Modernization with Automation Lifecycle Analysis

| Anita O'Brien

Automation Lifecycle Analysis

Does the Thought of Unscheduled Downtime Keep You up at Night?

As a plant manager, a top priority is always to keep the plant up and running and ensure minimal downtime. You work hard to make certain that production facilities and warehouses are safe for your employees. And you are always looking for ways to increase productivity and decrease plant operating costs. Plant modernization can help you increase the bottom line by adopting new technologies that increase efficiency, reduce operating and production costs—which in turn helps you sleep better at night. But how do you get started? An Automation Lifecycle Analysis is a good place to start.

50% of Downtime is Caused by Aging Equipment

As a manufacturer, you are challenged to leverage your automation investment to keep plant assets running efficiently. Critical equipment failures and lack of adequate spares impact your ability to keep assets optimized. Aging equipment often does not provide the visibility or reliability you need.

Actionable Intelligence and Analysis

An Automation Lifecycle Analysis is much more than simply counting parts. It’s a thorough analysis of your critical plant assets and their condition. This service provides the knowledge needed to help you make data-driven decisions regarding the support and obsolescence management of your installed base assets. With this service, we can help you better understand and pinpoint your lifecycle risk by site, area, line, machine, and panel. By optimizing your Maintenance, Repair, and Operations (MRO), we’ll help ensure you have the right parts, in the right place, at the right time.

Automation lifecycle analysis allows you to:

  • Identify critical assets
  • Achieve a life-cycle assessment of all automation assets
  • Reduce overall inventory and storeroom costs
  • Define viable and profitable modernization options to devise a modernization plan
  • Confirm the accuracy of spare parts, replacements, and other key components
  • Reduce risk from obsolescence

Product Life Cycle Status

When you clearly identify a product’s current life cycle stage, it makes it easier for you to proactively plan and manage the transition from existing equipment to new technologies. Products are typically categorized into one of four life cycle stages:

Automation Lifecycle Analysis Process

Note-1: Outages on specific items may occur prior to the Discontinue date. Note-2: Limited stock may be available in run-out mode, regionally.

  1. Active: Most current offering within a product category
  2. Active Mature: Product is fully supported, but a newer product or family exists.
  3. End of Life: Discontinued date announced – actively execute migrations and last time buys. The product is generally orderable until the discontinued date.
  4. Discontinued: New product no longer manufactured or procured.

If all your equipment uses active product components, that’s great! You will be able to easily source spare parts and replacements. If most or all your equipment uses discontinued products and you have a line go down, it may not be possible to find a replacement. This could represent an extended downtime event and lost manufacturing capacity for one very small part — a scenario you want to avoid.

Ask yourself these questions:

  • Do you have an aging infrastructure?
  • Could you benefit from broader visibility into your plant assets?
  • Are you concerned that you have the right spare parts if a critical line has a failure?
  • Are you looking to reduce your inventory levels without adversely affecting downtime?

If you answered yes, to any of these questions, you should consider an Automation Lifecycle Analysis. Don’t wait until it is too late. Contact us to learn more about the Automation Lifecycle Analysis services from Horizon Solutions and Rockwell Automation®.