Calculator · XLSX
ROI / Payback Calculator
Build the business case the budget-holder will approve.
Part 1 p01_roi-payback-calculator.xlsx
Available now Foundational → Practitioner Updated Jun 2026
Industrial Automation: Real-World Frameworks & Implementation Guide
Frame it, architect it layer by layer from field devices to the enterprise, then deliver and operate it — the whole arc of an automation project, made clear.
10 parts
46 sections
38 assets
28 figures
~190 pages
By Industry Digits · Automation Simplified What you'll be able to do
- Turn business needs into a clear, reviewable URS
- Select controllers, networks and I/O architecture with confidence
- Review PLC code, PID loops and alarms as maintainable systems
- Design high-performance HMI/SCADA screens operators can act on
- Structure OT networks and IEC 62443 cybersecurity zones safely
- Build FAT, SAT and commissioning plans that reduce rework
- Calculate OEE and run a structured troubleshooting method
Standards and scope
The guide is grounded in the standards and operating models that shape real automation projects. It avoids invented ROI claims; commercial decisions are framed through formulas, assumptions and reviewable planning ranges.
IEC 61508 / 61511IEC 62443ISA-95ISA 101ISA 18.2IEC 61131-3
Curriculum
1.1 · Discrete, process, or hybrid?The first architectural decision. Free preview
1.2 · Build vs. buyWhat to engineer, what to procure, and who delivers it.
1.3 · Writing a User Requirement SpecificationSaying what you need before anyone builds it. Free preview
1.4 · ROI & project justificationMaking the business case the budget-holder will approve.
1.5 · Stakeholder & risk mappingKnowing who matters and what could go wrong, before it does.
Figure preview
Each part includes decision-oriented figures and diagrams that support the implementation sequence.
2.1 · The automation pyramidHow a plant is built in layers, from sensor to boardroom. Free preview
2.2 · PLC, DCS, PAC, or edge?Choosing the controller — and the vendor — that runs the plant.
2.2c · Where HMIs and SCADA fitThe operator's window into the plant.
2.3 · Networks & protocolsWiring the plant so every device can talk.
2.4 · Redundancy & availabilityDesigning so a single failure doesn't stop production.
2.5 · I/O architectureHow the field connects to the controller.
Figure preview
Each part includes decision-oriented figures and diagrams that support the implementation sequence.
3.1 · Sensor selectionMeasuring the process.
3.2 · Final control elements & valvesWhere the decision becomes movement.
3.3 · Signal types & wiringCarrying data and power to the field.
3.4 · VFDs & motor controlStarting and driving the plant's muscle.
3.5 · Pneumatics & actuationThe plant's other muscle.
Figure preview
Each part includes decision-oriented figures and diagrams that support the implementation sequence.
4.1 · IEC 61131-3 languagesThe five ways to program a PLC.
4.2 · Program structure & modular code standardsWriting for the night shift.
4.3 · PID and control loopsClosing the gap to setpoint.
4.4 · Alarm managementTelling operators what matters, in time.
4.5 · Code reuse & librariesBuild once, deploy everywhere.
Figure preview
Each part includes decision-oriented figures and diagrams that support the implementation sequence.
5.1 · SCADA architectureSupervising the whole plant.
5.2 · High-performance HMI designThe screen that shows trouble first.
5.3 · Historians & data managementRemembering every value, cheaply.
5.4 · Screen hierarchy & navigationFrom 'where' to 'how'.
Figure preview
Each part includes decision-oriented figures and diagrams that support the implementation sequence.
6.1 · Industrial protocols comparedThe languages of the plant.
6.2 · Network segmentationContaining the blast radius.
6.3 · IEC 62443 hardeningSecurity by the standard.
6.4 · The IT/OT boundaryWhere the two worlds meet.
Figure preview
Each part includes decision-oriented figures and diagrams that support the implementation sequence.
7.1 · IEC 61508 / 61511When the process must fail safe.
7.2 · SIL determinationHow much protection is enough.
7.3 · Safety PLC architectureRedundancy that trips when it should.
7.4 · Risk assessment methodsFinding the hazards first.
Figure preview
Each part includes decision-oriented figures and diagrams that support the implementation sequence.
8.1 · IT/OT convergenceMaking the plant's data pay.
8.2 · Edge computingProcessing where the action is.
8.3 · MES & ISA-95The layer between plan and production.
8.4 · Digital twinsA living model of the plant.
Figure preview
Each part includes decision-oriented figures and diagrams that support the implementation sequence.
9.1 · The V-modelBuilding it right, and the right thing.
9.2 · Factory Acceptance TestingCatch it before it ships.
9.3 · Site Acceptance TestingProving it where it lives.
9.4 · The commissioning sequenceBringing the plant to life.
9.5 · Documentation handoverThe project isn't done until the documents are.
Figure preview
Each part includes decision-oriented figures and diagrams that support the implementation sequence.
10.1 · Maintenance strategiesFix it before it breaks, where it pays.
10.2 · OEEThe one honest number.
10.3 · TroubleshootingReplace the filter, not the fuse.
10.4 · Continuous improvementThe plant is never finished.
Figure preview
Each part includes decision-oriented figures and diagrams that support the implementation sequence.
The working asset pack
38 calculators, checklists, templates, references and HMI wireframes are cross-referenced to the guide. Practitioner includes the ready-to-use files; Team / Pro adds editable sources and future updates to this edition.
Part 1
Foundations & Project Framing
Part 2
System Architecture & Design
Part 3
Field Layer — Instrumentation & Devices
Part 4
Control Layer — PLCs & Programming
Calculators
11Files supporting the Industrial Automation implementation sequence.
Calculator · XLSX
I/O Count & Sizing
Tally DI/DO/AI/AO, spare capacity and the card count that follows.
Part 2 p02_io-count-and-sizing-calculator.xlsx
Calculator · XLSX
Controller-Selection Scorecard
Score PLC vs. DCS vs. PAC vs. edge against your real constraints.
Part 2 p02_controller-selection-scorecard.xlsx
Calculator · XLSX
VFD / Motor Sizing
Size the drive from motor duty, derating and cable length.
Part 3 p03_vfd-motor-sizing-calculator.xlsx
Calculator · XLSX
Cable Sizing & Voltage-Drop
Pick conductor size that holds voltage across the run.
Part 3 p03_cable-sizing-and-voltage-drop-calculator.xlsx
Calculator · XLSX
Instrument Range / Span
Set range, span and turndown so the reading stays honest.
Part 3 p03_instrument-range-and-span-calculator.xlsx
Calculator · XLSX
Panel Heat-Load / Cooling
Add internal losses and solar gain to pick the right cooling.
Part 3 p03_panel-heat-load-and-cooling-calculator.xlsx
Calculator · XLSX
PID Tuning Worksheet
Record loop terms and see rise, overshoot and settling at a glance.
Part 4 p04_pid-tuning-worksheet.xlsx
Calculator · XLSX
Network Bandwidth / Loading
Check the segment can carry the traffic before you commission.
Part 6 p06_network-bandwidth-and-loading-calculator.xlsx
Calculator · XLSX
SIL Determination / Risk-Graph
Screen hazards to a SIL target with a defensible method.
Part 7 p07_sil-determination-risk-graph-screening-worksheet.xlsx
Calculator · XLSX
OEE Calculator
Availability × Performance × Quality — the one honest number.
Part 10 p10_oee-calculator.xlsx
Checklists
12Files supporting the Industrial Automation implementation sequence.
Checklist · PDF
URS Completeness Checklist
Make sure the spec says what you need before anyone builds it.
Part 1 c01_urs-completeness-checklist.pdf
Checklist · PDF
Architecture Design-Review
Catch the architecture problems while they're still cheap.
Part 2 c02_architecture-design-review-checklist.pdf
Checklist · PDF
Alarm Rationalization
Trim the alarm list to what operators can actually act on.
Part 4 c03_alarm-rationalization-checklist.pdf
Checklist · PDF
HMI / Screen-Design
Design screens that show trouble first (ISA 101).
Part 5 c04_hmi-screen-design-checklist.pdf
Checklist · PDF
OT Cybersecurity Hardening
IEC 62443 zones, hardening and recovery for controls engineers.
Part 6 c05_ot-cybersecurity-hardening-checklist.pdf
Checklist · PDF
Safety Validation
Prove the safety function does what the SRS demands.
Part 7 c06_safety-validation-checklist.pdf
Checklist · PDF
Pre-Startup Safety Review (PSSR)
The last gate before the process is allowed to run.
Part 7 c07_pre-startup-safety-review-pssr-checklist.pdf
Checklist · PDF
Integration Readiness
Confirm the data actually flows before you connect MES.
Part 8 c08_integration-readiness-checklist.pdf
Checklist · PDF
Factory Acceptance Test (FAT)
Catch it before it ships.
Part 9 c09_factory-acceptance-test-fat-checklist.pdf
Checklist · PDF
Site Acceptance Test (SAT)
Prove it where it lives.
Part 9 c10_site-acceptance-test-sat-checklist.pdf
Checklist · PDF
Commissioning
Bring the plant to life in the right order.
Part 9 c11_commissioning-checklist.pdf
Checklist · PDF
Documentation Handover
The project isn't done until the documents are.
Part 9 c12_documentation-handover-checklist.pdf
Templates
6Files supporting the Industrial Automation implementation sequence.
Template · PDF
URS Template
A structured User Requirement Spec you can adapt in an afternoon.
Part 1 p01_urs-template.pdf
Template · XLSX
Build-vs-Buy Decision Matrix
Decide what to engineer, what to procure, and who delivers it.
Part 2 p02_build-vs-buy-decision-matrix.xlsx
Template · PDF
PLC Naming & Code-Standard Manual
Tag naming and modular structure — writing for the night shift.
Part 4 p04_plc-naming-code-standard-manual.pdf
Template · PDF
SCADA Navigation / Screen-Hierarchy Map
From 'where' to 'how' — a navigation model operators can follow.
Part 5 p05_scada-navigation-screen-hierarchy-map.pdf
Template · PDF
Data-Flow Architecture Template
Map sensor → edge → historian → MES → cloud, once.
Part 8 p08_data-flow-architecture-template.pdf
Template · PDF
Handover / O&M Documentation Pack
Everything operations needs the day you leave site.
Part 9 p09_handover-om-documentation-pack.pdf
References
5Files supporting the Industrial Automation implementation sequence.
Reference · PDF
Reusable PLC Code-Block Library
Build once, deploy everywhere.
Part 4 r01_reusable-plc-code-block-library.pdf
Reference · PDF
Architecture Reference Diagrams
Proven patterns from sensor to boardroom.
Part 2 r02_architecture-reference-diagrams.pdf
Reference · PDF
Protocol Comparison Matrix
Modbus, PROFINET, EtherNet/IP, OPC-UA — side by side.
Part 6 r03_protocol-comparison-matrix.pdf
Reference · PDF
Maintenance-Strategy Selector
Fix it before it breaks — where it pays.
Part 10 r04_maintenance-strategy-selector.pdf
Reference · PDF
Troubleshooting Decision Tree
Replace the filter, not the fuse.
Part 10 r05_troubleshooting-decision-tree.pdf
Wireframes
4Files supporting the Industrial Automation implementation sequence.
Wireframe · PDF
HMI: Plant / Area Overview
The at-a-glance screen operators live on.
Part 5 w01_hmi-plant-area-overview.pdf
Wireframe · PDF
HMI: Process Detail
One process area, everything you can act on.
Part 5 w02_hmi-process-detail.pdf
Wireframe · PDF
HMI: Alarm Summary
What's wrong, how bad, and what to do.
Part 5 w03_hmi-alarm-summary.pdf
Wireframe · PDF
HMI: Trend & Historian
See the value move, and remember every one.
Part 5 w04_hmi-trend-historian.pdf
About the instructor
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By Industry Digits - Automation Simplified
Industrial automation, IIoT and operational technology publishing
Industry Digits creates implementation-focused industrial guides for operations leaders, engineers and teams who need decision quality, capital discipline and practical delivery tools.