AUTOMATION PROJECT SURVIVAL GUIDE Ideas to help you land on your feet BROUGHT T

AUTOMATION PROJECT SURVIVAL GUIDE Ideas to help you land on your feet BROUGHT TO YOU BY: TABLE OF CONTENTS 3 12 Points to Consider Before Even Beginning Your Automation Project 5  Tips for Successful Project Development 7  Nine Tips for Automation Project Managers 9  Four IT Standards You Should Understand 10 Four Considerations for Upgrades & Migrations 11  Eight Ideas for Successful DCS Implementation 13  13 Suggestions for Control System Migrations 15  10 Steps to Creating the Perfect HMI 17 Safety: The Lifecycle Approach 19  Control System Security Tips 21  How to Avoid Mistakes with Control System Remote Access 23  Four Tips for Dealing with Wireless Latency and Bandwidth Issues 24  How to Properly Select and Vet a System Integrator AUTOMATION PROJECT SURVIVAL GUIDE | 2 The first step in any automation project is the most critical one: Define your objectives. The more thorough and detailed this definition is, and the earlier in the process it can be achieved, the greater the likelihood that the project will be completed successfully. 1. Visualize success. Try to visualize what a project would look like if it were a stunning success. Take note of how it will affect all the people in- volved and write down any others you think it might touch. Take all of these people and put them on a spread- sheet column. Now in rows across, write down the attributes they need in the machine/process. Use this when evaluating solutions and communi- cate shortcomings to those affected. Come up with workarounds or throw out the idea if the results won’t be acceptable. 2. What’s driving the project? You need to understand what is the most important motivation for doing this particular project and use that to guide your decision-making. 3. Helping people. Automation can do many things, but one must be aware that its purpose is to do real things in a given ecosystem. Keep in mind that the goal is to have systems engineered to serve humans, not the other way around. 4. Project definition is critical. Without doing true engineering work, everything you learned in school and in your career up to this point, you are not doing any project properly or professionally. By creating definition for the project and then verifying that the project will answer the need, you are on your way to successful project management. It is only the start, but without a properly defined starting point, it is difficult to complete (or de- fend) a meandering, ill-defined project that is meant to resolve a problem, ad- dress a challenge or complement your company’s engineering resources. 5. Start with the objectives. Don’t even begin to select suppliers and service providers until you’ve estab- lished a project’s objectives. Make sure everyone on the team agrees on what the project needs to achieve before it starts. If you don’t know where you’re going, you’ll never get there. 6. Get a second opinion. It pays to get a second opinion from an in- formed outsider like a system integra- tor or machine builder before final- izing project objectives—they’ll often AUTOMATION PROJECT SURVIVAL GUIDE 12 Points to Consider Before Even Beginning Your Automation Project It’s essential to understand each person’s expectations before a project starts. There are three parts to this definition process: y y What outcomes or desired results does the project team want to achieve? y y What do they want the project experience to be like (for example, no production line shutdowns during the project or communicate updates by email)? y y How will they define quality, such as on time/on budget or in- creased production volumes or zero downtime, at the end of the project? Different people will have different expectations and they all have to be satisfied. WHAT DO THEY REALLY WANT, AND WHY? AUTOMATION PROJECT SURVIVAL GUIDE | 3 do it for free. If you bring them in at this stage, so that they understand the history of the project, they can con- tribute to decisions that will improve the chances for a successful project. 7. Set rules for communication. De- fine what communications are expect- ed at the start of the project— what is to be communicated, how it is to be communicated, what the milestones of the project will be and how often things should be communicated. 8. Talk to everyone. Interview the stakeholders from various factory disciplines, such as operations, main- tenance, quality control, supply chain, shipping and management. They always have a stake in every automa- tion project. 9. Never assume. Don’t make as- sumptions about the ground rules— spell everything out in advance and define who is responsible for doing what. 10. Create a chart to keep objectives clear. Define the expected perfor- mance for each subsystem, and the expected steps to get there. Use Excel to list the task steps, and the hours/$ across a time matrix. Then that be- comes a calendar for the schedule, sort of a compressed MS Project. If you color the boxes, it becomes a Gantt chart. Putting all your objectives (the completion of functioning subsys- tems, integration) into one simple chart keeps those objectives clear to the whole team. 11. Spell everything out. If you want drawings in portrait vs. landscape mode, for example, or want certain brands to be used, such as for wire or PLCs or other components, state that up front. If a requirement is not written down, then it likely will not happen. 12. Scope! Nothing is more impor- tant than a scope that reflects both the well-defined areas of the project and the gray areas of the project. The gray areas should have a gen- eral framework put together by the customer and the implementer, with benchmarks that clearly indicate when project reassessment should occur. This way scope creep can be managed to the benefit of both parties.  AUTOMATION PROJECT SURVIVAL GUIDE 12 POINTS TO CONSIDER BEFORE EVEN BEGINNING YOUR AUTOMATION PROJECT Never start by defining technology-driven objectives. Use the following order: 1. Business objectives. What will the business gain from this project? 2. Operational objectives. How will this project impact operations— greater efficiency / better quality / compliance, etc.? 3. Integration objectives. Can data generated by this system be used by other systems? 4. People objectives. Skill development, ease in work pressures. Only when all of these have been defined can you establish the technology objectives. TECHNOLOGY COMES LAST AUTOMATION PROJECT SURVIVAL GUIDE | 4 AUTOMATION PROJECT SURVIVAL GUIDE AUTOMATION PROJECT SURVIVAL GUIDE | 5 Tips for Successful Project Development Project development is not an every- day occurrence at batch process facili- ties. To help ensure you are covering all the major issues involved in these infrequent work scenarios, here are some tips and considerations to facili- tate a successful project startup. 1. Clearly identify the project speci- fications. What do you want to do? What is your existing process? Define operator involvement, quality control issues, interface points with other sys- tems, and the technological capability available in-house. 2. Conduct a job risk assessment (JRA). Performing a JRA before the start of work highlights any hazards that could produce undesirable results to personnel or property. A safety assessment must be completed to ensure that the scheduled work can be performed in a safe manner and to address any hazards that are uncov- ered as a part of the review process. 3. Operator training is key. The operators must learn how to navigate and operate their process in the new control system. The training must be performed just in time (about two weeks before start-up) so that the information is fresh in their minds. During the instruction, it is critical that the operators be trained using the operator interface graphics they will encounter. 4. Emphasize communications. Communicating with the site mainte- nance and operations departments is critical to the success of the project. Maintenance and Operations need to schedule their duties with enough lead-time to support the installation and startup activities. With enough time, maintenance can even contract back-fill support for the duration of the project startup activities. For op- erations, the work and vacation relief schedule will have to be organized so that enough operators are available to cut-over and startup the plant. This is especially important if a hot cut- over is involved. 5. Have a detailed cut-over plan. Planning is crucial to any stage of an automation project. By putting together a detailed cut-over plan, the personnel performing the work will have a clear directive of the activities that need to be completed each day. The cut-over plan will help keep the activities on task and allow the proj- ect manager to assess the progress of the work, create workarounds for problematic situations, coordinate with the plant operations, and drive the project to completion. A cut-over plan, at minimum, should include the I/O to be cutover and tested (includ- ing the order in which they are to be tested), any water uploads/Management/ automation-project-survival-guide.pdf

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• Détails
• Publié le Jan 25, 2022
• Catégorie Management
• Langue French
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