Power Meets Simplicity: Revolutionizing Control Systems
The IBM Security X-Force Threat Intelligence Index 2023 concluded that manufacturing was the most attacked operational-technology-related industry in 2022. Since then, security threats have continued to weigh heavily on operators in the sector. However, with modernized technology that allows us to better gather data from control systems, we have the tools to help manage this challenge.
The Burden of Legacy Systems
As Carlos Buenano wrote for Manufacturing.net, “Latent vulnerabilities exist as a sort of technical debt inherited from a previous generation of solutions.” This is particularly true for operations technology (OT), which is a large part of the industry. Associated networks such as the distributed control system (DCS) are in great need of upgrading.
There are ways, though, to bring such operations into the new generation. While programmable logic controllers (PLCs) have served as a way to integrate predictive analytics in order to streamline processes, the continued rise of AI has accelerated the control system revolution.
AI and Control Systems
It’s no secret that AI is playing a critical role in both the modernization and simplification of industrial control systems. Operators are already adopting AI-led control systems that source real-time data to enhance overall production.
One example of a manufacturing field benefiting from AI control systems is the metal field. As one expert explained to the World Economic Forum, “Key AI applications include a smart machine learning powered control system that adjusts parameters in real time, reducing scrap and preventing defects in sheet metal forming, resulting in a 12.5% material cost savings.”
As we reckon with the demands of today, AI will only continue to drive the future of control systems that meet the call for both power and simplicity.
Sources:
● “Focus on new faculty: Dan Li safeguards manufacturing systems from cyberattacks” - Tom Ziemer, College of Engineering University of Wisconsin - Madison
● “Ghosts of Systems Past: Future-Proofing Industrial Control Systems” - Carlos Buenano, Manufacturing.net
● “Legacy Equipment: The Core of Your Digital Transformation” - James R. Koelsch, Automation World
● “Automation in manufacturing: Top 5 manufacturing trends for 2025” - The Manufacturer
https://www.themanufacturer.com/articles/top-5-manufacturing-automation-trends-for-2025/
● “How AI is transforming the factory floor” - Benjamin Schönfuß, World Economic Forum
https://www.weforum.org/stories/2024/10/ai-transforming-factory-floor-artificial-intelligence/