'Why 2020 will be the better than 2019 in automation

The industrial automation trends making waves in manufacturing

The shift towards digital transformation in industry has already taken place. Manufacturers have increasingly been encouraged to invest in new technologies, with automation as a key technological driver. 2019 saw the trial of the first 5G smart factory in the UK, but what will 2020 have in store? As we look ahead to a new decade, Stefan Reuther, Chief Sales Officer of industrial software provider COPA-DATA, gives three predictions for industrial automation in 2020.

copadata logoThe automation of manufacturing processes is at a turning point. Since the advent of the programmable logic controller (PLC), a number of automation islands have evolved that automate isolated steps in the manufacturing process. For example, a six-axis robot can stack and palletize products in a factory, but a manufacturer would need to invest in several different types of automation to fully automate its production line. This process-specific approach can result in some increases to operational efficiency. However, this does not provide a comprehensive, integrated view of manufacturing and thus doesn’t harness all the benefits of a complete automation system.

While it’s years since the emergence of the term Industry 4.0, we’re not quite ready to leave the buzzword in its founding decade. Here are three predictions for major trends in industrial automation for 2020 — manufacturers take note.

Vertical integration — with actionable insights

Vertical integration in Industry 4.0 looks to unite all logical layers in a business, so that information can be free flowing. Increasingly, organizations are demanding a seamless connection between IT and OT to provide an integrated and holistic view of manufacturing and business operations. This infrastructure has been deployed successfully in many facilities, but in 2020, we can truly begin to reap the rewards.

Vertical integration delivers multiple streams of data, but it doesn’t make decisions. Successful deployment should enable organizations to respond to changing markets and spot new opportunities seamlessly. We’re already collecting the data — let’s do something with it.

Improvements in software addresses this trend with platforms that are highly scalable, simple to use, flexible and easy to implement. Linking data from the sensor to the enterprise resource planning (ERP) system, intelligent software that has been specifically developed with vertical integration in mind can provide operators with a clear visualization of how to use vertical data.

Speaking of data… it’s getting bigger

Trends like vertical integration prove that data is an invaluable asset for manufacturers. According to a 2017 IBM study, 90 per cent of data available at the time of the study was created in the last two years. An ever-growing amount of data is being extracted from manufacturing processes, providing important information about quality, maintenance, and process optimization.

Unfortunately, many of today's solutions offer little flexibility in the collection, evaluation and analysis of these data points. If the information from production processes cannot be properly evaluated and used, manufacturers are unable to reap the benefits. In 2020, automated reporting and analytics functions must become standard. This technology is no longer a luxury, but is now essential to allow for effective interpretation, turning data into valuable information and providing important insights for process improvement.

Strengthening security in heterogeneous technologies

Production today is an integration of many heterogeneous technologies developed using different standards. While most manufacturers are aware of the security needs of increasingly smart factories, the presence of multiple communication standards on the factory floor can make security a complicated task.

To ensure machines, sensors and software systems can communicate effectively in the long term, choosing one software platform that can communicate across all platforms is beneficial. Furthermore, manufacturers should not overlook the need for this software to uphold the same security standards as information technology — encrypting communications, ensuring binaries are signed and developing regular updates.

It’s clear that software will play a significant role in the future of production automation and could be a main driver of Industry 4.0 for the next decade. Data collection certainly isn’t a new practice for manufacturers, but what they choose to do with this data is set to change.

From SMEs to large corporations, implementing cutting edge software should be a priority, no matter the size of the business. Manufacturers should focus on selecting technology carefully, focusing on scalable platforms that are easy to understand and implement.

Looking forward to 2020, digitalization should be approached in a practical manner — ultimately a steady, incremental transformation is better than a failed one.


COPA-DATA is the manufacturer of the zenon® software platform, used in the manufacturing and energy industries for the automated control, monitoring, and optimization of machines, equipment, and power supplies. Founded by Thomas Punzenberger in 1987 and headquartered in Salzburg, Austria, the independent, family-owned company employs approximately 270 workers around the globe. The distribution of software on an international scale is made possible through the company’s eleven subsidiaries and numerous distributors. In addition, more than 240 certified partner companies ensure efficient software implementation for end users in the food & beverage, energy & infrastructure, automotive, and pharmaceutical industries. In 2018, COPA-DATA generated turnover of EUR 44 million.

About zenon

zenon is a software platform from COPA-DATA for manufacturing and the energy industry. Machines and equipment are controlled, monitored and optimized. zenon’s particular strength is open and reliable communication in heterogeneous production facilities. Open interfaces and over 300 native drivers and communication protocols support the horizontal and vertical integration. This allows for continuous implementation of the Industrial IoT and the Smart Factory. Projects with zenon are highly scalable.
zenon is ergonomic, both for the engineer and for the end user. The engineering environment is flexible and can be used for a wide range of applications. The principle of “setting parameters instead of programming” helps engineers to configure projects quickly and without errors. Complex functions for comprehensive projects are supplied out-of-the-box to create intuitive and robust applications. Users can thereby contribute to increased flexibility and efficiency with zenon.