On the horizon

Evidence is growing that the role of the plant engineering function is headed up. Asset management, reliability, availability, and maintenance are being more and more recognized as essential to the success of the business plan. And from the plant level to the board level, the value of well-managed plant assets is taking on new meaning.

10/15/2002


Evidence is growing that the role of the plant engineering function is headed up. Asset management, reliability, availability, and maintenance are being more and more recognized as essential to the success of the business plan. And from the plant level to the board level, the value of well-managed plant assets is taking on new meaning.

Executives are increasingly interested in mining the "hidden plant"; that is, the under-utilized assets that can contribute to productivity and profitability. And mining those assets requires a shift in thinking away from the old philosophy that plant engineering and maintenance are strictly cost centers. The new thinking demands that they become integral to achieving the enterprise business goals.

While plant engineers have always known and believed in these values, their requests for commitments from management usually fell on deaf (or, at least, hard of hearing) ears. When it came to maintenance and reliability, for example, the mantra always seemed to be: cut costs, don't invest.

Now that many of the old philosophies about how to run a plant have changed, the real value of the plant infrastructure is better understood. As maintenance consultant Christer Idhammar says, "Equipment doesn't cost money when it operates properly. It costs money when it breaks down."

Technology is helping the cause. Through such technology-enabled programs as predictive maintenance, reliability-centered maintenance, and CMMS/EAM, the dream of nearly eliminating unscheduled downtime is becoming a reality. And the opportunity to relate plant engineering and maintenance to the business objectives is better than ever.

There are still substantial hurdles to overcome, of course. One is the question of who is going to make the dream a reality? The need for well-trained, highly skilled technicians is higher than ever — and growing. At this juncture, no one is quite sure where these technicians are going to come from or who is going to train them.

Equally important is the need for plant engineers to move beyond their traditional engineering role into the business environment. If plant engineers are not seen as having the financial and business management savvy to take on these new responsibilities, they will have lost the opportunity for the influence and authority they have longed for.

Excuse the cliche, but a new day is dawning. And the sun is about to shine brighter than ever on plant engineering.





Top Plant
The Top Plant program honors outstanding manufacturing facilities in North America. View the 2017 Top Plant.
Product of the Year
The Product of the Year program recognizes products newly released in the manufacturing industries.
System Integrator of the Year
Each year, a panel of Control Engineering and Plant Engineering editors and industry expert judges select the System Integrator of the Year Award winners in three categories.
May 2018
Electrical standards, robots and Lean manufacturing, and how an aluminum packaging plant is helping community growth.
April 2018
2017 Product of the Year winners, retrofitting a press, IMTS and Hannover Messe preview, natural refrigerants, testing steam traps
March 2018
SCCR, 2018 Maintenance study, and VFDs in a washdown environment.
April 2018
ROVs, rigs, and the real time; wellsite valve manifolds; AI on a chip; analytics use for pipelines
February 2018
Focus on power systems, process safety, electrical and power systems, edge computing in the oil & gas industry
December 2017
Product of the Year winners, Pattern recognition, Engineering analytics, Revitalize older pump installations
Spring 2018
Burners for heat-treating furnaces, CHP, dryers, gas humidification, and more
April 2018
Implementing a DCS, stepper motors, intelligent motion control, remote monitoring of irrigation systems
February 2018
Setting internal automation standards

Annual Salary Survey

Before the calendar turned, 2016 already had the makings of a pivotal year for manufacturing, and for the world.

There were the big events for the year, including the United States as Partner Country at Hannover Messe in April and the 2016 International Manufacturing Technology Show in Chicago in September. There's also the matter of the U.S. presidential elections in November, which promise to shape policy in manufacturing for years to come.

But the year started with global economic turmoil, as a slowdown in Chinese manufacturing triggered a worldwide stock hiccup that sent values plummeting. The continued plunge in world oil prices has resulted in a slowdown in exploration and, by extension, the manufacture of exploration equipment.

Read more: 2015 Salary Survey

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