Automation has been a driving force in shaping how we produce goods and manage industrial processes. From the early days of Alfred Nobel’s dynamite manufacturing process to the current fourth industrial revolution, technological advancements have revolutionised manufacturing efficiency, safety, and productivity. Hydraulic test and measurement specialist, Hydrotechnik, explores the functionality of process displays in the context of automation, emphasising the importance of local control and clear visibility for operators.

In the late 19th century, after an explosion in its Swedish nitro-glycerine production facility where, among the workers who lost their lives was Emil, brother of Alfred Nobel, the inventor of dynamite faced a critical challenge: how to prevent casualties during the production of explosives. Dynamite, a powerful yet volatile substance, requires careful handling and precise mixing of ingredients. Nobel’s solution was to design a safer manufacturing process that minimised human intervention and reduced the risk of accidents.

Nobel’s dynamite factory in Ardeer, Scotland, became the largest explosives factory in the world. He introduced innovations such as gelignite (a stable form of dynamite) and improved safety measures. However, the heart of his success lay in automating critical processes. By mechanising tasks like mixing nitroglycerin and other ingredients, Nobel significantly improved efficiency while minimising the danger to workers.

The role of process displays

Fast forward to the present day, where the fourth industrial revolution (4IR) is reshaping industries worldwide. The 4IR encompasses technologies, including artificial intelligence, robotics, the Internet of Things (IoT), and advanced digital production. Within this context, process displays play a crucial role in modern manufacturing. Let’s explore their functionality:

Real-time monitoring: Process displays provide operators with real-time information about production lines, machinery, and critical parameters. Operators can monitor variables like temperature, pressure, and flow rates, ensuring that processes remain within safe and efficient limits.

Local control: Local control through process displays allows operators to make immediate adjustments. Operators can intervene promptly when anomalies occur, preventing quality issues or production disruptions. For example, if a temperature exceeds the desired range, an operator can adjust the cooling system directly from the display.

Clear visualisation: Process displays offer a clear view of the entire production process. Operators can visualise the flow of materials, identify bottlenecks, and track product movement. Clear visualisation enhances decision-making and reduces the risk of errors.

Quick access to critical functions: Buttons and controls on process displays allow operators to switch views, adjust settings, or halt processes instantly. Whether changing a recipe, stopping a conveyor belt, or initiating maintenance, quick access to critical functions improves efficiency and prevents losses.

Preventing losses and enhancing efficiency

Efficiency and productivity are paramount in today’s competitive manufacturing landscape. Here’s how process displays contribute:

Reducing downtime: Downtime decreases when operators can swiftly address issues using process displays. Whether recalibrating sensors or troubleshooting a malfunction, every minute saved translates to increased production capacity.

Minimising product loss: Imagine a scenario where an undetected fault causes a chemical spill. With process displays, operators receive immediate alerts locally and can shut down the affected section, preventing further loss. Clear visibility ensures that no abnormality goes unnoticed.

Adapting to changing demands: Changing process parameters on the fly allows manufacturers to adapt to varying production demands. Local control ensures flexibility, whether adjusting batch sizes or switching between product lines.

Conclusion

Automation has come a long way from Nobel’s dynamite factory to the 4IR. Process displays empower operators, providing them with the tools to enhance efficiency, prevent losses, and maintain safety. As we continue to embrace technological advancements, let’s recognise the critical role of process displays in shaping the future of manufacturing.