The adoption of an open, flexible automation platform helps Oems and end users meet the challenges of traditional production while addressing new issues such as supply chain, labor shortages and cybersecurity.

The traditional challenges faced by original equipment manufacturers (Oems), machine builders, and the end users they serve often involve maximizing productivity, quality, and uptime. While these fundamental concerns remain important, there are other important external issues that are increasingly affecting Oems and their customers. Supply chain scarcity, a shortage of skilled labor, and cybersecurity concerns are increasingly affecting how Oems supply their equipment, as well as end-user demand.

In years past, the technology and capabilities needed to solve all of these problems may have been available only in a few flagship controllers, but now the options for automation have greatly expanded. Modern automation options, including high-performance compact controllers for all machine types, can help Oems and end users solve problems efficiently.

The modern and flexible automation platform allows it to continue to meet typical machine control needs while applying the latest innovations such as the evolving Industrial Internet of Things (IIoT) capabilities, providing new options for meeting the latest challenges faced in the current business environment. Adopting these advanced technologies will help Oems and end users meet many challenges while improving their partnerships.

01 Adapt and overcome supply chain constraints

Supply chain issues pose challenges for design and machine operations. When designing, developers may find it difficult to find suppliers for various components and smart devices. Once in production, due to changes in material sources and changes in manufacturing needs, parts may need to be replaced quickly, or production will be interrupted.

When designers choose an automation platform based on open hardware, software, and communication standards, it is best to integrate flexibility into machine control (Figure 2).

When machine automation architectures are built on platforms that support Gigabit Ethernet for integrated switching, and have native support for open standards and protocols, as well as modern programming capabilities, tight coordination can be achieved.

This will create a more open system and allow components to be replaced if something goes wrong in the supply chain, including, for example:

Devices with Gigabit Ethernet and integrated Ethernet switches.
Provides a development environment for IEC 61131 and more modern programming languages.
Support for open standards-based industry protocols such as secure OPC UA, Profinet, Modbus TCP, IO Link, and DNP3.
An open platform with a scalable runtime environment configured with a common toolset gives designers the flexibility to choose the most suitable device to meet their needs. Once the machine is up and running, these features can help designers make changes in real time to optimize operations, reduce risk, and improve competitiveness.

02 Match workforce skills with programming methods

While the traditional IEC 61131 industrial programming language is still important, this is all being transformed as the next generation of workers enters the engineering and maintenance workforce. New employees may be more familiar with modern programming languages such as C/C++ and Python. Advanced applications, such as data aggregation and analysis utilizing machine learning (ML) or artificial intelligence (AI), are best implemented in these languages.

Other recent programming approaches, including the use of portable code bases, promote coding practices that are reusable, extensible, and maintainable. Tag-based programming, user-defined data types (UDTs), and function blocks (UDFBs), implemented with a common set of automated tools and extensive built-in libraries, make it easy to standardize code, deploy quickly, and reduce risk.

03 Build automated systems that are resilient to cyber attacks

As automation platforms become smarter and more connected to higher-level systems and the Internet, cybersecurity issues become critical. To reduce the risk of cyber attacks and provide appropriate protection, each layer must have built-in security, including:

Product supply chain (using tools to verify whether products have been tampered with, traceability of product components);

■ Hardware boot system;

■ Core operating system services;

■ Software application;

■ Communication and networking.

A key feature of modern automation platforms is open connectivity. However, open connectivity is most effective only when it is designed with complete security in mind as a complement.