Introduction
Artificial Intelligence (AI) has become one of the most talked-about technologies in manufacturing, but many companies are asking the wrong question.
Rather than asking, “How do we add AI to our facility?”, manufacturers should first ask, “Is our automation infrastructure ready to support AI?”
The reality is that AI is only as effective as the information it receives. Poorly documented control systems, obsolete PLCs, disconnected machines, inconsistent sensor data, and aging industrial networks all limit the value AI can provide. Before investing in advanced analytics, machine learning, or autonomous robotics, manufacturers need to ensure they have a solid automation foundation.
An AI-ready control system is not necessarily a brand-new production line. In many cases, it is an existing system that has been modernized with future growth in mind. By making strategic improvements today, manufacturers can increase productivity immediately while positioning themselves to take advantage of future technologies as they become practical and cost-effective.
Strategy #1: Build a Reliable Source of Data
AI cannot make intelligent decisions without reliable information.
Most manufacturing processes already generates valuable data. Do your processes include any of the following:
- Motor current
- Cycle times
- Machine utilization
- Production counts
- Alarm history
- Temperature
- Pressure
- Flow
- Vibration
- Energy consumption
Unfortunately, much of this information never leaves the PLC.
Many facilities still rely on operators manually recording production numbers or maintenance personnel for troubleshooting equipment only after failures occur. This limits visibility into production and makes it difficult to identify trends.
How Trola Can Help
Trola Industries specializes in connecting machines, regardless of their age.
Whether the equipment uses modern Ethernet/IP communications or older serial protocols, Trola can develop solutions that collect and organize production data into meaningful information.
Examples include:
- PLC programming modifications
- Industrial networking upgrades
- Machine-to-machine communications
- Data historians
- Production dashboards
- OEE data collection
- SQL database integration
- ERP and MES connectivity
- Wireless sensors
Instead of replacing entire production lines, manufacturers can often unlock valuable production information from equipment they already own.
Strategy #2: Design Control Systems for Future Expansion
Many control panels are designed only for today’s project.
An AI-ready panel should also consider tomorrow’s requirements.
Adding sensors, cameras, barcode readers, robots, or edge computing devices several years from now should not require replacing the entire enclosure.
Forward-thinking panel designs include:
- Spare PLC capacity
- Additional network ports
- Extra power capacity
- Available DIN rail space
- Expansion terminals
- Proper thermal management
- Flexible communication architecture
These small decisions during initial design can significantly reduce future upgrade costs.
How Trola Can Help
As a UL 508A control panel manufacturer, Trola designs panels with long-term maintainability in mind.
When appropriate, our engineering team can recommend:
- Modular PLC architectures
- Managed industrial Ethernet switches
- Network segmentation
- Fiber optic infrastructure
- Future expansion space
- Higher SCCR ratings where applicable
- Remote I/O architecture for future equipment additions
Rather than designing a panel that simply meets today’s requirements, we help customers develop systems that continue supporting production for many years.
Strategy #3: Modernize Existing Equipment Instead of Replacing ItÂ
Many manufacturers assume AI requires purchasing entirely new equipment.
In reality, many mechanical systems remain in excellent condition long after their controls become obsolete.
Replacing only the automation components often provides significant improvements at a fraction of the cost.
Examples include:
- Upgrading obsolete PLCs
- Replacing aging HMIs
- Installing variable frequency drives
- Adding machine vision
- Integrating barcode scanners
- Improving alarm management
- Collecting production data
- Enabling remote diagnostics
These upgrades frequently improve reliability while extending equipment life by another decade or more.
How Trola Can Help
Retrofits are one of the most effective ways manufacturers can improve productivity without major capital expenditures.
Trola performs complete modernization projects including:
- PLC conversions
- HMI replacements
- Control panel redesign
- Field wiring documentation
- Electrical drawing updates
- Equipment commissioning
- Operator training
Our team can evaluate existing equipment and recommend practical upgrades based on production goals and available budgets.
Strategy #4: Make Information Available to the People Who Need It
One of AI’s greatest strengths is transforming raw data into useful information.
Operators should not have to search through multiple screens to understand why production has slowed.
Maintenance personnel should be able to quickly identify recurring failures.
Management should have access to meaningful production metrics without waiting for manually generated reports.
Modern HMI systems can provide:
- Real-time production dashboards
- Downtime analysis
- Alarm summaries
- Maintenance reminders
- Recipe management
- Equipment health indicators
- Energy monitoring
- Production trends
The goal is not simply displaying more information—but displaying the right information.
How Trola Can Help
Trola develops custom HMI applications designed around the needs of each facility.
Rather than using generic screens, we create intuitive interfaces that improve usability while reducing operator training time.
Additional capabilities include:
- Plant-wide dashboards
- Remote monitoring
- Mobile notifications
- Historical reporting
- Multi-machine production summaries
- Secure user access levels
Better information leads to faster decisions.
Strategy #5: Build Cybersecurity into Every Automation Project
As manufacturers become more connected, cybersecurity becomes increasingly important.
Adding remote access or connecting equipment to business networks creates opportunities for improved efficiency—but it also requires proper planning.
An AI-ready system should include:
- Secure network architecture
- User authentication
- Network segmentation
- Firewall implementation
- Managed industrial switches
- VPN access for remote support
- Regular software updates
- Backup and disaster recovery planning
Cybersecurity is no longer optional.
It is an essential component of modern automation.
How Trola Can Help
Cybersecurity considerations are incorporated into Trola’s automation designs whenever systems require connectivity beyond the machine level.
Depending on the application, we can assist with:
- Secure remote access implementation
- Industrial network design
- VLAN configuration
- Managed switch deployment
- User permission management
- Backup strategies
- Documentation that supports long-term system maintenance
Our objective is to help customers improve connectivity without unnecessarily increasing operational risk.
Bringing It All Together
An AI-ready manufacturing facility is not defined by whether it owns autonomous robots or advanced machine learning software.
Instead, it is defined by the quality of its automation foundation.
Reliable controls.
Accurate data.
Scalable networks.
Modern HMIs.
Secure infrastructure. These investments provide immediate operational benefits while creating a platform capable of supporting future technologies as they continue to mature.
How Trola Industries Can Help
Every facility is at a different stage of its automation journey.
Some need to replace obsolete PLCs.
Others need better production visibility.
Some are preparing to add robotics, while others simply want to reduce downtime and improve reliability.
Trola Industries works alongside manufacturers to develop practical automation solutions that align with both current operational needs and long-term business objectives.
Our capabilities include:
- Custom UL 508A industrial control panel design and fabrication
- PLC and HMI programming
- Robotics integration
- Industrial networking
- Machine vision systems
- Data collection and OEE reporting
- SCADA and plant-wide visualization
- Control system modernization
- Skid-mounted automation systems
- Field commissioning and startup
- Emergency engineering and call-out support
- Preventive maintenance and troubleshooting
Whether your goal is improving production efficiency today or preparing your facility for the next generation of intelligent manufacturing, the best place to start is with a control system designed for the future.
👉 [Reach out to Trola to get started].
Contact Trola today for a private consultation and discover how we can help you plan for the future while building for the now.