%  intend to incorporate digital platforms and applications within their operations.  Evaluate  how these technologies can be integrated into existing systems to  improve functionality and performance and incorporate them into  a strategic roadmap.

Integrating new technologies into existing systems and equipment improves functionality and performance. Courtesy: ACS

Designing systems with flexibility and scalability in mind is essential, using modular design principles that allow for adaptation to future technological advancements and changing needs. On the other hand, industries are only projected to become increasingly specialized and diversified. Niche developments increase customized solutions offerings and complicate systems and processes with hyper-specialization. This requires continuous learning and training for team members to stay updated with technological advancements while initiating knowledge-sharing among the industrial workforce, which can significantly improve employee capabilities. Building strategic partnerships with technology providers and industry experts can provide access to cutting-edge technologies and insights, supporting effective integration and adaptation.

Deliver on facility goals, schedule, budget  and scope without backtracking

As technologies become more capable and complex, it becomes imperative for manufacturers and industrial plant managers to match that level of capability and complexity with a dedicated systems integrator. Without SI, spending vital money and time making significant adjustments to facility design, re-working the space for use  or compromising overall testing objectives is inevitable.

With marketplace trends, ongoing digital transformation and customer interests, SI is rapidly becoming a corporate standard in the design- and- build process of manufacturing and R&D test facilities. Organizations that see and harness the value of SI are a step ahead of the competition, paving the path for SI to be the industry-accepted norm rather than the exception.

Do you have experience and expertise with the topics mentioned in this content? You should consider contributing to our WTWH Media editorial team and getting the recognition you and your company deserve. Click here to start this process.