Digitalisation seems to be on everyone’s mind as chemical industry professionals look to take advantage of exciting new technologies to improve processes, reduce costs and increase quality and safety. Nokia’s recent survey of industry leaders across Europe and the US asked C-suite executives, process engineers, supply chain managers and digital transformation engineers what new technologies they were incorporating and what their digital ambitions were for 2023. The simple takeaway from the survey is that everyone is putting a priority on digital.
End-to-end optimization
Most of the individual processes within a chemical or plastics facility today use digital measurement and control for managing production and have been doing so for decades. The systems tend to be purpose-designed and -built with proprietary hardware and software, including data formats that are incompatible with neighbouring processes and systems. As a result, companies have a lot of disconnected data lakes with little or no sharing between them. Bridging between legacy systems is expensive and the more that custom integration is used, the more difficult upgrades become.
According to the survey, this poses several challenges. For a factory manager responsible for optimising overall operations, this means that as well as isolated data lakes, many process areas have been too expensive to properly monitor. End-to-end optimisation data is incomplete, making analysis complex and time-consuming with no real-time dashboards reflecting the end-to-end process. This slows down decision-making, introduces more scope for human error, and makes management reactive instead of proactive.
New technologies like inexpensive, easy-to-install sensors, robust wireless connectivity and edge-hosted AI and machine learning software are helping to bridge the gaps in the data. Sensors now measure things like pressure, temperature, flow, and levels for processes that weren’t affordably measured before. One survey participant described IoT as enabling them to monitor “thousands of times more information” than in the past.
For most small to medium enterprises, the early stages of their digital transformation tend to focus on filling in the data picture by deploying sensors and storing and processing this new level of information. For the largest players, their challenge is making the data useful in real time. Many large players are already using digital twins or automated models that run alongside actual processes. They are not only able to see what the process is currently doing but can simulate where it is going or could go. This enables them to control for quality, adjust for resource and energy savings and avoid potentially dangerous outcomes.
The ultimate objective, which few of them have achieved yet, is to implement AI and machine learning (AI/ML) analytics to fully optimize their processes. A common roadblock is still a lack of good quality real-time data in some areas of their operations.
Workforce challenges
One of the other problem areas where managers see digital technologies helping was around knowledge management and training. As the working population ages, it poses recruitment challenges as the baby boomers retire. It is not just an issue of replacing workers, but the loss of senior engineers and how to pass on their knowledge to a younger cohort. Applying virtual reality for training and augmented reality for supplementing workers’ knowledge on the floor are seen as potential new digital solutions.
The other aspect to note is the importance that new recruits put on working in a digital workplace. They are easier to attract and retain if they are provided with digital tools to perform their jobs. Many companies are striving to provide workers with connected devices that display real-time data and insights to help them perform faster and more effectively wherever they are. This hands-on digitalisation should cover everything from scrutinizing raw material supplies to tracking customer deliveries and everything in between.
Simplifying complexity
As chemical industry players evolve their digital technologies, the goal is to reduce complexity and improve resilience. They need to move beyond the OT approach of deploying technology on a use-case basis and think in terms of platforms. IoT, edge computing and AI/ML analytics all supported by campus-level industrial wireless networks are the platform that will take small and large players alike to the next level in automation and end-to-end digital transformation.
Want to dig deeper into what chemical industry leaders are planning in the digital space? Download our full report of the survey here.