Plant Modernization Strategies for Industrial Automation

Transcription

1 Plant Modernization Strategies for Industrial Automation Sponsored by Copyright Gatepoint Research. All rights All rights reserved. This This report report is the is the sole sole property of of Gatepoint Research and and may may not not be be used, used, reproduced or or redistributed in any in any form form including, but but not not limited limited to, print to, print & digital & digital form form without without express express written written consent consent of of Gatepoint Research.

2 Survey Summary Between January and April, 2017, Gatepoint Research invited selected executives to participate in a survey themed Plant Modernization Strategies for Industrial Automation. Candidates were invited via and 151 executives have participated to date. Management levels represented are predominantly engineering and operations senior decision makers: 5% hold the title CxO, 10% are VPs, 40% are Directors, and 45% are Managers. Survey participants represent firms from a wide variety of industries including manufacturing (high tech, general and primary), financial services, healthcare, wholesale and retail trade, business services, construction, mining, utilities, education, media, telecom services and transportation. Responders work for firms with a wide range of revenue levels: 77% work in Fortune 1000 companies with revenues over $1.5 billion; 8% work in Large firms whose revenues are between $500 million and $1.5 billion; 1% work in Mid-Market firms with $250 million to $500 million in revenues; 14% work in Small companies with less than $250 million in revenues. 100% of responders participated voluntarily; none were engaged using telemarketing.

3 Executive Overview Industrial organizations need a constant stream of data to avoid or mitigate unplanned downtime while maintaining plant efficiency and processing plant data. Legacy systems can t always keep up with new technology and devices, making system maintenance and issue pre-detection more difficult. Representing both SCADA users and SCADA application managers, respondents to this survey are concerned about the effects of a SCADA failure, specifically the loss of revenue and data. This survey asks respondents to report: What are some of the day-to-day challenges they face with their SCADA system? What are the top concerns about a SCADA failure? For how long a period of time will the organization tolerate unplanned downtime? What type of changes would improve plant operations? Is migrating to a standards-based virtualized environment in your near-term plan?

4 Which of the following best characterizes your primary role with your company? My group uses the data from SCADA systems, e.g., for business or regulatory purposes 37% My group uses the SCADA systems to make operations run smoothly 24% My group is responsible for SCADA applications but IT chooses the servers 16% My group responsible for SCADA applications and for choosing servers that run them 9% Other: I don't use or manage SCADA 15% 0% 5% 10% 15% 20% 25% 30% 35% 40% 61% of all respondents use SCADA systems for business, regulatory or to run operations. 25% manage the applications and/or servers that run them.

5 What are your main challenges with day-to-day operation of your plant SCADA system? Legacy systems that have a hard time keeping up with 46% Multiple systems that are complicated and time consuming 35% The length of time it takes to get IT / Technical support Supporting the increasing number of devices in my plant 29% 28% Maintaining data integrity 26% Identifying the source of issues e.g., application slowdown 22% Meeting regulations / compliance requirements 13% Burdening 46% of all respondents is their existing legacy systems that can't keep up with new technology. More than a third say they are challenged by managing multiple, complicated systems (35%). Technical support lag time is a problem for 29%. More than a quarter of respondents cite the increasing number of devices in the plant and maintaining data integrity. 0% 5% 10% 15% 20% 25% 30% 35% 40% 45% 50%

6 What business consequences of SCADA failure concern you the most? Loss of revenue 58% Corruption / loss of critical data 46% Needing to justify budget for new equipment or software upgrades if something is broken Inability to meet regulatory requirements/noncompliance; legal implications 23% 26% Not sure 13% 0% 10% 20% 30% 40% 50% 60% 70% Revenue loss from SCADA failures is the top concern for 58% of respondents, and nearly half (46%) say data corruption or loss is a critical concern.

7 How much unplanned downtime is acceptable for your plant operations (per incident)? 35% 30% 32% 25% 20% 15% 21% 19% 21% 10% 5% 8% 0% Zero 5 minutes or less 5 to 60 minutes More than an hour Not sure 21% of respondents say their plant can not accept any unplanned downtime, and 51% say unplanned downtime exceeding 60 minutes is unacceptable.

8 When do you anticipate plant infrastructure changes that could impact SCADA downtime? 30% 25% 27% 28% 20% 15% 19% 10% 13% 5% 8% 5% 0% Within the next year 1 to 2 years 3 to 4 years 5 years or more Not sure Nothing planned Nearly half of respondents are anticipating changes that can affect their SCADA application downtime, with 40% looking at changes within the next four years.

9 When are you planning to move to a standards-based virtualized environment? Need to learn more about virtualization first 17% Already virtualized 14% 1 to 3 years 14% No current plans 50% Within 12 months 5% Although 19% of respondents are in the process or planning to move to a standards-based virtualized environment, 17% want to know more before they commit to a migration plan.

10 What are the top 3 factors that would improve your plant operations? Simple-to-manage / easy-to-service systems 73% Elimination of unplanned system downtime to ensure data integrity 61% Self-monitoring equipment that predicts performance issues in advance 59% Future-ready processes that handle changes in technology/applications such as virtualization and IIoT, etc. 35% Availability of on-demand access to IA / IT experts to supplement your own IT capabilities 19% 0% 10% 20% 30% 40% 50% 60% 70% 80% 73% of respondents say they need systems that are simple to manage and easy to service. Being able to ensure data integrity by eliminating unplanned downtime is cited by 61% as a top improvement factor, and nearly as many (59%) would like advance warning of performance issues enabled by self-monitoring equipment.

11 Profile of Responders: Industry Sectors Construction 2% Business Services 3% Other: 3% Utilities 3% Mining 3% Wholesale and Retail Trade 4% Healthcare 4% Financial Services 4% Mfg - Primary 10% Mfg - High Tech 41% Mfg - General 23% Nearly three quarters of respondents are in the manufacturing industry.

12 Profile of Responders: Revenue $ million 1% <$250 million 14% $500 million - $1.5 billion 8% >$1.5billion 77% More than three quarters of respondents work for firms with greater than $1.5 billion in revenue.

13 Profile of Responders: Job Level VP, 10% CxO, 5% Director, 40% Manager, 45% Respondents are in senior and executive level roles in their organizations.

14 Stratus takes the complexity out of keeping business critical applications running 24/7. Stratus technologies proactively prevent instances of unplanned downtime both in the data center and at the edge, and our services ensure any issues are addressed before customers need to. Global Fortune 500 companies and small medium sized businesses in a wide range of industries across the globe have been relying on Stratus for operationally simple, continuous availability for more than 35 years. Visit us at stratus.com/ia follow Stratus on