A Look at Data, Automation, and Expertise

Power generation manufacturing has always been a tough business. But lately, things have become even more complex. With the growing demand for energy and the push toward sustainability, manufacturers are under constant pressure to streamline operations, manage huge amounts of data, and ensure their processes are as efficient as possible. In this article, we’ll break down the key concerns power generation manufacturers face and how companies like Standard Electric, an industrial automation and electrical distributor, can provide the right solutions to tackle these issues.

What Are the Big Pain Points?

1. Outdated Processes and Aging Equipment: Let’s face it—many power generation plants are running on aging infrastructure, which means inefficiencies are bound to happen. When equipment breaks down, it doesn’t just slow down production; it leads to costly repairs and downtime. In the past, power operations were simpler and more predictable. Now, with renewable energy sources like solar and wind in the mix, things have gotten a lot more complicated (Kephart, 2024) Keeping everything running smoothly can feel like a juggling act.
2. Data Overload and Siloed Systems: Data is everywhere, but it’s only useful if you can actually do something with it. One of the biggest challenges power generation manufacturers face is managing all that data in a way that’s actionable. Unfortunately, data often ends up siloed—trapped in different systems that don’t communicate with each other. This makes it hard to get a real-time view of operations, and without that visibility, optimizing processes becomes a guessing game (Pettus, 2023)(Kephart, 2024).
3. Workforce Knowledge Gaps: The workforce in power generation is also going through a shift. A lot of experienced operators have retired, leaving behind a younger generation that’s less familiar with managing complex power systems. The problem? Plants don’t have time for long apprenticeships anymore. Today’s workers need intuitive tools and real-time data to help them make informed decisions quickly (Pettus, 2023). The challenge is finding ways to upskill them while keeping operations running smoothly.
4. The Push for Sustainability and Energy Efficiency: There’s no avoiding it—sustainability is the future. Manufacturers are being pushed to reduce their energy consumption and improve their environmental impact, all while maintaining high levels of production. Balancing these goals can be a headache, especially when the infrastructure wasn’t designed with sustainability in mind (Pettus, 2023).

So, What’s the Solution?

Thankfully, power generation manufacturers don’t have to go it alone. There are several solutions that can help streamline operations and make everything run a lot more smoothly. Here’s how:

1. Breaking Down Data Silos with Industry 4.0: One of the most effective ways to improve efficiency is by integrating data across systems. Industry 4.0 tools—like Ethernet-APL and 5G—are game-changers. They help break down data silos and allow real-time data to flow freely across operations. This means manufacturers can monitor equipment in real-time and gain insights that help them make smarter decisions (Pettus, 2023). It’s all about getting the right information to the right people at the right time.
2. Automating Key Processes: Automation is another huge win for efficiency. With smart sensors and advanced control systems, manufacturers can monitor processes in real time, predict when maintenance is needed, and keep everything running smoothly without constant human intervention. This is especially helpful for plants dealing with an inexperienced workforce—automation takes some of the pressure off and reduces the risk of errors.
3. Using Digital Twins for Testing and Training: Imagine being able to test changes to your plant’s operations without actually touching anything. That’s where digital twins come in. These virtual replicas allow manufacturers to experiment with different scenarios and see the impact in real-time without risking downtime (Pettus, 2023). It’s not only great for optimization but also for training newer employees. They can learn the ropes in a risk-free environment.
4. Upgrading to Energy-Efficient Equipment: Upgrading old equipment is another way to boost both efficiency and sustainability. Newer equipment uses less energy and is designed to integrate seamlessly with modern systems. It’s a win-win: you reduce your carbon footprint and save on energy costs, all while maintaining high levels of production.

How Standard Electric Can Help

At Standard Electric, we get it. Power generation manufacturers need more than just products—they need solutions tailored to their specific challenges. Here’s how we can help:

1. Automation and Control Solutions: We offer a wide range of automation products, from smart sensors to PLCs (programmable logic controllers) and HMIs (human-machine interfaces). These tools give you the control and visibility you need to keep your processes running smoothly and efficiently.
2. Data Integration Expertise: We’re experts at helping manufacturers break down data silos and make the most of their data. By using Industry 4.0 technologies, we can help you create seamless data mobility across your systems, giving you real-time insights and helping you make smarter, faster decisions.
3. Energy-Efficient Equipment: If you’re looking to upgrade to more energy-efficient equipment, we’ve got you covered. We offer products designed to help you reduce your energy consumption while maintaining peak performance. We’ll work with you to find the right solutions that fit your goals.
4. Hands-On Support: At Standard Electric, we don’t just sell products and walk away. With our Technical Solutions Team, we’re here to provide ongoing support and technical expertise to ensure you get the most out of your systems. Whether you’re integrating new equipment or need help training your team, we’re with you every step of the way.

The Bottom Line

The power generation industry is facing some big challenges, but with the right solutions and a little help from experts like Standard Electric, those challenges are more than manageable. By embracing data integration, automation, and energy-efficient technology, power generation manufacturers can optimize their processes and set themselves up for success in an increasingly complex world.

So, whether you’re dealing with aging equipment, data overload, or the push for sustainability, reach out to us at Standard Electric. We’ll help you find the right solutions to keep your operations running smoothly and efficiently. After all, the future of power generation is all about smart, data-driven decisions—and we’re here to help you make them.

References

Kephart, R. (2024, September 3). Data Mobility Will Define the Future of Power Operations. POWER. https://www.powermag.com/data-mobility-will-define-the-future-of-power-operations/

Pettus, N. (2023, July 10). Heralding a boundless automation future with Industry 4.0 technologies. Control Engineering. https://www.controleng.com/articles/heralding-a-boundless-automation-future-with-industry-4-0-technologies/

Standard Electric Supply Co. is a family-owned distributor, built on delivering outstanding service. For over 100 years, Standard Electric has been the best at what they do; delivering top-quality products, outstanding service, and providing value-added services to customers across the Midwest. Visit standardelectricsupply.com to see how Standard Electric can become the solution to your needs.

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