This activity converts available company resources into a Procedure Automation Lifecycle template for each specific automation project. The template gives implementers flexibility for different project scales while maintaining consistent core requirements from the automation philosophy.
Scope setting begins by gathering information including:
Key outputs: Physical Model (with gap assessment), prioritized list of procedures to automate with goals and objectives, and business justification with cost and ROI estimates.
Physical Model creation is an iterative process aligned with process design, I/O plans, and construction plans. The model is defined to the device level to support identification of automation candidates. This activity involves matching available I/O points with what is actually needed to automate specific procedures — additional control signals and measurement signals are often required.
When automating procedures, you will typically find that additional signals from field devices are required. Identify these gaps early — equipment procurement and installation significantly impact project schedules and budgets.
Candidate procedure identification considers the complete list of plant operating procedures. Sources include:
Not all procedures should be automated. Evaluate each candidate against these criteria:
| Criterion | Questions to Ask |
|---|---|
| Safety value | Does automation reduce risk of injury, equipment damage, or environmental incident? |
| Consistency value | Does variation in manual execution cause quality, efficiency, or safety problems? |
| Frequency | How often is the procedure executed? High frequency = higher automation ROI. |
| Complexity | Is the procedure complex enough that automation provides real value, but not so complex that automation is infeasible? |
| Feasibility | Does the control system have sufficient I/O, logic capability, and instrumentation? |
| Business justification | Does the cost of automation deliver sufficient return? |
A business justification with cost and ROI estimates is a required output of the planning phase. Quantify benefits including:
Costs include engineering, implementation, testing, training, and ongoing maintenance. ROI should account for the full lifecycle cost.
The work plan defines step-by-step workflows for implementation and maintenance of each lifecycle instance. It includes toolkits, workflows, test plans, and documentation templates customized for the project. Choosing the right team members early — including operations personnel — is a critical success factor.
Getting operations personnel involved early and keeping them engaged is essential. They understand the practical realities of the process better than anyone else. Missing their perspective early leads to costly redesigns later.