In today's rapidly changing technological landscape, industries are constantly looking for ways to integrate new solutions that enhance safety, efficiency, and overall operability. However, introducing new technologies, particularly in highly regulated and conservative industries, presents a unique set of challenges.
Why are we integrating new technologies?
The primary motivation for integrating new technologies is to enhance safety and operational efficiency. One of the biggest challenges in control room operations is the reliance on operator experience, which is difficult to formalize and retain. As experienced operators retire, industries face a loss of valuable knowledge. By embedding operational knowledge into digital models, companies can create a reference system that preserves crucial information and automates labor-intensive processes, like HAZOP studies.
Common challenges in technology integration
- Resistance to change
The industrial sector is traditionally conservative, dealing with high-stakes safety and financial concerns. Many organizations are hesitant to adopt unproven solutions, especially when existing systems are perceived as "good enough".
Additionally, convincing stakeholders of the value of new technology can be difficult, as any failure could result in significant operational and financial consequences.
- High IT security requirements
Security is a top priority in industrial environments, and integrating software solutions into plant operations requires meeting strict cybersecurity standards. Local installations can be complicated, especially if external developers do not have direct access to the plant. Also, extracting data from plants while maintaining security compliance adds another layer of complexity to the integration of new technologies.
The fact that it is possible at all to remotely support and deploy software to these very security-driven environments is unique and new to the “post-COVID world". So, while it is a challenge, it is also quite an opportunity, compared to pre-COVID where most of this technology would require on-site visits to be applied and developed.
- Integration with existing systems
New solutions must complement, rather than replace, existing systems. Many new technologies function as stand-alone applications initially, requiring careful integration strategies to ensure compatibility with current workflows.
- Limited direct access to key stakeholders
Establishing communication with facility personnel and decision-makers can be time-consuming. However, without direct access to key individuals, progress and integration can be slow, and critical feedback may be delayed.
Strategies for overcoming integration challenges
- Build strong client relationships
Maintaining consistent communication and collaboration with clients is crucial for successful technology adoption. Understanding client needs and fostering a sense of investment in the project ensures better cooperation and smoother implementation.
- Demonstrate proven value
Address concerns about unproven solutions by providing case studies, pilot projects, and demonstrations of successful implementations. Highlighting tangible benefits, such as efficiency gains and improved safety measures, can help build confidence in new technologies.
Developing good reporting tools can especially aid with demonstrating value. From our own experience, this has required both identifying what are good parameters/metrics to report, and how to automate & optimize the process of generating reports and showcasing them to the stakeholders.
- Ensure compliance with security standards
Work closely with IT and OT security teams to ensure all software solutions meet the industry and company’s stringent cybersecurity requirements. Develop strategies for secure local installations and safe data extraction protocols to mitigate security risks.
- Seamless integration with existing solutions
Rather than forcing complete system overhauls, design new technologies to work alongside current solutions. Adopting an incremental approach and allowing companies to gradually transition to more advanced digital tools without disrupting operations will help mitigate reservations.
- Proactively engage with key personnel and stakeholders
Identify key stakeholders early in the process and establish open communication channels. Ensure that project teams have direct access to decision-makers to facilitate timely approvals and feedback.
An example that seems to have worked quite well for us is regularly scheduled meetings / communications with stakeholders. For example, one person has had daily/weekly/bi-weekly meetings with customer personnel, which seems to have significantly improved both the adoption and impact of the software in that pilot project.
In conclusion
While integrating new technologies in industrial environments presents significant challenges, the potential benefits in terms of safety, efficiency, and knowledge retention make it a worthwhile pursuit. By building strong client relationships, addressing security concerns, ensuring seamless integration, and demonstrating the value of new solutions, companies can successfully navigate the complexities of technology adoption. As industries continue to evolve, those that embrace innovation while addressing integration challenges head-on will likely gain a competitive advantage in the future of industrial operations.
