Frequenty Asked Questions
SCADA & Automation FAQs
What is a SCADA system?
A SCADA (Supervisory Control and Data Acquisition) system provides real-time monitoring, control and reporting of industrial processes from a central interface.
When should a SCADA system be upgraded?
A SCADA system should be upgraded when it becomes obsolete, difficult to support, or no longer provides the visibility and reporting your operation requires.
Can SCADA replace manual Excel reporting?
Yes. Modern SCADA systems automatically collect and display production data, reducing the need for manual spreadsheets and reports.
What are the benefits of modern SCADA dashboards?
Modern dashboards provide real-time production data, alarms, KPIs and equipment status, helping teams make faster, informed decisions.
How can SCADA improve production visibility?
SCADA provides live visibility of machines, processes and production performance, helping identify issues before they impact operations.
What information should appear on a manufacturing dashboard?
Typical dashboards include production output, downtime, alarms, OEE, machine status, energy usage and key performance indicators.
Can older PLCs be connected to modern SCADA systems?
In many cases, yes. Existing PLCs can often be integrated with modern SCADA platforms, depending on the hardware and communication protocols.
What’s the difference between SCADA and HMI?
An HMI controls and monitors an individual machine, while SCADA provides centralised monitoring, reporting and control across multiple systems or an entire facility.
PLC & Automation FAQs
When should a PLC be replaced?
A PLC should be replaced when it becomes obsolete, unsupported, unreliable or unable to meet the needs of your production process.
What happens when a PLC becomes obsolete?
Obsolete PLCs can lead to spare parts shortages, increased downtime, cybersecurity risks and reduced manufacturer support.
Can legacy PLCs be upgraded without replacing the whole production line?
Yes. Many PLC migration projects can be completed while retaining existing equipment, reducing costs and production disruption.
What are the signs an automation system needs upgrading?
Common signs include frequent faults, obsolete hardware, limited reporting, slow performance and increasing maintenance costs.
How long should a PLC last?
Most PLCs provide reliable service for 10–20 years, depending on operating conditions, manufacturer support and spare parts availability.
What’s involved in a PLC migration project?
A PLC migration typically includes system assessment, hardware replacement, software development, testing, commissioning and ongoing support.
Control Panel FAQs
When should a control panel be replaced?
A control panel should be replaced when it becomes obsolete, difficult to maintain, no longer complies with standards or cannot support operational requirements.
Can a control panel be upgraded without replacing machinery?
Yes. In many cases, a new control panel can be integrated with existing machinery to improve reliability and performance.
What standards apply to industrial control panels?
Industrial control panels are typically designed to EN IEC 61439-1 and EN IEC 61439-2, with machinery panels also complying with EN IEC 60204-1.
What is IEC 61439?
IEC 61439 is the international standard covering the design, manufacture and verification of low-voltage electrical assemblies.
What is BS EN 60204-1?
BS EN 60204-1 is the safety standard for electrical equipment on machinery, helping support safe operation and compliance.
Why is control panel documentation important?
Accurate documentation simplifies maintenance, troubleshooting, upgrades and future modifications while supporting compliance.
What should be included in a new control panel design?
A well-designed control panel should include electrical schematics, component schedules, safety devices, clear labelling and complete technical documentation.
Smart Factory & Automation FAQs
What is a Smart Factory?
A Smart Factory uses connected automation systems, real-time data and intelligent technologies to improve productivity, efficiency and operational visibility.
What are the benefits of a Smart Factory?
A Smart Factory helps reduce downtime, improve production efficiency, automate reporting, optimise processes and support better decision-making through real-time data.
How can automation prepare manufacturers for AI and machine learning?
Modern automation systems generate accurate, real-time production data that provides the foundation for AI, predictive maintenance and advanced manufacturing analytics.
Can existing automation systems be upgraded to support Smart Factory technologies?
Yes. Many existing automation systems can be modernised to support connected devices, real-time monitoring and future digital manufacturing technologies without replacing the entire production line.
What is predictive maintenance?
Predictive maintenance uses production and equipment data to identify potential issues before failures occur, helping reduce unplanned downtime and maintenance costs.
Can BONNER help assess our Smart Factory readiness?
Yes. BONNER offers Operational Efficiency Reviews, Smart Factory Assessments and Automation Health Checks to identify opportunities for improving efficiency, digitalisation and future growth.
