Automation standards
Automation standards: collaborative tools driving innovation
In the complex ecosystem of industrial automation, standards serve as the foundational framework that enables technological interoperability, ensures safety, and drives innovation
Industrial automation expert Riddhi Padariya spoke with AMS about her extensive work with the International Society of Automation (ISA) and IEEE and offered some unique insights into the critical role of developing robust automation standards across various industrial sectors.
Standards development: A multi-sectoral approach
The development of automation standards is not a siloed endeavour but a comprehensive process that spans multiple industries noted Padariya. The industrial automation expert has been actively involved as a control standards chair at IEEE, participating in multiple standard committee groups. A significant focus has been on developing standards for ISA 88, which is specifically designed for batch control and is crucial in industries ranging from food and pharmaceuticals to automotive manufacturing.
The primary motivation behind standard development is addressing the variations and exceptions that occur when no standardised procedures exist. By creating a comprehensive framework, engineers worldwide can have a consistent approach to handling complex operational scenarios.
Expanding standard horizons
Padariya's standards work extends beyond batch control. In ISA 112, focused on SCADA (Supervisory Control and Data Acquisition), the work centred on life cycle assessment. Industrial plants typically have incredibly long operational lifespans, ranging from 60 to 80 years, and potentially lasting over a century. This longevity creates challenges with legacy systems, where older PLC systems become outdated as newer, more efficient technologies emerge.
The standards development process addresses critical questions: How can legacy systems be integrated with new technologies? How can organisations standardise approaches to minimise redundant engineering efforts?
Another crucial area of standards development involves electrical components, particularly cabling. Different regions worldwide – Europe, United States, South America, and Asia –follow varied standards for manufacturing. Padariya explained that this diversity leads to multiple wiring approaches for sensors, which increases troubleshooting time and necessitates extensive communication between technicians and engineers. The goal is to develop standards that can be submitted to organizations like NIST, ISO, and IEC, ultimately helping engineers globally adopt more consistent practices.
Riddhi Padariya – Automation engineer and Chair of the ISA's Technical Advisory Committee
Riddhi Padariya has led automation initiatives at Tesla, Heirloom Carbon Technologies, and The Boring Company – gaining firsthand expertise in scaling sustainable, cutting-edge technologies. Her work spans battery production, carbon removal systems, and tunneling automation, giving her a deep understanding of modern manufacturing challenges and opportunities.
In addition to her engineering roles, Riddhi serves as Chair of the International Society of Automation's Technical Advisory Committee and has served as a board member across three different divisions in the past year.
Global impact and collaborative innovation
Standards are not merely technical documents; they are collaborative tools that drive global innovation. By creating frameworks that allow different systems, manufacturers, and regions to communicate effectively, standards reduce friction in technological integration.
The ultimate objective is to create a stable platform that manufacturers can recognise and comply with, thereby avoiding costly discrepancies and mismatches in technological implementation.
Challenges in standards development
Developing comprehensive standards is not without challenges, notes Padariya. It requires deep technical expertise, cross-industry collaboration, and a forward-looking perspective. Engineers must anticipate future technological trends while creating frameworks flexible enough to accommodate emerging innovations. The standards development process involves rigorous testing, extensive peer review, and continuous refinement. It's a dynamic, ongoing effort that requires commitment from technical experts across various disciplines.
Padariya emphasised that automation standards represent more than just technical guidelines, explaining that they are the blueprint for technological interoperability, safety, and innovation. “By providing a common language and approach, these standards enable manufacturers, engineers, and technologists to push the boundaries of what's possible in industrial automation.”
As industries continue to evolve rapidly, the role of comprehensive, forward-thinking standards becomes increasingly critical. They are the invisible infrastructure that allows technological ecosystems to communicate, collaborate, and continuously improve.
Automotive automation challenges and solutions
The challenging shift to multi-power train (BEV, hybrid, ICE) production is driving the need for greater flexibility and efficiency in manufacturing operations. This coupled with labour and skills shortages, sees automation taking an ever more important role in the optimisation of production processes. Padariya highlighted a significant hurdle presented by the diversity of Human-Machine Interfaces (HMIs). The market is saturated with multiple platforms from manufacturers like Allen Bradley, Beckhoff, and Siemens, each with its unique approach to interface design. Padariya noted that integration engineers often prioritise and design templates that vary significantly, creating a complex ecosystem where troubleshooting becomes a nuanced art. Operators must then navigate intricate learning curves, adapting to different system logics and interface designs across various factory stations.
The path to seamless automation is fraught with technological and strategic challenges. Padariya explained that for controls engineers tasked with system revamps, selecting the appropriate communication technology represents a critical decision point. The current market offers an array of options, from modern protocols like Ethernet and EtherCAT to legacy systems such as CAN and Modbus.
As such, engineers frequently find themselves navigating a complex trade-off between immediate cost-cutting and long-term system efficiency. Many professionals opt for familiar, older communication technologies despite having access to more advanced, modular libraries. Padariya said this conservative approach stems from a deep-seated reluctance to disrupt existing systems and a natural resistance to technological change and emphasised the importance of a strategic, forward-looking perspective: “Understanding the nuanced differences between short-term cost savings and long-term operational efficiency requires a holistic view of technological integration. This approach demands not just technical expertise, but also a strategic vision that can anticipate future technological trends and manufacturing requirements.”
AI supported automation
Artificial Intelligence emerges as a transformative force in industrial automation, offering unprecedented opportunities for innovation and efficiency. Padariya offered an intriguing picture of AI's potential, envisioning sophisticated AI companions that can bridge critical gaps in technological implementation:
“One of the most promising applications is AI-powered programming assistance. These intelligent systems could potentially translate between complex programming languages, creating a bridge between software engineers and controls engineers. This capability addresses a significant skills gap in the industry, potentially democratising advanced automation technologies.”
In HMI development, AI could revolutionise template creation and system integration noted Padariya: “The technology shows particular promise in navigating complex cybersecurity configurations, offering intelligent suggestions and streamlining what is traditionally a complex and time-consuming process.”
Perhaps most intriguingly, AI's predictive capabilities could transform equipment analysis. By analysing extensive PLC operation data, these systems could help organisations make more informed decisions about equipment necessity, potentially identifying redundant systems and optimising resource allocation with a high level of precision.
Balancing investment: Smart factory vs legacy systems
The transition to smart factories represents a delicate balancing act between innovation and pragmatic resource management. Padariya advocated for a nuanced approach: “When mechanical design is predictable and sound, prioritise digitization over wholesale replacement.” This strategy acknowledges the significant capital investment required for mechanical and electrical upgrades.
Software optimisation emerges as a more cost-effective and flexible alternative. However, Padariya cautioned against blind trust in AI-generated solutions, emphasising the continued importance of human oversight and manual intervention: “The review process remains critical, ensuring that technological innovations align with operational requirements.
Automation features for flexible factories
Recent technological advancements have dramatically enhanced the adaptability of industrial robotics. Padariya noted that vision systems now enable robots to recognise similar products with greater accuracy, automatically adjusting vision offsets and continuing operations with minimal human intervention.
Lightweight robots have developed sophisticated path learning capabilities, particularly valuable in high-mix, low-volume manufacturing scenarios: “This adaptive intelligence allows for more flexible manufacturing processes, where robots can dynamically adjust their operations based on subtle variations in product specifications.”
The ability to change end-of-arm tools dynamically represents another significant leap forward, observed Padariya. Robots can now seamlessly switch between different tools based on specific recipe requirements, enabling unprecedented manufacturing flexibility.
Cybersecurity and interoperability
Cybersecurity in modern manufacturing demands a sophisticated, multi-layered approach. Padariya described a strategic multi-level system that carefully manages information flow and system access:
“From foundational sensor networks through to enterprise resource planning systems, each level is designed to share only the necessary information. When multiple plants need to communicate, they can strategically expose specific parameters, ensuring that no single system can compromise the operational integrity of another.
“Advanced security measures include sophisticated gateway systems that block unauthorised third-party requests, robust authentication protocols, and carefully controlled read/write access to critical system parameters.”
People-centric approach to automation
Drawing from industry standards like ISA 101 and ISA 112, shows a strong commitment to human-centred design in automation technologies: “This approach recognises that technological innovation must prioritise user experience and operational intuition’” said Padariya.
Offering HMI design principles as an example, Padariya emphasised the need for clarity and simplicity, utilising neutral colour palettes as a default, with bright, attention-grabbing colours reserved exclusively for critical faults requiring immediate intervention. Visual guides with step-by-step instructions can reduce reliance on complex documentation, making systems more accessible to operators with varying technical backgrounds.
Padariya observed that standardised iconography can help to reduce cognitive load, ensuring that system status and warnings are universally understood and noted that modern interfaces can even adapt to environmental conditions, automatically adjusting to lighting variations and operational contexts.
Taking a holistic approach to automation
For Padariya the future of automotive automation goes beyond just technological advancement. It represents a holistic approach that balances cutting-edge artificial intelligence, strategic system design, and a deep understanding of human operational dynamics.
As manufacturers navigate this complex landscape, success
will depend on their ability to integrate advanced technologies while
maintaining a fundamental focus on human capabilities and operational
efficiency.
