Atul Govil, Chief Transformation Officer, Head (SAP & IT), India Glycols

What IIoT is certainly not- it is not about replacing current Systems (considering some Automation/Control infrastructure that have been around for a decade or more and will continue such for more years) with completely new systems. To achieve holistic enterprise control, break down enterprise silos and facilitate better business control, we carefully integrated and leveraged the current automation systems to run our Processes, Operations more efficiently, safely, profitably with greater flexibility
and responsiveness to current volatile market conditions. Additional sensors, interfaces were deployed to setup a contextual, real time decision support on aspects linked to vital Assets & Plant Processes performance.

While most of our IoT use cases are Brownfield, considering costs, efforts and system’s downtime impact of replacing entire OT infra can be prohibitive.

Certain IOT interventions, particularly linked to track & trace, logistics costs and performance optimisation were done as Greenfield, set up from scratch in a new environment with no legacy code interfaces, no integration with pre-existing systems.

Why now, why this can be an existential issue: Smart, connected factory & logistics setup provides us the following:

Accuracy, Timeliness of data availability allows us to make course corrections, avoids losses and delays in deliveries against promise to Customer.

Provides Cost savings (including Batch costs & digitally enabled workflows to a significant extent. Customers get products at a more competitive price than those who rely on manual processes.

Able to avoid Customer rejections with detection of any abnormality while production work is in progress. Facilitates necessary modifications in the processes, to eliminate identified root causes.

Ability to access information on critical parameters from anywhere, at any time, on any device – this helped us during lockdown situations and also during off-office hours considering most of our plant operations run 24/7. For select business segments, Information linked to likely time to delivery, distance from destination is provisioned to the Customer on their mobile handset. Earlier there used to be several non-productive, follow ups to track the delivery status.

Better management of safety (critical from EHS standpoint), reduce emissions impact (through efficient running of Boilers, Turbines, Cooling Systems, Other key plant processes) and importantly breaking down of enterprise silos. The technology has
provided contextual integration of upstream, downstream production processes and associated Utility systems.

Last but not the least, helps automate mundane tasks like data collation from disparate systems and creating MIS manually for review by senior leadership team, QA, Tech Services team, thereby reducing the need for human intervention (& repetitive efforts) for such tasks.

Issues to keep a close watch when you start your IOT journey.

The adoption of IIoT in Brownfield setups created new connectivity from certain legacy systems to Enterprise ICT or cloud based systems, thereby increasing the potential for safety and security related breaches. Rising cases of cyberattacks & digital fraud globally have triggered an urgent need to ensure a secure fabric on digital applications. Any security breach can harm the user, stakeholders, damage their trust and slow digital adoption.

Interoperability with legacy, closed systems to be validated. Likewise interoperability and seamless integration of cross-department team members is fundamental to the project.

Buying Tech does not assure us its desired adoption. Re-skilling, up-skilling, change management interventions are key to drive success and avoid conflicts. In practice, that will mean continually orienting employee development around
digital skills.

What is next on the radar?
Optimally priced computing power, communication bandwidth and analytical sophistication is opening doors to smarter workplaces, new innovations and new business models.

Setting up Video Analytics leveraging 5G & the expansive video streams available through existing cameras.

Setting up a Renewable energy generation system with a leading Renewables player, to drive & achieve sustainability objectives.

Expand use of AI, ML for digital twins, predictive maintenance, smart robotic processes automation & augmented intelligence of the workforce.