Industrial DevOps: High-Level Languages & Virtualization Reduce Service Costs

Industrial automation is facing major challenges: ever faster product cycles, increasing software complexity, and a shortage of skilled experts. But the IT world has already found a solution: DevOps. This approach, which looks at development and operations holistically, enables fast cycles and high software quality. But how can this principle be transferred to automation technology (OT)?

The answer is Industrial DevOps – and the keys lie in high-level languages and virtualization.

The Problem: Inefficiency and High Costs 📈

In traditional industrial automation, modifications and updates are often very labor-intensive. The reason lies in a highly fragmented and incompatible software landscape, often relying on proprietary and outdated programming languages. Software tests can often only be performed at the end of a project on the real system, leading to high risks and costs.

A graphic illustrates the problem: while 85% of errors occur during coding, about 75% are only discovered during system tests shortly before the end of the project. The later errors are found, the more expensive they are to fix.

One example shows: a machine builder with 1,000 systems requiring four updates per year may spend €800,000 annually on service interventions. Costs like these put profitability into question.

The Solution: Industrial DevOps with High-Level Languages & Virtualization 💡

Industrial DevOps transfers the successful IT approach into the OT world. To achieve this, two essential prerequisites are required:

1. Programming in High-Level Languages: Instead of outdated, proprietary languages, all components of an automation cell are programmed in high-level languages, without compromising real-time capability. This eliminates incompatibilities and makes modern, powerful IT tools accessible.
2. Virtualization: Plant components are mapped virtually. This allows software to be developed and tested independently of the availability of physical hardware.

By using a unified code base and identical interfaces (APIs) for both virtual and real components, test coverage of over 95% can be achieved – compared to often less than 30% with classical PLC programming. Errors are detected much earlier, and the costs of fixing them drop dramatically.

Conclusion: Fast Cycles and Digital Sovereignty 🚀

Industrial DevOps solves the core problems of industrial automation by providing a holistic, modern, and powerful toolchain. Fast development cycles with guaranteed quality thus become reality in the OT domain.

At the same time, users regain their digital and technological sovereignty, as the approach avoids vendor lock-in. It also enables the seamless integration of big data and AI methods into the automation pyramid.

What do you think? How could Industrial DevOps revolutionize efficiency in your industry?