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As plant floors become more connected – from the equipment to the systems – the way manufacturers manage internal and external access to that technology is evolving. Digitization has myriad benefits, but it also comes with inherent risks, and IT/OT convergence doesn’t make it any easier. Every manufacturer should be concerned about the rise in ransomware and cyber attacks that have taken advantage of the vulnerabilities specific to the OT environment.

Sometimes, when we’re presented with disruptive change – like we are today with the industrial IoT – we can learn a lot by looking to the past. For decades, industrial producers have built their production systems by turning to a mix of vendors – distributors, machine builders, system integrators and many others.

Traditional methods of machine and production line design, commissioning and startup can be costly and impede speed to market. CPG producers are turning to emulation as a tool to research, test and validate their process in a virtual space. Before making physical changes to plant layout and workflow.

When is the best time for downtime? For most, the answer is, “No time is a good time.” The real question becomes, how long can your aging DCS limp along before an upgrade is unavoidable?Today’s pulp and paper mills operate under constant pressure to reduce production costs and increase yields. “If it isn’t broken (yet), don’t fix it,” is a risky approach and with any legacy system, and especially a DCS that has seen more productive days.

Plant managers and technicians have their hands full – not only are they responsible for ensuring day-to-day operations are status quo, they are also tasked with helping to increase production and revenue. So when problems come up, as they inevitably do, there’s nothing like knowing you’ve got back-up at the ready, 24-7.

Wouldn’t it be nice to know when the devices in your home are on their last legs, so you could fix or replace them before they break? Just imagine how much better life would be. No more air conditioner breakdowns in the dog days of summer. No more unusable dishwashers on busy weeknights. No more computer crashes before you can back up your family photos and personal files.

You’ve been through it before. Just days away from a scheduled plant or platform launch and you’re scrambling to connect OEM skids and at risk of missing your launch deadline. Almost every oil and gas company has experienced the chaos that comes with trying to finish a start-up in its final days. The good news – this doesn’t have to be your status quo.