How Industrial Controls Improve Safety and Efficiency in Australian Factories

Manufacturing industries in Australia will never be the same again having adopted industrial control in their system.  Take the case of the mining sector which is using integrated advanced industrial control to monitor conveyor systems, manage processing plans, and handle heavy machinery.  And yes, with this automation, mining operations are now safer and more efficient.   So, if you are a manufacturing manager consider the adoption of industrial controls and see and experience the the improved safety and efficiency in your factories.  

What comprises industrial control systems?  It involves the use of various automation devices such as programmable logic controllers (PLCs), distributed control systems (DCS), and human-machine interfaces (HMIs).  Factories combine the power of these devices to monitor and control factory processes in real-time resulting in greater consistency, precision, and safety.

Enhancing Safety in Australian Factories

Real-Time Monitoring 

Industrial controls in Australia monitor the factory floor and collect data on machinery conditions and environmental factors.  When a problem is detected, the system can activate an automatic shutdown and alert operators to avoid a more serious aftermath.  Thus, both workers and equipment are protected from potentially dangerous areas. 

Dangerous Threat Alert

Industrial automation eliminates the high-risk tasks from human hands, instead delegating them to technology.  So workers don’t handle dangerous chemicals or work near heavy machinery anymore.  In effect, there are reduced accidents and injuries while at work.  

Safety Intelocks and Emergency Protocols

In emergencies, operators can activate safety protocols through HMIs which may include shutting down entire systems or isolating a specific hazardous condition.  For example, if a machine door is open, an interlock will automatically disable the machine to prevent injury.  

Regulatory Compliance

Australia requires serious compliance with safety regulations for manufacturing companies.  Noncompliance with these regulations equates to stricter regulatory penalties.  Integrating industrial controls in the factory operation will enforce safe operating limits and record data for better regulatory adherence. 

Improving Efficiency and Productivity

Optimized Manufacturing Flow 

With industrial control automation, each step in the production line becomes more coordinated and optimized.  A faster turnaround time and higher production quotas are achieved while bottlenecks and idle time are reduced.

Lower Downtime 

Industrial controls can produce data to enable checking on equipment wear and tear, and then generate alerts when components need servicing or replacement.   Because of this, preventive maintenance can be conducted just on time leading to reduced downtime, cost reduction, and eventually improved overall productivity.

Energy-Efficient Consumption

These controls can also be programmed to optimize energy consumption.  How?  By adjusting operational parameters such as motor speed and lighting based on demand, their carbon footprint is reduced together with the energy expense incurred with them.

Quality Control Ensured

Even minor deficiencies can lead to substantial losses, especially in the food and beverage, pharmaceutical, and electronic industries.  However, automated quality checks can check on defects early in the production process,  so corrections can be incorporated before faulty products reach the market.

Informed Decision Making

Data provided by industrial controls will give insights into production trends, machine performance, and efficiency metrics.  The strategic use of these data enables a proactive approach to factory management.

Indeed, industrial controls are transforming Australian factories in terms of safety and efficiency in the production facility.   Adopting this industrial technology gives them a continuous advantage in productivity, safety, and sustainability even in the years to come.