Unlocking Value: How Capturing Data from Industrial Automation Improves your Business
In today’s highly competitive, fast-paced environment, data is more than just numbers — it is a strategic asset. I’m sure we’ve all heard the phrase “data is the new gold,” and it’s absolutely true. As manufacturing and process industries shift toward “smart factories” and Industry 4.0, capturing data from our manufacturing facilities has become a vital link in transforming operations from good to great.
At the centre of this transformation are our PLCs (Programmable Logic Controllers), DCS (Distributed Control Systems), smart sensors and SCADA (Supervisory Control and Data Acquisition) systems. Traditionally used to automate our factories, these systems generate vast amounts of data with enormous untapped potential. However, what’s often missing is an efficient way to extract this information and turn it into meaningful insights — insights that improve efficiency and enable smart, informed decisions, ultimately reducing downtime and increasing profitability.
What data can be captured?
This is not meant to be an exhaustive list, but includes:
Sensor data (temperature, pressure, speed, flow, voltage, current)
Machine status (on/off states, error states, cycle counts)
Production metrics (measuring throughput, downtime, product conformance)
Alarms and events
Energy usage and environmental factors
Operator inputs and manual overrides
5 examples of how data capture can help you
Establish a performance baseline to monitor changes over time, enabling a shift from reactive repairs to proactive, preventative maintenance.
Lower operational costs by optimizing equipment to run at its efficiency “sweet spot”
Run “what-if” analyses — for example, assess potential savings from reducing heated water temperature by 5 degrees.
Identify performance anomalies – capture events leading up to a circuit breaker trip or fault condition.
Support regulatory compliance and traceability by automatically logging key process parameters, ensuring accurate records for audit and certifications.
In the following example, we recorded the current drawn by a newly installed three-phase motor as its RPM (frequency) increased throughout its operating range. This information was used to establish a performance baseline, which can be referenced during routine maintenance to identify any changes in operating parameters that might signal potential problems or contribute to unexpected downtime.
Figure 1 – Data retrieved from a Variable Frequency Drive (VFD)
In conclusion…
Data is the lifeblood of Industry 4.0. When captured, analysed, and applied effectively, it unlocks new levels of visibility, control, and intelligence across the entire manufacturing process. From improving operational efficiency to reducing downtime and enhancing product quality, the value of data is clear.
But the real power lies not just in collecting data — it’s in using it to drive continuous improvement and smarter decision-making. As the industrial landscape continues to evolve, those who invest in data-driven strategies today will be best positioned to adapt, innovate, and stay ahead of the competition tomorrow.
Now is the time to move beyond traditional approaches and embrace data as a core driver of industrial performance and transformation.
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