The Road to AI in Day-to-Day Manufacturing

It is clear that AI kicked off a revolution, yet only a small percentage know the necessary fundamentals behind applying. This has become a buzzword in conference calls, "just use AI for that", unaware of the focus required, let alone the effort it would take. Working with multiple DCS and PLC installations, I have seen and experienced first-hand the gap of design & thought when it comes to advanced implementations. Industry statistics put APC abandonment at greater than 50%, if so, what chance does AI have if we cannot properly implement the tier below it?

In Process Control, there are various levers to use to achieve a desired result. AI does not have to be the pinnacle, rather an enabler at each stage throughout the journey. All of this could culminate in the use of Deep Learning or Neural Networks to look ahead where our systems and minds cannot in present stage.

Key Takeaways from this session:

• AI Requires Strong Operational Foundations

Successful AI implementation depends on having solid control systems, processes, and automation strategies already in place. Without a strong foundation, advanced AI initiatives are likely to fail.

• AI Is Often Overhyped and Misunderstood

Many organizations treat AI as a catch-all solution without understanding the complexity, focus, and resources required for effective deployment.

• Existing Automation Challenges Signal AI Risks

With Advanced Process Control (APC) abandonment rates reportedly exceeding 50%, the industry must address current implementation gaps before expecting large-scale AI success.

• AI Should Be Viewed as an Enablement Tool, Not the End Goal

AI can provide value throughout multiple stages of process control and optimization, supporting decision-making and operational improvements rather than serving only as a standalone “ultimate” solution.

• Future Potential Lies in Predictive and Adaptive Intelligence

As systems mature, technologies like Deep Learning and Neural Networks may enable organizations to anticipate conditions and outcomes beyond current human and system capabilities.