ABB's Automation Extended: A Game-Changer for Control Systems

“Costly shutdowns are a thing of the past.” That’s the bold promise behind ABB's newly launched Automation Extended program, which aims to help industries modernize their control systems without the disruption that often accompanies such upgrades.

For decades, companies have faced the daunting challenge of upgrading their distributed control systems (DCS) while maintaining operational continuity. Many have opted to delay modernization out of fear of the downtime, lost production, and significant capital expenditures that come with replacing aging equipment. Now, ABB is offering a solution that seeks to alleviate these concerns while ushering in a new era of digital technology.

The Automation Extended program builds on ABB's extensive installed base of DCS, paving a structured path for companies to adopt advanced technologies such as cloud computing, machine learning, and IoT integration. This approach is particularly timely; production data shows that nearly 60% of manufacturers are still using outdated control systems that were deployed more than a decade ago.

The key selling point here is the promise of minimal disruption. According to operational metrics from early adopters, facilities can implement updates incrementally, allowing them to phase in new technologies without completely overhauling their existing setups. This gradual integration can result in a significant reduction of operational risk, which is particularly crucial in sectors where downtime can cost thousands of dollars per hour.

Furthermore, the solution is designed with scalability in mind. Integration teams report that companies can start small—perhaps by integrating new data analytics tools—before expanding into more complex upgrades. This not only helps manage cash flow but also allows companies to see real-time benefits and ROI before committing to larger-scale investments.

However, the path to modernization is not without its challenges. Hidden costs often emerge during implementation, such as the need for additional training hours for staff to become proficient in new technologies. Floor supervisors confirm that while the technology may be user-friendly, effective deployment still requires a well-trained workforce that understands both the legacy systems and the new digital tools.

Moreover, while Automation Extended positions itself as a seamless upgrade solution, savvy plant managers know to mentally add potential delays and budget overruns to the vendor's promises. Historical data suggests that even with the best-laid plans, unexpected issues can arise, particularly when integrating complex systems that depend on real-time data sharing across various platforms.

In terms of performance, early indications from pilot programs reveal that the implementation of Automation Extended has already led to impressive cycle time improvements. For example, one facility reported a 20% boost in throughput within the first month of integrating new data analytics capabilities. Such metrics could very well lead to quicker payback periods, something CFOs will be eager to note as they evaluate capital expenditures.

For organizations struggling with legacy systems, ABB’s Automation Extended could represent a vital opportunity. However, as with any significant technological shift, it requires careful planning, budgeting, and, most importantly, a commitment to training the workforce that will ultimately make or break the new system's success.

As the manufacturing landscape increasingly adapts to digital technologies, ABB is positioning itself at the forefront of this transition. Their Automation Extended program, if executed correctly, could indeed change the game for industries that have long been tethered to outdated control systems.

Sources

ABB launches ‘Automation Extended’ to help industries modernize control systems without disruption