Minimize Risk in Food Automation Systems

A key part of the FAT involves thorough testing of control equipment to ensure that it hasn’t been damaged in transit and performs to specification. Make sure the factory test is scheduled well in advance of the installation at your facility, to allow time for any required corrective action.

In addition to the FAT, another best practice is to test the software. Depending on the nature of your plant process, the custom software will go through a variety of dry runs and wet runs prior to moving into production.

Trained Staff = Success

Although it may seem obvious, don’t overlook the fact that automation success requires trained staff. An essential part of minimizing risk means properly training those responsible for operating and maintaining the system.

It’s imperative for the technical team to schedule operator and maintenance training during installation. Operations staff needs hands-on training with the new system; maintenance needs more detailed training in troubleshooting and maintaining control equipment.

As soon as the technical team has confirmed proper operation, operations personnel should run the system. This will accelerate their ownership of the system and their ability to effectively operate and maintain it. It’s important to have the systems integrator revisit the system with the operations staff after a few weeks of operation to be sure everything is working as intended.

Reaping the Rewards

The goal of any automation project is to complete it sooner rather than later in order to more quickly reap the benefits of the new technology. But reaching the finish line in record time means little without project success. The key is to establish clear objectives up front, carefully plan the project, and ensure that everyone is on the same page from start to finish. The experience and capabilities of the project team, including the systems integrator who designs and executes all or a majority of the project, also cannot be overstated.

David McCarthy is president and CEO of TriCore, a national systems integration firm based in Racine, Wis., with offices in Glendale, Calif., and Mesa, Ariz. Before he founded TriCore in 1991, McCarthy served in various capacities at Alfa Laval/Tetra Pak, including manager of engineering for its U.S.-based food engineering company.