Distributed control system vendors are revolutionizing the manufacturing industry by helping industries upgrade from traditional analog control systems to DCS systems that employ digital technology. DCS (distributed control system) systems are used in manufacturing processes across a number of different industries.

DCS systems are not set up in one location, but instead are manufactured such that each component has its own controller with all controllers connecting to a common network. Therefore all a distributed control system manufacturer needs to produce is a DCS system complete with a central and remote control panel and a communications system.

Gain an adequate introduction to distributed control systems before visiting a distributed control system supplier with distributed control systems (DCS) education and training. Below are some suggestions:

1. Complete training courses offered by DCS systems manufacturers

2. Online training courses can help provide an overview of DCS systems fundamentals.

3. Hire a trainer to come to your workplace or go to them to learn more about DCS systems.

Action Steps
The best contacts and resources to help you get it done

Complete training courses offered by DCS systems manufacturers

Most major manufacturers can provide insight into how DCS systems are applied to business applications. They also showcase the wide array of uses for their DCS systems.

I recommend: Eaton's Product Training Team provides comprehensive courses on the company's distributed control systems and all of their other products. Also, check out Mitsubishi University sponsored by Mitsubishi Electric Automation which provides training in all Mitsubishi DCS systems.

Complete online training courses to learn DCS systems fundamentals

Get an introduction to distributed control systems from the comfort of your PC with online training. This training can provide you with an overview that hopefully will help form the foundation for future education on the subject.

I recommend: Maintenance Resources sells three different CDs offering training on Distributed Control Systems and Fundamentals. PAControl online training covers topics related to process automation and control, including Distributed Control Systems.

Hire training experts to teach you about distributed control systems

It is possible to receive training either at a training facility or hire a DCS systems expert to train you and your employees at your workplace. Whichever you choose, taking a course taught by a subject matter expert is an optimal way to learn a subject in depth.

I recommend: IDC Technologies workshop covers the practical applications of the modern distributed control system. Their training centers are located in Dubai and in the UK, but are open to anyone regardless of nationality. IIR Holdings' PTi International offers DCS training at your workplace.

Tips & Tactics

Helpful advice for making the most of this Guide

• •  If you are technologically savvy and understand the basics around DCS systems architecture, consider teaching yourself about specific models via a distributed control system manual. These manuals provide instructions, overviews and even troubleshooting information concerning manufacturer-specific DCS products.

Whether you need to install a distributed control system or you have to upgrade one to fit in with today's technology, keep in mind that manufacturers usually custom make DCS systems. DCS systems do not function with one central unit or in one location, rather each component has its own controller and all controllers connect to a network for communication and monitoring. You will find large DCS systems in power plants and electrical grids.

Distributed control system vendors have received competition from other control systems such as PACs and PLCs. Yet, distributed control system providers have closed the gaps between the functions that users of large systems continually use.

1. DCS users control the manufacturing processes such as power plants, food and beverage production, pharmaceutical production and oil refining.

2. Distributed control systems vendors are transitioning from supplying DCS hardware to software development, although they do hardware support for their projects.

3. Manufacturers of distributed control systems application portfolios custom build for each project and contain the flexibility for future value-added services.

4. Distributed control system vendors can upgrade old DCS systems to up-to-date standards.

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Anticipate your company's need for DCS

An introduction to distributed control systems begins with understanding what this system can provide. Essentially it can control the processing of materials that go through a production process needing different steps to get to completion. What once took teams of workers to do, a DCS systems does through controls at set points that a network coordinates.

I recommend: Rockwell Automation develops DCS systems for companies new to the technology. It provides a DCS system that reduces expense and offers a user-friendly network. Foxboro manufacturers DCS systems and outlines a number of success stories for DCS applications in different industries.

Use a DCS for big and small operations

A distributed control system is all about managing your manufacturing processes. A manufacturer can modify all DCS systems to fit your specialized business needs.

I recommend: ABB is a distributed control system manufacturer that produces DCS systems for large and small businesses. It customizes its systems with add-ons. Yokogawa's Centum CS 3000 R3 is adaptable for small and large systems. It is compatible with existing systems and has the built-in flexibility for adapting to future technology.

Invest in DCS built to evolve with new technologies

DCS technology has gone through changes. US manufacturers no longer make the hardware but concentrate on the software end. However, US DCS companies are customer savvy and make DCS compatible with other systems. Look for software that plans to incorporate new DCS technology.

I recommend: UCOS offers lower overall costs to its DCS systems and schedules upgrades according to your budget. It uses off-the-shelf hardware to cuts costs and makes problems easier to fix. Emerson works in nine different industries and gives full service to all clients. Emerson's team of experts appraises your operations and designs a distributed control system for you. The team will even train your employees to use the system.

Tips & Tactics

Helpful advice for making the most of this Guide

• •  DCS systems require WAN and LAN networks. If your company doesn't have the network support required for DCS, installing a network will be an additional expense.

Distributed control systems are prevalent in manufacturing and utility industries because they are connected to a single control panel. Knowing distributed control key terms can help you with buying or upgrading DCS systems. A distributed control system uses a number of controllers (all connected to a network) for different functions. DCS applications are more prevalent than before because they've been designed for smaller companies, not just the huge ones that need remote connections to function efficiently.

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Microprocessor, also known as central processing unit (CPU)

Microprocessors-those tiny chips that store incredible amounts of information and perform myriad functions-are the basic components of distributed control systems.

I recommend: Check out How Stuff Works for insights into the microprocessor and its capabilities.

Digital technology

Digital technology is taking over from analog technology because it's faster and has more functionality. DCS uses digital technology.

I recommend: HelloDirect.com, an online telecom resource, describes the difference between analog and digital technology.

Remote control panels

Remote control panels, digital communication units (DCU) and remote transmission units (RTU)-these all perform the same functions and are made up of I/O modules, terminal blocks, a processor and a communications interface.

I recommend: Remote control panels are used in PCs with DCS. GlobalSpec discusses DCS and the role played by remote control panels.

Dedicated system

A dedicated system is a DCS system designed to perform a number of tasks to produce something; for instance, the assembly of 'widgets.' A dedicated system for making widgets would use remote control panels to analyze the quality of material, take the parts of the widget and assemble them and ultimately wind up with a widget.

I recommend: In real life (and in real-time) the Norway Railway wanted to integrate its various communication needs into one system, including all the communication requirements of its train stations. It used a dedicated system to connect more than 500 stations and 650 tunnels.

DCS applications for small businesses

DCS was developed for huge, remote automation needs. However, new applications for small businesses are being developed because DCS provides integration and functionality, which smaller manufacturers also require.

I recommend: ControlGlobal.com discusses DCS applications (designed by Honeywell) for smaller manufacturers.

Distributed control system supplier

A distributed control system supplier is the term used for the original manufacturer or a provider of DCS manufacturers' products.

I recommend: Emerson provides information for businesses and designs the systems. GlobalSpec also provides a list of DCS suppliers, which can provide you with further information on all the DCS can do. If you're not able to see the list immediately, then you need to register online for the list. Registration is free.

A DCS, otherwise known as a "distributed control system" is a system commonly found in the manufacturing industry. It is the system that controls the machines of whatever is being manufactured. However, a distributed control system does not have one central location (such as a brain) but is made up of many sub-sections that all control their own portion of the machinery.

Take the time to learn about how a DCS operates and how it might be implemented into your manufacturing business operation. Here are some resourceful links to get you started. Think of your tutorial as "distributed control systems (DCS) for beginners."

1. Locate a distributed control system manufacturer and see how their machines and systems operate.

2. Find distributed control system vendors that sell software for use in integrating DCS products.

3. Take a training course that specializes in DCS systems.

Action Steps
The best contacts and resources to help you get it done

Find a distributed control system manufacturer and see if their solutions are right for you

When it comes to an introduction to distributed control systems, a great resource is to visit the websites of the companies that actually make the distributed control systems. There you can see how the smaller pieces of their system align to make up a greater whole. You can also request literature and a consultation from many of these companies to see how a DCS distributed control system might fit into your operations.

I recommend: Go to the website for Rovisys. This is a manufacturer of distributed control system, parts and associated integration tools. Also Control Systems International is another distributed control system supplier.

Locate distributed control system vendors and the software they sell

Like many things in today's world, the real brains behind the DCS systems are the software programs that run them on a daily basis. View some of these software programs for various industries and see how it might be integrated into your business. Many of the distributed control system providers offer free demos of their software.

I recommend: Go to the website for DCS Online to view the multitude of software applications. Pi Control Solutions is also another great resource for learning about and using a demonstration of DCS software.

Enroll in a class or course that specializes in DCS systems

There are many components to DCS systems. From the actual machinery that manufactures the product, to the set of sub-systems that control those machines, to the software that is keeping track of all of it, DCS systems are complex to say the least. Enroll in a class that gives a cursory education of all of these pieces and more so you'll get a feel for how to implement and operate one of these systems for your business.

I recommend: Visit the website for Training Classes.com. It offers a comprehensive list of locations that offer training for DCS software and implementation. Wentzell Controls also offers DCS training.