Industrial Technicians: Unsung Heroes in Keeping Our Facilities Running Smoothly
Industrial automation has become an integral part of manufacturing today. Behind this automation are the people who make sure everything works right: the industrial technicians. These professionals possess that rare combination of attention to the smallest detail and big-picture understanding.
The technicians have to apply highly specialized knowledge regarding machinery and circuitry to provide the root of the problem at hand when a minorish problem occurs, instead of just fixing the early symptoms. This expertise in troubleshooting does not stay confined to doing repairs; other areas where such expertise is invaluable are operator training and routine maintenance of machinery. Trained technicians even handle tasks that are usually outsourced to other professional engineers and accomplish equipment installation and modification. As automation systems become increasingly networked, cybersecurity knowledge becomes an essential part of their skillset.
Filling the Ranks of Tomorrow's Industrial Technicians
So says Aaron Dahlen, an applications engineer at DigiKey, who explains that most of the companies employ technicians from a mechanical background. As much as this proves their adeptness in hands-on areas, there is definitely a growing need to bridge the gap in electrical and computer control aspects of automation. Moreover, factors such as temperament and a desire for practical learning should be held out as vital in the selection of potential candidates.
The Power of Hands-on Learning: Why "Doing" Trumps "Knowing"
Traditional learning methods of lectures and even simulations fall well short in delivering the needed abilities to technicians. As Dahlen says, there is a great proverb that summarizes ideal training: "Tell me and I forget, show me and I may remember, involve me and I understand".
Hands-on learning can be described as actually connecting wires and investigating actual circuits while learning from an instructor who has valuable experience. The students practice by trial and error, such that even mistakes lead them to a fuller understanding of the principles at play. Thereby, they easily troubleshoot these problems and operate various equipment related to a facility.
Expanding Scope: Beyond PLC
With automation, PLCs indeed are the major building blocks; however, it should be noted here that more than 80% of electrical failure occurs outside a PLC. Bad wiring, a faultier sensor, and physically damaged external relay more regularly are the faults. This is also a fact that because some PLC programs are proprietary or covered under certain warranty conditions of specific manufacturers, technician access may become limited.
Dahlen would train more holistically on the broader field-device interface than just the PLC. This also would include information such as how the interposing control relays, which most commonly are needed to provide step-ups in voltage and current capacity for most systems.
Prioritize Training for Impact
Given time constraints, training programs need to focus on the most important skills. Here, Dahlen recommends using the Arduino and Phase Dock relay and PLC trainer as a versatile platform for students to experiment with relays, motor starters, and small PLCs. This is an affordable solution that enables trainees to learn core concepts through hands-on activities, thus giving them a better understanding of how circuits work and how to troubleshoot them.
Conclusion: Investment in the Future of Industrial Automation
The unsung heroes of our automated facilities are the industrial technicians. Focusing on hands-on learning, expanding the focus beyond PLCs, and recruiting for aptitude will prepare a new generation of technicians for maintenance and optimization of these critical systems. Their work is important to ensure smooth operations, prevent costly downtime, and help further advancements continuously in the ever-evolving industrial automation world.