future of process automation
Dump Trucks transporting Platinum ore for processing

Last Updated 3 months ago by Kenya Engineer

In today’s fast-evolving industrial landscape, automation plays a pivotal role in transforming operations, optimizing efficiency, and promoting sustainability. We had the privilege of interviewing Jehrene Devagopaul, Product Manager for Process Automation at ABB South Africa, who shared her valuable insights on the current trends, challenges, and future of process automation in the Sub-Saharan region.

From digital transformation to the integration of advanced technologies such as IoT, AI, and machine learning, Devagopaul delves into how ABB’s cutting-edge solutions, like the System 800xA, are shaping the future of industries like mining, manufacturing, and energy. Join us as we explore how ABB is empowering industries with innovative, scalable, and sustainable automation solutions that meet the demands of today and tomorrow.

Read on for an in-depth discussion on these key topics!

Can you briefly describe your role in leading process automation efforts at ABB South Africa? What key projects are you currently working on?

Jehrene Ann Devagopaul, Automation Product Manager, ABB South Africa
Jehrene Ann Devagopaul, Automation Product Manager, ABB South Africa

I am responsible for managing the technical and commercial portfolio of Industrial Automation Solutions such as our world leading System 800xA DCS for the Sub-Sahara Africa region. I support our customer and partners with technical advice, architecture best practice concepts and recommendations to empower the customer to get the most out of our technology hardware and software solutions.

 Industry & Trends

What are the latest trends in process automation that are shaping industries in South Africa and what role is ABB playing in this?

Companies are increasingly embracing digital transformation, integrating IoT devices and smart sensors to collect real-time data, which enhances decision-making and operational efficiency. The move towards Industry 4.0 is also prominent, with a focus on smart manufacturing and interconnected systems that leverage advanced robotics, machine learning, and data analytics to optimize production processes.

Additionally, there’s a strong emphasis on sustainability and energy efficiency. Industries are seeking automation solutions that not only reduce energy consumption but also minimize waste, particularly in sectors like mining and manufacturing. The demand for remote monitoring and control has surged, with a strong driving force for safer operations and connectivity to your assets from anywhere at any time and as we advance in the direction of interconnected systems, the focus on cybersecurity is accelerated.

ABB maintains our world leadership position in the DCS (distributed control system) portfolio by continuous investment into R&D to provide continuous enhancements that convert to tangible benefits to our customers through the applications of interfaces, libraries and visualization techniques that ultimately empower the customer with world class Industrial Automation.

ABB’s Role through the Automation portfolio

ABB’s System 800xA is a cornerstone of its automation offerings, designed to effectively address these trends. This platform integrates control, safety, and automation functions into a single environment, enhancing operational efficiency and simplifying the management of complex systems.

With advanced data visualization and analytics capabilities, System 800xA empowers organizations to make informed decisions based on real-time insights, supporting their digital transformation initiatives. Its scalability makes it suitable for various industries, allowing companies to start small and expand their automation solutions as their needs evolve.

Moreover, the system’s features for remote access and control enable operators to monitor and manage processes from anywhere, addressing the growing demand for operational continuity and safety. ABB places a strong emphasis on cybersecurity within System 800xA, aligning with the increasing need to protect industrial control systems from cyber threats. Additionally, by adhering to industry standards, the system promotes compliance and interoperability, making it easier for companies to integrate new solutions.

Through the implementation of System 800xA, ABB significantly advances process automation across various sectors in South Africa. In the mining sector, for instance, the system enhances safety and efficiency in operations while managing complex processes.

In manufacturing, it supports the development of smart factories by integrating diverse automation technologies, thus promoting productivity and resource optimization. In the energy sector, System 800xA helps companies optimize their processes, contributing to sustainability goals.

 

 Technology & Innovation

What cutting-edge technologies or innovations are you most excited about in the process automation space at ABB?

ABB Ability™ MineOptimize portfolio, which integrates electrification, automation, and digital technology to enhance mining operations through real-time monitoring and control, optimizing both operations and energy usage. Notably, ABB has been delivering this cutting-edge technology for many years already and the real topic of interest it understand the rate of adoption by our customers that is now accelerating with the pressure of cost and also decarbonization initiatives.

Key Pillars:

  1. Automation Solutions:
    • Minerals Library: best practice DCS library to standardize for efficiency & future upgrades
    • Audit Report: tracking of every signal change and operator interaction
    • Power Control Library: best practice DCS library of Electrical equipment
    • CameraConnect: Real-time monitoring and surveillance.
    • Process Simulation: test and simulate performance prior to live implementation
    • IROC: Central hub for remote monitoring and control.
  2. Underground Mine Solutions:
    • Ventilation Optimizer: Improves airflow and energy efficiency.
    • Dewatering Library: Manages water removal effectively.
  3. Mine House Solutions:
    • Stockyard Management System (SYMS)
    • Condition Monitoring for Belts: proactive monitoring of conveyor belt infrastructure to empower early maintenance interventions before they become downtime events
    • Battery Charging and Trolley Assist Control: monitor and control of Battery Electrical Vehicle charging and also Trolley Assist solutions for large Mine Vehicles
  4. Supporting Services: Comprehensive services for implementation, maintenance, and continuous improvement.

 

How is ABB incorporating artificial intelligence (AI) and machine learning into its process automation solutions?

  • Predictive Analytics: Leveraging machine learning algorithms to analyze historical data, ABB helps predict equipment failures before they occur, shifting maintenance strategies from reactive to predictive.
  • Smart Control Systems: AI enhances control systems by enabling adaptive control strategies that optimize processes in real-time based on changing conditions.
  • Data-Driven Insights: By applying AI to vast datasets, ABB enables organizations to uncover patterns and insights that drive informed decision-making and operational improvements.
  • Autonomous Operations: AI and machine learning facilitate the development of autonomous systems that can self-optimize, improving efficiency and reducing the need for human intervention in routine tasks.

 

Challenges & Solutions

What are the biggest challenges facing process automation in South Africa, and how is ABB addressing them?

South Africa (Africa) encounters several significant challenges in the adoption of process automation. One major issue is aging infrastructure, which hinders the effective implementation of modern automation technologies. This is further complicated by a substantial skills shortage, as there is a lack of trained labor in advanced automation and digital technologies, making it difficult for companies to successfully deploy new systems.

Additionally, many organizations remain hesitant to invest in new automation solutions due to perceived high upfront costs, particularly in the context of a challenging economic environment.

ABB is committed to empowering clients to navigate the challenges of process automation. We partner with organizations to modernize their existing systems and infrastructure, ensuring they can effectively support advanced automation technologies.

ABB’s scalable automation solutions allow businesses to begin with manageable investments and expand as they experience positive returns, making automation financially viable and sustainable in the long term.

 

How does ABB ensure that its process automation solutions are energy-efficient and align with sustainability goals?

ABB is dedicated to optimizing energy usage through automation solutions that monitor and manage energy consumption in real-time, ensuring efficient operations. We support the integration of renewable energy sources into these systems, enabling companies to reduce their carbon footprint and embrace sustainable practices.

Our focus on lifecycle optimization enhances efficiency and minimizes waste through predictive maintenance and continuous monitoring of equipment. ABB collaborates closely with clients to align automation solutions with their sustainability goals, ensuring that operations remain environmentally friendly. Additionally, we leverage advanced data analytics to identify inefficiencies and promote better resource utilization, further contributing to our clients’ sustainability efforts and driving operational excellence.

 

Safety & Reliability

Process automation often involves critical safety considerations. How does ABB ensure safety and reliability in its automated systems?

ABB prioritizes safety and reliability in its process automation solutions through a comprehensive approach. The company designs its systems with integrated safety features that comply with international standards, helping to prevent hazardous situations.

To proactively address potential risks, ABB conducts thorough risk assessments before implementation, allowing for the design of systems that effectively mitigate hazards. Extensive testing and validation ensure that automation solutions perform reliably under various conditions, with comprehensive simulation and real-world testing verifying their safety.

Continuous monitoring capabilities are built into ABB’s systems, enabling real-time oversight of operations. This facilitates quick detection of anomalies and timely interventions to maintain safety. Additionally, ABB offers training programs to equip operators and maintenance personnel with the knowledge necessary to manage automated systems safely, complemented by ongoing support to reinforce safety practices.

ABB’s commitment to regulatory compliance further enhances the reliability of its solutions, ensuring that all systems meet relevant local and international standards. In an increasingly connected landscape, robust cybersecurity measures are also implemented to protect against potential threats that could compromise safety and operational integrity.

Through these integrated strategies, ABB effectively ensures the safety and reliability of its automated systems, empowering clients to operate confidently in critical environments.

 

 Future Outlook

Where do you see the future of process automation heading in South Africa and Africa at large over the next 5 to 10 years?

I envision there will be an ongoing wave of digital transformation as industries increasingly integrate advanced technologies like the Internet of Things (IoT), artificial intelligence (AI), and machine learning. ABB is at the forefront of this shift, enabling real-time data collection and analysis to enhance decision-making and operational efficiency.

Additionally, the adoption of Industry 4.0 principles will accelerate, with a focus on smart manufacturing. Companies will implement interconnected systems that leverage automation, and data analytics to optimize production processes and reduce costs.

Sustainability will play a crucial role, as organizations prioritize energy-efficient automation solutions.

As automation systems become more interconnected, the need for enhanced cybersecurity will intensify. Companies will invest in advanced security measures, and ABB’s expertise in cybersecurity will be essential in this space, ensuring the integrity and safety of operations.

Remote monitoring and control solutions has already shown great advantages, and the demand will continue to increase, to allow for enhanced operational continuity.

 

Closing Thoughts

What advice would you give to companies in South Africa that are just starting their journey toward automating processes?

It’s crucial to start with clear objectives that guide your strategy. Conduct a thorough assessment of existing processes to identify where automation can add the most value, focusing on solutions that alleviate repetitive tasks and bottlenecks. Invest in training to ensure your workforce is equipped with the skills needed to operate and maintain automated systems.

Choosing the right technology is essential; leverage the expertise available to you from ABB consultants to select solutions that align with your specific needs and can scale as your business grows.

Emphasize change management by engaging employees early in the transition and communicating the benefits of new systems. Monitor and measure outcomes through key performance indicators to identify areas for improvement. Stay adaptable to the evolving landscape of automation, remaining informed about emerging technologies and trends.

LEAVE A REPLY

Please enter your comment!
Please enter your name here