Selecting an OLE, MES or SCADA software solution can be complex, however following these 8 steps when upgrading or implementing OLE, MES or SCADA will simplify the process and make it less expensive.
Let's look at this process from a high level. Modem manufacturing supervisory control systems can integrate with just about any control device imaginable, most commonly PLCs (Programmable Controllers) or other devices with their own specific protocols used to control some part of your manufacturing. The key term used to refer to this capability is a standard is called OPC. This allows all industrial automation systems to be integrated regardless of past product or technology selections of the electrical engineers who designed the system.
Any plant floor supervisory or data acquisition system can be done more affordably than ever before if the right approach is taken and the right partnerships are made.
1. Start Small Without Getting Suckered. Many of the traditional offerings charge a low fee for small tag counts and client run-times (log ins) and then charge much more for higher tag counts and run-times. New competitive products charge nothing for run-times/users and include unlimited tag bases without breaking the budget. Many of the sales pitches from the leaders are geared at OEE (Overall Equipment Effectiveness), which attempts to make one KPI (Key Performance Indicator) to measure productivity, out of the few most important ones. This is a noble goal but the reality in most cases is that it will take a lot of work to get there and will not be a drop-in solution.
2. It's the Network Dummy. Don't over pay for software and ignore the network infrastructure. Hardware and software costs are coming down across the board and this is especially true of network equipment. Old hubs and overrated network switches have no place in a modern Ethernet network. It was once acceptable to have a certain amount of data loss on your network; this is no longer true. Routers and managed switches do not have to cost a bundle either, allowing for real security. Diagnostics in the device now let us see that we no longer have any data loss in the network connection. 3. Get the Right Tools. Find tools to help document existing equipment, documentation and related software. Doing this the old fashioned way is a waste of time, effort, and money. The rewards go far beyond a software roll out. Passive solutions that work, like network port scanners, can help you locate and diagram the network in hours instead of weeks. You will then be able put existing related material against those devices and publish them for the organization. The reward for this effort will be realized every time you quickly find answers in the system.
4. Understand What You Are Buying. Who is the man behind the curtain? OPC is a standard over which no major players has ever had control aside from the body that publishes it, the OPC foundation. Many have packaged their solutions with licensed offerings from third parties. These third party solutions are certified and tested by the software foundation. Many of the platforms rely on code libraries that are GPL (General Public License) and which cost them nothing. It is not uncommon for a PLC (Programmable Logic Controller) product to be based on Linux or free BSD that are also GPL. These free or low cost solutions dramatically lower the cost for new entrants into the market.
5. Don't Get Fooled by the Name. As we have seen recently no company is too big to fail. This is just as true for the big players in the industrial automation market. Some of their best customers are going through incredibly trying times. Many of the big industrial automation firms are already struggling in a market that is increasingly competitive to make their acquisitions and licenses offerings bring in the expected revenue. Outsourcing and layoffs are happening and often important knowledge goes out the door as well.
6. Not All Platforms Are Built for the Web. Web launched applications built on platforms and languages built for web technology are key in assuring that secure, functional and manageable solutions can be developed. Everyone will assure you that you can access the product via the web. It is security and licensing that will make or break this as a reality. For example Microsoft charges licensing fees for active directory users on servers. IT departments have a strong sense of ownership over Active Directory, allowing for security and authentication (Computer / Server Log-in) to a network resource. Web application platforms will have their own security model that function separately from the office domain.
7. Be Skeptical of the "Legacy." Many of the next generation packages from market leaders have a start fresh approach to address this. It comes as no surprise that large companies have trouble reinventing themselves around these new offerings. It is not uncommon to see complete false starts and forced migrations to competing products after acquisitions. The market leaders all have an incentive to bring current customers to the new base platform. Don't get caught up in the next newest thing that was made to look simply like the next new version.
8. Focus on Total Solution Cost. Not Initial Cost Many software companies spend a great deal of time and money trying to corner the market with low up-front fees. Eventually this strategy falls apart. The key is to find an integrator that has the experience and knowledge to provide the best solution at the best total cost.
