General benefits
The concept of modelling is used extensively in the design of complex physical products e.g. cars and buildings. General benefits of this approach include:
- Easier requirements gathering
- Enhanced understanding across multiple teams leading to better feedback and collaboration
- Faster error detection
- Better conflict resolution
- Continuous evaluation
- Faster iteration
- Concurrent working
- Reduced cost
These benefits are replicated when using a control system design and modelling tool. Initially the process, or individual elements of the process, can be quickly wire-framed out forming a low fidelity version of what one is trying to achieve. This low fidelity version can be continually built upon during the project. At the end of the design phase there is a comprehensive model of what is required of the control system, and the interaction of that control system to all other relevant systems. The beauty of this approach is that this model can then be used as a basis for a corporate standard or best practice. Specific benefits of using a control system modelling tool include:
Once-off project benefits
- Timely and more accurate cost estimation
- Significant reduction in design hours (whether internal or external)
- Significantly reduced FDS (functional design specification), URS (user requirement specification) and FAT (factory acceptance test) documentation hours
- Ability to produce outline eMBR (electronic master batch record)
- Increased quality of documentation
- Ability to have cross discipline interactive design reviews at all stages of project lifecycle
- Reduced time to market
- Increased collaboration
- Emulation of control system interaction with ERP (enterprise resource planning), WMS (warehouse management system), LIMS (laboratory management system) or any other system for improved supplier engagement and control
Ongoing benefits of having modelled a plant, line or process
- Training and simulation
- Process improvement
- To assess ‘what-if’ scenarios for Process Analytical Technology, continuous processing, real time release, or any other proposed system change
- To assess possibilities for IT / OT convergence and Industrial Internet of Things / Industry 4.0 implementations
- Initial model available for entire organisation to review and improve
Benefits of using concept across organisation
- Use corporate standards and models to further enhance cost, time and risk savings
- Understand and apply best practices across plants, regardless of control platforms used
- Performance benchmarking
For more information see Detailed Benefits.
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