Leveraging Data and Optimizing Systems for Business Success

Welcome to the final 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. Be sure to learn how automation integrates the physical with the digital and what makes OT the foundation of digital transformation.

Data-driven decision-making has become a cornerstone of modern manufacturing. Collecting, organizing, and analyzing data allows you to gain real-time visibility into your plant operations, anticipate equipment failures, and optimize processes for both immediate and long-term benefits. From reporting and dashboarding to advanced PID loop monitoring and network health assessments, Interstates is ready to be your guide for leveraging the power of data to enhance your business outcomes.

The Importance of Data Analytics

Data analytics is more than just gathering information—it's about transforming raw data into actionable insights that improve business performance. Dan Riley, Analytics Manager at Interstates, highlights the importance of data-driven intelligence in modern operations: "We provide custom reporting capabilities on a variety of platforms, from Microsoft Power BI to Rockwell systems. The key is offering clients visibility into their operations in a way that helps them make informed decisions quickly."

By visualizing trends and patterns that may not be evident in traditional data sets Interstates helps you understand and act on critical information faster. Riley says, "When you can see data represented visually, you grasp the scope of potential issues more intuitively. Whether it's monitoring spending trends or plant efficiency, dashboards help uncover hidden problems and expedite troubleshooting."

This capability becomes even more powerful when paired with advanced analytics. Interstates offers solutions like model predictive control and custom batch optimization, which don’t just generate reports—they provide real-time insights that help you anticipate and solve problems before they happen. “Our tools, like PID loop monitoring, use advanced technology to automatically adjust key variables in the process,” says Riley. “This helps our clients keep tighter control over production, reduce waste, and improve overall efficiency without constant manual oversight.”

Optimizing Plant Performance with Continuous Monitoring

Optimization doesn't stop at data collection—it extends into real-time monitoring and proactive system management. Maintenance and support activities play a crucial role in ensuring your manufacturing processes run smoothly. Adam Van Schepen, Automation Manager at Interstates, describes the importance of ongoing support, saying, "Our network monitoring service continuously checks the health of a plant’s operational technology network. We track performance metrics to detect irregular network traffic, allowing us to address issues before they lead to downtime."

Network monitoring is essential for keeping systems running smoothly, especially as production environments grow in size and complexity. David King, Analytics Client Delivery Manager at Interstates, adds, "By establishing a baseline of network performance, we can detect anomalies like unexpected traffic spikes, system slowdowns, or unusual access attempts. Tracking these issues and collaborating with our clients on solutions helps protect both system performance and data integrity."

Interstates’ PID loop monitoring is another critical service that helps clients maintain optimal plant performance. Van Schepen explains, "By continuously monitoring the performance of PID loops, we can alert clients when a loop is not performing optimally. This proactive approach reduces process disruptions and helps ensure product quality remains high."

Overcoming Challenges in Data Utilization

Despite the clear benefits of data-driven insights, many manufacturers face challenges when implementing advanced analytics and monitoring solutions. One of the most common hurdles is data readiness. "Often, the desire for digital transformation is there, but the data infrastructure isn't fully prepared," says Riley. "Clients need to invest in foundational technologies like process historians and transactional databases to make the most of advanced analytics. Without those fundamentals, it becomes difficult to achieve digital transformation goals quickly and cost-effectively."

Additionally, some clients may struggle to identify which data is most relevant to their goals. "It's not always obvious what data will have the biggest impact on a process," Riley says. "That's where working with a trusted partner like Interstates comes in. We help clients define their goals and ensure that their data environment is set up to support future use cases."

Once a system is up and running, ongoing support and maintenance are vital to long-term success. Van Schepen emphasizes, "Maintaining your digital transformation is not a one-time effort. Network patches, software updates, and regular checks on systems like PID loops ensure that your operations stay optimized and secure over time."

The Future of Data-Driven Manufacturing

The role of data in manufacturing will only grow as companies seek to stay competitive in an increasingly digital world. Van Schepen says, "Collecting data from your production environment is just the first step. To add value, that data needs to be visualized and analyzed in ways that lead to better decision-making. Tools that alert you to potential issues before they escalate are critical for maintaining efficiency." Interstates' ability to provide customized monitoring solutions, from network health to PID loop performance, means our clients can more easily optimize their operations. "With our services, we help clients move from reactive to proactive system management, reducing unplanned downtime and improving overall plant performance," King says.

As you continue along on your digital transformation journey, Interstates is ready to guide you every step of the way. With a comprehensive approach to data analytics, monitoring, and maintenance, we will help you fully leverage the power of data to achieve your business objectives.

For a deeper dive into the power of the digital age and optimizing industrial systems, explore the other articles in this series. Learn about building the right OT infrastructure and leveraging automation for efficiency. Together, these resources provide a comprehensive guide to advancing your facility’s digital capabilities, security, and overall performance.