SCADA & HMI

WI N T E R E D I T I O N
Contents
3 — Five ways SCADA systems can improve sustainability

5 — Built-in SCADA Features are Better

6 — How one iron foundry fostered a competitive edge by

incorporating SCADA and ERP

16 — 5 Steps To Keep Your SCADA Forever Young

19 — Are manufacturing plants prepared for the benefits

eSCADA systems offer?

26 — Why it’s critical to integrate distributed control systems

31 — How to incorporate digital transformation into SCADA

master planning

2
Five ways SCADA systems can
improve sustainability  Back to TOC

SCADA systems, when combined with cloud-based monitoring systems,

will be crucial in helping industry achieve better resource utilization, more
resilient operations and sustainability objectives.

S CADA systems are frequently overlooked in discussions about green technolo-

gies. However, they are critical for ensuring operational efficiency, reducing re-
source consumption, and enhancing overall sustainability in various sectors. Here are
five reasons why.

1. R
 emote monitoring and control: SCADA systems can help reduce the need
for travel to physical sites, thereby decreasing carbon emissions associated with
transportation. The systems allow for the remote monitoring and control of devic-
es and systems from any location.

2. E
 nergy efficiency: By monitoring in real-time and storing historical data, SCA-
DA systems help optimize energy usage. They can, for example, detect leaks or
inefficiencies in systems like pumps, enabling timely maintenance and reducing
unnecessary energy consumption. Additionally, SCADA systems provide the op-
portunity to use electricity when the price is low by using data to check the pric-
es. This capability allows operators to adjust energy consumption patterns based
on price fluctuations, further enhancing cost efficiency and energy management.
This is exemplified by leak detection projects, where customers can monitor leaks
and pump activity, thus optimizing maintenance and improving energy efficiency.

3
Five ways SCADA systems can improve sustainability

3. C
 ompliance with environmental regulations: SCADA systems can generate de-  Back to TOC
tailed reports and track key metrics related to environmental regulations. SCADA
systems can rack the running hours of pumps and other devices, enabling main-
tenance to be scheduled based on actual usage, reducing unnecessary mainte-
nance, minimizing downtime and enhancing the longevity of equipment, contrib-
uting to sustainability by reducing resource consumption.

4. P
 redictive maintenance: SCADA systems support predictive maintenance by
tracking the running hours and performance of equipment. This helps in schedul-
ing maintenance activities proactively, preventing breakdowns and extending the
lifespan of equipment. Consequently, this reduces waste and the environmental
impact of manufacturing new parts or machinery. SCADA systems provide re-
al-time data and immediate notifications in case of issues like leaks.

5. R
 apid response to issues: SCADA systems can support rapid response by inte-
grating with Internet of Things (IoT) devices using protocols like message queu-
ing telemetry transport (MQTT). This enables real-time monitoring, immediate
alerts and automated responses to operational anomalies and environmental
incidents. Such rapid response capabilities help address issues promptly, prevent-
ing larger environmental problems like major leaks or system failures that could
cause significant environmental damage.

Sylvana van de Scheur

Sylvana van de Scheur is a product designer at Ovarro.

4
Built-in SCADA Features are Better

 Back to TOC


Built-in SCADA Features are Better
Nothing ages worse than custom code. So why rely on it for
for critical systems that need to last decades. VTScada includes
everything you need for an advanced SCADA application
with no scripting required. Unlike other platforms, VTScada
provides a stress-free forward migration path so you are never
forced to start over.

5
How one iron foundry fostered
a competitive edge by  Back to TOC

incorporating SCADA and ERP

One foundry invested in digital transformation initiatives and found
themselves in a safer –– and more competitive –– position.

M ost American foundries are family-owned and privately held small- to mid-sized
companies that have minimal capital to invest in digital transformation initiatives.
However, in an increasingly competitive market, organizations like Ferroloy, Inc., a
50,000 square-foot cast iron foundry and machine shop in Wichita, Kansas, understands
new approaches and innovative technologies are vital to success.

Ferroloy needed to find an alternative to its highly manual data collection processes,
which were riddled with inaccurate and unused data. The company was seeking a solu-
tion to improve throughput and quality, reduce equipment downtime, and integrate
with its existing software and specialized machinery.

All of this was top-of-mind for Mark Soucie, Ferroloy’s president and owner, when he
attended a presentation from Folsom, California-based system integrator Artek Inte-
grated Solutions about the benefits and return on investment of a connected, integrat-
ed factory.

After that initial meeting at the AFS Conference, Ferroloy chose Artek to implement
Ignition — an industrial automation platform for SCADA, HMI, IIoT and more — into its
foundry (see Figure 1).
6
How one iron foundry fostered a competitive edge by incorporating SCADA

Figure 1: Ferroloy’s 50,000 square-  Back to TOC

foot cast iron foundry and machine
shop in Wichita, Kansas. Courtesy:
Inductive Automation

SCADA implemen-
tation as a team
effort
SCADA systems are not as
common in foundries as Ex-
cel spreadsheets or scratch
paper (see Figure 2).

“The truth is that a lot of other foundries are looking for something like what we’ve
implemented for Ferroloy, and they just don’t know where to start,” said Jerry Eppler,
co-founder and chief executive officer of Artek. “Mark [Soucie] was in the exact same
position and thankfully found us at the right time and right when he was beginning
his journey, and we helped guide him through this process to really take the ideas
that he had and the opportunities that he knew were there and really bring them to
fruition.”

To ensure the success of the project, Soucie brought on an in-house engineer, Clint
VenJohn, as process engineer at Ferroloy. VenJohn, along with Jim LaPratt, design
service engineer at Artek, were instrumental in designing and implementing Ferroloy’s
Ignition system, even though each came into the project with vastly different levels of
Ignition experience.
7
How one iron foundry fostered a competitive edge by incorporating SCADA

LaPratt had logged 25 years  Back to TOC

in the foundry industry, com-
bined with extensive knowl-
edge of Ignition. In contrast,
VenJohn had no prior ex-
perience with the platform.
Far from a setback, between
VenJohn’s OT background as
a Plant Operations Manager
and strong knack for IT, and
Inductive Automation’s free learning resources, he was Figure 2: SCADA systems are
not as common in foundries as
quickly contributing “some marvelous ideas” to the proj- Excel or scratch paper. Courtesy:
ect, according to LaPratt. Inductive Automation

SCADA as a centralized data repository

With this Ignition system, Ferroloy wanted to implement lean manufacturing practices
to drive overall behavioral change and to rely more on systems versus individual skill.

“What we’re trying to accomplish is to digitize an aged process and gain better visibili-
ty to unlock the latent potential within the process,” said VenJohn.

Previously, data was mostly used to solve individual problems rather than to bolster
companywide initiatives. To create a SCADA system that was beneficial to operators
as well as upper management, Artek built and configured a MySQL database on Fer-
roloy’s servers, which was then connected to Ignition, specifically the Tag Historian
Module, as a centralized repository for maximizing data collection and analytics. This
8
How one iron foundry fostered a competitive edge by incorporating SCADA

Figure 3: Ignition’s Tag  Back to TOC

Historian Module created
a single source of truth.
Courtesy: Inductive
Automation

combination creat-
ed a single source
of truth anyone
could reference (see
Figure 3).

“The goal with the

Ferroloy project was to digitally transform their disconnected foundry that relied heavi-
ly on manual paper data collection through efficient data collection and analysis,” said
Eppler.

Ferroloy’s target is to increase capacity by 25 to 30% while reducing scrap by 30 to

35%. The Ignition system allows Ferroloy to identify methods for improving efficiency,
backed by quantitative data.

“With Ignition, we’re able to see more or less up-to-the-minute production data,
whereas before we would lag behind by a week or so,” said VenJohn. “We’re able to
identify trends, shift reports and that type of thing can come out almost in real time.
Those have been huge improvements and have allowed us to identify and more quickly
react to problems.”

9
How one iron foundry fostered a competitive edge by incorporating SCADA

Ignition was a cost-effective solution for achieving this new level of data collection, which  Back to TOC
is critical for a foundry the size of Ferroloy. The low initial cost isn’t what gives Soucie confi-
dence; it’s the flexibility to adapt and make changes quickly based on real-time data.

With the data analytics facilitated through Ignition, Soucie said the opportunities could
be endless.

Achieving effective digitization with minimal inputs

The digitization process proved more complicated than a simple transition from paper
to human machine interface (HMI). There was also a human element. The last thing
Ferroloy or Artek wanted was to distract operators in a fast-paced environment while
they were pouring 2,700ºF molten iron (see Figure 4).

While the initial impulse was to adhere to a high-performance grayscale philos-

ophy, LaPratt and VenJohn adapted their approach to better suit the workforce,
keeping the screens
straightforward, fo-
cusing on ease of use
and legibility.

Figure 4: Ferroloy did

not want to distract
operators while they were
pouring 2,700ºF molten
iron. Courtesy: Inductive
Automation 10
How one iron foundry fostered a competitive edge by incorporating SCADA

“We have a lot of employees out there that are not very tech-savvy, some older and  Back to TOC
some that there’s a language barrier with. The simplicity of [the HMI] just makes it easy
for them to interact with and be able to do what they need to do easily and properly,”
said VenJohn.

All visualization for the system was designed using the Perspective Module and each
screen features a minimal set of buttons, reducing interaction to the essentials of a giv-
en process. With so few visual components, the HMIs needed to retain color to make
key information “pop” so that operators could quickly ascertain the status of the pro-
cess in progress.

“Due to the extreme heat needed to melt iron, safety is a high priority in a foundry. We
wanted to make sure our screens were extremely intuitive and simple as to not distract
operators from the potential hazards around them,” said Eppler.

Interoperabiity built into programmable logic controllers

(PLCs)
Ferroloy, like many foundries, has a heterogeneous mix of programmable logic control-
lers (PLCs) from a variety of manufacturers across a range of vintages, plus other types
of equipment that do not communicate via PLC at all.

Ignition’s built-in suite of device drivers allowed Ferroloy to connect to all their hardware.

This freedom also sparked ideas for additional creative solutions; the foundry environ-
ment is inherently dusty, making it particularly harsh on electronics, so Ferroloy needed
a software that could run on equipment that was inexpensive to replace. Leveraging
11
How one iron foundry fostered a competitive edge by incorporating SCADA

Ignition, Ferroloy is using smart televisions to display key performance indicator (KPI)  Back to TOC
dashboards above each of the six production lines for quick reference.

“Ferroloy’s main problems were that the data that they were gathering on the floor
was siloed from their equipment through that software. If you needed that infor-
mation, you had to walk there to get it,” said LaPratt. “Ignition brought the siloed
data from their Hitachi and Heraeus equipment directly into screens that could be
used on the floor for verification that the product was good at the point it was be-
ing used.”

Another key aspect of the project was connecting Ignition to Ferroloy’s Sinto molding
machines so molding
production could be
fed back to its Odyssey
ERP system through an
API. This eliminated the
need for the operator
to input the data on the
floor and reduced the
risk of data entry errors
(see Figure 5).

Originally, Artek
Figure 5: Integrating Ignition and
planned on utilizing a third-party solution to connect Odyssey was vital because certain
Ignition to the Mitsubishi PLCs collecting data from the steps in the iron casting process
have rigorous time limits. Courtesy:
molding machines, but thanks to some fortuitous timing, Inductive Automation
12
How one iron foundry fostered a competitive edge by incorporating SCADA

Inductive Automation released the beta version of the Ignition Mitsubishi Driver during  Back to TOC
the project’s development phase.

The driver, which supports Mitsubishi MELSEC over TCP, allowed for a direct connec-
tion, eliminating the need for any additional software and lowering the overall cost of
the project in the process.

SCADA and enterpise resource planning (ERP)

Beyond simply moving process data out of desk drawers and into a database, Artek
needed to integrate Ignition with B&L Information Systems Inc.’s Odyssey software,
an off-premises ERP software-as-a-service (SaaS) Ferroloy implemented over a de-
cade prior.

Pulling data from Ferroloy’s ERP system was a cornerstone of the project, eliminat-
ing data reentry and its corresponding human error. Artek created sync routines
that run through an API interface to monitor Odyssey and look for changes in real
time.

When a change occurs, the updated information is brought into the Ignition system so
that operators can have an immediate understanding of the order in progress, includ-
ing the work order and associated product, along with statistics like weight and tem-
perature range.

The integration of Ignition and Odyssey is vital because certain steps in the iron cast-
ing process have rigorous time limits. The HMI displays what is currently on all six pour
lines, each of which have molds coming down them, along with data synced from the
13
 How one iron foundry fostered a competitive edge by incorporating SCADA

ERP system. This allows operators  Back to TOC

to know what is being poured
when they tap the furnace and
put the molten iron into the ladle,
because once a new ladle is start-
THE ONE
ON-DEMAND
SYSTEM HEALTH TRENDING
MONITORING
SLIPPY
MAPS ed, the iron is only usable for 10
SOLUTION
ONLINE/OFFLINE
BATCH & RECIPE DEPLOYMENT
MANAGEMENT
THIN
CLIENTS
minutes.
ALARM IIoT &
NOTIFICATIONS SPARKPLUG B
FOR ALL YOUR SCADA
CHALLENGES
ADVANCED
CYBERSECURITY

REPORT
GENERATOR
GRAPHICS
One Platform
Our uniied SCADA toolset is more reliable than
SCADA implementation
is only the beginning
LIBRARY

ENTERPRISE hand-coded third-party add-ons.

HISTORIAN

One Install
Pre-integrated features reduce risk and development
time and make upgrades easy.
Ferroloy now leverages Igni-
One Failover/Synchronisation Strategy
Only VTScada supports unlimited server failover and
tion from the plant floor to up-
VERSION
MULTI-SERVER
FAILOVER
CONTROL historian synchronisation. No custom code required.
per management, but even so,
One Upgrade Path
REAL-TIME
Seamlessly grow your system to any size. We never
Soucie said that this is only the
HISTORIAN BACKUP

retire versions forcing you to start over.

ISA 18.2 ALARM
Powering mission critical
beginning of Ferroloy’s Ignition
MANAGEMENT
One Support Team
applications for 38 years.
REAL-TIME APP No need to chase down support for third-party pieces.
DEVELOPMENT
Our in-house team has your back.
COMMUNICATION
DRIVERS
journey. Befitting a server-centric
platform with unlimited licensing,
DRAG & DROP
MASTER/SUBORDINATE SCREEN CREATION OPC, ODBC, REST,
APPLICATIONS WEB SERVICES

HIERARCHICAL ENCRYPTED

Ferroloy has found that the more

EASY DEPLOYMENT OF TAG BROWSER OPERATOR NOTES REUSABLE
NEW & UPDATED SYSTEMS TEMPLATES

See for yourself why built-in is better, now and 38 years from now.
they use Ignition, the more uses
We develop all VTScada’s core components in-house, ensuring critical features like historians, alarm notiications, and communication drivers work seamlessly
with every version update. This unique design vastly simpliies licensing, development, deployment, performance, renewals, upgrades, training, and support.
they find for it.
VTScada.com
“Ignition is already expanding
into other areas of the plant. As
we speak, they’re working on inte-
© Trihedral Engineering Limited 2025. ScadaFest, VTScada, and Trihedral are registered trademarks of Trihedral Engineering Limited.
grating their QA lab into Ignition.
We’re getting spectrometer data
14
How one iron foundry fostered a competitive edge by incorporating SCADA

into Ignition now,” said Eppler. “On top of that, now we’re starting to work on getting  Back to TOC
some of the grinding room data into Ignition and also working on dashboards for the
break room.”

By integrating Ignition with their spectrometer, which analyzes the elemental content
of the iron being poured, Ferroloy plans to increase the traceability of the iron produc-
tion process. This also allows Ferroloy to closely monitor variations across all measured
elements and make small adjustments timelier. This improves the workflow for lab
technicians, giving them direct data access instead of requiring them to hunt down the
information on the foundry floor.

“Over the next several months, I can only imagine the level of knowledge and informa-
tion I’ll have available at my fingertips,” said Soucie.

Aaron Block
Aaron Block, marketing content writer, Inductive Automation.

15
5 Steps To Keep S calability is one of the most important considerations
when choosing SCADA software. Once this significant
investment has been made, how do end users get the

Your SCADA most from it? Or more simply, how long will it last? Here
are five ways to keep your SCADA young at heart.

Forever Young 1. Choose Built-In Core Functionalities

The first step is to ask your consultant, integrator, or OT de-
partment how many third-party software products will need
to be integrated to provide the required functionality. Using
third-party alarm notification products with SCADA systems
often leads to issues with compatibility after numerous soft-
ware or firmware updates. Additionally, if a third-party com-
ponent is discontinued, it can cause significant problems.
Choose a SCADA platform where all core functionalities,
including the historian and communication drivers, are built-
in. This approach prevents SCADA applications from becom-
ing outdated prematurely. VTScada, for example, develops
and maintains every part of its software, ensuring that each
critical component works seamlessly with every update. See
integrated VTScada features here: VTScada.com/features

2. Minimize Custom Coding – AKA

Technical Debt
Another common issue with SCADA systems is the reli-
ance on custom coding. While many integrators are accus-
5 Steps To Keep Your SCADA Forever Young

tomed to scripting standard features as well as those specific to individual customers,  Back to TOC
it becomes problematic over time. Maybe the person who wrote it has left or maybe so
much time has passed that it’s difficult to understand how the code is meant to work.
The more code you write, the more time it will take to maintain in the future. This prob-
lem is known as Technical Debt. Additionally, custom code makes it risky to upgrade
the SCADA software or the operating system. To avoid this, choose a platform where
core components like logging, trending, reporting, alarm management, mapping, and
version control are pre-configured out-of-the-box. VTScada allows robust customiza-
tion where needed but provides a standard set of advanced, ready-to-use features. This
vastly reduces development time and makes it easy to grow and maintain indefinitely.

3. Don’t Assume Offline Servers Age Better

Many users attempt to manage reliability and security by locking SCADA servers in a
room with no internet access and avoiding any updates to the SCADA software or the
server operating system. The fear is that updates will disrupt custom coded features or
break compatibility with third-party components. However, this eliminates new efficien-
cy features, and more importantly, critical security updates. Note that offline servers
are not inherently secure. Sophisticated malware can still piggy-back in on unknowing
users and developers. Also, Microsoft® regularly deprecates older versions of their
Windows®. Unlike other products, the most recent version of VTScada is compatible
with the latest version of Windows. See VTScada’s compatibility chart here: VTScada.
com/requirements/

4. Use Multiple Servers

Another reason many don’t update their systems is that they only have one server and
don’t want to take it offline for fear of permanently missing logged data or critical
17
5 Steps To Keep Your SCADA Forever Young

alarms. Adopting one or more redundant servers allows you to transfer control to a  Back to TOC
backup while you make necessary updates. For critical systems, having multiple dis-
tributed servers is a critical part of ensuring resilience. Unlike other platforms, VTScada
supports any number of redundant hot-backup servers that sync automatically over a
WAN or LAN. No fragile scripting is required. This means that every server is a com-
plete real-time backup of Historical data, alarms, and configuration history. The cost of
an additional VTScada license and PC hardware is negligible compared to the cost of
downtime and lost data. In addition to making redundancy practical for systems of any
size, VTScada also provides discounted software bundles: VTScada.com/pricing

5. Be Cautious with Unlimited I/O Tag Licensing

Recently, many end users are pressured to pay extra for “unlimited” SCADA I/O tag
licensing based on the misconception that this will improve the scalability of their
systems. The idea is that as they grow, they will always have enough tags. However, the
reality is that most SCADA users will pay for far more than they need. No computer can
run an unlimited number of tags and few users grow their systems rapidly and continu-
ously. VTScada allows users to only pay for what they need and easily add tags, licens-
es, and optional features by simply updating their installation key.

Ask Before You Choose

What is the typical life expectancy of the software? Does the vendor periodically re-
tire software versions? How many third-party products are required for basic SCADA
functionality? How much custom code is required? What is the strategy for updates
decades down the road? How many tags are needed now and over the next few years.
How difficult is it to add tags and features over time? How many levels of redundancy
are supported?
18
Are manufacturing plants
prepared for the benefits  Back to TOC

eSCADA systems offer?

Electrical supervisory control and data acquisition (eSCADA) systems are
used to monitor power distribution systems. But manufacturing plants must
prepare for their use.

T oday’s industrial manufacturing operations require modern-day tools and technol-

ogies like artificial intelligence (AI), machine learning (ML), augmented reality/vir-
tual reality (AR/VR) and the industrial internet of things (IIoT) to help people effectively
run, maintain and sustain equipment and processes. Using these technologies with
data-retrieval tools and visualization systems, people can make insightful operational
decisions in real time.

Most people who work in automation have heard of a supervisory control and data
acquisition (SCADA) system and understand it monitors and controls industrial devic-
es and processes. But what is eSCADA? The “e” stands for electrical, and it is used to
monitor and control power distribution systems. With an eSCADA system, operators
gain insight into electrical power distribution systems and process control systems to
understand the entire manufacturing process better.

Any worker who has witnessed a sudden stop in manufacturing operation due to a
circuit breaker trip in their power distribution system knows it typically takes a consid-
erable amount of time to track down the issue. With eSCADA, this information is read-
ily available, saving valuable time in getting to the root cause of the problem quicker
19
Are manufacturing plants prepared for the benefits eSCADA systems offer?

than with traditional methods. Retrieving this data at a moment’s notice helps facilities  Back to TOC
maximize uptime.

The current and future workforce expects more integration and use cases with the rise
of technologies like AI and ML. These technologies empower workforces and support
sustainable manufacturing.

Manufacturers can integrate fourth-generation IIoT devices into control systems and
use eSCADA to manage the data. Additionally, they can set the stage for integrating
some of the earth’s renewable resources into power and energy management systems
to make operations more sustainable.

eSCADA can enable innovations, but are manufacturers ready?

Before manufacturers can take advantage of new technologies and innovations, they
must ask, “Is our facility ready?” Determining the starting point is critical and likely fits
into one of three stages: zero connectivity, some connectivity and intelligent infrastruc-
ture ready.

Zero connectivity is usually found in legacy facilities that have unintelligent, obso-
lete networks, non-existent network devices or contain analog devices that des-
perately need replacing because parts or replacements are no longer available.
Many manufacturers are generally comfortable in this status quo stage, because no
additional funding is required until something goes wrong. Also, a lack of required
workforce skills or bandwidth might prevent them from adding intelligent devices
and connectivity.

20
Are manufacturing plants prepared for the benefits eSCADA systems offer?

For manufacturers to benefit from an eSCADA system, they must have modern IIoT  Back to TOC
devices and connectivity. Without eSCADA, it is much more labor intensive to track
down problems, understand the root causes and determine the right action to re-
mediate.

Digitally transforming a facility with modern technology like an eSCADA system can
help manufacturers reduce the amount of time it takes to perform tasks, like electrical
issue identification. Think about how long it takes, for example, to receive a call on the
radio, find the location of the call, discuss what happened with the operators, walk to
the electrical room and finally see where a fault or breaker trip occurred.

Performing a root cause analysis is another time-consuming task where an eSCADA

system can bring efficiencies. Facilities often collect relevant data in different ways for
sustainability actions. For legacy facilities, this data-collection task is a manual process
where an individual or team walks through a plant and collects data points from me-
ters –– both electrical and non-electrical devices –– which takes hours. This task can be
done instantly with modern technology.

Some connectivity is where manufacturers have aftermarket bolt-on devices added

in the form of power quality meters or other devices that have metering capabilities.
However, this solution is inelegant, and there are often gaps in data and metering
locations. Extra hardware is most likely required as there are no fundamental com-
munication capabilities on the motor controls, circuit breakers or protection relays. In
this stage, manufacturers often struggle to get full connectivity and communication
throughout the facility.

21
Are manufacturing plants prepared for the benefits eSCADA systems offer?

Developing a modernization strategy helps prioritize key areas for additional bolt-on  Back to TOC
metering and/or total replacement with intelligent IIoT devices. Once goals are set and
well-understood, the projects can be prioritized against capital or expense budgets
to take the right steps in getting the advantages that come with an eSCADA system.
Most facilities are in the zero connectivity or some connectivity stage.

In the intelligent infrastructure stage, facilities have connected devices on a unified

platform. Ideally, this is the best place for manufacturers to be. Within this stage, man-
ufacturers take preventative measures and proactive approaches to their environmen-
tal, social and governance (ESG) goals. Actionable data helps them respond faster to
prevent or remediate failures. They actively seek out ways to attain their sustainability
goals through monitoring and prioritizing projects that have a greater impact on effi-
ciency with utility usage like water and energy and find ways to eliminate excess waste
and be more efficient in the overall operations of the facility.

Greenfield facilities or modernizing major brownfield facilities with intelligent devices

and eSCADA systems might seem risky and take some effort but building a resilient
facility and significantly improving manufacturing processes is worth it for long-term
success. Plan early as costs increase when changes are made late in a process and im-
plementing technology like eSCADA is an afterthought.

Setting the stage for success with eSCADA

Take a strategic approach and set the facility up for success based on where it is to-
day. To get to the intelligent infrastructure stage and beyond, expanding possibilities
requires trust and the right expertise. The number-one priority for all manufacturing
facilities is keeping people safe. When eSCADA systems are in place, the groundwork
22
Are manufacturing plants prepared for the benefits eSCADA systems offer?

 Back to TOC

is set with technology that can improve Figure 1: Electrical supervisory control and data
acquisition (eSCADA) systems can help manufacturing
manufacturing operations and enhance plants monitor and control power distribution systems.
the safety of personnel that maintain and Courtesy: Rockwell Automation
operate the systems.

Imagine the best possible way to enter potentially dangerous spaces, like electrical
rooms, where people don’t have to put on bulky arc flash protective gear (see Figure 1).
New technologies, such as AR/VR and AI, provide a time-saving and safe alternative to
train people in various situations. New personnel can easily train and get acclimated to
their new environment and dangerous applications before they complete a procedure in
real time. AR/VR can also act as a measure to test different scenarios to fix certain shut-
down or malfunctioning situations. An eSCADA puts these technologies within reach.
23
Are manufacturing plants prepared for the benefits eSCADA systems offer?

Now more than ever, companies are targeting lofty ESG goals but take many differing  Back to TOC
avenues to reach those specific goals. With these targets in mind, the first step is to
fully understand the facility and how energy is consumed and then correlate that ener-
gy consumption to production. Once again, having an eSCADA makes this step easy.

Green energy is a sustainability pillar that is most certainly part of the overall strategy.
Nothing sets a company up better than to put those goals within reach. Implementing
an eSCADA system helps set the stage for bigger and better applications. Consider
some of the best strategies to fully capitalize on the head start that an eSCADA system
can provide.

Many variables affect power quality and energy prices, especially when manufacturers
rely on traditional utility providers. One green energy strategy is to take away the vari-
ables and have the facilities take charge of the way energy is not only consumed but
the way it is received.

Today’s power generation trend is focused on using smaller distributed energy resourc-
es (DERs) that can supply a more constant and improved power quality without the gi-
ant complex infrastructure of traditional power transmission and distribution. Medium
to large manufacturing facilities are well-positioned to take advantage of this trend by
installing and operating their own DERs to integrate solar, wind and energy storage, to
supplement energy usage and keep the risky utility as a backup or secondary option.

This approach keeps energy costs down by eliminating the potentially costly peak
demand charges from the utility. It also creates improved power quality while ensur-
ing there is a verified green energy source. With major pushes and advancements for
green hydrogen, it is within the realm of possibility that hydrogen can also be used for 24
Are manufacturing plants prepared for the benefits eSCADA systems offer?

energy storage when combined with fuel cells. This provides a clean source that can be  Back to TOC
used for various applications.

Facilities can also choose to replace the diesel or natural gas backup power generators
or supplement peak loads with hydrogen power. These advances become much more
attainable when facilities and plants begin with intelligent infrastructures and an eSCA-
DA system that is required to manage and coordinate energy usage with power man-
agement systems.

eSCADA as an influence on the future

Manufacturers that stay ahead of the curve are more likely to stay resilient and be vigi-
lant when it comes to successful data management. While it is important to stay ahead
of trends, many of these changes can be gradual to help spread the capital expendi-
ture over a reasonable time frame. In addition, companies might want to make sure
their new technologies are safe from cyberattacks.

Manufacturers can get to where they want to be with the right automaton solutions
provider. Many of these strategies of energy management and integrating fourth-gen-
eration IIoT devices can happen as soon as today.

Be the change that our future wants and needs. An eSCADA system is a great place to
start.

Wes Sutton
Wes Sutton is a Market Development Lead for Horizontal Solutions at Rockwell Au-
tomation. He has more than 15 years of experience in the Power Systems and Control
Systems space
25
Why it’s critical to integrate
distributed control systems  Back to TOC

The distributed control system (DCS) is still the heart of modern automation,
driving today’s most optimized plants, while preparing for a future of data-
centric operations.

S ince its inception, the distributed control system (DCS) has been one of the most
critical components of any automation strategy, bringing what used to be indepen-
dent applications together. No other automation technology provides the ability to
bring the same level of out-of-the-box integration of automation components, along
with powerful data contextualization. Plants around the globe rely on their DCS to
make it easier to implement the complex process control strategies that provide their
critical business differentiators.

The world has changed dramatically in the last few years. Organizations worldwide are
facing new calls for increased efficiency of production to meet changing and expanding
global needs, while they simultaneously heed the call from government and the public
to operate more sustainably. These shifts, requiring a never-ending wave of digital trans-
formation, have increased the complexity of plant operations, requiring far more optimi-
zation and connectivity. Real-time control is still critical, but it is not everything.

The DCS as the integrated data broker

It would be easy to assume that as the process control world becomes more data-cen-
tric, the proportional-integral-derivative (PID) loop- and interlock-focused control
system would grind away in the corner, siloed, performing its tasks while engineers and
IT teams build new networks of independent systems to connect sensors needed for
26
Why it’s critical to integrate distributed control systems

monitoring and optimization. Hypothetically, this strategy would allow organizations to  Back to TOC
bring data to key applications without having to deal with the complexity and expense
of moving it through the DCS controllers.

However, as teams have begun that journey over the last decade, they have learned a
valuable lesson: process optimization requires data contextualization. Leaving out the
DCS and its ability to contextualize data results in a decreased ability to effectively use
the collected data. This, in turn, forces teams to find new ways to integrate systems
and gather context, which increases complexity, making it extremely difficult to main-
tain the resulting systems of systems, while reducing flexibility to drive future business.

Forward-thinking automation suppliers have taken note of this conundrum and are
evolving the modern DCS. Instead of an architecture based on everything passing
through controllers, the DCS is evolving into a comprehensive, software-based auto-
mation platform that is data centric, secure, extensible and easy to use, while maintain-
ing its out-of-the-box capability to integrate different applications.

As a result, the best strategy to improve optimization is not to build complex rings of
new solutions around a controller-centric DCS, but rather to engineer with a modern-
ized DCS at the center of the automation strategy. Doing so empowers organizations
to take advantage of the new capabilities available now and prepare for the coming
paradigm shift, where operational excellence will be driven by a data-centric DCS at
the heart of a comprehensive automation platform.

Powerful DCS capabilities are already available

When people think of control systems, they typically imagine field devices commu-
nicating with input/output (I/O) cards, which then transmit that communication to a 27
Why it’s critical to integrate distributed control systems

controller and display the result  Back to TOC

on a human machine interface
(HMI) in the control room. Yet
today’s modern DCS solutions
are already so much more than
that (see Figure 1).

Technologies like advanced

process control, alarm man-
agement, device management,
advanced analytics, historians,
simulation, advanced HMIs,
Figure 1: Modern control systems
open-source cross-platform unified architecture incorporate advanced process control,
(OPC UA) and other applications are critical to alarm management, device management,
advanced analytics, historians, simulation,
managing complex processes with tighter control advanced HMIs, OPC UA and more to
and lower variability, and they are already a part of create a cohesive, connected solution that
the DCS today. Breaking these applications into a eliminates data silos. Courtesy: Emerson

wide array of disparate solutions to isolate control

can quickly create a complex web of custom-engineered connections that require sig-
nificant overhead to manage and maintain.

A better approach is putting a modern DCS at the center of an automation platform,

providing organizations with the ability to build solutions that provide all those capa-
bilities but without the required complex engineering effort.

In addition, new technologies at the edge continue to increase the data flow from the
DCS to external systems. Today, edge environment solutions provide secure data mo- 28
Why it’s critical to integrate distributed control systems

bility via a data diode, unidirectionally moving data from the control system to a wide  Back to TOC
array of third-party applications, simplifying and making it more cost-effective to dis-
tribute contextualized DCS data to optimization applications running anywhere.

New technologies will augment the DCS as the central auto-

mation platform
In coming years, new technologies like Ethernet Advanced Physical Layer (APL) will
reshape the face of control, bringing more data from more devices connected via
much faster networks. Not only will plants need a way to bring that data into their au-
tomation architecture — a task best accomplished with a modern control system that
is Ethernet-APL ready — they will also need ways to keep it moving efficiently through
the control system to other applications. Doing so efficiently and affordably will require
avoiding the need to perform complex engineering.

Modernizing to a new DCS designed to operate at the heart of a comprehensive auto-

mation platform is the solution. Automation suppliers are already piloting new technol-
ogies, such as enhancing DCS flexibility with software-defined controllers. This decou-
ples the controller software from its hardware, while creating new data pathways to
move data through the DCS more efficiently and effectively. These solutions will make
it easier to apply context, without adding complexity or reducing flexibility.

Moreover, innovators are designing new data fabrics, leveraging open protocols like OPC
UA and MQTT, to move the control system from its primary focus on PIDs and interlocks.
This evolution will create a platform for data-centric, secure, and efficient movement of
data — while still providing real-time control. This new platform will allow a wide variety of
applications to be fully integrated, benefiting from the contextualized data from intelligent
field devices, without relying on controllers as the single data pathway for field data. 29
Why it’s critical to integrate distributed control systems

A future with Boundless Automation  Back to TOC

Boundless Automation is the end goal where automation systems come together, with-
out silos, to deliver operational excellence. As sustainability, reliability and efficiency
goals continue to put pressure on teams to accomplish more with the automation they
have, the boundless automation-driven integrated architecture for seamless data mo-
bility from field to edge to cloud will help them accomplish those goals.

The DCS performs mission-critical operations, but legacy DCSs have an over-depen-
dency on controllers, which makes handling field data and interacting with other sys-
tems significantly more complex. However, isolating the DCS by creating new architec-
tures (and, by proxy, new silos) for every necessary functionality is not the answer — the
data contextualization provided by the control system is simply too valuable. Instead,
the right step is to modernize the DCS and position it at the center of the modern
automation platform, leveraging the advanced functionality that is already available, as
well as preparing for the new technologies and capabilities just over the horizon.

The flexible, data-centric automation platforms of the future will be critical to capturing
competitive advantage in the years ahead. Those solutions are not decades away —
forward-thinking suppliers are currently building their foundations. Today’s innovators
are already using modern automation platforms that leverage the full value of the DCS,
while seamlessly implementing their most valuable optimization technologies and
process control strategies. In doing so, they not only improve performance today, but
ready themselves for the technologies that will create a boundless future.

Claudio Fayad

30
Claudio Fayad serves as vice president of technology of Emerson’s Process Systems
and Solutions business.
How to incorporate digital
transformation into SCADA  Back to TOC

master planning
The critical integration of digital transformation into supervisory control and
data acquisition (SCADA) systems master planning is important in enhancing
operational efficiency, decision-making and predictive maintenance amid
technological advancements and cybersecurity challenges.

S upervisory control and data acquisition (SCADA) systems have reshaped process
automation with the implementation of technology advancements, especially un-
der Industry 4.0 and Industry 5.0. These changes have a farther-reaching impact than
sustaining operational continuity, especially in the context of sustainability and accom-
plishing more with a reduced workforce.

Several important factors must be considered when developing a SCADA master plan
(SMP). The tradeoff between budget and implementing emerging technologies is one
of the main factors to consider. On the other hand, digital transformation is forcing
an exercise of reimagination of products, services and operations to extract value. As
Massachusetts Institute of Technology’s Sloan Management Review puts it, “This is an
ever-ongoing process about continuously adapting to the never-ending changes of the
landscape and building a robust base for fluctuating market and global dynamics.”

Investigating a SCADA master plan, Industry 4.0 and 5.0 and

digital transformation
An SMP is a strategic document that defines the vision, objectives and roadmap for
31
How to incorporate digital transformation into SCADA master planning

developing and implementing SCADA system. The SMP framework includes architec-  Back to TOC
tural specifications, standards, interfaces, functionalities, performance, security and
governance for SCADA’s technical, operational and organizational setup.

Industry 4.0, known as the Fourth Industrial Revolution, signifies the transition of in-
dustrial sectors towards digitization, integrating digital technology into production and
physical processes. Industry 4.0 introduces the concept of smart factories, where inter-
connected machines and systems communicate, enabling automated and optimized
production processes.

Industry 5.0 refers to the next industrial development phase, emphasizing human
intelligence. Industry 5.0 introduces collaboration between people and machines to
solve complex problems. This includes innovation and productivity improvement in
efficient and sustainable industrial procedures.

In recent years, the pace of the industry revolution has rapidly increased due to in-
creased connectivity, enhanced collaboration and the swift expansion of computing ca-
pabilities. Effective planning for industry revolutions Figure 1. Digitalization evolution time
is crucial. It helps anticipate changes to maintain a frame. Courtesy: CDM Smith.
competitive edge,
allocate resources
efficiently, ensure
smooth transitions
to avoid disruptions,
stay ahead of reg-
ulatory shifts and
32
How to incorporate digital transformation into SCADA master planning

ensure compliance. This strategic planning gives companies an advantage over their  Back to TOC
competitors (see Figure 1).

Digital transformation refers to the use of technology to create new or restructure current
business processes, products, services and customer experiences. Digital transformation
in industrial control systems may include new ways of integrating with other information
systems, such as manufacturing execution systems (MES), enterprise resource planning
(ERP), computerized maintenance management systems (CMMS), business intelligence
(BI), geographic information systems (GIS), reporting and data analytic tools.

An SMP provides tools that guide the SCADA system’s design, implementation and
management. It ensures the SCADA system considers the latest technological devel-
opments in interconnected, automated, data-driven operations. In an Industry 4.0 envi-
ronment, the SCADA system is not isolated; it is integrated with other digital technol-
ogies and systems, such as the Industrial Internet of Things (IIoT), artificial intelligence
(AI) and cloud computing. This is where the SMP must look at how it can use these
technologies to boost the SCADA system’s performance, efficiency and security. The
SMP must identify organizational goals that can be achieved by using technology.
The benefits of digital transformation in SCAD

Digital transformation in SCADA can bring significant benefits to an industrial organi-

zation, such as:

• Increased efficiency. Integration with other information systems, such as SCADA,

should lead to an optimized production process, minimizing waste while increas-
ing quality. It should increase productivity.
33
How to incorporate digital transformation into SCADA master planning

• Data analytics. The organization can leverage big data and AI to derive insights  Back to TOC
from SCADA data, such as trends, patterns, anomalies and predictions.

• Real-time monitoring. The combination of IIoT, cloud computing and edge com-
puting expands SCADA capabilities for real-time access and monitoring. Edge
computing also helps reduce latency and accelerates data analysis, vital to indus-
trial operations where time is critical.

• Predictive maintenance. An organization would implement condition-based

monitoring, fault detection and diagnosis into its equipment using IIoT and AI in
its strategies.

• IIoT for remote monitoring. IIoT enhances new remote monitoring and control
methods for systems that operate at widespread locations.

Digital transformation challenges and considerations

Digital transformation can also bring many benefits to the SCADA system itself, such as
efficiency, reliability, secu-
rity and innovation. How-
ever, it also poses some
challenges and consider-
ations that must be bal-
anced when developing
an SMP (see Table 1).

Table 1. Digital transformation

challenges. Courtesy: CDM Smith. 34
How to incorporate digital transformation into SCADA master planning

Breakdown of SMP and digital transformation  Back to TOC

An SMP explains how different elements in a SCADA project are coupled correctly in
terms of system architecture, instrumentation and control (I&C) specification, appli-
cation standard and interface integration. These are all aligned with functionality and
performance requirements and create a robust cybersecurity framework (see Table 2).

Operational technology (OT) technical experts developed

Table 2 Traditional outcomes
a survey to explore critical aspects of modern SCADA sys- of a SCADA master plan.
tems, including the significance of cloud computing and IoT Courtesy: CDM Smith.
35
How to incorporate digital transformation into SCADA master planning

integration, the challenges encountered during digital technology integration and  Back to TOC
the top skill development needs for digital transformation. Additionally, it seeks to
uncover perspectives on the future roles of AI and machine learning (ML) in SCADA
systems and the criticality of data analytics in enhancing system performance and deci-
sion-making processes. Here’s a glimpse into the key findings:

• Cloud computing and IoT integration. Opinions varied among respondents, with
many emphasizing their value for noncritical SCADA assets. However, consensus
on their necessity was not unanimous.

• Challenges in digital technology integration. Cybersecurity emerged as a

paramount concern when integrating digital technologies into existing SCADA
architectures. Respondents emphasized the urgency of cybersecurity measures
to safeguard critical infrastructure and assets, highlighting the need for effective
cybersecurity strategies amidst the convergence of digital technologies. Many
respondents also emphasized the importance of compatibility and addressed skill
gaps within SCADA systems.

• Skill development priorities. The survey highlighted the growing importance of

data analytics and AI expertise in digital transformation for SCADA systems. Pro-
fessionals and organizations were urged to prioritize developing these skills to
leverage digital technologies effectively.

• Prospects of AI and ML. Envisioning AI and ML’s future role in SCADA systems
revealed diverse opinions. Respondents anticipated a supporting or central role,
emphasizing the need for continued exploration to advance SCADA capabilities.
36
How to incorporate digital transformation into SCADA master planning

• Criticality of data analytics. Data analytics is almost unanimously recognized as  Back to TOC
critical for enhancing SCADA system performance and decision-making, as well as
essential for optimizing performance, ensuring reliability, and enabling informed
decision-making (see Figure 3).

Figure 3. Summary of survey results.

37
Courtesy: CDM Smith.
How to incorporate digital transformation into SCADA master planning

Preparing for digital transformation  Back to TOC

Digital transformation is essential to avoid organizational obsolescence. But adopting
this transformation may be cumbersome, especially in sectors whose operation is high-
ly dependent on SCADA systems. These systems are complex, sensitive and typically
outdated with obsolete or unmaintained instrumentation. They are considered soft tar-
gets due to devices not made with security in mind, adding an extra layer of challenge
to the digital transformation process.

This complexity is heightened because SCADA systems, often embedded with lega-
cy technology, have not effectively been updated to withstand current cybersecurity
threats. The convergence of needing to modernize these critical systems while ensur-
ing they are secure and capable of integrating with newer, more digitally agile frame-
works underscores the multifaceted challenges facing sectors reliant on SCADA for
their operations.

Understanding the current

SCADA systems landscape
From this perspective, understanding
the current technology framework is
critical to embarking on digital trans-
formation for the OT organization. This
evaluation helps identify potential en-
hancements and areas for innovation,

38
Figure 4. Key factors for a SCADA master plan
technology assessment Courtesy: CDM Smith.
How to incorporate digital transformation into SCADA master planning

laying the groundwork for the strategic integration of these technologies. Still, it is also  Back to TOC
essential to determine what is currently being collected and historized. You cannot
develop a digital strategy without gathering the necessary information. This founda-
tional step ensures the digital transformation journey is informed by a comprehensive
understanding of existing data practices, enabling targeted improvements and more
effective integration of new technologies (see Figure 4).

Identifying areas for improvement –– incorporating digital

technologies
This stage entails leveraging advances to improve operational efficiency, better use of
data and fortifying cybersecurity. It is the process of identifying how these technologies
can automate processes,
optimize the performance
of systems, and provide
strategic insights for deci-
sion-making (see Figure 5).

Setting realistic
SCADA goals and
objectives
In this phase, the increased
focus is to align the dig-
ital transformation goals
with the latest capabilities
that technologies offer. This would include clear Figure 5. Key aspects when incorporating
strategic goals on enhancing operational efficien- digital technology in a SCADA master
plan. Courtesy: CDM Smith. 39
How to incorporate digital transformation into SCADA master planning

cy, security, and other  Back to TOC

functional requirements
aligned with broader
business strategies (see
Figure 6).

Key components
of digital transfor-
mation in SCADA
The SMP identifies and
delivers the standard specifications necessary to con- Figure 6. Aligning technology to business
objectives with measurable goals.
figure, support, maintain and operate the system. Courtesy: CDM Smith.

A standard specification for IIoT in SCADA should

cover some of the following minimum elements based on the given design criteria.

• Connectivity. The specification should indicate which communication protocol,

standard and IIoT sensor interface the device can support to ensure the device
can share data with other devices more uninterrupted and dependable over the
internet or other IP-based networks.

• Interoperability. Specify data format, model and protocols to be used by IIoT

sensors and avoid vendor lock-in so multiple systems and platforms can interoper-
ate or integrate.

• Embedded intelligence. The specification should include algorithms, functions

and processing capabilities that dictate what IIoT sensors, embedded intelligence 40
How to incorporate digital transformation into SCADA master planning

and edge computing should offer to allow the possibility of local decision-making,  Back to TOC
event detection or anomaly identification.

•R
 emote management and diagnostic. The specification should indicate which
management capabilities, protocols and tools must be part of the IIoT sensors for
remote management and configuration.

•E
 nhanced security features. The specification should define advanced security
features other than traditional sensors, such as encrypted communication, secure
boot, trusted hardware, VPN, etc.

•E
 nergy efficiency. The specification should cover the power efficiency of the IIoT
sensors; therefore, energy management for IIoT sensors is also necessary.

Using data analytics for improved decision-making

There are several key factors to consider when evaluating data analytics for improved
decision-making in SCADA systems. These factors encompass the choice between
software as a service (SaaS) and on-premises tools, vendor support, low-code versus
no-code solutions selection and other considerations.

SCADA’s predictive capabilities extend to proactive maintenance, allowing for the

early identification of potential issues to minimize downtime and associated costs. This
proactive approach ensures timely equipment servicing, preventing costly breakdowns
and prolonging the lifespan of critical infrastructure. Ultimately, SCADA data analytics
offers more than just efficiency; it holistically enhances operational resilience and pro-
motes financial prudence.
41
How to incorporate digital transformation into SCADA master planning

SaaS versus on-premises tools  Back to TOC

SaaS solutions frequently come with the benefit of a scalable and flexible nature with
low, upfront costs. On the other side, an on-premises solution best supports increased
control in the context of data security up to a greater level of customization and better
compliance for regulatory needs.

It is essential to evaluate the level of support that will be given through vendors, both
for SaaS and on-premises software. Specifically, the quality of technical support, reac-
tion rate to problems and reputation in the industry should be measured.

Solution providers must have a profound knowledge of SCADA systems and existing
infrastructure.

Selection of low-code versus no-code solutions

Low- and no-code solutions refer to platforms or tools allowing users to develop soft-
ware applications or solutions with minimal programming knowledge or involvement.
Low-code and no-code development further accelerate app development cycles of
analytics and their deployment within the SCADA system. For example, direct stake-
holders like users on the ground with varied levels of technical experience taking part
in these processes.

Considering the complexity of the analytics task and the level of technical proficiencies
that may be required in data analytics problems, low-code could enable much more
room for provision toward customizability and flexibility on solution types that might
impose higher technical demands.

42
How to incorporate digital transformation into SCADA master planning

Consciously, the no-code solutions are more likely to have a friendlier face but give up  Back to TOC
some of this flexibility.

The benefits of edge computing

When considering real-time decisions, especially for process optimization and ad-
vanced control, the SMP must evaluate typical plant controllers’ current and prospec-
tive technical capabilities, such as programmable logic controllers (PLCs) and distrib-
uted controller systems (DCS). Edge computing is becoming the proposed tool either
as a data collector for IIoT sensors or as an interface to execute advanced ML models
in integration with PLC, DCS and SCADA systems. Vendor selection is a crucial compo-
nent of this analysis.

The benefits and methods of using cloud services for SCADA

Evaluating the core interrelations of SCADA integration with cloud computing services
must be critical. This evaluation could be provided as a technical memo.

• Objectives and scope of evaluation. Provide clear definitions of the evaluation’s

purpose and identify the problem statement looking to pursue but lack the capac-
ity to confront the scope, criteria and stakeholders to enable knowledge of appro-
priate mechanisms for realigning user expectations.

• Evaluation of cloud computing services and providers. Explain the catego-

ries of services to be provided by cloud-based services in terms of features, costs
and availability and computing power. Indicate other points such as service level
agreements (SLA) and compliance certification, location of data centers, etc.

43
How to incorporate digital transformation into SCADA master planning

• Integration and migration strategies. Understand the provider integration strat-  Back to TOC
egies, associated risks and steps to ensure a smooth transition and a minimum
disruption of the existing operations, including disaster recovery plans and data
gaps during transition.

• Pros and cons of cloud computing services for SCADA systems. The proba-
ble benefits, such as scalability, elasticity, cost-efficiency, reliability and security,
generally include integration capabilities and return on investment (ROI). Among
probable risks, one should underline risks for data security, along with regulatory
compliance problems, system reliability challenges, network latency problems and
integration complexity.

Incorporating digital transformation on a SCADA master plan

For most organizations, and more so for industries, digital transformation has become
a strategic investment. Four basic steps are relevant in the context of SMP:

1. Evaluate stake-
holder’s needs.
Understanding
stakeholder’s needs,
including stakeholders
inside and outside the

Figure 7. SMP mechanism

to understand
stakeholder’s needs.
Courtesy: CDM Smith.
44
How to incorporate digital transformation into SCADA master planning

OT domain is critical to integrating emerging technologies that align with all needs  Back to TOC
and capabilities (see Figure 7).

2. Planning and strategy development. This includes a comprehensive strategy for

the technologies that will be integrated, the processes affected and the expectations
on benefits, including a timeline for implementation and a plan for managing risks or
challenges.

Cybersecurity has become a

paramount concern, so prioritiz-
ing cyberspace security to pro-
tect infrastructure and assets is
necessary (see Figure 8).

3. Selecting the right technol-

ogies and partners. Selecting
technologies and partners is im-
Figure 8. Realistic schedule
portant for success. Choosing partners with expertise, a strong
is a crucial part of an SMP.
track record and support capabilities is an ongoing and inten- Courtesy: CDM Smith.
sive exercise that should not be overlooked (see Figure 9).

4. Training and skill development plan. Digital transformation is more about people
than technology. Success relies on your staff’s ability to use and manage the new tech-
nologies effectively. This can involve formal training programs, training or hiring peo-
ple with the requisite skills.

45
How to incorporate digital transformation into SCADA master planning

 Back to TOC

Approaches to tackling digital transfor- Figure 9. The selection of technology

and partners on SMP in a digital
mation with SCADA systems transformation project helps reduce
Organizations embarking on digital transformation uncertainty. Courtesy: CDM Smith.
within SCADA systems should:

Embrace a strategic approach. Develop a comprehensive SMP that integrates digital

technologies seamlessly while addressing operational needs and cybersecurity concerns.
46
How to incorporate digital transformation into SCADA master planning

Prioritize cybersecurity. Given the integration of digital technologies, cybersecurity  Back to TOC
must be at the forefront of the digital transformation strategy to protect critical infra-
structure.

Invest in skill development. Equip teams with the necessary skills in AI, data analytics
and cloud technologies to leverage the full potential of digital transformation.

Foster a culture of innovation. Encourage a culture that embraces change, innova-

tion and continuous learning to adapt to the evolving digital landscape.

Select the right partners. Choose technology partners with proven expertise in dig-
ital transformation and SCADA systems to ensure a smooth transition and successful
implementation.

Francisco Alcala and Srisylesh Balaji

Francisco Alcala is a senior automation engineer with CDM Smith. Srisylesh Balaji is a
junior automation engineering with CDM Smith.

47
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