Why Smart Automation Fails Without Proper Interoperability Implementation

Automation is the goal for every facility, because its anticipated promises for competitive advantage are too great to ignore. However, many embrace the trends without careful planning, purchasing expensive software and equipment without considering how it will sync and embed with existing legacy systems. These reasons explore why interoperability is the most essential element to a successful transition to Industry 4.0 and 5.0 systems that are sustainable and scalable for corporations.

Crippling Data Silos

If operators fail to consider interoperability, they will have even more data silos than they had before. In fact, many industries suffer from disparate and disconnected data and information sources that they want smart automation to address. Failing to think about how old systems and new tech mesh together could create even more barriers to seamless communication and information transfer. 

Consider how an enterprise resource planning (ERP) system communicates with a robotic arm. If it is not compatible, then it will never gain value from the images it sees or the performance metrics it maintains. On the floor, technicians can inspect and verify device compatibility before purchasing new automation tools. This way, every defect and key performance indicator is tracked and stored in connected systems.

Inefficient and Error-Prone Workflows

With data silos come inefficient work processes. The idea behind automation is immediate communication. The visuals and metrics from one machine immediately translate to someone’s desk thousands of feet away. They supply reports and spreadsheets without manual entry. This is the dream. If the machines are not compatible, then workers have to bridge the gaps. These labors leave workers fatigued and resentful of modern technologies, especially when the equipment fails to deliver on the promise of simpler operations.

Someone may have manually delivered paperwork from a machine because the information will not sync to the new software. Teams may spend weeks, rather than days, gathering data for an audit. Neglecting interoperability will reintroduce even more cumbersome, manual processes back into a place that promises to be a pillar of automation and innovation.

Lack of a Single Source of Truth

Automated systems gather data from countless assets and place them into a single, user-friendly dashboard. The promise is transparency, visibility and accuracy, reducing human error through manual data entry. If nothing communicates, or even if only some assets communicate effectively, there are still multiple places where usable, true data exists — but it is not unified. These resources may provide conflicting or incomplete pictures of operational reality.

A programmable logic controller could tell you how many units passed through production that day. The manufacturing execution system could read something completely different. Then, workers have to spend time identifying the discrepancy and determining which is more accurate. The financial and time-related risks associated with these miscommunications are more costly than the machinery in the long term.

Impossibility to Scale

Incorporating a single automation system that is not compatible with legacy devices is a problem. Incorporating 10 more is a nightmare. The scaling problem becomes more convoluted the more integrations a facility attempts to make without considering interoperability. Then, stakeholders have to design a plan exclusively to fix these communication problems, when it could have been considered during isolated pilot projects before purchases were made.

Technicians should frequently test and review automation systems before expanding into new technologies. Then, they can use process discovery to see what they really need to improve, versus what is just a current industry trend.

Inability to Leverage AI and Advanced Analytics

It is inarguable — artificial intelligence and data analytics are synonymous with competitive advantage in the modern manufacturing landscape. Old technologies cannot handle AI due to their energy consumption and computational power requirements. 

Therefore, if companies want to build their dream automated organization that leverages the power of AI, they have to understand what these tools need to run. If new computers, robots and software cannot run AI processes, then adopting the model and training them will be a waste of company resources, leading to disruptions and downtime.

Increased Cybersecurity Vulnerabilities

Legacy technologies pose greater cybersecurity risks than modern tools because they are not actively maintained. They do not regularly get patches to protect them against novel threats. Therefore, they are easy to exploit. Additionally, hackers who gain access to modern systems could move laterally or adjacent to a facility, taking advantage of assets of all kinds. 

Workers need to work together to make machines interoperable so they can embrace the same robust digital defenses that meet modern standards. Simultaneously, teams need to extract confidential and business-critical information from legacy systems that are at high risk of exploitation. This will keep information safe and protected while undergoing digital transformation.

Poor or Negative Return on Investment (ROI)

A poor return on investment for expensive automation machinery should be motivation enough to consider interoperability. High ROI occurs when teams can immediately bank on a machine or program’s highest-value operations. If workers spend years compensating for a lack of planning or doing manual processes alongside them, then it will take much longer to justify the costs.

During these growing pains, other costly mistakes could occur. In addition to the growing cost of cybersecurity breaches, inefficiency, human error and inability to scale also prevent businesses from reaching their fullest potential. They may even lose stakeholder interest if they notice that these transitions did not yield the results they anticipated. If overall equipment effectiveness is verified at the beginning of these projects and automated troubleshooting and support systems are in place early in the life cycle, then ROI can be easier to achieve.

Unlocking a Factory’s True Potential

To earn the benefits of automation, stakeholders need to create an interoperability blueprint before they start dreaming of how the company will function in the coming quarters. It is not enough to hope for the best, as every machine and program may have limits and specifications for what they can function with, potentially rendering a purchase obsolete on installation day. However, if everyone collaborates, including production workers, engineers, IT professionals, and everyone in between, then enough research can occur to find the perfect solutions.