What Are the Best Practices in Process Management?

Process management is a critical component of modern industrial operations, encompassing strategies and technologies used to optimise production, enhance efficiency and maintain standards.

The global industrial control and factory automation market is expected to grow from US$256bn in 2024 to US$399bn by 2029, according to a report by MarketsandMarkets.

This growth is driven by the increased adoption of IoT and AI in industrial environments and the growing focus on operational efficiency and productivity. 

Leading companies in the field, such as Honeywell, GE Digital, ABB, Schneider Electric and Rockwell Automation, have all developed innovative approaches to process management.

One key practice in process management is implementing advanced control systems. 

These systems use real-time data to adjust production parameters automatically. For example, Honeywell’s Experion PKS IT Highly Integrated Virtual Environment (HIVE) enables manufacturers to reduce project delivery and lifecycle costs while improving security management.

Data and automation

Data visibility is another crucial aspect of effective process management. GE Digital's Proficy suite provides comprehensive data analytics capabilities, allowing managers to gain insights into production processes and make informed decisions. The suite's rapid deployment times and effective hardware and software integration have contributed to GE Digital's strong market position.

Automation too plays a significant role in modern process management. ABB's System 800xA Asset Management solution offers scalable and modular ISA95-based solutions with Manufacturing Execution System (MES) functionality, helping companies streamline their production processes while reducing reliance on manual labour.

Artificial intelligence and remote management

Integrating the Internet of Things (IoT) with artificial intelligence is transforming process management. Schneider Electric has partnered with AutoGrid to help energy providers integrate customer-owned or -operated flexible distributed energy resources (DERs) into their distribution management operations. This collaboration aims to enhance energy grid flexibility and efficiency.

Remote management of factory assets is becoming increasingly important in process management too. This enables companies to monitor and control their operations from a distance, improving responsiveness and reducing downtime. Siemens has developed innovative functionality in this area, including low/no-code solutions.

Cloud - a growing trend 

The adoption of cloud and Software as a Service (SaaS) solutions is a growing trend in process management. These technologies offer scalability and flexibility, allowing companies to adapt quickly to changing market conditions. However, the implementation of cloud solutions varies among vendors, with some showing more advanced capabilities than others.

Vertical market expertise is another valuable asset in process management. Rockwell Automation, for instance, has developed pre-built MES vertical applications specifically for life sciences, automotive, consumer packaged goods and metal industries. This tailored approach helps companies address industry-specific challenges more effectively.

Digital twin

The concept of digital twins is gaining traction in process management. Siemens' acquisition of MultiMechanics, a material modelling and simulation platform, has expanded its digital twin capabilities for material engineering. This technology allows companies to create virtual replicas of physical assets, enabling more accurate simulations and predictions.

Cybersecurity is a critical concern in process management, particularly as systems become more interconnected. GE Digital's industrial automation and management software suite incorporates cybersecurity measures to protect against potential threats. This focus on security is essential for maintaining the integrity of industrial processes.

The integration of human-machine interfaces (HMI) is crucial for effective process management. Rockwell Automation's FactoryTalk suite offers advanced HMI capabilities, contributing to its strong market position. These interfaces enable operators to interact more efficiently with complex industrial systems.

"One key distinction among vendors is between those offering both industrial automation hardware and software and those providing software exclusively,” says James Prestwood, Industrial & Manufacturing Technologies Research Analyst at ABI Research.

“Most of the offerings are part of a software portfolio to some extent, with Siemens Xcelerator, GE Digital's Proficy, and Rockwell Automation's FactoryTalk being the most comprehensive.”

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