Why an App-Based Approach is the Future of Automation

Control solutions utilizing apps can provide OEMs and end-users greater insight and monitoring over each element of production. Image courtesy of Bosch Rexroth.

Control solutions utilizing apps can provide OEMs and end-users greater insight and monitoring over each element of production.

By Dave Cameron, Director of Project and Product Management – Automation & Electrification, Bosch Rexroth

Automation within consumer packaged goods (CPG) manufacturing is becoming increasingly digitalized as a direct reflection of our society’s reliance on digital technology. Examples of this that are growing in adoption are control solutions that utilize apps, which can provide OEMs and end-users with greater insight and monitoring over each element of production. These control solutions operate best in an open platform, which is not only a clear departure from the legacy, monolithic landscapes that were previously prevalent in manufacturing, but also represents the future of flexible operations.

Using apps for different elements of an industrial control allows for pre-engineered, more easily customized systems. This is an efficient way to design systems that directly impact speed to market, scalability, and customization for OEMs. It also allows the freedom of choice for preferred automation providers, such as sensor companies, robot manufacturers, IoT solutions for dashboards, and visualizations.

App-based Manufacturing Solutions

This concept is like a smartphone that’s used in daily life, which we configure to our individual needs with apps. We choose a preferred solution, such as a navigation app, and it efficiently handles data and information, and can be customized or upgraded to newer apps. Similarly, automation solutions must be flexible and easier to implement than in older control environments. It’s paramount that automation devices connect seamlessly, scale for flexibility of production, and speed up the time to market.

With the increased integration of app-based solutions within manufacturing, there is a parallel influx of information. Data is always key to understanding the quality of production, prevention of downtime, and trends of the system. The discussion of what to do with all this data is a key point to consider, and each customer determines that value based on the ultimate desire of the production system. The controller for production machinery has evolved to manage an increased amount of process data, while connecting the data to IT elements and even analyzing and using AI. Since the controller requirements have changed dramatically, the smartphone concept of using apps on a secure device is a good approach as it can be upgraded and changed easily. Data remains a critical component to successful manufacturing that, when leveraged properly, can guide strategic decisions regarding processes and resources.

Security is an Absolute Necessity

It’s important to note, however, that with all the data that’s being leveraged in today’s CPG manufacturing, security is an absolute necessity. The Cyber Resilience Act (CRA), which will go into effect in Europe in late 2027, is an initiative that will impact European manufacturers that have any digital footprint within their operations.

Because similar measures could be instituted in the United States, compliance with CRA and a growing number of cybersecurity standards will lead to more robust controllers to ensure they’re safe. This will undoubtedly mean ongoing optimization through Linux-based landscapes. Still, these compliance measures will help identify solutions that enhance productivity by protecting a manufacturer’s most sensitive information.

Our app-based system reflects the smartphone approach to industrial automation to achieve various demands. The system is designed for required security, easy programming, and modularity by choosing the desired apps to connect devices and implement solutions quickly. Updates within system are handled with a secure tool, and much like a smartphone, end-users can manage updates of the apps running on the controls.

An Endless Array of Possibilities

This collaborative and open framework for manufacturing represents the future of CPG production, particularly for greenfield environments. By implementing a flexible control system from day one, manufacturers and end-users aren’t limiting their integration capabilities as they potentially would with a more traditional single-source platform.

Consumer demands are constantly changing, and utilizing an open platform gives manufacturers and end-users an endless array of possibilities to optimize their production through a growing network of app-based integrators. Mirroring the functionality of the smartphones that have become part of our daily routines, this technology follows in the continued trend of digitalizing the CPG manufacturing footprint of tomorrow.

About the Author

Dave Cameron is the Director of Product & Project Management for Automation & Electrification at Bosch Rexroth, where he has worked 27 years of his 35-year career in the field. For more information on the ctrlX platform mentioned in the article, please visit www.ctrlx-automation.com.