The first steps on the way to the Selmo machine

Retrofit

What is a retrofit?

A retrofit means modernizing and improving existing equipment by using new technologies without having to replace the entire facility. Although many production facilities are still functional, they do not meet today's technical and ecological standards.

Why is this important?

Many factories were built decades ago – long before rapid digitization was foreseeable. These old plants, often referred to as "brownfield", have been in operation for years and are different from modern "greenfield" new plants. With a retrofit, companies can adapt their existing systems to new requirements and at the same time save costs and resources that would be incurred if they were to purchase a completely new one.

Advantages of a retrofit

A retrofit offers numerous advantages compared to the construction of a completely new system:

• Cost savings: Up to 62% of companies opt for a retrofit due to the lower investment costs.
• Space saving: Existing space is used optimally without needing additional space for a new plant.
• Fewer bureaucratic hurdles: Since many existing systems are already certified, many regulatory requirements are no longer necessary.
• Targeted process optimization: Existing processes are improved without the need to develop new, untested processes.
• Sustainability: Reusing existing plants saves resources and significantly reduces the ecological footprint.

Which areas can be modernized?

A retrofit usually includes three core areas:

• Mechanics: Replacement or optimization of moving parts such as conveyor technology or robot systems.
• Electrics: Modernization of control systems, sensors and safety technology.
• Software: Update or integration of new control software for better networking and increased efficiency.

The OT strategy: Successful pre-engineering during retrofit

To ensure that a retrofit runs smoothly, we rely on a structured OT (Operational Technology) strategy. This strategy ensures that existing systems are optimally analyzed and further developed.

The OT strategy consists of three key steps:

Process analysis

• What processes are in place?
• Where are there vulnerabilities, unmonitored areas or inefficient processes?
• What new requirements are there, e.g. better sensor technology or control logic?
  
  Technology analysis
• Which existing technologies can be used?
• Which components need to be supplemented or modernized?
• How can new elements be seamlessly integrated into the existing infrastructure?
  
  Functional analysis 

• Which control functions are available, which are missing?
• How can simple and complex control elements be optimally controlled?
• What adjustments are necessary to ensure smooth communication between old and new technology?

Creating

What is a new plant?

A new plant, also known as a "greenfield project", means that an entirely new production plant or process is developed. At the beginning, there is only one idea – whether it is to automate a manual process or to improve an existing production method with new technologies. Since no existing hardware or software needs to be considered, companies have the freedom to design their optimal solution.

The current engineering process for new plants

Traditionally, the development of new systems is based on a fixed sequence, first the mechanics are planned, then the electrics, and only finally the software is developed. This means that older, proven systems are often preferred, even if there are already more modern alternatives. This creates potential restrictions during the planning stage, which are later noticeable in implementation.

The process can be divided into four phases:

In this phase, all requirements for the new plant are collected and documented. This includes mechanical and electrical components, as well as basic software requirements. In practice, however, it often turns out that this documentation is incomplete or inaccurate. This leads to misunderstandings, misplanning and problems in choosing the right technology. Inadequate planning can run through the entire further process and cause high costs later on.

The construction of the plant begins with the mechanical construction. Only when this is completed will the electrical planning be tackled, followed by software development. This sequence can be problematic: important aspects such as sensor technology and software requirements are often not considered early enough.

If, for example, too few sensors are planned or the mechanics use outdated technologies, software development is limited later on. This can lead to the software having to be adapted at great expense to compensate for the existing hardware limitations. This complicates the entire development process and often leads to inefficient solutions.

After the design, the test phase follows, the software is connected to the mechanical and electrical structure and tested in the real environment. Errors often occur that result from unclear requirements or suboptimal decisions in the previous phases. Since the hardware is already fixed at this point, the software has to compensate for many errors – a time-consuming and costly process.

Each change requires retesting, resulting in delays and rising costs. If commissioning does not go smoothly, unplanned downtime can occur, which has a negative impact on the entire production.

After successful commissioning, the responsibility for ongoing operation and maintenance lies with the production and maintenance teams. If problems arise, the cause is often insufficient requirements from the planning phase or incorrect design decisions during implementation.

A common problem is inadequate sensor technology or incorrect software adaptation, which makes errors difficult to identify. This can lead to longer downtimes and inefficient production processes. So, poor planning at the outset means long-term challenges and higher operating costs.

OT strategy for new investments

The Selmo OT strategy revolutionizes this process by focusing on software and using behavioral engineering from the start. The entire automation process is defined in three clear steps:

Process analysis:

Instead of focusing on the hardware first, planning starts with the question:

What should the process look like?

• The entire process is modelled and precisely defined.
• All requirements for material flow, sensor technology and control logic are defined.
• Sources of error due to inadequate process monitoring are avoided.
  
  Technology analysis:

Once the process has been clearly defined, it is examined which technologies are necessary for implementation.

• Which sensors and actuators are required to control the process efficiently?
• Which control systems and interfaces are suitable for modern automation?
• How can scalability and future proofing be guaranteed?
  
  Functional analysis:

In the last step, it is determined which functions the software needs.

• Standardized control functions are used to ensure efficiency and stability.
• Special process requirements such as adaptive controls or predictive maintenance are integrated.
• The entire automation is tested in a digital environment before it is implemented in the real plant.