Industry 4.0

The most common reason IPCOS is contacted for alarm management projects is a corporate push to bring alarm rates down. In addition, the lack of a standardized system often triggers customer requests, usually because external auditors point out a deficiency (i.e., the Seveso directive imposes the...

Topics: Plant performance, Data Management, Industry 4.0, Operational Excellence

Beam pump wells are critical to the oil and gas industry, and monitoring their performance is essential for productivity and minimizing downtime. One way to achieve this is through dynacard classification, which involves analyzing measurements of load and displacements in sucker rod pumps or beam...

Topics: Digitalization, Industry 4.0

Classroom training often gives vague and non-applicable examples while following a pre-cooked script. After a few hours of tutoring, participants are certified, but have they learned anything practical that will serve them in their daily life? What knowledge do they retain once the training is...

Topics: Data Management, Industry 4.0, Operational Excellence

In many processing plants, the network architecture is identified as follows:

Topics: Advanced Process Control, Industry 4.0, Operational Excellence

In 2021, IPCOS had the chance to work on a global project for one of the leading chemical companies with around 100 sites spread over more than 60 countries. Often sites work independently, and sharing knowledge between teams does not happen naturally or is only done verbally. In some cases,...

Topics: Data Management, Digitalization, Industry 4.0, Operational Excellence

One of IPCOS’s clients has plants all around the globe, from the United States to Italy to Germany, each with unique process operations and different principles in calculating performance, with Overall Equipment Effectiveness (OEE) being the Key Performance Indicator (KPI). The management of the...

Topics: Data Management, Digitalization, Industry 4.0, Operational Excellence

The project in this blog is typical of batch chemicals producers who need to digitalize their highly distributed plants. In this case, relevant data was not collected in an automated fashion, and data centralization did not exist. Deploying performance management solutions on a site-by-site basis...

Topics: Data Management, Industry 4.0

According to the U.S. Environmental Protection Agency, sustainable manufacturing is “the creation of manufactured products through economically-sound processes that minimize negative environmental impacts while conserving energy and natural resources.” This definition attempts to balance economic...

Topics: Industry 4.0, Emissions

In the broad process industry, units operating automatically, e.g., through the application of advanced process control (APC) or real-time optimization (RTO) digital technology, can become up to 10% more efficient. By automatically calculating product quality and adjusting key process parameters,...

Topics: Advanced Process Control, Industry 4.0