The Impact and Influence of Software-Based Controls

The Future of Manufacturing: Part 2

In the first blog in this series, we looked at the ways in which the future of manufacturing will be transformed by the supercharged capabilities of AI and increasingly sophisticated predictive technology. Unlocking the full potential of those breakthroughs requires transitioning away from the traditional control architecture of manufacturing environments and utilizing software-based controls.

In this second installment in the series, we’ll explore the profound impact of this ongoing shift—and the challenges and opportunities this change presents for manufacturers at a time when software-based controls and human-tech synergies are actively changing the way we think about manufacturing processes and environments.

The Software-Based Revolution

In the traditional control architecture of manufacturing systems, almost all automated functions are managed via programmable logic controllers (PLCs). A PLC is essentially a simple way of translating basic data into instructions. But PLC-based systems have a number of significant limitations. PLC functionality boils down to a series of yes/no questions: a black-and-white structure that is perfectly fine for basic scenarios, but is incapable of processing nuance, complexity, or the kind of conditional circumstances that are both necessary for and unavoidable in modern production environments.

In contrast, software-based controls are ideally suited for customization and complex production variation. On a practical level, industrial systems with software-based control are much more flexible and scalable than their PLC predecessors. That makes them ideal not only for large manufacturers, but also for small to mid-sized operations. Software-based controls are applicable to a much wider range of assembly and production environments, as well as a virtually unlimited list of products and processes. That flexibility means software-based controls can be used to optimize a production environment with granular monitoring and sophisticated tools by “talking” to IoT devices—but can also be leveraged to do something as simple as integrate straightforward operator feedback. It all comes down to what the device, the process, and the environment demand. In other words, software-based controls unlock new efficiency for manufacturers who may not have thought their operational model—or their bottom line—was a good fit for a more sophisticated production management system.

Another advantage of software-based control is that unlike with PLC-based systems, you don’t need the knowledge of a controls engineer to write new code for every change. Software-based control means you can operate with a no-code platform—one where existing staff can easily manage the system without any outside assistance.

The Human Element

While there are plenty of practical economic and operational reasons why software-based controls are superior to their PLC antecedents, perhaps the biggest reason why software-based control is the wave of the future is that it not only provides a framework for evolving AI innovation, it also accommodates the secret key ingredient in our automated manufacturing future: people.

To the casual observer, automation evokes autonomous robots or independent machine functionality. But experienced manufacturers understand that the best and most powerful new automated technologies all involve the human element to some extent. After all, AI is created and powered by human input. Systems powered by software-based controls can guide operators through the process, can detect when something goes wrong (or right!), and can automate the way information is gathered and transmitted across the factory floor. But people are still integral to acting on that information and performing a whole host of essential tasks; even fully automated processes must be defined by people.

In addition, it’s important to remember that high-level automation can and often does fail. Human engagement is still preferred—even required—as part of a procedural check or an analytical review. It’s impossible to think of every possible scenario that will unfold, and even the most sophisticated AI tools are unlikely to provide the contextual decision-making power of the human brain. The best solutions integrate the human element as a fundamental driver of automation.

The future-forward factory is powered by advanced technology, but animated by evolving industrial landscapes: environments where trained professionals and automated elements work seamlessly in concert to deliver extraordinary new benefits. In the third and final piece in this series, we will explore what those environments look like, as well as how they are evolving to keep pace with the explosion of connected process control technology.

Learn how Epicor solutions can help your business get ready for what’s next.