Remote monitoring and control

Remote monitoring
and control

Digital twin technology not only contributes to significant time and cost savings during commissioning, but also in the day-to-day management of facilities. Traditional wisdom would have it that manufacturing is a manual process that requires the physical presence of operators. However, remote monitoring via real-time video feeds is well established and the digitalization of other processes, accelerated by the COVID pandemic, has proven that many discrete manufacturing processes can not only be monitored, but managed remotely.

With the use of digital twin technology it should be possible to create a virtuous circle – identifying new opportunities for digitalization which could, in turn, contribute to a more comprehensive twin.

Remote operations management requires access to detailed, real-time operational and performance data. Where maintenance activity may have been based on physical observation, analysis of remote data can establish priorities and preventative schedule in absentia, reducing engineer time on-site. IoT connected equipment and assets makes remote monitoring simple.

With access to the right data, scenario planning and process optimisation initiatives can take place in a virtual environment. This means a wide variety of potential configurations or settings can be simulated without the need to “bend metal” or physically adjust the production line. Simulation can also support remote learning for operators, reducing the need for “hands-on” training.

Access to critical data at the right time, in the right volume and at the right velocity, is essential for remote operations management. However, it also requires a platform for effective analysis, reporting and communication. Process automation certainly has a role to play in remote management, as the objective is to minimize the need for a physical presence on the manufacturing floor.

A move to remote monitoring and control also enables one individual to carry out the work of many. Without the need to be physically present at a site, a single management interface can be used to monitor multiple sites simultaneously. Efficiency benefits extend beyond simply saving on travel time and could include: