Dalilin Tattalin Arziki na Sabunta Tsarin Kula da Metallurgy
Manyan masana’antar metallurgy da ke aiki da tsarin kula da kayan aiki tun farkon shekarun 2000 na fuskantar wani nauyin tattalin arziƙi da ba a gani a fili. Waɗannan tsoffin tsarin suna cin wuta da yawa, suna buƙatar kayan haɗin gyara (spare parts) da ke ƙara wahalar samu, kuma ba su da ingantattun tsarin gano matsala (diagnostic capabilities) da ake buƙata don hana manyan lalacewa masu tsada. Wani binciken kwatance ya nuna cewa masana’antar da ke amfani da tsarin automation mai shekaru 15 suna kashe kusan kashi 40 cikin ɗari ƙarin kuɗi a gyara a kowace shekara fiye da waɗanda suka sabunta tsarin kulawarsu—ba saboda yawan lalacewar kayan aiki ba, amma saboda gano matsala yana ɗaukar lokaci sau uku fiye da yadda ya kamata idan babu isasshen bayanan gano matsala.
Saboda haka shawarar sabuntawa tana maida hankali ne kan kuɓucewa daga hauhawar kuɗaɗen “bashin fasaha” (technological debt). Sabbin dandamalin PLC da DCS na zamani suna kawo riba mai auna daraja ta hanyar inganta amfani da makamashi, rage tsayawar aiki ba tare da shiri ba, da kuma ƙarfafa daidaiton tsarin aiki da tsofaffin tsarin ba za su iya cimmawa ba.
Daga Kula da Inji zuwa Hankalin Aiki (Operational Intelligence)
Tunanin gargajiya yana ɗaukar tsarin automation a matsayin kayan aikin sarrafa na’ura kawai. Wannan ra’ayi yana raina abin da suke iya yi a yau. Dandamalin kulawa na zamani suna aiki ne a matsayin cibiyoyin hankali na tsakiya da ke tattara bayanai daga ɗaruruwan na’urorin auna (sensors), suna amfani da samfuran nazari (analytical models), sannan suna samar da bayanan da za a iya ɗaukar mataki a kai ga ma’aikata da masu gudanarwa. DCS na zamani ba wai kawai ya ba da rahoton kifewar zafin jiki ba. Yana alaƙanta wannan abin da ya faru da halayen abin da ake sarrafawa (raw material), ayyukan gyara da aka yi kwanan nan, da abin da ma’aikata suka yi, don ba da hasashen abin da zai fi yiwuwa ya jawo matsalar. Wannan ci gaba yana mayar da automation daga ɗaukar kuɗin aiki na yau da kullum zuwa zama muhimmin ƙwari na dabarun kasuwanci da ke tura ci gaba mai ɗorewa.
Nazarin Lamari: Sauya Masana’antar Narkar da Tagulla a Kudancin Amurka
Wata masana’antar narkar da tagulla mai matsakaicin girma ta fuskanci ƙarin matsin lamba daga hauhawar kuɗin makamashi da rashin daidaiton matten (matte) da ke shafar matakan sarrafawa na gaba. Maimakon sauya dukkan tsarin gaba ɗaya, ƙungiyar injiniyoyi ta ɗauki dabarar sabuntawa ta gaurayyiya. Sun kafa sabbin PLC masu saurin aiki musamman don sarrafa murhu yayin da suka bar tsohon tsarin DCS don sarrafa manyan ayyukan shuka gaba ɗaya. An ƙirƙiri middleware na musamman da ya haɗa yarukan sadarwa tsakanin tsarin biyu.
Sakamakon ya zarce hasashen farko. Amfanin makamashi ya ragu da kashi 18 cikin ɗari a cikin watanni shida saboda sabbin PLCs sun ba da damar yin gyare-gyaren ƙananan allurar oxygen kowane daƙiƙa biyu—irin wannan saurin martani tsohon tsarin bai iya yi ba. Daidaiton matten ya ƙaru da kashi 22 cikin ɗari, wanda ya rage buƙatar sake sarrafa kayayyaki a matakin gaba sosai. An maido da dukkan jarin cikin watanni 14, abin da ya nuna cewa mayar da hankali wajen sabunta muhimman wuraren cunkoson tsari yawanci yana bayar da riba mafi girma fiye da sauya komai gaba ɗaya.
Sarrafa Haɗin Sadarwa ta Hanyar Tsarin Sashen-Sashen (Segmented Architecture)
Yawan magana a masana’antu kan cewa cikakken haɗin yanar-sadarwa fa’ida ce marar sharadi. Amma injiniyoyin shuka suna fuskantar gaskiya mai sarkakiya. Kowace sabuwar alaƙa tsakanin tsarin kulawa da hanyoyin sadarwa na kamfani na iya ƙara gurɓatattun illoli (vulnerabilities). Wata babbar masana’antar ƙarfe a Turai ta fuskanci hakan kai tsaye lokacin da sabuntawar IT na yau da kullum ta katse sadarwa zuwa DCS ɗinta ba da gangan ba, lamarin da ya haifar da tsayawar samarwa na sa’o’i shida.
Masana’antu masu nasara a yanzu suna aiwatar da tsarin sassan-sassa, inda ake raba hanyoyin sadarwar tsarin tsaro masu muhimmanci daga sauran na’urorin juna, sannan a yi amfani da “managed gateways” don fitar da bayanai zuwa tsarin kasuwanci. Wannan dabara tana kiyaye fa’idodin haɗin kai—kula da nesa, hasashen matsala (predictive analytics), da rahotanni na tsakiya—ba tare da fallasa muhimman ayyuka ga haɗarin da ba dole ba. Wannan daidaitacciyar hanya ce ta balagaggen tsarin dijital na masana’antu.
Kare Sanin Gado (Institutional Knowledge) ta hanyar Automation
Rashin isasshen ma’aikata na kalubalantar ayyukan metallurgy a duniya baki ɗaya. Gwanayen tsofaffin ma’aikata suna yin ritaya cikin sauri fiye da yadda sababbin ma’aikata ke koyo da kai matakin ƙwarewarsu. Kamfanoni masu hangen nesa suna amfani da automation ba don kawar da ma’aikata ba, amma don kama da adana sanin gado kafin ya bar wurin aiki.
Wata masana’antar ƙarfe na musamman a Japan ta shirya tsarin kulawarta don kwaikwayon yadda ƙwararrun ma’aikatan murhu ke yanke shawara. Tsarin ya koyi alaƙanta ƙaramin sauyin zafin jiki da mafi kyawun jadawalin zubar da narkakken ƙarfe (tap schedule) da daidaiton kayan masarufi. Sabbin ma’aikata yanzu suna kaiwa kashi 92 cikin ɗari na ingancin aikin tsofaffin ma’aikata cikin watanni uku, maimakon shekarun koyo guda biyu da ake buƙata a da. Wannan amfani ya nuna cewa tsarin kulawa na zamani suna kawo ƙima ta hanyar kiyaye sani da ƙarfafa ma’aikata—ba wai kawai ta hanyar inganta amfani da kayan aiki ba.
Aiwatarwa ta Fasaha: Tsarin Kayan Tsaro na Musamman (Safety-Instrumented Systems)
Masana’antar metallurgy na da ƙalubalen tsaro na musamman da ke buƙatar tsarin kulawa na musamman. Safety-instrumented system yana aiki ne dabam da babban dandamalin kulawar tsari, yana ci gaba da sa ido kan muhimman sigogi. Hanyar da ke ƙasa mai tsari tana nuna mafi kyawun aikin da masana’antu ke bi.
Kimanta Hadari da Haɗari (Hazard and Risk Assessment): A fara da cikakken nazarin hadarin tsari (process hazard analysis) don gano yanayi da ke buƙatar kariya ta atomatik. Wannan nazarin ne ke tantance matakin Safety Integrity Level da ake buƙata ga kowane aikin tsaro.
Zaben da Sanya Sensors: A zaɓi sensors da aka tantance don SIL da ake nufi, a kuma saka su nesa da sensors na tsarin kulawa na yau da kullum. Wannan redundancy ɗin yana tabbatar da cewa gazawa guda ɗaya ba za ta lalata tsarin kulawa da na tsaro lokaci guda ba.
Tsara Logic Solver: A tura PLCs na tsaro na musamman da aka shirya da “cause-and-effect matrices” da aka samo daga nazarin hadari. Wadannan controllers suna amfani da “certified function blocks” da aka gwada sosai—abin da ke bambanta su da na shirin automation na yau da kullum.
Tabbatar da Kayan Ƙarshe (Final Element Verification): A gwada dukkan bawulolin tsaro, contactors, da na’urorin kashe aiki a yanayin kwaikwayon gazawa. A rubuta lokutan martani da hanyoyin sake kunnawa don amfani a nan gaba.
Tsarin Proof Testing: A kafa jadawalin “proof-testing” da ke tabbatar da dukkan safety loops a lokuta da suka dace da SIL da ake buƙata. A rubuta sakamakon kowane gwaji don ci gaba da samun takardar shaidar tsaro da bin ƙa’ida.
Masana’antar da ta aiwatar da wannan tsari mai kyau yawanci tana rage tsayawar aiki da ke da alaƙa da tsaro da kashi 30 zuwa 40 cikin ɗari idan aka kwatanta da waɗanda ke amfani da tsarin kulawa guda ɗaya ba tare da rarrabe tsaro ba, domin tsarin tsaro na musamman yana kawar da ruɗani a lokacin yanayin aiki na ban mamaki.
Nazarin Lamari: Hasashen Matsala (Predictive Analytics) da ya Hana Babban Lalacewa
Wata masana’antar extrusion ɗin aluminium a Arewacin Amurka ta saka cibiyar sadarwar PLC ɗinta da sensors na girgiza da zafin jiki a kan muhimman tsarin hydraulic. Tsarin kulawa yana ci gaba da nazarin waɗannan bayanai tare da kwatanta su da bayanan aiki na al’ada. Watanni takwas bayan girka tsarin, ya gano rashin daidaiton girgiza a babbar injin extrusion. Ma’aikatan kula da gyara suka bincika, suka gano farkon lalacewar bearings wadda da, idan aka bar ta, za ta haifar da gagarumin lalacewa cikin ‘yan makonni. Kudin gyaran ya kai $45,000. Idan wannan lalacewa ta faru yayin aiki, an kiyasta asarar ta kai kusan $1.2 miliyan na abin da za a rasa a samarwa, banda kuɗin maye gurbin kayan aiki.
Wannan iya aiki—hasashen gazawa kafin ta faru—shine mafi muhimmin ci gaban aikace-aikace a automation na masana’antu a cikin shekaru goma da suka wuce. Lissafin tattalin arziƙi bayyananne ne. Kuɗin saka jari a sensors da analytics ƙalilan ne idan aka kwatanta da asarar tsayawar aiki ba tare da shiri ba a masana’antu masu ci gaba ba tare da yankewa ba irin na metallurgy.
Gaskiyar Aiwatarwa Bayan Ikrarin Masu Sayarwa
Masu sayar da kayan aiki sau da yawa suna jaddada cewa haɗa sabbin kayayyaki cikin tsofaffi abu ne mai sauƙi kuma sakamako yana fitowa nan take. Masu aiwatar da aiki masu ƙwarewa suna sanin cewa gaskiyar abu ta fi haka rikitarwa. Rashin dacewar yarukan sadarwa (communication protocols) na jawo jinkiri na makonni. Takardun bayanai na tsofaffin kayan aiki sau da yawa ba su cika ba ko kuma ba daidai ba. Kin amincewar ma’aikata da sabbin “interfaces” na buƙatar kulawar “change management” mai kyau.
Aiwatarwa masu nasara suna da abubuwa gama-gari. Jadawalin aiki na gaskiya yana ɗaukar tsammanin ƙalubale da ba a zata ba. Ana ware ma’aikata na musamman don horo da rubuce-rubucen bayanai. Ma’aikatan aiki suna shiga tun daga matakin tsara aikin. Masana’antar da ke gaggauta ayyukan automation don su cimma wa’adin da aka ɓullo da shi ba bisa ƙididdiga ba kusan kullum suna rage lokutan gwaji da horo—wannan kuma yana haifar da matsalolin aiki na dogon lokaci saboda kawai a cika wa’adin gajeren lokaci.
Duban Gaba: Tsarin Kulawa a Matsayin Abin Da Ke Bambanta Gasa
Shekaru goma masu zuwa za su raba masu sarrafa ƙarafa gida biyu. Masu kare kansu (defensive users) suna amfani da tsarin kulawa ne kawai don ci gaba da ayyukan da ake yi yanzu cikin farashi mai rahusa. Masu kai farmaki a kasuwa (offensive users) kuma suna amfani da su don kwace kasuwa ta hanyar ƙwarewar da abokan hamayya ba za su iya yi ba—saurin sauya nau’in samfur, tsauraran daidaiton inganci, ko ikon sarrafa ƙananan kayayyakin masarufi marasa tsada ba tare da rage yawan fitarwa ba.
Masana’antar da za ta iya juyawa daga wani nau’in samfur zuwa wani cikin mintuna 20 maimakon sa’o’i biyu tana samun babbar damar bin odar da ke da riba mai yawa. Shuka da ke sarrafa “scrap” na sake amfani da ƙarfe tare da ƙarin kashi 5 cikin ɗari na amfanin kayan (yield) fiye da abokan takara za ta iya rage farashi sosai a ayyukan da ke da ƙuntatawar kayan masarufi. Waɗannan fa’idodi ba su fito daga wata fasaha guda ɗaya ba, sai dai daga haɗa tsarin kulawa cikin hikima da tsare-tsaren kasuwanci.
Tambayoyi da Ake Yawan Yi
Ta yaya za mu tabbatar da darajar sabunta tsarin kulawa alhali na yanzu yana ci gaba da aiki?
Asarar ɓoyayyu na tsoffin tsarin suna taruwa ne a wurare da ba a gani nan da nan—yawan cin makamashi, jinkirin gano matsala, rashin ikon amfani da advanced analytics, da kuma hauhawar kuɗin spare parts. Cikakken bincike da ke kwatanta ma’aunin aikin yanzu da abin da za a iya samu da tsarin kulawa na zamani yawanci yana bayyana hujjar kasuwanci mai ƙarfi. Wata masana’anta ta gano cewa suna kashe $280,000 a shekara a kan wutar lantarki da za a iya kawar da ita ta hanyar inganta tsarin kulawa.
Menene ke bambanta tsarin kulawa “open” na gaskiya da wanda aka kulle da mai siyarwa kaɗai (vendor-locked)?
Buɗe tsarin na gaskiya yana nufin amfani da yarukan sadarwa na ƙa’ida kamar OPC-UA, da takardun bayanan “programming interfaces”, da ikon haɗa kayan ɓangare na uku ba tare da sai an kira mai siyarwa ba. Ku tambayi masu siyarwa tambayoyi kai tsaye game da yadda suke ganin ‘yancin fieldbus da ko suna tallafawa harsunan shirye-shirye da yawa. Masana’antar da ke fifita tsarin bude-baki yawanci suna da ‘yanci mai yawa wajen faɗaɗa ayyuka a gaba da kuma rage kuɗin gyara na dogon lokaci.
Ta yaya rawar mai aiki a shuka (plant operator) ke canzawa bayan an aiwatar da advanced automation?
Rawar operator tana canzawa daga sarrafa inji da hannu zuwa kula da tsarin gaba ɗaya. Maimakon yawan juya ƙwayoyi (knobs) da maɓallan sauya wuta, ma’aikata suna sa ido kan trends, suna fassara sakamakon nazari (analytical outputs), sannan suna yanke shawarar dabarun kan abin da ya fi dacewa a samarwa. Wannan yana buƙatar sababbin ƙwarewa—son nazarin bayanai da tunanin tsarin (systems thinking) maimakon dogaro da fasahar hannu kawai. Canje-canjen da suka yi nasara suna haɗa cikakken shirin sake horarwa da ke mutunta ilimin da ma’aikatan yanzu suka riga suka mallaka yayin da ake gina musu sababbin ƙwarewa.
