At Gerhart, we understand that every automation system is unique, and that’s why our approach to automation audits is customized to meet the specific needs of each client. Our audits are designed to not only ensure your automation systems are functioning efficiently but also to uncover opportunities for improvement that you may not have considered. We perform audits using a systematic and detailed process that combines technical expertise with a deep understanding of your operational goals.
Why Are Automation Audits Important?
Automation audits are essential because they simplify system maintenance and upgrades. By providing a comprehensive understanding of the components and systems that make up an automation process, audits offer a clear roadmap for ongoing support and future modifications.
Without proper insight into the systems and their components, companies can face prolonged downtimes, higher repair costs, and difficulties in troubleshooting when issues arise. Automation audits mitigate these risks by offering clarity on system configurations, potential vulnerabilities, and strategies for improvement, thereby streamlining operations and reducing the impact of unexpected breakdowns.
What Do Automation Audits Entail?
An automation audit involves a thorough examination of the automation system, which is then documented in a detailed report. This report includes:
- Hardware Component Inventory
- A comprehensive list of all hardware components, categorized by their current status (supported, obsolete, requires attention, needs upgrade, etc.).
- Software Inventory
- A list of all software required to support the automation system, including PLC (Programmable Logic Controllers), HMI (Human Machine Interface), SCADA (Supervisory Control and Data Acquisition), and data management systems.
- Recommended Spare Parts
- A list of essential spare parts that should be kept on hand. This ensures that critical components are readily available to minimize downtime in case of system failure.
- System Overview
- An overview of the entire system, including reverse engineering to familiarize us with the system’s configuration. This allows our team to provide quick and effective support during equipment breakdowns.
- Inputs and Outputs List
- A detailed list of all inputs and outputs for field devices, along with their connections. This simplifies future troubleshooting by offering a clear understanding of device interactions.
- Program Backup
- A backup of all programs used within the control system, ensuring data integrity and enabling faster recovery during a system failure.
- Comprehensive Documentation
- Full documentation of both hardware and software aspects of the control system, providing a clear record for ongoing support and upgrades.
- Produce Drawings
- If you don’t have current drawings on hand, our team will use the audit to produce panel and field drawings if needed.
Major Perks of Automation Audits
Automation audits offer several key benefits to businesses, ensuring that they are prepared for future challenges and minimizing potential risks:
- Easier Support in the Future
With a complete understanding of the system’s components and configurations, our support team can respond to issues more swiftly and effectively. - Simplified Upgrades
Having a clear roadmap of the system’s current state makes it easier to plan and execute future upgrades without disruption to operations. - Predicting Failures
Audits help identify potential failure points, allowing you to address issues before they result in significant downtime or equipment failure. - Preparation for Unexpected Breakdowns
With a comprehensive understanding of the system, you will be able to respond to unexpected breakdowns more quickly, reducing operational delays. - System Familiarity
Automation audits ensure that you fully understand the components and workings of your system, increasing operational efficiency and confidence.
Consequences of Not Having Automation Audits
Failure to conduct regular automation audits can have serious consequences. Without an audit, companies may face:
- Prolonged Downtime
A breakdown can result in significant production losses if the support team is unfamiliar with the system or lacks the necessary resources to fix the problem quickly. - Lack of Spare Parts Inventory
Without an inventory of recommended spare parts, companies may experience longer downtimes while waiting for critical components to be sourced. - Slow Recovery After System Failures
In the absence of a thorough audit, reverse engineering must be done when the system is already down, leading to longer recovery times and increased costs. - Obsolete Systems and Components
Without an audit, you may discover that key components or systems are obsolete only after a failure has occurred, complicating repairs and forcing costly replacements.
An automation audit ensures that any breakdowns can be promptly addressed, minimizing downtime and enabling a swift recovery. Without an audit, however, recovery can range from a day to several months, depending on the severity of the issue and the availability of necessary parts.
Conclusion
Automation audits are critical for maintaining efficient, reliable systems. They provide key insights into components, software, and spare parts, helping businesses prepare for unforeseen breakdowns. Regular audits reduce downtime, enhance performance, and future-proof operations.
By choosing Gerhart for your automation audit, you’re partnering with a team that is dedicated to ensuring your automation systems are optimized for long-term success. Our audits are more than just a routine check—they are a strategic tool for enhancing efficiency, predicting issues, and planning for the future. With our support, your automation systems will not only meet today’s needs but be adaptable to future challenges and technological advancements.