Case study: problems after implementation

The question text is cut off in the scan; it is read as: problems that might occur after implementing the proposed (automatic control) system in the case-study plant.

Technical problems

1. Electrical noise and EMI from motors, relays and VFDs corrupt sensor signals and cause false triggering (need shielding, grounding, filters).
2. Ground loops and power-quality problems: voltage dips, surges and power cuts reset the controller (use UPS, surge protection).
3. Sensor drift and failure, needing periodic calibration; wiring faults.
4. Software bugs and controller hang-ups (watchdog needed); loss of settings.
5. Communication errors on the network (RS-485 faults, wrong baud rate or addresses).
6. Single point of failure if there is no redundancy or manual bypass.
7. Compatibility problems with old equipment.

Organisational problems

• Operator resistance and lack of skills; training needed.
• Dependence on a few experts or on the supplier for spares and support.
• Higher maintenance cost and spare-part availability.
• Data and cyber security, and production stoppage during commissioning.

Remedies

Pilot run, parallel operation with the old system, training, preventive maintenance, spares stock, manual override, documentation and a support contract.