Driving Digital Transformation through Automation: Connecting the Physical to the Digital
Welcome to the third article in Interstates’ Guide to Digital Transformation series. In this series, we will delve into the comprehensive approach Interstates takes to guide companies through the complex yet rewarding journey of digital transformation. Over the course of these articles, we will define what digital transformation entails, explore the four phases we recommend for a successful digital transformation, discuss our available solutions for digital transformation, and highlight what sets Interstates apart from competitors. If you missed it, read the previous post in the series, Building the Foundation for Digital Transformation: OT Infrastructure & Security. Check back later to see the last article to learn all about using data in your plant.
In manufacturing, staying ahead of the curve means embracing digital transformation. At the heart of this transformation lies automation, the key to connecting the physical world of equipment and processes to the digital realm of data and insights. Interstates’ approach to industrial automation enables you to optimize performance, improve efficiency, and make informed decisions. In this third installment of our digital transformation series, we delve into how automation is the center of the digital transformation journey.
The Role of Automation in Digital Transformation
Automation is more than just control systems for equipment—it’s about integrating the physical with the digital. Companies can unlock valuable insights and make better business decisions by automating processes and integrating advanced technologies. Michael De Boer, Director of Automation at Interstates, highlights automation’s critical role in this journey: “Automation is often the first step down the digital transformation path. It enables businesses to collect real-time process data, which tells the story of what’s happening on the production floor. This data empowers production leaders to optimize performance and connect the dots between previously unrelated operations.”
Interstates offers a range of services in automation, including automation retrofits and upgrades, new automation services, and I-Control—a control platform that optimizes production by managing multiple inputs and outputs while balancing factors like cost and quality for maximum efficiency. These services are tailored to help you modernize your systems, improve operational efficiency, and enhance your overall production capabilities.
Key Automation Services for Digital Transformation
- Automation Retrofits and Upgrades
Many manufacturers start their digital transformation by modernizing outdated equipment. “This step is often the enabler for future advancements,” says De Boer. Upgrading legacy systems extends the life of existing assets and lays the groundwork for integrating advanced digital solutions. - New Automation Solutions
For those looking to implement cutting-edge automation technologies, Interstates works with clients to design solutions that enhance the operator experience by removing mundane tasks and enabling predictive maintenance. “Blue-sky conversations are common in this area,” says De Boer. “From automatic sampling and advanced process control to predictive models, these solutions help operators focus on higher-value tasks and improve overall plant performance.” - I-Control: Advanced Process Control
Interstates’ I-Control solution offers a sophisticated approach to managing production by optimizing processes based on real-time adjustments. De Boer explains, “With I-Control, clients can achieve better consistency in their products while reducing the use of expensive ingredients. The platform’s predictive maintenance capabilities and self-adjusting batching systems deliver both cost savings and improved quality.”
Navigating the Automation Journey
Digital transformation through automation is not a one-size-fits-all solution. Organizations can be at many different stages of the journey, from using basic automated work cells to fully integrated systems using AI and predictive models. “It’s a journey where each company must assess their current state and map out the steps needed to reach their goals,” says De Boer. He advises clients to start with a vision but focus on quick wins to gain momentum. “Many companies struggle to get started because they overcomplicate the scope or aim for large-scale implementations that are financially challenging.”
To avoid these pitfalls, De Boer recommends starting small and expanding gradually. Technologies in automation are evolving rapidly, and staying focused on solving specific operational challenges is critical. “It’s easy to get distracted by the latest shiny technology, but companies should prioritize solutions that align with their strategic goals,” he adds.
Challenges and Opportunities in Automation
As with any transformation initiative, there are challenges to be navigated when implementing automation to help with your digital journey. One common obstacle is managing an organization’s varying opinions and expectations, which can cause scope creep and lead to delays. Another challenge is ensuring robust network operability and security to allow for seamless data flow. Additionally, filtering out the noise from the constant influx of new automation technologies can be difficult. De Boer emphasizes the importance of staying focused on the core objectives: “The challenge is identifying what’s real and what will provide lasting value.”
Despite these challenges, the benefits of automation are clear. Interstates has seen significant improvements in client facilities through better visibility into operations, consistent measurement and analysis, and the ability to address deviations before they become significant issues. “Sometimes, it’s simply about making operators aware of small deviations from the gold standard before they escalate,” says De Boer.
One notable example of automation’s impact is a recent project where Interstates implemented BlendIQ, a control module that optimizes product quality while reducing ingredient usage. “By making real-time target adjustments, our client was able to reduce the use of costly additives and achieve a more consistent final product at a reduced cost,” says De Boer.
Automation as a Catalyst for Future Growth
Automation is more than just an operational tool—it’s a strategic enabler for long-term growth and sustainability. Automation helps businesses tackle key challenges such as labor shortages and sustainability goals by reducing waste, enhancing worker safety, and optimizing resource use. “Automation not only improves efficiency but also creates a better employee experience by removing dangerous and mundane tasks,” says De Boer.
Looking to the future, automation will continue to be a critical component of digital transformation. By integrating automated systems, manufacturers can achieve greater operational resilience, reduce costs, and stay competitive in a rapidly changing industry. Interstates remains committed to guiding clients through the digital age, helping them leverage the full potential of automation to unlock new levels of performance and innovation.
Stay Tuned: In the next article of this series, we will explore how your digital transformation journey can help you leverage data to improve your business outcomes. Join us as we continue to uncover the strategies and technologies that power successful digital transformation. If you missed it, see how operational technology is the foundation to your digital transformation journey.