Demystifying the Role of Industrial Automation Consultants

 

Introduction to Industrial Automation Consulting

The field of industrial automation continues to grow in scope and complexity. As manufacturing facilities aim to increase productivity and efficiency through automated processes, many seek the services of specialized consultants like industrial automation consultants. These experts can provide invaluable perspective and guidance when adopting or optimizing automated systems.

Core Responsibilities of an Industrial Automation Consultant

Industrial automation consultants typically serve mechanical design firms as well as manufacturers directly. Their core responsibilities include:

• Analyzing existing processes and identifying areas for performance improvements or cost savings through automation. This may involve conducting time studies, evaluating production bottlenecks, and calculating potential return on investment.
• Designing optimal automated solutions tailored to the client’s specific needs and production environment. This requires expertise in various automation technologies like PLCs, robotics, HMIs, and process control systems.
• Overseeing equipment selection and integration of new automation systems to ensure smooth implementation. This requires understanding implications on safety, regulatory compliance, as well as impacts on personnel.
• Providing training and support to the client’s team to leverage maximum benefits from the automated systems. Managing changeovers and helping troubleshoot issues are critical for sustainable success.
• Continually monitoring automated processes against key performance metrics and suggesting enhancements over time. The systems require periodic maintenance, upgrades and reconfigurations.

Key Skills and Qualifications

To deliver on these diverse responsibilities, industrial automation consultants require well-rounded skill sets encompassing both technical and business domains:

Technical Expertise

• In-depth knowledge of industrial automation applications, technologies and integration techniques. Familiarity with PLC/HMI programming, robotics, networked control systems, sensors, process control, and automation safety protocols.
• Understanding of manufacturing processes, equipment capabilities and mechanical systems design. Ability to evaluate production environments and workflow.
• Hands-on experience in implementing automation solutions, troubleshooting issues, and performing equipment integration. Keeps updated on latest innovations and best practices.

Business Acumen

• Strong analytical abilities to construct cost-benefit analyses, interpret process data, and estimate return on investments for proposed projects.
• Project management skills to develop implementation roadmaps, manage timelines, budgets, resources and risks to drive successful outcomes.
• Communication and leadership competencies to liaise between stakeholders, provide guidance and training, and maintain collaboration.
• Commercial awareness to devise automation solutions balancing performance goals, business objectives, staffing needs, regulatory mandates and technology constraints.

Impact of Hiring an External Industrial Automation Consultant

While some larger manufacturers maintain in-house teams for automation needs, most mechanical design firms and small or mid-sized producers can benefit greatly from partnering with industrial automation consultants. Reasons for hiring an external consultant include:

Unbiased Insights: External consultants can impartially audit existing processes and systems and bring fresh perspectives on where and how to implement automation based on experience across various industries.

Specialization: Consultants focus exclusively on automation allowing them to deliver highly specialized expertise. Firms need not train or hire specialists when consultants can fill intermittent needs.

Risk Mitigation: With intricate technologies and huge investments at stake, consultants help avoid pitfalls at every stage - from designing failsafe systems to ensuring smooth deployments and transitions.

Scalability: Consultants can be leveraged to any extent - from one-time improvement projects to serving as temporary specialists to providing full-time automation leadership roles. This on-demand flexibility enables scaling automation initiatives.

Key Takeaways

As industrial facilities increase their reliance on automated systems for enhanced productivity and reliability, industrial automation consultants are playing a pivotal role in planning, optimizing and integrating these solutions. Their specialized skills, hands-on experience and unbiased perspective equip them to improve processes, reduce risks and maximize the performance of clients’ automation investments. For mechanical design firms and manufacturers aiming to stay ahead in a highly competitive marketplace, leveraging the expertise of automation consultants can deliver significant long-term advantages.