Advanced Process Control (APC) is a powerful technology that can significantly optimize industrial processes and improve efficiency. However, many enterprises, particularly in China, find themselves trapped in disappointing cycles of poor outcomes despite investing substantially in APC initiatives. The root of this issue lies in a fundamental mismatch between the enterprises (clients) and the APC service providers.
The Core Problem: Mutual Misunderstanding
The heart of the issue is a critical gap in understanding and capability between the two parties involved—enterprises and their APC providers.
Enterprises Lack Technical Expertise
Many enterprises do not have qualified personnel who deeply understand their own technical requirements and operational scenarios. Consequently, they manage APC projects superficially, relying excessively on standardized and superficial KPIs to control project deliverables. While this approach appears rigorous, it often lacks practical effectiveness and does not address actual operational issues.
Service Providers Lack Domain Understanding
On the other hand, service providers often remain stuck at the “tool implementation” level. Their project teams seldom understand the enterprise’s business deeply enough to solve underlying operational pain points. Such superficial engagement leads to ineffective solutions that fail to address core issues.
This mutual misunderstanding generates a negative feedback loop: unclear project demands lead to superficial technical solutions, further exacerbating communication and quality issues.
Vicious Cycle of Low Quality and High Constraints
Enterprises frequently adopt restrictive measures to reduce project risks by lowering service prices while imposing extensive KPIs. Under these stringent budget constraints, service providers struggle to allocate truly competent and experienced personnel. As a result, the delivered solutions tend to be low-quality, further reinforcing the negative perception of APC as ineffective and unprofitable.
This situation creates a cycle of “low-quality delivery – declining performance,” ultimately causing failure in achieving the desired operational optimization goals.
Complex Control Requires Deep Understanding, Not Just Tools
Having previously worked abroad extensively on APC projects, I was initially enthusiastic about promoting APC implementation domestically. However, upon deeper engagement with local industries, I realized that many companies lacked the necessary foundation for effective APC implementation.
APC is fundamentally about deploying complex control strategies, and the cornerstone of effective complex control lies in deep, detailed understanding of the enterprise’s processes, equipment, and operational workflows.
If an enterprise’s internal capability remains undeveloped, APC implementations quickly become costly experiments that deliver minimal practical value, effectively turning the investment into wasted resources.
Recommendations for Breaking the Cycle
To transform this challenging scenario into a productive one, the following steps must be pursued:
Enterprises Need to Evolve
Enterprises must actively cultivate internal technical expertise by establishing dedicated, knowledgeable teams capable of managing complex projects. Companies can:
Invest in regular, targeted training sessions and professional workshops.
Foster collaborations with academic institutions and professional bodies for ongoing knowledge enhancement.
Employ or develop internal specialists who deeply understand both business operations and technical requirements.
This internal competence allows enterprises to accurately define their requirements and evaluate external solutions critically, reducing dependency on service providers and avoiding costly misunderstandings.
Service Providers Must Upgrade
APC service providers need to transition from mere “tool implementers” to comprehensive solution providers. They should:
Gain in-depth understanding of client industries, operational workflows, and pain points.
Provide tailored, sustainable solutions rather than generic, superficially attractive tools.
Prioritize quality and effectiveness over rapid delivery and competitive pricing, which often undermine long-term project success.
Only by deeply aligning their solutions with the specific needs of enterprises can service providers genuinely create lasting value and justify the investment in APC technologies.
Conclusion: Raising Technical Cognition is Key
Ultimately, upgrading technical capability and knowledge is essential. Enterprises must recognize that the solution does not lie simply in acquiring expensive software or hiring prestigious consultants. True success stems from systematically and patiently enhancing their own technical understanding and operational competencies.
Once enterprises achieve this foundational capability, APC projects can deliver their intended value effectively, driving overall industry advancement toward sustainable, optimized operations.