Advanced analytics is becoming imperative for industrial companies looking to optimize performance and make intelligent business decisions. With innovations in Industrial Internet of Things (IIoT) devices, cheaper sensor costs, expanded connectivity options, and increased computing power—there is an abundance of plant and machine data waiting to be unlocked. But data alone provides little without the ability to contextualize it and act upon its insights. Enter Rockwell Automation’s Allen-Bradley analytics solutions!

What Allen-Bradley by Rockwell Automation Brings to the Table

Allen-Bradley by Rockwell Automation offers a range of analytic software and services so process engineers, operators, and executives can better capitalize on operational data. Solutions span flow, energy, quality, and overall equipment effectiveness (OEE) metrics. Out-of-the-box tools make it simpler to visualize KPIs, while advanced machine learning algorithms uncover issue root causes and opportunities.

For example, the Allen-Bradley PlantPAx DCS platform has built-in analytic modules allowing managers to monitor OEE, track maintenance schedules, analyze batch processing, and configure custom reports. PlantPAx leverages the vast data context available through an integrated control system. Allen-Bradley Stratix industrial switches also contain software to analyze network health, authentication patterns, and bandwidth/packet inspection to harden security.

On top of its portfolio of analytic-enabled hardware, Allen-Bradley offers various software packages, such as FactoryTalk InnovationSuite and Monitornomics, to drive further intelligence.

The key differentiation of Allen-Bradley analytics lies in its tight integration with industrial control systems. Data flows seamlessly from PLCs, sensors, drives, and HMIs. Analysis can trigger real-time actions right at the source rather than requiring roundabout IT infrastructure.

Pre-built algorithms accelerate time-to-insight, based on common use cases, compared to other analytic tools that require intensive upfront configuration. Allen-Bradley solutions speak the language of operations through native industrial protocols like EtherNet/IP.

Trusting Analytics for Enhanced Safety

In environments with hazardous materials or sensitive production lines, relying on software to guide decisions raises understandable skepticism. Faulty analytics could potentially recommend changes leading to accidents if not carefully validated. This lack of trust typically restricts the scope of analytics to purely rearview mirror reporting.

The right automation system alleviates these concerns through defense-in-depth measures across hardware, software, and overall system integrity. Inbuilt sensor redundancy checks for consistency before feeding data to algorithms. Software undergoes extensive testing in simulation environments reflecting real-world conditions. Data transmission occurs over secure, locked-down networks. Credentials and access policies prevent unauthorized tampering with analytic tools.

These provisions allow even risk-averse industries like oil and gas, chemicals, and pharmaceuticals to embrace analytics for driving safety and compliance. Recommendations undergo extensive scrutiny rather than directly activate the equipment.

Users verify insights through HMI visibility before approving any optimizations. This facilitates a collaborative dynamic between human oversight and AI guidance. Over time, the accuracy and reliability of Allen-Bradley analytics builds trust in its outputs to gradually enable more automation where appropriate.

Maximizing the Value of Analytics

Given the upfront effort required to deploy analytics, simply adding another data solution into your architecture may seem daunting. The key to success lies in aligning use cases to clear business goals, whether improving yield, shortening changeovers, boosting equipment longevity, or other targets. Well-defined metrics and data flows not only simplify deployment but maximize benefit realization from the investment.

This is where working with an experienced automation and analytics integration specialist proves game-changing. The team at Pacific Blue Engineering leverages decades of hands-on expertise guiding manufacturers through analytics implementations on top of Allen-Bradley systems. Tight partnerships with both Rockwell Automation and leading software vendors in the space facilitate seamless deployments.

Control Systems Design Engineering: Focus on Data Analytics

Pacific Blue Engineering begins every customer engagement with a thorough assessment of the environment, infrastructure, and objectives around analytics. This informs recommendations on the appropriate Allen-Bradley platforms and solutions to fulfill data needs.

System architects design efficient architectures, while navigators handle the intricacies of rollout planning and change management required for user adoption. Ongoing support provides maintenance, solution expansion, and continuous training as analytic capabilities scale across the organization.

In the end, analytics presents tremendous potential for new levels of operational visibility, efficiency, and control—but only with thoughtful planning and partnerships. Combining innovations like Allen-Bradley PlantPAx and FactoryTalk with integration services de-risks deployments for faster time-to-value. Data contextualized into decision support fuels smarter real-time actions and long-term improvements.

Partnering with domain experts like Pacific Blue Engineering paves the path to fully capitalizing on analytics investments.

Contact Pacific Blue Engineering today at (657) 201-8603 or request a consultation to discuss your control systems engineering needs.