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November 2012

Wireless Sensor Networks Here to Stay p. 38 Harley Davidson, GlobalFoundries Dish on Diagnostics p. 42 Optical Inspection of Pharmaceutical Labels p. 46 Industrial Software: Buy vs. Build p. 59

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Pharma's Supply Chain Serialization Mintchell: Who Says Engineers Can't Talk? Pinto on Industrial Cloud Computing

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Answers for industry.

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Contents
November 2012

Volume 10 Number 11

32

32

From Workflow To Knowledge Transfer

Industrial software applications that have workflow built in enable operators to work a documented and proven process, instead of relying on memory and manual data entry. The benefits are smoother processes and higher product quality. 38

38

Why Wireless Sensor Networks Are Everywhere [Almost]

It seems like it was not so long ago that there was a serious debate over whether or not wireless sensor networks and wireless communications in general were a technology suitable for industrial applications. If you take a look around, that debate is over. 42

46

Diagnostics: Why Worry About Maintenance?

Advances in sensing, networking and algorithms are streamlining the flow of diagnostic and prognostic data for Harley Davidson, GlobalFoundries, Laricina Energy and others. Technology is alleviating concerns over the amount, usefulness and availability of maintenance-related information. 46

Optical Inspection of Pharmaceutical Labels

Small information labels and data carriers optimize logistics processes for pharmaceutical manufacturers and protect against damage caused by counterfeit products. A German maker of carton-folding machines uses an intelligent vision system to ensure every piece is exactly positioned.

42
On The Cover: Step by step, knowledge can be transferred.

November 2012 l Automation World

n ov Emb Er 2012 contents

Columns
8

Who Says Engineers Cant Talk? Gary Mintchell, Co-founder and Editor In Chief 59 60 61 62

FeedForward IT View

Gary Mintchell Co-founder and Editor In Chief


gmintchell@automationworld.com 937.726.1798 rbassett@automationworld.com 312.222.1010 x145 ggerke@automationworld.com 312.222.1010 x118

Editorial

Renee Robbins Bassett Managing Editor Grant Gerke Digital Managing Editor Jim Pinto Columnist
jim@jimpinto.com

Industrial Software: Buying Versus Building

Test Stand Replicates Extreme Personnel Conditions

Integrator View

11 21

Overall Equipment Effectiveness: Benchmark Data by Industry

Enterprise View Industry View Pintos Prose

C. Kenna Amos, Jr., PE, Terry Costlow, Greg Farnum, James R. Koelsch
Contributing Editors

a rt & production
312.222.1010 x120

Maybelle Pineda Art Director George Shurtleff

Wireless Sensing Benefits from New Technology and Standards 64

gshurtleff@automationworld.com 312.222.1010 x117

Ad Services & Production Manager

Industrial Automation and the Cloud Jim Pinto, Columnist

Departments
6

jchrzan@automationworld.com 312.222.1010 x147 dnewcorn@automationworld.com 312.238.9315 dgreenfield@automationworld.com 312.238.9315 damario@automationworld.com 312.222.1010 x171

Jim Chrzan Publisher

publishing

Balancing Production and Security 11

AutomationWorld.com Perspective
l NAFTA l Fieldbus:

David Newcorn VP/Digital & Custom Media

David Greenfield Director, Media and Events Sue DaMario Director of Marketing Courtney Richards

Hollowed Out What Industry We Had Left All-Digital Diagnostics Solves Problems l Fully-Automated Threaded Insert Installation l Pharma Trends: Fewer New Products, More Generics l Pharma Industry Faces Urgent Need for Serialization Planning l Biologics Production Growing l Food & Beverage Industry: Growth Trickles l Virtual Reality Training for Coal Plant Operators l Wireless Technology Enhances Tank Gauging System

crichards@automationworld.com 312.222.1010 x 113 jacinto@automationworld.com 312/222-1010 ext 111

Promotion and Industry Events Manager

Joan Jacinto e-Media Support Manager

ggudino@automationworld.com 708.207.3895 Chicago, Texas, Southwest and West Coast jpowers@automationworld.com 312.925.7793 Chicago, East, South and New England

Glen Gudino Associate Publisher Jim Powers Regional Manager

s al Es

21

News

49

for Process Industries? ODVA, Endress+Hauser Think So l Survey: Process Engineers Are Some of the Happiest Workers in the U.S l DuPont Lauds Profibus at PI NA Meeting l Wireless Shines at Emerson Global User Exchange l OpenO&M Demonstrates Information Interoperability for Oil and Gas Applications l OMAC Machine Tool Working Group Hosts Meeting at IMTS l GE, Boeing Help Veterans Get Advanced Manufacturing Jobs l Kennedy Space Center Gets Smart About Power l Italian Input Sculpts New Drive Family l Automation Is Becoming Increasingly More Mobile

l EtherNet/IP

Keith Williams at PARS International 212.221.9595 Ext. 319 All Automation World editorial is copyrighted by Summit Media Group, Inc. including printed or electronic reproduction. Magazine and Web site editorial may not be reproduced in any form without the written permission of the publisher.

Bruce Sprague Audience Development Manager Omeda Communications Circulation Fulfillment For a reprint quotation, contact

c irculation

330 N. Wabash Ave., Suite 2401, Chicago, IL 60611 Phone: 312.222.1010 Fax: 312-222-1310 Circulation fax: 847.291.4816

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Web site: www.automationworld.com

49

Engineering School Innovations


Wireless Automated Assembly

60

52

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Automation World l November 2012

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Balancing Production and Security


At the recent ODVA (www.odva.org) annual conf erence, held in Atlanta, Ga., Peter Anderla, ITS consultant f or Kimberly Clark, said his most significant challenge is my users [operations,] and the need to educate them about security. He mentions their lack of knowledge regarding USB drives and password management when connecting to machines on the plant floor. This statement resonated with me as I read in this months Industrial Ethernet Reviews feature article, titled, Industry Interrupted: Tablets and Smart Phones Poised to Make a Big Impact (http://bit.ly/awfeat097). In it, Automation World contributing editor Terry Costlow addresses security issues with tablets and smart phones. Anderla, an IT prof essional since 1996, cited in his presentation that business needs and technology are moving quickly, but security policies are much slower to change. In Terrys article, Erik Nieves, technology director f or the Motoman Robotics Division of Yaskawa America, drives home that fact: Tablets and smart phones work very well as a dashboard so people can look at live data

Videos | Automation Alley


Emerson Exchange | Smart Wireless Navigator

remotely, Nieves says. Im very bullish on the role apps can play. Any time you can increase access to inf ormation about the production system, you get a lot of benefits. These apps democratize data and let users do anything they like with that data. One way to lessen the security risk with smart phones and tablets is to limit them as just monitoring devices, and block downloading of information from devices. As the article points out, in order to block downloading, this may require some upgrades to the existing network infrastructure. Another great point Anderla made at the conference is that vendors, especially consumer vendors, dont think about secure communication during product design. Anderlas audience at the ODVA event was network industrial vendors and he emphasized that IT personnel would like to see more vendors thinking about secure communication when developing new products.
Grant Gerke

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Digital Managing Editor

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Finance |

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DCS |

IMTS 2012 | Multi-Touch Panels

Proper Use of Standard Cost Methods Enhances Efficiency


Using standard costing techniques, manufacturing managers can more efficiently measure cost of goods sold, and allow for more effective budgeting and price setting on future job.

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Is There an Industrial Tabletphone in Your Future?

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Feed Forward

Who Says Engineers Cant Talk?


Gary Mintchell Co-founder and Editor In Chief

gmintchell@automationworld.com

Ever hear the one about the extraverted engi-

Engineers lead productivity

neer? He looks at your shoes when he talks to you. Then there are the stereotypes of engineers exemplified by Scott Adams cartoon creation, Dilbert: logical, dry, analyzes everything to death, cant carry on a mundane conversation, points out inconsistencies in others, sees most things in terms of black and white, and so on. I described all of this to one of my sisters-in-law once. She had just started working as an admin in an engineering department. Ah, ha, she exclaimed. Now she understood the people she worked with a little bet-

This issue of Automation World contains a couple of stories about the results of the abilities of engineers to design and implement new automation systems that serve to make manuf acturing a more valuable part of the enterprise. Jim Koelschs article (p. 42) on diagnostics and prognostics shows how engineersincluding Ph.D. engineering candidates and post-doctoral researchersare working to f ind better ways to discover potential or actual machinery and process faults. Predictive or condiON THE WEB
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If I could only bottle that energy a transfer of enthusiasm would take place that could transform lives and society.
ter. The problem is that, like all stereotypes, the truth is much messier. Yes, engineers are more analytical than the median person. But that makes engineers excellent problem solvers. And some engineers actually go into sales or senior management. I wish more went into senior management. Picture a large hotel ballroom set up for lunch with about 2,500 people, er, engineers, ready for lunch and an awards ceremony. Figure it would be a pretty dull place, right? Wrong. We were recently at the Emerson Global Users Exchange in Anaheim in just such a situation. The noise and energy from the conversations occurring in the room made it difficult to hear at times. So much so that our Associate Publisher, Glen Gudino, leaned over and said to me, Who says engineers cant talk? The halls at both the Emerson Exchange and the Invensys Sof tware Users Group, which was going on at a hotel across the street, were f ull of the energy of people passionate about what they are doing, sharing ideas. A friend asked at dinner one evening what more could I do to help show young people what a great calling engineering in manufacturing and automation is. If I could only bottle that energy and show it to high school and middle school classes, a transfer of enthusiasm would take place that could transform lives and society.

tion-based maintenance holds the potential to increase availability (which really means increasing productive capacity) while deploying maintenance resources in more efficient and effective ways. Getting more productivity from assets is a driver for economic health of a country. After Dave Greenfield finished his article (p. 38) on wireless in manufacturing, we were provided information that Emerson Process Managements wireless sensor network instrumentation and sensors based upon WirelessHart have accumulated a total of 1 billion hours of operation. And that is just one vendor. There are many suppliers who are selling WirelessHart products. In just the space of a couple of years, so many engineers have worked to develop the standard, and then the products, and then implemented the systems that wireless technology has become mainstream. I once had the ultimate engineers personality. I remember when, as a freshman engineering student taking a history class, my first test results came back and I received a D. Whats up, I asked the graduate assistant. I answered the questions. Yes, he said, but you didnt explain them enough. Next test, I f illed two blue books with prose and got an A. So, I learned that something that can be answered in 50 words sounds better when you use 600. Gosh, with that education, I could have become a politician!
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perspective
Letters p. 11 l Technology p. 14 l Industries p. 15 l Applications p. 18

Reader Feedback: NAFTA Hollowed Out What Industry We Had Left

Letter to the Editor Re: The Myths of Manufacturing Jobs, AW September 2012 We cant educate enough to make up f or giving away the f arm. NAFTA hollowed out what industry we had lef t where I live. My home town use to make ref rigerators, f urnaces, lawn equipment, sporting goods and so on. All those jobs went to Mexico. The day NAFTA passed, trucks started backing up to our docks to take tooling to Mexico. I find it best to take things to extreme to disprove or prove an idea. Lets pay teachers a million dollars a year and have a teacher f or every pupil. Everybody graduates with a high school diploma. And lets say that all this was done before NAFTA. Would it have keep the jobs here? No, of course not. Heres why. The company I work f or was ready to build a plant in Mexico in order to continue supplying parts to Whirlpool which by the way moved all our home town ref rigerator manuf acturing there.

We were ready to break ground when the deal f ell apart. We were told by our Mexican consultant that the wage for the Mexican workers would be two dollars an hour. That two dollars included benefits. So should we pay our employees two dollars an hour to compete with Mexico? Oh wait, all the talking heads say we need to be more productive. So we automated. Productivity per employee is way up where I work due to automation and

robotics. However, the shipping costs to transport parts to Mexico is fixed by locality. Every employee here could have a PhD and it would not make a difference in our competitiveness. Are robots and automation illegal in Mexico? Are they so sophisticated only people in the U.S. can use them? Productivity through automation can be increased for an employee in any country.
NAFTA Continued on page 13

Costs can certainly be measured, and we expect them to be higher. The question is whether productivity, innovation and agility can be translated into [outcomes like] better vehicles and more sales. David Rutchik, partner, Pace Harmon Consultants, on GMs decision to hire 10,000 IT workers instead of keeping them outsourced. Source: Reshoring News, www. reshoringmfg.com

DID YOU HEAR?


November 2012 l Automation World

11

Pers Pective

LETTERS

Reader Feedback: All-Digital Diagnostics Solves Todays Problems


Letter to the Editor Re: Field Device Diagnostics: Desire and Reality, AW September 2012 I read with interest the article by Peter Ebert on f ield diagnostics. To me and to many of us that deal with fieldbus technology on a regular basis, the diagnostics issue is really an information management problem that can be solved with the technology we have today, and there are key differences in how Foundation f ieldbus handles diagnostics versus HART and other protocols. Lets start with NAMUR NE 107, which the Fieldbus Foundation has incorporated into our specif ication. NE 107 diagnostics have been part of our specif ication since 2010. Our Field Diagnostics specif ication was developed in close collaboration with NAMUR [a German process industry

NAMUR NE 107 is extremely valuable. It creates standard symbols, terms for reporting diagnostic conditions and makes it easier to classify diagnostics.
user organization]. Many of the requirements outlined in the NAMUR recommendations, such as support of alarms, were already included in the specification. In fact, all new devices that will be registered from this point on with Version 6 of our Interoperability Test Kit (ITK) must support NAMUR NE 107 graphics and diagnostic management capabilities. All of our host systems tested through our Host Prof ile Testing and Registration program must also conformthats especially applicable to our integrated DCS hosts. We are currently the only organization with this mandatory requirement for NAMUR NE 107 support for testing and registration of devices and hosts. NAMUR NE 107 is extremely valuable because it not only creates standard symbols and terms f or reporting diagnostic conditions, it makes it a lot easier to classif y diagnostics in terms of severity and root cause (i.e. is it a process problem? A sensor problem? An electronics problem?) Yes, both HART and Foundation fieldbus and lots of other protocols offer diagnostic information. However, when you go completely digital as you do with Foundation fieldbus, the volume and type of diagnostics that are available to you increase exponentially, as does the bandwidth to report these diagnostic conditions (all-digital, so you can transmit multiple process variables and diagnostic conditions across the network). The Foundation publish/subscribe architecture also means that diagnostic inf ormation is continuously pushed to the people that need it, when they need it, with no delay and no requirement for polling devices. All of a sudden you find yourself able to access thousands of diagnostic parameters at a time from many different devices across your fieldbus network. Its like seeing television in high definition for the first time, and it goes way beyond the ability to detect a plugged impulse line. You need a common sense way to manage the information you are getting so that it is actionable, and people only get the right inf ormation to the right people at the right time. Thats the real beauty of NAMUR NE 107 and why our end user clients decided it was time to make these recommendations part of the Foundation fieldbus specification. Because we are an open standard guided by our end user council, we can make additions and improvements to the specification as they are required. The all-digital nature of our diagnostic capabilities also allow users take the whole diagnostics platform up a level, by looking at interrelationships between diagnostic conditions on dif f erent devices across the unit or the plant to create diagnostic profiles of the process itself and even plant equipment. This takes diagnostics into a whole new dimension, where it becomes part of your overall plant optimization strategy. I would be happy to write more about this topic, as I think it is one of the most misunderstood topics facing our industry today.
Larry OBrien, larry.obrien@fieldbus.org, is global marketing

manager with Fieldbus Foundation


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12

Automation World l November 2012

Pers Pective

Letters

NAFTA Continued from page 11

Im picking on your first point invest in education because thats everyones panacea for our bad economy. If we pay teachers more and have more of them. If all children got a college degree. If those two things happened, the sun would come out and all would be good again. Yeah, right. I picked NAF TA because its the trade agreement that I have seen and felt personally. Heres my answer to bringing things back around: If its made in a f oreign

Productivity per employee is way up where I work due to automation and robotics. However, the shipping costs to transport parts to Mexico is fixed by locality.
f actory, dont buy it. If people demand U.S.-made goods, the corporate world will respond with U.S. made goods. No easy answers, but our best vote is not in a booth but with our dollars.
Jock Stucki, jstucki@wabashplastics.com

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Gary Mintchell responds: I

tend to not agree with you on NAFTA, but thats always subject to debate. We were moving plants to Mexico in the 80s. I remember building a complex assembly machine for a company that in mid-project decided to ship it to Mexico. We always wondered if the machine ever went into production. That was 1984. Managers are essentially short-sighted. The cost of labor is almost always a small percentage of the selling price. Now those managers have discovered (duh!) that supply chain costs and risks outweigh labor savings. (I spent 5 years doing cost analysis in a mid-sized manufacturing company as part of my job in product development.) And youre right about consumer choice. Remember when Wal-Mart touted made in America? Then suddenly switched to lowest price? And people f locked to the store. That single handedly drove quality down and jobs away.

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Technology

Fully-Automated Threaded Insert Installation


ponents and structures are assembled in aerospace, def ense, automotive, and other industries. Fully automated threaded insert installation signif icantly improves high-volume fabrication of assemblies produced from aluminum, magnesium, and more. In addition to the superior strength, sealing capability, and customization that Fredserts of f er, the ability to f ully automate installation also reduces overall process time and cost. Development of the f ully-automated Fredsert installation process was achieved through the cooperation of General Dynamics, ERI America, R&E Automation, Kuka Robotics, Atlas Copco, Robot Vision Technologies, Miller Precision Industries, and Welker Engineered Products. This report was authored by Jason Deters, a process & technology development specialist f or General Dynamics Land Systems in Sterling Heights, Mich. Fredsert threaded inserts are designed by General Dynamics to deliver unparalleled strength, sealing capability, and design flexibility in the most challenging applications. Fredserts are unique in that they can be easily removed and replaced without drilling or rework - great for applications with limited access, or where f ield service is needed. Used by General Dynamics f or over a decade, theyve only recently been of f ered to the commercial market. Design and Manufacturing Engineers in Def ense, Aerospace, Naval, and Heavy Equipment industries now have an alternative that overcomes limitations associated with traditional threaded inserts.
Fully-automated threaded-insert installation could dramatically change the way aluminum com-

Fully-automated installation of Fredsert threaded inserts using a torque adaptor in a CNC machining center.

Fully-automated installation of Fredsert threaded inserts using an electric nutrunner on a robot.

For low to medium volume applications, Fredserts are installed manually with a torque wrench, or semi-automated with an electric nutrunner. For production volumes, however, Fredsert installation can be f ully automated - using either a CNC machine or a robot to deliver the necessary torque. This capability provides significant advantage over traditional inserts, which are difficult or impossible to fully automate due to the mechanical-clamping aspect of their installation. The CNC installation method uses an adaptor similar to a tension / compression tap holder to pull Fredserts f rom a tray and install them into tapped holes at a specified torque value. The user machines a part as they do today - but after the holes are tapped, the CNC program pulls the adaptor from the tool magazine and proceeds to install Fredserts. This capability enables users to combine machining and insert installation in one setup, a significant step toward Lean Production. This level of process control also ensures consistent and accurate installation every time, since the location and installation are precisely controlled by the CNC program. Incorporating this process requires relatively little investment, because the most expensive component, the CNC machine, is already there to machine the part. General Dynamics has also developed a robotic installation cell, consisting of a robotic arm with an electric nut-runner that picks Fredserts from a tray and installs them into tapped holes. Like the CNC installation process, robotic Fredsert installation provides the unique ability to f ully automate installation of a heavy duty threaded insert. Guided by an on-board vision system, robotic installation ensures proper placement regardless of variation in the workpiece. This approach allows installation into multiple surfaces in a single setup; perfect for applications involving large, complex parts. More details, along with video footage of the automated process, can be found at www.fredsert.com.
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14

Automation World l November 2012

Pers Pective

Industr Ies

Pharma Trends: Fewer New Products, More Generics


Structural and other trends characterize pharmaceuticals now, says Jamie Hintlian, vice president for pharmaceuticals at Aspen Technology Inc. (www.aspentech.com), Burlington, Mass. A structural trend Hintlian sees is companies looking at their core competencies and differentiating themselves along strategic differencesfor example secondary manufacturings filling, packaging and distribution of final product. The rise of contract manufacturing and contract research organizations is clear, he adds. Another trend Hintlian sees is a decline in approvals for new products. This is symptomatic of drug pipelines also getting smaller, he says. CompaniesBig Pharmaare not making the same level of investment in the small-molecule [pharmaceutical] area [as they once did]. But thats not to say theyve given up entirely, Hintlian explains. Theyre being more efficient with modeling than during experimentation with chemicals. Theyre more integrated, flatter organizations. An ongoing trend Hintlian sees is the rise of generics. Over

the next f our to f ive years or so, its anticipated that $140 billion of branded drug sales will be f acing generic competition. He notes that this year and next year will see the highest level of patent expirees. About half of todays top products f ace generic equivalents. Overall, the reduction in prices would be dramatic, he predicts. It could be that half to two-thirds of prices go away. Already generics hugely af f ect consumers. As recently as 2010, 75 percent of American prescriptions were filled with generics,Hintlian says. Thats driven Big Pharma to establish relations with generics companies, he says. And he notes branded generics, seen sometimes in emerging markets, give an extra sense of quality and safety to consumers.
C. Kenna Amos, ckamosjr@earthlink.net, is an Automation World

Contributing Editor.

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Industr Ies

Pharma Industry Faces Urgent Need for Serialization Planning


The complexity of serialization in the pharmaceuticals industry and its impact on organizations was the focus of the Pharma Exchange, a free, two-day seminar put together by Mettler Toledo. At the event this summer, Ellott Abreu of automation solution vendor Xyntek, Inc. said, No doubt the U.S. is behind, but lagging behind has its privileges. We have let the others pay the price to sample approaches and find what works. What is true now is if you are a pharmaceuticals company that has not started, you are going to miss deadlines for Californiaor be superseded by some Federal regulations. Either way, starting now with available standards and assessing and planning strategy, is a move that will position you for success in the global market.

Remember, Calif ornia is the catalyst, but creating your own global supply chain serialization program is going to pay off with visibility into your operation like you have never had before. IT is the blood and heartbeat of any serialization project, said Abreu. The management of data tracked across an enterprise requires standards, methodologies, project ownership, and management from every discipline. You have multiple, complex technology platf ormsPLCs, vision, sensors, encoding, inspection and verification systems, all feeding information to complex IT layersat device, line, plant, and enterprise levels. Serialization requires input both at the planning stage and at execution including team members f rom IT, Engineering, Quality, Marketing, Label/Package Design, Supply Chain, and all partners. And training, offsite, totally focused on all possible impact points. is a terrific challenge. Planning a complex project, in a complex environment, involving complex processes must have a structured approach incorporating program governance and project management where all stakeholders are in from the beginning. Standardized policies, procedureseven standard inf ormation dashboardscommunicate clearly stated goals to measure progress, allow for flexibility and change. You must balance resource allocation internally, define ROI, manage procurement and contracts, define scope and schedule events throughout life cycle. Supply chain partners, CMOs, and CPOs must understand compli-

ance is mandatory. If a warehouse has to buy a special scanner to read the new Japanese government mandated code, for example, they are going to have to make the investment to keep the business. Japan has recently updated its serialization requirements to replace the 2D data-matrix data carrier with the DataBar (a stacked linear bar code). This allows lower cost and more widely available linear scanners to be used. Many life sciences companies have focused on the data matrix and may not be prepared to support a variety of data carriers. One contract packager worried aloud about making the investment to allocate and aggregate serial numbers. (This is all that should be happening at the plant level, most agreed; the rest is an IT information challenge at the MES level.) But if they are not equipped with any electronic communication f ramework , they will have to turn to Cloud providers who are offering these data packages. Engineering, operations, and maintenance will not be happy to hear turning on a line set up for serialization will result in an initial 10 percent drop in OEE. It will eventually stabilize near 4 percent, but you never are as efficient, said one speaker. Operators have to understand they can no longer take a carton off the floor to complete a case. Quality can no longer come out, grab a few samples, and disappear back into the lab. Rework stations have to be set up. A pilot test has to be end-to-end and provide an assessment for improvement before rollout. Its a process. Whole facilities have to be altered in 20 percent of the cases to accommodate serialization-related space, according to Mark Hollowell, director Barry-Wehmiller Design Group. Hollowell said you know when a project is in trouble during the initial assessment phase when you meet resistance at the plant level where people basically tell you they are not interested in doing anything differently. Here managements buy-in and the realization that serialization is a wide-impact corporate challenge goes a long way. Imagine having dozens of lines with dozens of pieces of equipment, from dozens of suppliers. Just getting those drawings is an 80-hour exercise. Who has the time? What else are they NOT doing now that they have been assigned to the serialization? You may have to hire extra personnel. You even have to factor in return logistics.There are times where product is damaged and not readable. Who destroys what and where, how do you put an end to the pedigree? Clearly, the IT challenge is enormous. No wonder pharmaceutical companies have put it off for years. Older pilots now may be obsolete. If you are not planning right now, you will pay a higher and higher price for delay.
Jim Chrzan, jchrzan@ automationworld.com, is Publisher of

Automation World and Healthcare Packaging magazines.


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Automation World l November 2012

Pers Pective

Industr Ies

Biologics Production Growing


The biggest challenge life scienceswhich

includes biologics, biotechnology and, generally, large-molecule therapeuticsfaces now includes rapid growth, exclusivity around products and the ability to command much more substantial margins, says Jamie Hintlian, vice president f or pharmaceuticals at Aspen Technology Inc. (www.aspentech.com), Burlington, Mass. With biologics, research and development (R&D) and production has never been greater, Hintlian says. Overall, biologics are facing tremendous growth, he adds. Strategically, biologics make a lot of sense, Hintlian believes. Some of the newest and most important remedies are biologicsbased; for example, in oncology. The goal of such biologics-based cancer-treatment medicines, he notes, is to maintain and extend human life. Tbo-filgrastim is one such example of a recently U.S. Food and Drug Administration (FDA)-approved biologic used in treating cancer. Manufactured by Vilnius, Lithuania-based Sicor Biotech UABpart of Teva Pharmaceuticals Industries Ltd., Petah Tikva, Israelthe biologic received FDA approval at the end of August. According to Teva, tbo-filgrastim represents the first new granulocyte colony-stimulating factor to be approved in the U.S. in more than 10 years. The medicine reduces the duration of severe neutropenia in patients with certain types of cancer (non-myeloid malig-

nancies) who receive chemotherapy that affects the bone marrow, Teva says. The American Cancer Society says non-myeloid cancers include all types of carcinoma, all types of sarcoma, melanoma, lymphomas, lymphocytic leukemias and multiple myeloma. The FDA explains that severe neutropenia is a decrease in inf ection-f ighting white blood cells called neutrophils. That decrease leaves patients more susceptible to potentially life-threatening bacterial infections, Teva adds.
C. Kenna Amos, ckamosjr@earthlink.net, is an Automation World

Contributing Editor.

Food & Beverage Industry: Growth Trickles


Economically, supermarket and food-store sales have

picked up since the f irst of the year, according to Brian Todd, president and CEO of The Food Institute (www.f oodinstitute. com), Upper Saddle River, N.J. This is some sort of return of an upward trend. But, unfortunately, most of that is being eaten up by inflation. Also, consumers are very hesitant to open up their pocketbooks, he adds. To cope with this, f ood & beverage manuf acturers may have gone to ondemand production where they can, says Todd, a 32-year veteran of the industry. This has probably impacted companies expansion plans, too. Manufacturers have had to become more creative. Lots of manufacturers have had some success in producing more convenient packaging. Theres also smaller packages; f or instance, the 100-calorie packages, Todd says. As f or new products, companies are

more aggressively looking f or true new ones, Todd observes. But thats not some Lite extension of an existing product, or a new f lavor of a cereal. The new products about which The Food Institute has been reporting are health-based onesf unctional f oods that have health benef its. Gluten-f ree products seem to be one of those new foods, Todd says. But, still the biggest current challenge to the industry ties in with the economy, Todd states. Were waiting f or the economy to increase and waiting f or consumers to spend more. He laments that the industry was used to much more steady growth than it sees now and thats whether it was a 3, 4 or 5 percent increase. But its just slowed down so much over the past three years. Growth trickles, he says.
C. Kenna Amos, ckamosjr@earthlink.net, is an Automation World Contributing Editor. November 2012 l Automation World

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Pers Pective

Applic Ations

Virtual Reality Trains Coal Plant Operators


Three-dimensional virtual reality simulation is being used to help train power plant control room and field operators at the National Energy Technology Laboratorys (NETL) Advanced Virtual Energy Simulation Training and Research (AVESTAR) Center in Morgantown, W.Va. Wearing a stereoscopic headset, integrated gasif ication combined cycle (IGCC) power plant field operators are immersed in a virtual environment with the ability to move throughout the plant, coordinating their activities with control room operators and interacting as if they were in the actual facility. This unique operator-training simulator f or the U.S. Department of Energy (DOE) uses the SimSci-Esscor Eyesim virtual reality training solution from Invensys Operations Management, Houston. The formal site acceptance test was completed on July 16, 2012, after a complete plant start-up. IGCC with carbon capture technology captures 90 percent of the CO2 produced by traditional fossil-fuel burning processes, while at the same time reducing sulfur, mercury and other NOx emissions. The IGCC process is extremely complex. IGCC operators are effectively running both a chemical processing plant and a power plant. Training IGCC operators require us to simulate the chemical process of coal-gasification with CO2 capture together with combined-cycle power generation, said Stephen E. Zitney, Ph.D. and director of NETLs AVESTAR Center. No one has ever done that before. But now with help from Invensys, we can simulate almost any operating scenario, including disturbances, malfunctions and

emergency shutdowns. We can even train operators on diff erent coal and biomass feed stocks. Zitney added that the developments theyve accomplished at the AVESTAR Center show the growing viability of IGCC power plants and indicate the growing demand for a well-trained work force. The Eyesim solution is integrated with plant operating models built on Invensys Operations Managements SimSci-Esscor Dynsim dynamic simulation software, so actions taken by a field operator aff ect the plants process, and actions perf ormed in the control room change the information visible to the field operator. The solution combines stereoscopic 360-degree views with collision effects, sounds, lighting and weather conditions to give the plant operator a realistic walkthrough environment and simulated hands-on experience with the plants physical operation. A separate Eyesim virtual reality training system will be installed and commissioned at West Virginia University in Morgantown for student education.
Renee Robbins Bassett, rbassett@automationworld.com, is

Managing Editor of Automation World.

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Wireless Technology Enhances Tank Gauging System


Tank farm automation became

easier, f aster and less costly with the integration of Emerson Process Management s Rosemount Raptor tank gauging systems with wireless technology. System installation costs can be reduced up to 50 percent by wirelessly connecting the tank farm to the control room, with the added benefit of reducing implementation time as much as 60 percent. The tank gauging systems are custody transf er-approved and can be applied on many types of storage tanks, including fixed roof and f loating roof tanks. Applications range f rom light products such as LPG, LNG and gasoline, to heavier products like crude oils and asphalt. Many such tank storage f acilities that could benefit from modern, non-contact gauging currently use obsolete signal wiring, or are not connected from the tank storage area. Retrof itting an obsolete gauging system is expensive and time consuming because the distance between storage tanks and the control room can be more than one kilometer, requiring extensive trenching and cabling. Wireless technology enables the radar-based Raptor system to be installed without new long distance signal wiring. This can radically reduce material and labor costs, as well as engineering and project execution time. Announced in September 2012, the Raptor System with Smart Wireless technology f rom Emerson includes a range Rosemount tank gauging components, such as high precision radar gauges, that use self -conf iguring, two-wire, high-speed Foundation f ieldbus

technology. The combined communications technologies enable use of a wide range of standardized equipment. The resulting Raptor system f orms a network of digital intelligence that helps users improve inventory management, loss control, over f ill avoidance, and maintenance ef f iciency throughout a plant. Mikael Inglund, technical product manager for Emerson Process Management, says Our customers struggle with costs of replacing aged wiring, obsolete

measurement instruments, and proprietary gauging systems. Our wireless Raptor systems give them the flexibility and freedom to implement an eff ective modernization strategy. They can be changed out and wirelessly integrate new gauging systems one tank at a time. Most upgrades are done without taking the tank farm out of service.
Renee Robbins Bassett, rbassett@ automationworld.com, is Managing

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NEWS
Ins Ide Th e n ew s

EtherNet/IP for Process Industries? ODVA, Endress+Hauser Think So


At the recent 15th annual meeting to ODVA held Oct. 16-19 in Atlanta, Ga., the organization of f icially welcomed Endress+Hauser as a principal member and pointed towards a bigger process automation play f or EtherNet/IP and CIP technologies. In April, Ann Arbor-basedODVA(www.odva. org) announced that Endress+Hauser became a new principal member of the networking group and this addition signaled a major push by the

organization to include more EtherNet/IPenabled f ield instrumentation technology f or the process industries. Af ter Endress+Hauser was f ormally introduced in the general session meeting, Dr. Raimund Som mer, managing director of Endress+Hauser, said, The company has always had a strong commitment to openness and we offer products and solutions, not ideolEtherNet/IP Continued on page 22

Survey: Process Engineers Are Some of the Happiest Workers in the U.S.
Are you happy in your job? Apparently you are, if youre a process engineer or field technician. CareerBliss, an online job site, compiled a list of the 20 h a p p i e s t jobs based on analysis f rom more than 100,400 employee-generated reviews between February 2011 and January 2012. Tied f or ninth place are process engineers and field service technicians with an index score of 4.01. As reported on Forbes.com, CareerBliss Chief Executive Heidi Golledge said, Since we tend to spend more waking hours working than doing anything else, our work happiness is a huge factor in our overall happiness. Nearly every person has a desire to feel valued and content, and a workplace or a career that provides that for its employees is key to not only happiness for the employees but the long-term success of the business. Surveyed employees were asked to rate 10 factors that affect workplace happiness, including ones relationship with the

21 EtherNet/IP for Process Industries? ODVA, Endress+Hauser Think So 21 Survey: Process Engineers Are Some of the Happiest Workers in the U.S. 22 DuPont Lauds Profibus at PI NA Meeting 24 Wireless Shines at Emerson Global User Exchange 24 OpenO&M Demonstrates Information Interoperability for Oil and Gas Applications 26 OMAC Machine Tool Working Group Hosts Meeting at IMTS 26 GE, Boeing Help Veterans Get Advanced Manufacturing Jobs 27 Kennedy Space Center Gets Smart About Power 28 Italian Manufacturers Input Sculpts New Drive Family 29 Automation Is Becoming Increasingly More Mobile

boss and co-workers, work environment, job resources, compensation, Find news online at growth opportunities, company AutomationWorld.com/news culture, company reputation, daily tasks, and control over the work one does on a daily basis. The employees valued each factor on a five-point scale, and also indicated how important it was to their overall happiness at work. The happiest profession overall, with a score of 4.24, is software quality assurance engineer. Bank teller and warehouse manager round out the top five happiest jobs in America, with index scores of 4.14 and 4.13, respectively, according to CareerBliss. We have also noticed that happiness definitely does not align with pay, Golledge adds, and once someones basic needs are met, the additional money on the job is a nice perk but is not what drives employee happiness. The roles that we did not expect to see were teller, accountant and financial analyst, Golledge says. Even though all three of these positions ranked low on compensation, they all ranked very high on the company you work for and the people you work with. Clearly, working with likeminded folks who share a love for calculators and numbers drive their happiness.
Renee Robbins Bassett November 2012 l Automation World

21

News

DuPont Lauds Profibus at PI NA Meeting November 2 012


North America, both Profibus and Profinet network protocols are showing robust growth in North America as well as globally. PI NA leaders, believing that a market inflection point is upon it for Profinet, so the organization will be undertaking a more aggressive marketing campaign for that technology in the next year. Customers who have implemented Prof ibus and/or Prof inet are always f eatured speakers at PI NAs annual meeting and Jim Simmons of DuPont presented one of the best, most down-to-earth implementation discussions Ive heard in my 14 years as an editor. And, despite this being a Profibus conference, he was frank in his evaluations and wound up implementing a mixed fieldbus system. Simmons was doing controls at DuPont when the company wanted to build a facility at its Fayetteville works to produce PVF polymer in 2005. The project came in $5 million under budget and 2.5 months ahead of schedule. That, in itself, is a miracle. Prior to him, someone had chosen Siemens PCS7 as the preferred DCS system, so he stayed with that. Simmons had little knowledge of f ieldbus networks at the time, but he decided to investigate them to see if they would help his controls implementation. He did a thorough analysis of potential networks. There are many, he deadpanned. His analysis began with looking at categories of devicesinstrumentation, automated block valves, analytical devices, motors/ drives and remote I/O. He then looked at the requirements for each category. The result was Profibus PA for instrumentation (it worked well with the PCS7), AS-i for the block valves, Profibus DP or Modbus f or most of the rest. The company standard f or variable frequency drives was Rockwell Automation, and those
According to Mike Bryant, executive director of PI The conference season is drawing to a close and the SPS IPC Drives 2012 event is getting bigger by the moment. As of mid-September, the event has 388 international companies exhibiting at the Exhibition Centre in Nuremberg, Germany. Forty countries will be represented at the event, with Germany in the top spot; followed by Italys 73 companies and China with 44. The events conference runs in parallel with the exhibition and offers 48 presentations, two keynote speeches, three tutorials and a trend session on Sustainable Automation. Other pavilions called, Joint Stands, include AMA Center for Sensors, Measuring and Testing Technologies, Open Source meets Industry and Wireless in Automation. Last years event attracted 56,321 global visitors. For more information, visit http://bit.ly/event026

27th29th

devices talk DeviceNet. So he used an Anybus connector from HMS to connect Profibus DP to DeviceNet. Some of the benefits DuPont realized included advantages of initial installed cost, plant flexibility, reduced time for project execution and time for ongoing plant changes. Simmons concluded that there was not one perfect fieldbus for every possible application, so engineers should select wisely per design requirement. However, engineers should have to justify NOT using fieldbus on a project, he said.
Gary Mintchell

EtherNet/IP Continued from page 21

Dr. Raimund Sommer, managing director of Endress+Hauser, says customers are asking for more EtherNet/IP-enabled devices.

ogies. However, we do see a big opportunity to have EtherNet/ IP-enabled field devices in the hybrid process industries. These hybrid industries includef ood and beverage,lif e sciencesand environmental. Sommer added that customers in the hybrid industries have different requirements and E&Hs North America customers are asking for more EtherNet/IP enabled devices. Demand for these devices are coming primarily f rom North America, but Europe will come on board soon. Katherine Voss, executive director of ODVA, added, ODVA will define its strategic market requirements for an EtherNet/ IP based process strategy starting with the next term of ODVA, the 16th termwhich officially started after the general session
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Automation World l November 2012

News

Katherine Voss, executive director of ODVA, reveals that new Territory Alliance Groups (TAGs) for Europe will emerge.

meeting this week. ODVAs terms are defined by 18-month intervals. The general session kicked of f with an update f rom Voss, where she documented ODVAs global distribution of membership by principal place of business. A slide documented 44 percent in North America, 17 percent in Germany and Japan, 13 percent in other European countries, and 9 percent for the rest of Asia. Voss added that growth in Europe was a key strategic driver in the groups 15th term, so it has now restructured its Territory Alliance Groups (TAGs) f or Europe. The organization used to have one umbrella group f or Europe, Middle East and East Africa, called EMEA. Now, ODVA will create TAGs for individual countries in Europe; specifically, France, Germany and Italy. These TAGs are currently in development, as is one in Brazil. The general session also included multiple user perspective case studies from various integrators and end users. One presentation, given by Peter Anderla, ITS consultant f or MOSAIC, Kimberly-Clark, stressed that products are not being built with secure communication in mind and do not come with clear explanations on how a component can be ef f ectively secured against vulnerabilities. But, Anderla added, his biggest challenge is his operators, and the need to educate users about how easy security intrusions can happen.
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News

Wireless Shines at Emerson Global User Exchange


Emerson Process Managements Smart Wireless networks,

OpenO&M Demonstrates Information Interoperability for Oil and Gas Applications


O&M Initiative (www.mimosa.org) organized a demonstration project of inf ormation interoperability run like a real project building a debutanizer. The demonstration, held during the ISA Automation Week Sept. 25-26 in Orlando, showed inf ormation f low throughout all the f acets of a plant, f rom design through construction to operations and management. One of the most important advances in the project was that the three major design sof tware suppliersAveva, Bentley and Intergraphwere all involved with enabling export of design data to a standard interface. The engineering procureAfter years of preparatory work, the Open

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Automation World l November 2012

TWORK
1 BILLION

which are based on WirelessHART technology, have now achieved 1 billion hours of operating experience across more than 10,000 wireless networks. This was some of the biggest news to come out of the Emerson User Exchange event, held in Anaheim, Calif. in October, and it represents a coming out party of sorts for industrial wireless technology. This is a milestone event revealing how engineers now consider this a proven technology, said Bob Karschnia, vice president of the Wireless business unit f or Emerson Process Management. Some customers have even written practices where they look at wireless solutions before wired ones when evaluating new projects. Bef ore end of the calendar year, Emerson expects to have exceeded 100,000 wireless devices installed, he added. Karschnia said Emerson customers have been adopting the technology at such a rapid rate that installations are now measured by the number of gateways installed and the number of operating hours. The total number of hours was calculated conservatively, he said, allowing for customer installation time before operation commenced. You dont get to 2 billion hours without going after broader set of applications, Karschnia said, and we have. Many of customers

0,000 1

Renee Robbins Bassett

have challenges that are odds compared to the general IT industry, but wireless communication is proving effective. Among the industries benefiting the most from wireless technology are upstream oil & gas producers, refineries and chemical facilities. In addition to multiple ref inery/wellhead/pipeline applications, Emerson lists dozens of others on its PlantWeb/Smart Wireless application site. These include sugar bin motor monitoring, boiler and heater gas flow, steam flow accounting, blast furnace health, and control network bridging, to name just a few. We knew wireless technology offered substantial savings and it is gratifying to see its rapid and widespread adoption, Karschnia added. Many companies started out with small installations to prove the concept in their operating facilities. Today, those starter systems are rapidly expanding to site-wide facilities. He cited projects in their early stages in which theyre installing 4, 000 wireless nodes. Another with 6,000 nodes, and one 15, 000 nodes planned, he said. Not just the number but the scope [of wireless sensor projects] is growing pretty dramatically. So how long before Emerson hits 2 billion operating hours for wireless? By the time were here next year, well have exceeded 2 billion hours, Karschnia predicted.

NE

ment and construction (EPC) company f or the project was Worley Parsons. Cormac Ryan, Worley Parsons manager of Engineering Data Management for the Americas, explained the development of the P&IDs using Intergraphs Smart Plant P&ID generator. It produced a traditional P&ID diagram, as well as full database of reports and data. The data were published in ISO 15926 format and made available to the rest of the team. Jim Klein, industry solutions consultant f rom Aveva, used a schema similar to the Intergraph one. Aveva acted as a second EPC, duplicating the data with an object-based database behind the drawing. It can store and link to an engineering
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database that contains much more data. For example, clicking on a pump diagram can show specifications and other important design inf ormation. This data was published out to instantiate the object in a maintenance management system or to create new data as it gets revised during the engineering process. Information can communicate to a MIMOSA cloud server. George Grossmann, Ph.D., research f ellow at the Advanced Computing Research Centre at the University of South Australia, explained a transform engine using Bentley Open Plant that was received in two formatsowl and ecxml. These data go to the iniSA 15926 transf orm engine, which takes input from all three suppliers, exports it in ISO 15926 format, then transfers it to MIMOSA standard exports in CCOM XML. Next up Ken Bever, with Assetricity and also CTO of MIMOSA, discussed the transf orm f rom CCOM XML to the Assetricity iomog register, assuring that information was mapped to the asset and then sent to IBMs IIC application

in a standardized way. The information was then sent to OSIsof t PI historian. From PI, data is then accessible to maintenance management and operations management applications. All data references back to the ISO 15926 ontology. Bruce Hyre, f rom IBM, explained how the IIC application is a standardsbased platform that federates data and provides analytics. It takes CCOM, feeds it into a model server, which then provisions tags in OSI PI server. His demonstration showed the actual live P&ID from the EPC. He added, But our f ocus is on the data supporting that P&IDthe tag list/model tree. You can subscribe to a tag, see inf ormation from the upstream systems. There ore, f the demonstration showed that data have gone end-to-end f rom design to the PI server to provision the tags with the live data f rom the design. More than one thousand tags (1,092) were provisioned in this demonstration.
Gary Mintchell

November 2012 l Automation World

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News

OMAC Machine Tool Working Group Hosts Meeting at IMTS


Representatives of three aerospace companies, two tool-

ing vendors and three computer-aided manufacturing (CAM) vendors attended a meeting of the OMAC Machine Tool Working Group Sept. 13 at the IMTS Show in Chicago. Three additional aerospace companies and two additional CAM vendors expressed strong interest but were unable to attend on the day due to logistical problems. Attendees at the meeting reviewed the CAM data exchange business case. Business advantages o standardized data exchange f include f aster process planning, more data reuse and increased enterprise integration. The advantages apply particularly to communication with the supply chain where there will be more flexibility, less need for visits to suppliers to explain models, fewer data entry errors and more synergy between the engineers of different organizations because both sides will be able to access the data describing the current manufacturing solution. Leaders reviewed some of the new shop floor applications that will be enabled when standards-based process data can be delivered to intelligent machines there. These include adapting manufacturing operations for the setup changes that occur when the holding fixtures are adaptive and flexible; enabling the on-machine acceptance of parts to avoid the time, waste and potential errors that can occur when parts are moved to measurement centers; reduced tool wear by dynamically adjusting the manufacturing process for the

Gary Mintchell

current schedule of a plant; last minute changes to tooling to meet the current availability of machines, tools and fixtures; and more accurate cost modeling. Technology developed to support the implementation of CAM data exchange includes software libraries to make CAM data conform to the ISO 10303-238 STEP-NC standard; software tools to view the system-neutral CAM data on the desktop and in web browsers; and software tools to convert the neutral data into legacy M&G codes (for CNC programming). The meeting also reviewed the test parts that were developed during the testing phase of STEP-NC. They include 3 and 5-axis aerospace parts, power train parts and mold parts that were both machined and measured on multiple machines at multiple sites thus demonstrating the interoperability and portability of the STEP-NC data. Attendees agreed that the Boxy part, previously machined at Boeing, National Institute of Science and Technology (NIST) and Scania should be used as the test part f or the CAM data exchange deployment. A 24-month schedule was adopted for the project with the CAM vendors each allocating half of a systems programmer to the project, and the end users each contributing the equivalent of a full time person to work on testing, verification and business development.

GE, Boeing Help Veterans Get Advanced Manufacturing Jobs


Manufacturing industry giants like General Electric, Boeing, Lockheed Martin and Alcoa are collaborating to provide training and support to veterans wanting to pursue careers in manufacturing. The initiative, called Get Skills to Work, aims to match 100,000 veterans to manufacturing jobs by 2015. According to a report in the Washington Post, the coalition hopes to raise awareness about manufacturing opportunities for veterans who dont know exactly what they want to do upon returning from service, said Kris Urbauer, program manager for GE veteran initiatives. On the blog, Joining Forces, U.S. Deputy Assistant Secretary of Defense John Campbell, Through a blend of business, digital, academic, and not-for-profit partners, Get Skills to Work aims to close the advanced manufacturing gap, bolster the talent pipeline, and enhance American competitiveness. Get Skills to Work will be managed by the Manufacturing Institute and supported through financial and in-kind commitments from GE, Alcoa Inc., Boeing and Lockheed Martin. These initial investments will help 15,000 veterans translate military experience to corresponding advanced manufacturing opportunities and gain the technical skills needed to qualify for careers. The coalition is seeking additional partners to meet its goal of reaching 100,000 veterans by 2015. The initiative includes three main components: an accelerated skills training program; translation of military experience to civilian manufacturing job opportunities through an online badging system; and partnership with the Institute for Veterans and Military Families to create an employer toolkit for expanded hiring, developing and mentoring of veterans.
Renee Robbins Bassett Visit www.AutomationWorld.com

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Automation World l November 2012

News

Kennedy Space Center Gets Smart About Power


NASA has taken delivery of data historian and analysis tools in order to increase operational efficiencies and monitoring of the Kennedy Space Centers electric distribution system. The Kennedy Complex Control Systems (KCCS) include the two systems that control the entire electric distribution system including the Vertical Assembly Building, the fourth largest building by volume in the world, and launch pads 39A and 39B, which were used to launch the Space Shuttle. The electric distribution system provides power for the entire electric power system, and all Kennedy Space Center buildings, covering more than 219 square miles. Canary Labs, Martinsburg, Pa. supplied its Canary Enterprise Historian and TrendLink analysis software tools. The Canary Enterprise Historian and TrendLink applications transparently collect and log data for approximately 150,000 real-time data points from power quality meters, protection relays and PLCs throughout the complex, working in sync with the power distribution networks SCADA system. In the past, archiving this data into one system for long periods of time while making the data accessible to system users was a challenge for NASA. According to Ed Stern, vice president of Canary Labs, Our solutions address a problem that NASA has had for years. Using the Canary Labs solutions, NASAs users are able to access long-term data archives from one system, quickly and easily. In addition, our cost-effective solutions will provide historical data to users that do not have direct access to the KCCS, achieving lower operational costs and faster time to value.
Renee Robbins Bassett

New historian software helps power Kennedy Space Center.

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News

Italian Manufacturers Input Sculpts New Drive Family


This way, seven macro-groups of funcmain cities of the Old Continent, the Control tionalities, indicated as a priority by the Techniques European Roadshow finally landed interviewed, were selected. The f inal in Milan. Control Techniques is an Emerson result has been the development of a Group business, and the technical press was f amily of seven drives, each one f eaturinvited to a preview of the companys newest ing high levels of performance and carefamily of drives, the Unidrive M, tailored to the f ully designed to meet the requirements needs of manuf acturing automation (M stays of , and improve productivity in, a specific area of the manufacturing ON THE WEB market. Energy Efficient? Read why manufacturers dont take simple Even if this new f amily money saving steps, such as adding efficient electric drives has the same name of one of and motors to their operations. Visit http://bit.ly/slant104 our historical drive ranges, it is not expected to replace it, as it presents specif ic technical characteristics designed to meet the needs of a vertical sector of manuf acturing automation, said Guido Colombo, marketing director f or Italy. The new top range product, the Unidrive M800, f or example, integrates a new breed of high perf ormance machine controller within the drive. The solution utilizes the industry-leading CoDeSys programming environment with standard IEC 61131-3 programming languages and standard Ethernet f or communication across drives, I/O, HMIs, PLCs and Italians got to preview the Emerson Groups Control Techniques other industrial devices. Unidrive M family of drives. Separately, another important industrial player confirmed f or Manuf acturing). The products will be of fiits conf idence in Italy: the well-known cially presented to the market in November at German company Rittal decided to invest SPS Nuremberg 2012. by building a new production line in the To develop these drives, f irst the company plant of Valeggio sul Mincio, near Verona. focused on its customers needs, asking important In the Valeggio plant the TopTherm Blue end users and main buyers about todays and e family will be produced, a new solution tomorrows expectations, said Carlo Previder, for industrial air conditioning which will general manager of Drive Centre Milan for Conbe more efficient and eco-compatible. trol Techniques. Our company conducted more than 100 qualitative interviews with end users and Ilaria De Poli, ilaria.depoli@ fieramilanoedimachine builders and sent more than 800 custore.it, is an editor at Fiera Milano Editore, a tomized surveys to its main buyers to understand magazine covering automation and manufactheir feeling about the future. turing in Italy.
Last month, after reaching other

News Bri efs


Panduit , Rockwell Fo Rm alliance Industrial automation vendor Rockwell Automation and Panduit, a maker of wiring, network cabling and communication products, systems and accessories, have expanded their long-standing productreferencing relationship into a strategic alliance focused on accelerating adoption of the EtherNet/IP industrial network protocol. invensys acqui Res

ReFine Ry s o Ftwa Re c om Pany Privately held Spiral Software of Cambridge, U.K. has been acquired by Invensys Operations Management to strengthen the companys offerings in the hydrocarbon processing industry. Spirals software complements SimSci-Esscor offerings. s iemens Plm acqui Res FRench c omPany Kineo CAM, headquartered in Toulouse, France, is a provider of computer-aided motion software and has more than 200 customers worldwide.

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News

Automation Is Becoming Increasingly Mobile


Automation technology is currently find-

ing its way into more and more areas of everyday life. Next to industrial solutions, process engineering and building automation, energy technology has become an important industry sector. Another field is evolving greatly without attracting much attention: automation of mobile machinery and special-purpose vehicles.

ON THE WEB
International Perspective Find industry trends, emerging control strategies and general insight from Martin Buchwitz, editor SPS magazin in Germany. Visit http://bit.ly/spsslant

Inside a higher quality tractor, more than 20 controller units are to be found.

The market f or construction machinery and agricultural machinery has been developing well for years, and the growth prognoses for the next years are certainly optimistic. This development sends a good message to automation manufacturers active in the field. Im currently attending a conf erence on Electrical components and electronics in mobile machinery, the Martin Buchwitz, mbuchwitz@sps-magzin.de, is first of its kind in Germany. It takes place during a genEditor in Chief of SPS-Magazin in Germany. eral symposium on electronics in passenger cars, commercial vehicles and mobile machines. More than 500 people attend the event in total, with over 100 of them attending the aforementioned symposium The inaugural on mobile automation of work machinery. Manufacturing Industry Although the conf erence f ocuses on Summit pinpoints agricultural machinery and construction management challenges machinery, the field is much wider than facing global manufacturing that and includes municipal vehicles, fire companies. Held at the fighting vehicles, railway vehicles, waterWestin River North in craft and others. Chicago, Ill., the events theme is Real-World Solutions The best example f or the evolution from Design to Delivery and will spotlight business of mobile automation might be tractors. process management. Tracks will include how best-in-class Nowadays, they have become high-tech companies manage to control costs, product priorities, devices, as a speech given by John Deere improve new product introductions, and overall service at the conf erence made obvious. Inside delivery. Drawing on a seasoned managers, these sessions a higher quality tractor, more than 20 will feature vice presidents and C-level manufacturing controller units are to be f ound: touch executives revealing top strategies and tactics applied by screen displays, steer by wire and telemattheir organizations to not only manage change, but to use it ics systems included. Several parallel CAN as a competitive advantage. For more information visit, bus strings and several miles of cables are http://bit.ly/event027 installed. Interconnectivity is of very high

significance in the field and takes precedence in the field. The trend moves towards Ethernet, as is already established in the industrial automation sector. EtherCAT is the most often named real-time solution. The beginnings of machine-to-machine communication (M2M) are interesting to observe as well. Fendt is currently developing a solution that has a driverless tractor following a manned guiding tractor on a parallel path. The driver is constantly informed about the guided vehicles status and is of course also able to operate it and ensure its safe status. This brings us to the next important topic: functional safety. Because of the increasing use of wireconnected and wireless networking, safety goes hand in hand with access security. The conferences second day will predominantly cover those themes. It is extremely fascinating observing how mobile automation for mobile engines and devices develops further. We are just at the beginning of our journey, and it is definitely worth it to keep an eye on the developments and, hopef ully, see them through. Automation is becoming more mobilewe have an exiting future ahead of us.

December 2 012

03rd05th

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Industrial software applications that have workflow built in enable operators to work a documented and proven process, instead of relying on memory and manual data entry. The benefits are smoother processes and higher product quality. By Gary Mintchell, Automation World Co-Founder and Editor in Chief

anu acturing f execution system (MES) and manf acturing u operations management (MOM) applications automate manuf acturing workf low. Such workflow software captures the knowledge of individuals and the data f rom sensors and shares it so processes are smoothed, quality is improved and knowledge is transferredshift to shift, batch to batch or step by step. Broadly based, [workf low sof tware] is an MES of f ering based on database, execution, product management. The idea is to turn data

into profit, says Jon Kadane, director of product marketing for AspenTech, a Burlington, Mass. supplier of advanced process control sof tware. He says workf low product evolution follows the requirement of what customers require: Pharma is compliance-oriented, while chemicals customers have fewer regulations on product and compliance, but need safety and health reporting. To show the range of workf low sof tware applications and benefits, here are three stories: f rom a medical products manuf acturer, a

semiconductor manuf acturer and a pharmaceutical manufacturer.

A leading medical products manufacturer serving a growing demographic of aging baby boomers needed to rapidly expand production capacity to keep up with growing demand. With limited space in its facility to add new lines, the company needed to f ocus on improving cycle time and yield by gathering more data and establishing ideal operating parameters.

I ideal parameters

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Our customer had some challenges f or control on the f actory floor, says Chris Monchinski, director, manufacturing IT at Automated Control Concepts (ACC), a Neptune, N.J.-based systems integrator. (Monchinski also volunteers as a co-chair of the ISA 95 committee.) They had been acquired and in the acquisition there was new capital available. They wanted to advance their technology. Its a high quality GMP [good manuf acturing practices] company in an organic growth period. Many of their operations grew out of best practices developed

internally. But the paper trail was not always accurate. The challenge was how to maintain quality and grow 200 percent. To address yield while operating under tight regulations and reporting requirements, the company needed to reduce or eliminate losses and shipment delays caused by reporting or quality issues. ACC designed and implemented an inf ormation system based on the FactoryTalk so tware suite f rom f Rockwell Automation and ACCs own sof tware, processRecords. Since

its implementation, the new in ormation system has f helped operators attain a 5 percent increase in equipment efficiency through better equipment utilization. In addition, the manufacturer saw an increased productivity of 20 percent over the previous system, while plant floor staffing has remained the same. Monchinski continues, Control over the records was essential. Trying to find a piece of paper was becoming more and more dif f icult. Then we needed to streamline inter-department communication. Their products are pretty

November 2012 l Automation World

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Mistake proofing the process would deliver economic benefits with faster batch release times, less required labor, and fewer quarantined or discarded batches.
custom, so that added complexity to the problem. Streamlining information flow was essential. The customers requirements were to get control of data f rom departments, machines and devices on the factory floor, as well as data f rom the quality and

order management areas. The source would be either manually or automatically generated data. Another challenge was that production was a combination of discrete and process manufacturing. Rockwells FactoryTalk Historian and FactoryTalk View SE gathered the data and gave visibility. Because ACCs processRecords product is work f low-driven, it helped determine what data needed to be collected and provideed the status of a part through production. In addition to the basic IT f unctionality, ACC also provided security, disaster recovery plans, f ault tolerance, back up, operator acceptance and training. processRecords basically presents forms for the operator or tester to f ill out either automatically, via keyboard or by scanning a bar code, explains Michael Blechman, ACC president. Since installing the system,

the medical products maker has seen the benefits. They now have no paper on the f actory f loor. Now they have all this historical data and can make decisions about tolerances and process improvement, says Blechman. They had so much manual data entered into massive Microsof t Excel spreadsheets. Now its all in one place. Not to mention there is also a predictive maintenance tool.

A U.S-based semiconductor manufacturer, operating a 200,000 squaref oot f acility that includes 62,000 square f eet of cleanroom space f or waf er f abrication, was in pursuit of better control of its processes. To that end, it worked with Minnetonka, Minn. based Savigent Sof tware, using Savigents Catalyst Workf low (workf low automation software) to take run-to-run control to new levels of efficiency.

M semiconductors

aking better

Thousands of enclosures Hundreds of sizes Next-day shipping


POWER DISTRIBUTION ENCLOSURES POWER DISTRIBUTION CLIMATE CONTROL IT CLIMATE CONTROL INFRASTRUCTURE

The semiconductor makers manufacturing facilities include a six-inch (150mm) and an eight-inch (200mm) waf er f ab. With these f abs, this semiconductor manuf acturer has the ability to process more than 4,000 wafers a week. Semiconductor f abs put a pattern on a wafer using a photolithography process. On subsequent layers, they put down another pattern. The layers need to overlay nicely to ensure high yield and device perf ormance. Thats the principal technical challenge addressed by overlay control. About three years ago, when overlay control was initially becoming an issue here, we f ound a poor mans solution, says a photolithography process engineer at the company. For a given lot of wafers, the company set up what it called a restricted aligner. Out of maybe 22 photolithography layers, maybe three were designated critical to have good

overlay to each other; the rest were considered non critical. The manufacturer recorded wherever that first critical layer went down on a particular step or lithography tool number. Later, when the waf ers came back f or the second of the critical layers, engineers made sure that the automation system f orced the waf er back to the same lithography tool that had been used previously (hence the term run-torun control). This process achieved what is called single tool overlay perf ormance. It was a move in the direction the manufacturer wanted to go, but not quite enough. So the company began working with Savigent to improve the process. In our lithography program, we were looking to make adjustments from lot-to-lot, and to gain feedback inf ormation based on output, says the engineer. In this case, f eedback

is based on metrology perf ormance metrics that company has for materials. Then, based on that metrology inf ormation, adjustments are made to the lithography tool recipe for the next lot to be processed. Integrating the f eedback inf ormation f rom the metrology tool to the process tool was critical to making these run-torun adjustments. A station controller cues up the stepper job so that an operator can run a lot of waf ers through a lithography tool. The run-to-run controller is integrated to the manufacturers MES system, the lithography tool (through the station controller) and metrology equipment, providing the means f or real-time communication of critical data such as lot numbers, routes, metrology data

Streamlining information flow was essential.

SOFTWARE & SERVICES IT INFRASTRUCTURE

SOFTWARE & SERVICES

ENCLOSURES

and more. Now when a lot is coming to a particular lithography tool thats about to do an align layer, inf ormation is shared by all the tools involved, says the engineer. Once that information is handed off, a decision is made. The manuf acturer is now able to take what were baseline numbers with no corrections applied and look at key output metrics f rom the overlay tool: registration maximum, registration minimum, and mean values f or both the X and Y dimensions. With the Savigent technology, were able to drive those metrics to lower and lower numbers, says the engineer. Zero would be our ultimate goal f or the mean. Max and min wont ever go to zero, but were always trying to make them smaller. That shows weve achieved a better overlay than without the run-to-run controller. Since implementing the new system, the company has reduced a typical max/min value in the range of 100 nanometers into the range of 60 nanometers, an improvement of 40 percent.

the Quality and Production departments. In addition, the ef ort f involved in releasing a batch included many non-valueadded steps. Over 20 percent of the atypical events f ound were due to manual recording errors. Mistake proofing the process would deliver economic benefits with faster batch release times, less required labor, and f ewer quarantined or discarded batches. The manuf acturer had an existing manufacturing execution system (MES) at its various facilities, but it was centered on the historization of simple automated processes. Some

Now they have all this historical data and can make decisions about tolerances and process improvement.
examples included data trending and recording as well as comments and e-signatures. The system was minimally connected with the control system via OPC. The other major issue was the MES was customized for each site, and the manufacturers approach is conf igure, not customize for site validation. Achieving the desired level of mistake proof ing would require close integration between the MES and control system. This mistake proof ing approach required the inclusion of complex automated and manual processes with long residence times to be incorporated automatically into the batch records. The project team was comprised of representatives from key departments with overall site

Jim Cahill, writing in his popular blog, Emerson Process Experts (www. emersonprocessexperts.com), relates a story f rom the pharmaceutical industry. Emersons Michalle Adkins shared a story of one pharmaceutical manuf acturers journey to justif y workflow technology to reduce deviations, eliminate redundant work, and improve production efficiency. The existing method of operations included paper batch records and manual data transcriptions throughout the work process. As a result, batch release times were not optimal due to the time involved with paper record reviews by

M pharmaceuticals

istake proofing

leadership sponsorship. Team members represented Operations, Quality, IT, Engineering, Automation, Plant Management, Corporate Management, and Validation departments. A key part of the process was the delivery of a prototype to visually show how mistake proofing could be accomplished and how the requirements could be realized. The team followed the Operational Excellence process and involved members f rom the corporate automation and information technology (IT) teams. The prototype timeframe was three months and included the MES recipe integrated with their DeltaV control system. The team included members of Emersons Life Sciences consulting team to provide system setup, proof of concept criteria development, implementation & testing, presentation assistance, and proposal development for project implementation. The Syncade MES applications in the prototype included Recipe Authoring, Electronic Batch Records, Equipment Tracking, Materials Management, Weigh and Dispense, Document Control and Archiving, and the Security and Audit application modules. The process to develop f unctional requirements grew out of an initial draft developed by the manufacturer. Paper records were deconstructed with mapping all of the data entry and parameter fields in the MES and DCS. Definitions were developed for ISA88 unit operations, parameters, recipe-specif ic values, operator text displays, sequencing logic including ON THE WEB
More MES Applications Find more case studies, news, columns and primers on MES and MOM. Visit http://bit.ly/findmes

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From Jay Mellon, vice president at Savigent, Minnetonka, Minn., who blogged (blog.savigent. com) this Top 10 list, edited here for brevity:
Tell me about your product. Where has it been implemented? How it is being used? Will your product fit my business? In asking this question, you are seeking to understand the configurability and adaptability of the vendors product. 3 Does your product comply with Industry standards such as ISA95? 4 Will your product help me leverage my existing MOM (manufacturing operations management) investments? 5 Can you integrate with my other related systems? 6 Is your product scalable and ready to support my Enterprise? 7 Can I use your product or will I need to hire a bunch of IT guys to help use it? 8 How will your product help me drive actual improvement in my operations? How can I know that I am realizing results? 9 How long will it take to implement your product? Can the vendors product be implemented in a matter of weeks versus months? How will the product be implemented? 10 What questions havent I asked that I should be asking?
1 2

manual steps, and signature requirements. These f unctional requirements were reviewed and revised with stakeholders representing each of the functional departments. Based on this iterative process, the prototype was designed, built and tested. Prototype presentations were given to smaller groups by department to allow focused questions and f eedback based on the perspective of the department. A justif ication based on the Operational Excellence process was developed and tangible benefits identif ied through value stream improvements in reduced document handling time, document review time, data

entry time, calculations and document rework. Other tangible benef its included reduced inventory, storage, material losses, and deviations/event comments. Intangible benef its included greater f ocus on true product quality, greater availability of inf ormation and the empowerment it provided staff members at all levels. This approach better organized the information to spot improvement opportunities including the identif ication of situations to apply Process Analytical Technology (PAT) methods. The benef its were quantif ied and return on investment (ROI) calculations were perf ormed f or

overall project justification. So, is all this workf low sof tware? If it improves the process and the transfer of knowledge, yes. Dan OBrien, Honeywells director f or collaborative sof tware solutions in Phoenix, explains it this way: Workf low is a layered-up IT word. Were making investments that use workflow as a pillaras, say, part of the approval process or automatic notices. Lots of applications have work sequencing or workf low built in. It also encompasses knowledge capture. This has people working to the process thats documented, instead of by memoryknowing theyre doing the right thing at the right time.

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It seems like it was not so long ago that there was a serious debate over whether or not wireless sensor networks and wireless communications in general were a technology suitable for industrial applications. If you take a look around, that debate is over.

By David Greenfield, Automation World Media & Events Director

he increased adoption of wireless sensors across industry is due, like most industrial technologies, to solid, practical reasons. Chief among these reasons is ease of implementation (no long cable runs), ability to operate in harsh environments, easy troubleshooting and repair, and high levels of performance. If youve been f ollowing the adoption of wireless sensor networks in industry at any level, youre bound to be aware of their prevalence in the oil and gas and water/wastewater industriesespecially for use in tank farm and wellhead monitoring, where traditional wired communication is simply too costly when compared to wireless. Stories of wireless sensor successes in these applications abound. But what about other industry applications?

Robinson Brothers, a specialty chemical manufacturer in the West Midlands, U.K., has deployed a wireless transmitter on the steam main supplying its plant. The ABB transmitter the company installed uses energy-harvesting technology to make remote temperature measurements without the need f or a power supply connected to the transmitter. Powered by a microthermoelectric generator, which is driven by the temperature difference between the steam pipe and the ambient surroundings, and communicating with the plants control system via WirelessHART, the temperature sensor/transmitter operates without the need for power or communication cabling. Wireless monitoring of the open/close status of gates and doors in large warehouses and outdoor storage and service areas has also grown tremendously. In one example, a Honeywell

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Gate Monitoring | Remote gates for storage areas or access to sensitive production equipment can be monitored with wireless switches like the Honeywell Limitless switch to provide reliable real time updates whether the gate is open or closed.

Limitless switch has been installed on the entry gates of a storage yard used for train cars loaded with a variety of hazardous chemicals. The switch automatically communicates the status of the entry gates to the facility supervisor. Laf arge Plasterboard, Bristol, U.K., is using ABB FieldKey wireless adapters to monitor critical f ield instruments from the plant control room. These adapters fit on existing 4-20mA HART devices to create a wireless means of communication with the devices. In this application, the adapters are used to: verify that the instruments are experiencing no system f aults; check calibrations; and make f ine-tuning adjustments. Like the Robinson Brothers example above, these adapters are energy harvesters and therefore require no external power or batteries. These FieldKey wireless adapters

harvest the energy they need from the existing 4-20mA loop. Fume hood doors in f actories and research labs cannot be closed automatically due to safety concerns. In a step that can lead the way for numerous industry applications, a major university has recently installed a wireless sensor that sends out a notification if a fume door is left open. A wireless switch placed on f ume hood doors communicates wirelessly to a receiver,

Over the next couple of decades, youll see the number of wireless sensors grow by 50 percent or more.
Steve Toteda, chairman of the Wireless Industrial Networking Alliance

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which then sends status data through an existing wired Ethernet infrastructure to a local server. A server program then facilitates cloud access. A cloud message of individual fume hood status is communicated via email, text or smartphone app to notif y someone to physically close the open hoods.

Where the Wireless Networks Arent

Well-established technology

For reasons ranging from safety to the high cost of lost production due to shut downs, the industrial community is a cautious one when it comes to implementing new technologies. In many cases, the technologies commonly deployed on modern plant floors have often been proven over a 50- to 100-year time span. And wireless is fast approaching that mark. Ive heard that acceptance of Wi-Fi in the home is what helped boost industrys use of wireless technology, says Steve Toteda, vice president and general manager of the wireless business unit at Cooper Industries and chairman of the Wireless Industrial Networking Alliance (WINA), but its just the

ireless may be one of those technologies whose wide applicability range takes it seemingly everywhere. But there remain some aspects of automation for which wireless sensors networks are not the best option. At least not yet. In high-speed loops, such as those used for flow and pressure control, battery-powered wireless instruments must balance battery life and data update rates. In cases where battery life is expected to exceed five years, a data update period of 60 seconds may be required. Gareth Johnston, global wireless product manager for ABB, says such a relatively slow update period is not compatible with high-speed loops. Machine control is not so hot for wireless, says Steve Toteda, vice president and general manager of the wireless business unit at Cooper Industries and chairman of the Wireless Industrial Networking Alliance (WINA). A lot of people have looked at this, but machine controls have a different set of characteristics for which wireless is not as well suited in most cases. He adds, however, that using wireless to interconnect machines is a perfect application for the technology. PID control. According to Johnston, trials are currently being conducted for PID control where wireless loops are involved. As with the high-speed loop issue, the PID applications are also limited by the battery life/update period balance. Despite this issue, he expects PID loops to include wireless instruments in the near future.

Air Hood Control | Like the factory and R&D fume hood door example in this article, wireless sensors such as Honeywells Limitless switch hood monitors can also be used on high-performance, variable air volume (VAV) hoods to reduce heating and air conditioning operating costs.

Resources

he following links have information on industrial wireless communication applications and technologies.

reverse. We have wireless products in the field in oil and gas that have been there for more than 20 years. Whether its mining, oil and gas, or water, use of wireless goes back a long ways because it was the only way to get things done. Despite the enormous amount of installed wireless input/ output (I/O) points as a result of all the implementations going on f or more than two decades, one wonders why wireless is often treated by some in industry as a new technology. Toteda contends that the only thing really new about wireless these days is that the standards bodies have f ormalized around the ultra lower power rating IEEE802.15.4. The industrial wireless business continues to grow at 20 to 30 percent a year, and Toteda believes that were still only at the very beginning of the wireless age in industry. Over the next couple of decades, youll see the number of wireless sensors grow by 50 per-

ABB Fieldkey Wireless Adapters http://bit.ly/VvHccm Cooper Bussman on the mix of wireless and cellular technologies http://bit.ly/wifi-cell Emerson Process Management Wireless Applications http://bit.ly/Rq9a3e Honeywell, ISA100.11a and The Wireless Plant http://bit.ly/UsWAF4 WirelessHART Communication in Process Industries http://bit.ly/TCJoaV Wireless Industrial Networking Alliance http://linkd.in/VkaJQC

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cent or more, he says. And thats not just in areas where sensors This combination of technologieswired, wireless and celluare already installed, but in new areas to get information to run larhas really brought wireless to the forefront because youre processes more effectively, and improve safety and production. mixing multiple technologies to monitor pipelines in 20 to Bob Karschnia, vice president of the Wireless business unit 30 kilometer segments. As you do this with several segments, f or Emerson Process Management, said that Emerson has youre ef f ectively able to monitor hundreds of kilometers of seen its oil and gas and chemical industry customers adopting pipelines. In addition to multiple ref inery/wellhead/pipeline the technology at such a rapid rate that installations are now application examples, Emerson Process Managements list of measured by the number of gateways installed, and the number other applications of its Smart Wireless technology includes of operating hours. He estimates that Emersons Smart Wiresugar bin motor monitoring, boiler and heater gas flow, steam less networks, which are based on WirelessHART technology, f low accounting, blast f urnace health, and control network have achieved 1 billion hours bridging, to name just a few. of operating experience across A major pharmaceutical more than 10,000 wireless netmanuf acturer recently decided works. Some customers even to instrument all of its R&D have written practices where equipment, such as incubators they look at wireless solutions and cryo reezers, and conf before wired ones when evalunect them to the companys ating new projects, he said. control systems f or 24/7/365 In discrete manu acturing f monitoring. Because much of industries, Toteda said excitethis equipment has casters, it ment over the possibilities f or was dif f icult to wire them, as wireless sensor networks is due they need to be moved around. to the rise in interest around the This project is still ongoing, Internet of Things (http://bit. Tank Overflow Prevention | This image depicts a tank overflow pre- but there are currently nearly vention application for wireless limit switch networks. As the tank fills ly/IntOf Things). [It] gets the 2,000 pieces of equipment on up, the fluid level forces a change in the position of the limit switch (1 imagination going about all the and 2). The wireless limit switch then sends a signal to the pump con- the companys R&D campus information that can be carried troller to start pumping out the tank to lower the level (3 and 4). When equipped with wireless sensors back in real time, he added. the fluid level drops to a safe level, the switch then sends a signal to over an area of about 1.5km. the controller to turn off the pump (5 and 6). In more traditional automaCommonplace tion sectors like automotive or applications food and beverage, which have If youre working in a f acil- ON THE WEB high-speed indoor operations, ity without a great dealor the wireless networks of ten New Wireless Video New software tool allows you to handle up to 300 gateways and address battery problems. Visit http://bit.ly/awvid098 anywireless sensors in place, deployed are standard grades you may be suspicious about of Wi-Fi with connectivity this articles position that wireless sensor networks are everybetween people and controls rather than sensors and controls. where. To help illustrate how ubiquitous industrial wireless The reason for this, in most cases, is due to the prevalence of sensors have become, the f ollowing are a f ew examples of motors in these environments. wireless sensor deployments that have become so common However, industrial grade, f requency-hopping wireless systhat they could be considered textbook application examples. tems are based on technologies that in an elegant way, assure Wireless limit switch networks are commonly used to prevent theyll work in those environments, says Toteda. the overflow of liquid storage tanks. Their operation is simple: Wireless network advances like ISA100 (promulgated by As the tank fills up, the fluid level forces a change in the posithe International Society of Automation) and WirelessHART tion of the limit switch. The wireless limit switch then sends a make wireless sensors networks a more viable possibility in signal to the pump controller to start pumping out the tank to traditional manuf acturing environments, but the challenge of lower the level. When the fluid level drops to a safe level, the latency remains. Latency in wireless networks is in the tens of switch then sends a signal to the controller to turn off the pump. milliseconds, but that is still too slow for robotic functions that The safety and security of oil pipelines is largely handled by operate in sub-millisecond range. wireless sensor networks, according to Toteda. Were doing For now, wireless sensor network applications are extremely a lot of work in Mexico now to monitor and maintain oil broad, but with fairly well defined boundaries. However, just as pipelines, he says. In these applications there is a hierarchy weve all seen the industrial application of wireless sensors of networking tools with sensor networks being used with exceed expectations over the past two decades, dont be surprised instrumentation on the pipeline itself to capture data and to see more developments push the boundaries even further in transmit it back to the control system via high-speed backhaul. the coming years.
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Does the potential f or f ailure somewhere in your automated process worry you? Will the unexpected downtime and spoilage cost you in money, time and aggravation? If so, perhaps you ought to consult with experts like those at the Center for Intelligent Maintenance Systems (IMS Center) at the University of Cincinnati. Prof essor Jay Lee is concentrating research there on what he calls the worry-free factory. Patrick Brown, the IMS Centers program manager, says, We want you to have all the information available for making the right decisions. This focus is indicative of an important trend among providers of diagnostic and predictive maintenance technology. Researchers at academic institutions and commercial vendors alike have been busy marshalling advances in sensing, networking and algorithms in holistic ways to streamline and automate the necessary flow of information. They have been aiming both their individual and collaborative efforts toward the common goal of improving predictive maintenance. An example is the work at the IMS Center f or installing a prototype of a wireless vibration sensor in the machine tools producing motorcycle engines at the Harley Davidson plant. Because spindle vibration greatly influences the quality of the engines, the manufacturing engineers at Harley Davidson wanted to

monitor the health of the spindle motors so they could take corrective action early. The cutting f luids, chips and motion of the machine make installing wired sensors extremely difficult, so the engineers decided to explore wireless technology. They turned to the IMS Center to solve the important problem of powering the sensor. Not having any wires to connect it to an external power source, the sensor must store its own power. Consequently, energy conservation was a central concern for the project. The sensor has to be turned on at specific times, give out a few lines of data, and go back to an idle state to conserve energy, explains Edzel Lapira, PhD and research associate at the IMS Center. Besides looking for ways to add sensors for gathering prognostic and diagnostic data, Edzel and his colleagues are also working on nonintrusive methods f or monitoring the health of automated equipment. This line of research is investigating how to extract more information from the signals and data that already exist in the machine and its controller. Not only does the approach save the cost of adding sensors and other hardware, but it also permits offloading the computations to another computer on the network or even to the cloud. Industrial robots have been a good application for this approach. Because the multi-axis motion and close quarters makes attach-

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Automation World l November 2012

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ing sensors to these machines quite difficult, researchers at the IMS Center often analyze the torque signals coming from each axis. As components start to go bad, the torque signals change in predictable ways. There is a lot of information in the patterns in these signals and in the relationships among them, says David Siegel, senior PhD graduate researcher. To interpret what these changes mean for the health of the robot, the IMS Center has been continuing to develop statistical-analysis and pattern-recognition tools f or its Watchdog Agent software. The tools can process various kinds of signals to detect faults, diagnose problems and even predict performance. The latest of these tools uses a new technique called trajectorybased prediction, which matches a degradation pattern to previous patterns to determine how far along the degradation trajectory a developing problem is. With this intelligence, the software can predict how much useful life is left in the mechanism, so the user can schedule the necessary repairs. Other tools help the researchers to develop good predictive models when too much data exists. It could be that the duration of the data set is too long, or that there are too many variables, such as in a heavily instrumented system, notes Wenyu Zhao, senior PhD graduate researcher. The challenge in these cases is to figure out which variables are the most relevant to the failure mode or to the overall health of the equipment. GlobalFoundries Inc., a semiconductor manu acf turer based in Milpitas, Cali ., ran into this probf lem when it decided to develop a predictive model f or an electrostatic chuck on etching equipment. Because manufacturing was monitoring about 100 signals and calculating more than 1,000 statistics throughout its processes for control and fault detection, the GlobalFoundries Inc. engineering staf f was overwhelmed. Consequently, they turned to the IMS Center for help in sifting through all that information in a systematic way, and developing the prediction model. The IMS researchers used the data-analysis and parameterselection tools in its software to reduce the signals to a manageable set of about five. By picking the key signals and variables, they were able to generate the prediction model. In the continuous process industries, vendors are developing tools help users to track the health of their field devices from the control room and diagnose most problems before sending technicians into the field. The AMS Device Manager and DeltaV historian from Emerson Process Management, for example, are monitoring and troubleshooting the f ield devices in the

steam-and-solvent process that Calgary-based Laricina Energy Ltd. is using to extract oil f rom bituminous-sand deposits in northeastern Alberta, Canada. Because the f ield devices are smart transmitters equipped with self -diagnostics, not only do they regularly report their status to the device manager software, but they also send alerts when they are having problems. Technicians, therefore, can look at the data from the control room before going into the field. And they can take along what they need, says Russ Ritchie, the now-retired Laricina Energy Ltd. automation project manager responsible for the AMS Suite and DeltaV startup. Ritchie reports that his counterparts in the mechanical group will eventually make use of the predictive maintenance capabilities of the asset-management software. For example, they will be able to be proactive by performing such tasks as vibration analyses on pumps to look for wear, cavitations and misalignments. We on the automation side have put all the pieces in for them says Ritchie. The software and end devices run on the wireless [network], and the plants are already wireless-capable. Vendors specializing in connecting f ield devices to distributed control systems (DCSs) like DeltaV are also offering tools f or monitoring the physical layer of networks and diagnosing developing problems on them. Among the f irst of these vendors was Pepperl+Fuchs of Twinsburg, Ohio, which released its Advanced Diagnostics module about five years ago. Its module ties into an asset-management system and sounds an alarm when it detects deviations f rom a known baseline. This way, the maintenance department can correct developing problems before they take the network down. The release of such products has bridged a gap that had existed in monitoring programs f or a while. End users have embraced f ield bus technology in large part because of the added diagnostic inf ormation that they could get f rom their instrumentation, explains Bernd Schuessler, business development manager f or Pepperl+Fuchs f ield bus remote I/O and wireless Hart products. This inf ormation, however, can get back to a DCS or asset management system only if the physical layer remains intact. Before the release of tools for monitoring this layer, most users could only react to problems in it when they lost communications. They would have to send maintenance into the field armed with handheld tools for troubleshooting the problem. By then, its already too late, notes Scheussler; the process is down.

November 2012 l Automation World

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Tools like P+Fs Advanced Diagnostics Module, on the other hand, alert maintenance whenever a perf ormance parameter exceeds a limitwell bef ore a f ailure has a chance to occur. Using a built-in oscilloscope, engineers and technicians can look at segments of the network and take screen shots of noise, jitter and framing errors on the line. You can see exactly what the signal looks like at all times before you send somebody into the field, says Aaron Severa, a product engineer at P+F. Besides preventing unplanned downtime, this capability saves unnecessary trips, he says. Diagnostics modules can pay dividends in other ways, according to Chris Williams, an electrical engineer in the Controls Technology Dept. at the DAK Americas plant in Gaston, S.C. He has installed several of the modules in a process producing purif ied terephthalate acid (PTA) f or making polyethylene terephthalate (PET), the plastic used for beverage bottles. The installation was part of an expansion in which the company installed advanced instrumentation that used Foundation Fieldbus. Because the process involves various acids that eventually corrode instruments and cables over time, Williams wanted the ability to monitor their health from the control room and streamline their replacement in the field with a quick-change method used by a sister f acility. To avoid the risk of igniting volatile organic vapors, yet permit having up to 16 instruments on each line running the long distance to the field, he specified a combination of high-power trunk lines and the Fieldbus intrinsically safe concept from Pepperl+Fuchs. With this design, the lines operate at full power until they reach a field barrier near the instruments, but outside the hazardous area. From there, they branch out to the field instruments with too little energy to ignite the vapors. To mitigate the risk of a bad line taking down all of the instruments on it and shutting down the process, Williams installed a P+F diagnostics module on every four lines to monitor their health. We installed the diagnostics on our Foundation Fieldbus with the primary intent to catch failures in the cabling systems before they could affect our live instrumentation and process control, he reports. So far, the investment has not had a chance to pay for itself in this way because the cabling has yet to fail, he says. However, the system has more than paid f or itself in other ways: It has been able to prove to instrument vendors and contractors that the DCS and Fieldbus lines are working well and that the problem lies with a field device. The first thing that vendors say is that you have a network problem, notes Williams. I simply show them screen shots of the oscilloscope traces and diagnostic f ault logs built into the advanced diagnostics module to prove that the field instrument is indeed the problem, not the network. At startup, the module caught some termination errors and crossed wires missed during the physical checkout of the system, says Willams. Later, after the process had been online for a few months, it also found corroding wires inside a device not sealed properlylong before the DCS was aware that there was a problem.

While a growing body of users is installing diagnostics technology f or their own operations and maintenance staf f s, others are installing the technologies for use by remote service providers. An example is a recycling plant making packaging material in South Carolina. That site used a beta version of a new ServicePort portal f rom ABB Inc. to gain access to the automation vendors experts, configuration tools, diagnostic applications and other services from afar. The mill had been a user of ABBs DCS for a while and had just installed some of the vendors advanced quality control systems (QCSs). As part of its continuous-improvement program, engineers at the site consulted with their counterparts at ABB after installing the QCSs for help with cutting service costs. The portal seemed to be a way of making those cuts without sacrificing their ability to tap the vendors expertise in optimizing process performance. Through the portal, ABB specialists were able to monitor, troubleshoot and optimize the process remotely. Not only did providing service online generate considerable savings in time and money, but it also has helped the site to increase product quality by reducing variability (the average paper basis weight 2-Sigma is below 0.5 and the average paper moisture level 2-Sigma is below 2). The portal is a concept that grew over 15 years, evolving from the various service tools that ABBs engineers had developed and refined for their colleagues who traveled from site to site troubleshooting problems on automated equipment. The tools automated the collection of data from process control systems, as well as its subsequent analysis. Although the software tools and associated hardware were originally designed to go to the job, their developers realized that service technicians could access and analyze the data remotely just as easily if the hardware were left at the customer site. Rather than building unique hardware, we developed a common infrastructure that interfaces nicely with anyones DCS, says Kevin Starr, senior optimization engineer for the Process Automation Service at ABB Inc. in Wicklif f e, Ohio. This has allowed us to leverage our service delivery talent, grow our knowledge base and resolve problems in days that could have taken weeks, if not months, in the past. Remote access also cuts travel costs, making it much more cost effective to offer these services more often on a regular basis. In short, we put the human back into service, notes Starr, and there are advantages of having an expert in the loop. He believes that ABBs decision to buck the trend of completely automating preventive maintenance will reduce the risk of false positivesa risk that has led to the death of many service products. What often kills them are the nuisance alerts triggered by false positives. To avoid wasting time on these alerts, users set alarm thresholds higher and then the inevitable happens: A failure does occur, and no one gets notified, he says.
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Automation World l November 2012

Starr says that automating the human being out of the loop through continuous monitoring is sometimes the right answer, and points to his companys 800xA Asset Monitors. However, there are other instances where degradation over time needs to be identif ied by human experts, he explains. Process degradation is, or can be, more expensive than hardware failures. ServicePort can automate this kind of monitoring by dividing raw data into asset classes and aligning them with key perf ormance indicators connected to alarms that experts adjust based on historical perf ormance. An example is loop optimization, a task that Starr notes was nearly impossible to do on large-scale automation. Now, we can provide ROI-based solutions for thousands of control loops per day, he says. Starr points to a mill making fine writing paper in the Netherlands. The engineering staf f there wanted ABBs help in identifying loop inefficiencies on two paper machines. They gave ABB a list of control loops that they wanted analyzed on each machine, which uses ABBs QCS, DCS and drives and motors. A 10-person ABB team worked together remotely f rom locations in the United States, Canada and India to format, compile and scrutinize the data that they collected through ServicePort. The performance problems found by the service team ranged f rom oscillations to interactions. The team members also learned which key perf ormance indicators were stable and which were not. Hence, they were able to provide the mills engineering staff with action items for improving the process.
For More Information: ABB www.abb.com Emerson www.emersonprocess.com IMS Center www.imscenter.net Pepperl+Fuchs www.pepperl-fuchs.com

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rtur Theis GmbH & Co. KG of Wuppertal, Germany has decades of expertise in the field of manufacturing folding cartons for pharmaceutical products. With one of its latest machines, the company affixes the high-quality packaging with different identification and information carriers. These include labels with one-dimensional codes, genuine lettering and holograms, as well as bollinos (Italian f or coupon or trading stamp,), which are pharmaceutical stickers that can be partially or completely removed from the packaging. The new machine can affix labels, stickers, and bollinos to up
Automation World l November 2012

to 200 different types of folding cartons and check that they are in the correct position. To ensure that every sticker is accurately in place, Artur Theis uses an intelligent vision system with integrated pattern matching technology to check the positioning. Zertrox GmbH & Co. KG of Aachen implemented the imagebased testing station for the machine. Zertrox specializes in measurement and control technologies. The company is a systems integrator working with Cognex, maker of the vision system, to assist companies in the design, development and operation of PCbased measuring and image processing systems and laser controls.
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Max pattern matching technology that determines all of the important position values without errorseven under variable lighting and position conditions, and despite changing angles, sizes and shading.

Lighting technology is key

The illumination of the testing station is provided by an LED ruby light. It helps the In-Sight Micro 1400 with PatMax vision technology accurately identify labels at volumes of up to 40,000 cartons per hour. Photo source: Cognex

Better than the human eye

In the past, Artur Theis performed the inspection of product characteristics with the human eye. However, the increased level of automation in the pharmaceutical industry made it much more difficult to inspect packages for important information and data carriers. In addition, affixing additional information on the packaging requires far greater precision than the human eye can provide. Pharmaceutical manuf acturer routinely need to include the use-by date, product and lot numbers, as well as information for healthcare providers such as health insurance funds. If the labels and stickers are not perfectly aligned to the central features of the folding cartons, then the additional information cannot be applied correctly. The Cognex In-Sight Micro 1400 intelligent vision system with PatMax pattern matching technology is integrated into the new Artur Theis machine to check the exact positioning of the labels. The In-Sight Micro 1400 provides extremely high repeat inspection accuracy within specif ied tolerances, and identif ies possible defective products so they can be reliably removed. One of the biggest challenges in this process was the identification of the labels at extremely high volumesup to 40,000 cartons per hour. Only the In-Sight Micro 1400 with PatMax was able to do the job at the speeds needed. Due to the large variety of products with very different label shapes and colors, it could not be assumed during the system design that all of the boxes would reach the testing station on the conveyor belt with the same position accuracy. The InSight Micro 1400 intelligent vision system had to orient itself to certain predefined geometric features of the cartons in order to set and precisely determine the position of the labels and stickers in relation to it. This process was made possible by the image-based Pat-

The illumination of the testing station is provided by an LED ruby light. The trigger pulse f or the In-Sight Micro is provided by a f luorescent sensor. This sensor recognizes the outer edge of the f lat boxes using the f luorescent properties of the box in contrast to the non-fluorescent material of the conveyor belt. In selecting the In-Sight Micro 1400, the packaging experts of Artur Theis were also impressed by its small size (30 x 30 x 60 mm). The complete and f ully self -contained system is particularly well-suited to measuring, guiding, inspecting, counting and identifying products on fast-moving production lines. It also offers particularly flexible mounting options. An important part of the intelligent vision system is the Cognex image processing library. Using this library, the operating sof tware can be used f or an extremely wide variety of image processing tasks. The calibration of new products in Artur Theis new machine, for example, is very simple and can be carried out

In the past, Artur Theis performed the inspection of product characteristics with the human eye. Now the answer is an intelligent vision system. Photo source: Cognex

by the machine operators themselves. For new products, they simply set a characteristic feature of the packaging in relation to a characteristic f eature of the sticker using the Cognex In-Sight Explorer sof tware that comes with the In-Sight Micro. Based on the stored master job, product changes can be perf ormed in just a f ew minutes, even f or completely new folding boxes.
For more information, visit: www.cognex.com November 2012 l Automation World

47

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Engin EEring School

in no VATion S

STUDENTS
Members: l Jason Wintz l Ryan Streu l David Burroughs l Mike Harrington l Aaron Burns l Derrick Andrews l George Hinote; Faculty Advisor: l Professor Brad Harriger

Wireless Automated Assembly

The Purdue Automated Assembly project team has developed an auto-

SCHOOL
Purdue University

EQUIPMENT
Phoenix Contact 802.11 wireless radio l Phoenix Contact ILC 150 PLC l Phoenix Contact safety relay, Ethernet switch and power supply l Bus coupler with two 16 channel input and two 16 channel output modules l Two touchscreen human machine interfaces l Four SMC pneumatic cylinders l SMC multiport pneumatic valve pack l PC Worx programming software l Autodesk Inventor software
l

mated machine to assemble two-piece, customized, plastic injection molded Purdue hammer souvenirs. The machine is comprised of a controls cabinet and the assembly machine. These segments are separate units that communicate wirelessly through a Phoenix Contact 802.11 wireless radio. The assembly machine is designed to produce a plastic souvenir hammer based on customer input to a human machine interface (HMI). Users interact with one of two touchscreen HMI devices (one located in the controls cabinet and the other located on the assembly machine). Order entry can also be done via an iPad app. The customer can choose one of three colors to be applied on the head of the hammer head (black, green, or grey), as well as one of three colors on the hammer handle (gold, blue, or white). Once the colors are selected, the user submits his order using the submit button. The machine then positions

the pneumatic f eeders holding the hammer heads and hammer handles so that two pneumatic cylinders can push the hammer handle into the hammer head. Once the hammer is assembled, a pneumatic robot device retrieves the finished product from the assembly fixture and delivers it to a tray where the customer can take possession of the product safely. Using Autodesk Inventor computeraided design modeling sof tware, the team f irst designed the hammer head and handle, designed and analyzed the injection mold. Next, the students designed each piece of the machine, from the frame/cart system, fixtures and feeders to the complete layout of each mechanical component, pneumatic device and control module. The students then f abricated and assembled everything according to their designs. The programming of the project was completed using Phoenix Contacts PC Worx software and combined several different programming techniques including ladder logic, f unction block, sequential f unction charts, and structured text.
1. Purdues Automated Assembly Team includes (front, from left) David Burroughs, Jason Wintz, Aaron Burns. Second row: Mike Harrington, Ryan Streu, Brad Harriger (team advisor) and Kelley VanBuskirk (Phoenix Contact mentor). Team members Derek Andrews and George Hinote are not pictured.

2
Engineering School Videos

2. The wireless radio connects to the Ethernet switch.

Engineering School Innovations Call for Entries


If you would like to have your engineering school project profiled in Automation Worlds Engineering School Innovations, or you know an engineering school student whose work should be spotlighted, contact: David Greenfield, Automation Worlds director of media and events at dgreenfield@automationworld.com

Watch a video of the machine in action along with an explanation of its components at http://bit.ly/esi015 Also, visit http://bit.ly/ awesi001 for all the Engineering School innovations highlighted in Automation World.

November 2012 l Automation World

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Products
Integrated Valve, Actuator Control Solves Pneumatic System Problems
Reduced energy consumption, simpler installation and maintenance, and easy washdown are the key advancements of a new integrated valve and actuator control (IVAC) cylinder. Working within the same footprint as a standard actuator, the company developed a modular motion control unit that combines the cylinder, pilot and control valves, position sensors and speed regulators in a single integrated unit. By eliminating the tubing and remote valve islands typical of pneumatic operations, the IVAC reportedly reduces the energy costs of compressed air by up to 50 percent, while delivering faster response times. Eliminating tubing also saves space, improves aesthetics and simplifies cleaning. The cleanline version of the IVAC has switches and valve inside a smooth casing and an ingress protection rating of IP 67, making it suitable for food or beverage handling where frequent washdowns are required. The IVAC can be used as a retrofit or installed in existing designs with no mechanical changes. With just one electrical and one pneumatic connection, the IVAC is installed quickly and simply.
Norgren www.norgren.com/us 303.794.2611

Operator Interface Panels with Multiple Communication Options


Two additions to the G3 Kadet series of operator interface panels provide complete human machine interface (HMI) functionality for PLCs, motor drives and other communications-capable devices. The high-resolution, wideformat screens of the new G304K2 and G307K2 panels drive productivity in industrial environments through improved visibility, management and control. The 4-in. G304K2 includes an Ethernet port (10 base-T/100 base-TX) and supports up to four Ethernet protocols from a list of over 70 supported protocols. Two serial protocols chosen from a list of over 150 may also be assigned to the units RS232 and RS485 ports, allowing it to communicate with an unlimited number of disparate devices simultaneously. The 7-in. G307K2 offers a WVGA wide screen with a resolution of 800x480 for organizations who require a larger display. The high-definition display supports 32K colors to provide superior clarity for detailed user interfaces. The panel supports up to four Ethernet and three serial protocols simultaneously. The companys Crimson 3.0 software, which includes access to over 220 communications protocols, comes standard with either model.
Red Lion Controls www.redlion.net 717.767.6961

Upgrade Legacy Digital I/O Systems to Ethernet


The G4D32EB2-UPG and G4EB2 I/O processors allow automation professionals to upgrade a legacy mistic or Pamux G4 digital I/O system on a serial network to operate as part of an Ethernet/TCP-based control system using existing I/O or field wiring. Upgrading a legacy I/O system like this is an economical strategy that preserves the investment of time and money made over many years in the I/O and field wiring. The processors are upgrades for legacy G4D32RS and B4 digital I/O processors, or brains, used in legacy mistic and Pamux digital I/O systems, respectively. When upgraded with a new I/O processor, digital I/O points on the I/O system can be accessed over a standard Ethernet network, and can be included as part of a control program running on the companys programmable automation controller (PAC) or as part of a custom software application running on a PC. The units support multiple Ethernet protocols including OptoMMP, Modbus/TCP, and EtherNet/IP, and a standard TCP/IP interface is used with software development kits and developer toolkits.
Opto 22 www.opto22.com 800.321.6786

November 2012 l Automation World

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Products

Embeddable Wireless Gateway Module


The SureCross B2Q embeddable gateway module is designed for use in building out a wireless sensor network to coordinate multiple machines and processes. Designed for use with the companys Q45 wireless sensor network, it initiates communication with the wireless Q45 sensors and controls timing and configuration for the entire network via: two sourcing discrete outputs; a site survey that analyzes the networks strength and reliability and conveys results through a bi-color LED indicator; DIP switches that allow users to select one of eight defined I/O mapping configurations to automatically map inputs to outputs; transceivers that provide bi-directional communication between the gateway and Q45, including acknowledged data transmission; and the ability to detect lost RF links and set relevant outputs to user-defined conditions.
Banner Engineering www.BannerEngineering.com 888.373.6767

Controllers Gain Ethernet Capability


The Modicon Quantum Ethernet I/O (QEIO) system adds Ethernet capability to the companys line of automation control solutions. Part of the companys PlantStruxure collaborative and integrated automation architecture, this solution was created to ensure high operational availability of processes and improve data flow - key issues for most industrial control systems today. With the additional flexibility of Ethernet, it is free of the limitations of traditional proprietary network topologies. The network design is made easier with optimally sized modular drops and six times more I/O capacity per I/O drop when compared to a well established proprietary S908 network. Network processes remain optimized at every stage of network development. Operators can stay connected remotely through the embedded service ports on the CRA/CRP modules. With the embedded ports, they will also have the ability to optimize their architecture by connecting an HMI screen on a remote I/O drop. Additionally, with Unity Pro software, operators can easily perform maintenance or modification of their installation, including adding I/O modules or additional racks of I/O without stopping the CPU.
Schneider Electric www.schneider-electric.com 847.397.2600

PID controller
The PAX2C is designed specifically for process and temperature control applications. The controllers field installable plug-in option cards simplify configuration by enabling users to use different cards seamlessly to build their own controllers. This eliminates the need to order additional products to meet changing application requirements. A dual-line tri-color display provides at-a-glance visual representation of up to 16 changing alarm conditions with seven programmable color zones. The display is customizable to allow users full access to bar graphs, annunciators, color zones and display mnemonics. The unit accepts current, voltage, resistance, temperature and process signals, and operates on AC or DC power regardless of power polarity. Programming firmware and software upgrades are done using a standard built-in USB connector and the companys Crimson software to support both current needs and future requirements. Suggested applications include food & beverage, plastics, packaging, energy, gas, heat treating and glass processing.
Red Lion Controls www.redlion.net 717.767.6961

Precision RTD Temperature Data Logger


Other features include multiple start/stop function, ultra high speed download, 670,000 reading storage capacity, memory wrap and programmable high and low alarms. The storage medium is nonvolatile solid state memory, providing maximum data security even if the battery becomes discharged. Using the software, starting, stopping and downloading from the unit is simple and easy. Graphical, tabular and summary data is provided for analysis and data can be viewed in C, F, K or R . The data can also be automatically exported to Excel for further calculations. A real time clock ensures that all data is time and date stamped. An optional password may be programmed into the device to restrict access to configuration options. Data may be read out without the password. Suggested applications are in lab, HVAC and R&D in the chemical, water and food industries.
Omega Engineering www.omega.com 888.826.6243

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Automation World l November 2012

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Products

USB Configurable Transmitters


The TT230 series of transmitters and feature universal sink/source 4-20 mA output for easy installation. These isolated transmitters are PC/Windows-programmable via USB for conversion of temperature, voltage and current inputs to sink/source-compatible 4-20 mA control signals. They measure just 12.5 mm wide for high-density mounting on DIN rails and provide a convenient USB connection to a PC for simple, precise configuration using Windows software. Models are available to isolate and convert thermocouple, RTD, voltage or current input signals to a 4-20 mA output. These two-wire instruments are loop-powered and support both source or sink output wiring connections on the current loop with a 12-32 VDC supply. A ruggedized design features -40 to 80 C operation, electrical noise immunity, and surge protection. CE and UL/cUL Class 1 Division 2 Zone 2 hazardous location approvals are pending. Thermocouple units accept eight different sensor types (J, K, T, R, S, E, B, N), as well as 100 mV inputs. RTD units accommodate 2-, 3-, and 4-wire 100 ohm platinum sensors or 0-900 ohm linear resistance inputs. Voltage models convert bipolar signals from 10 mV to 150 VDC with multiple selectable ranges. The current units are widely adjustable to support 20 mA, 0-20 mA, and 4-20 mA DC input signals.
Acromag www.acromag.com Schmersal_AutoWorld_ToBuild 877.214.6267

Stainless Steel Front Operator Interface Computers


These ruggedized stainless steel front operator interface computers with IP66 stainless steel front bezels have been designed for use in: food and beverage, cosmetics and personal care products, pharmaceutical and healthcare packaging industries. The units meet federal regulations Title 21, Sec. 110.80 processes and control regulations requirements in the manufacture of consumer packaged goods. With housings of IP66/stainless steel, or IP65/ aluminum, they feature a lower power Intel ATOM 1.66 GHz N455 processor in a fan-free system. Units are available with LCD displays with high brightness and contrast ratio in 10.4-in. 400 cd/m2, 700:1, 15-in. 400 cd/ m2, 700:1, and 17-in. 350 cd/ m2, 1000:1 models. The trueflat screen and complete overlay in front of the touch panel, along with the stainless steel or aluminum bezel, protects the display from dust, water and accidental contact. The I/O configuration offers flexible design, with a combination including 2x RS232/422/485 ports COM1, 2, 1x VGA port, 2x USB 1.1/2.0 ports, 2x Gigabit Ethernet ports. HDD and CF card are both easily accessible for installation and maintenance.
American Industrial Systems, Inc. www.aispro.com 888.485.6688

10/23/12

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To Build.

Not To Build.

BDF200 FLEX-MOUNTABLE MACHINE-GUARD CONTROL

The Schmersal BDF200 machine door control station helps reduce time of installation and assembly costs with a completely integrated design. The BDF200 with an E-Stop actuator is available with up to 3 positions for multiple pushbutton or pilot light combinations. All wiring is done internally giving users the simplest form of connection to the machine control while the slim design mounts seamlessly to the door frame for a clean look. When combined with a safety interlock switch, the BDF200 gives operators and maintenance personnel enhanced guard door control at the point of entry.
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Products

Carbon Dioxide Detector for Harsh Offshore Environments


This infrared fixed-point carbon dioxide gas detector is wellsuited for monitoring CO2 to detect a loss of containment. It is designed to operate effectively under the rapidly changing temperature and pressure conditions that occur during a CO2 release. It features multiple communications options via 4-20 mA, Modbus, relays and HART, and its non-intrusive calibration helps to reduce maintenance costs and improve uptime. A heated optics feature allows constant operation even in extreme environments, making it suitable for petrochemical oil and gas applications, and the unit has been tested and certified to meet CSA, ATEX, INMETRO and IECEx requirements.
Det-Tronics www.det-tronics.com 800.765.3473

Access to Alarms from Mobile Devices


The TopView Mobile Web App lets users monitor alarms and data values, acknowledge alarms, filter by alarm category, and examine tag details. Released with the companys TopView 6.14, the new app provides access to TopView alarms and all monitored data values from mobile devices. Support for any platform with a modern browser allows phone, tablet, and desktop access to tag data and alarms. The app runs within the mobile browser but appears and operates like an installed mobile application. Because it targets the mobile browser, there is no app to install on each device. And because the app is not specific to the device, it will work on most modern mobile devices including Apple iOS (iPhone, iPad), Google Android, Microsoft Windows Phone, and Blackberry. Since there is no external web server configuration and nothing to install on client devices, a user can be up and running in less than 5 minutes.
Exele Information Systems, Inc. www.exele.com 585.385.9740

Inductive Sensor with 4 nm Resolution


The IPRM 12 inductive sensor offers improved measuring resolution of up to 4 nm. This noncontact inductive sensor has been redesigned for finer resolution, making it suitable for monitoring concentricity and vibration of shafts and for highly precise measurement of manufacturing tolerances and deflections in shafts, leaf springs and levers. Since it is non-contact it will not leave scratches or pressure points on delicate finished products. The sensor features a measuring speed of 1 mm/s, and its high linearity and temperature stability allow extremely precise measurement, while the robust metal housing and protection class IP67 provide excellent durability. With all electronics integrated in its 90 mm short M12 housing, the unit is easier and less costly to integrate into compact machines than measuring systems with external evaluation units. Three versions are available: a high resolution and high linearity sensor; a high resolution, long-range sensor; and a sensor with an extended measuring range upon a minor temperature drift.
Baumer www.baumer.com 800.937.9336

Point-to-Point Fiber Connection for Long Distances


Offering two SFP+ ports and supporting 3R optical signal regeneration, the FCU-5002-SFP+ provides a point-to-point fiber connection for long distance deployment with a reliable and stable link over 10 Gigabit devices. When transmitting long distances, fiber transmission systems can be affected by many factors such as noise, dispersion, crosstalk, etc. This media converters 3R signal regeneration relays or regenerates the optical signal that may have been degraded during the transmission, allowing the signal to reach longer distances without fear of instability or degradation. The unit comes with a five-year warranty, complies with IEEE 802.3ae 10GbaseR, and is compatible with the companys FCURack16 Series. SFP plug and play modules are sold separately, and can reach up to distances of 40 km. The unit comes with LEDs to show link and power status, can run on 5 VDC or 100-240 VAC, 50 or 60 Hz, and consumes just 4.3 W on DC or 5.8 W on AC.
Aaxeon Technologies www.aaxeon.com 877.229.3665

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Products

Instant Network View for Fast Problem Resolution


A new version of the OptiView XG v9 network analysis tablet provides an intuitive, graphical view of network infrastructure to help speed root cause problem identification and resolve issues fast. The new Network Navigator capability reduces the time it takes to understand network issues by instantly and simply displaying network topology and problems. It gives a clear view of who is plugged into what in the network. The Network Navigator draws a line to the server or other device to logically and physically show the connections and allow drill down for further for additional details. The new version of OptiView XG also includes new in-line testing that eliminates the need for an external tap or span port when observing conversations between clients and application servers. This delivers fast and exact insights into real time traffic flows, and visibility into client/server conversations without the need for packet capture and port spanning.
Fluke Networks

Data Logger for Carbon Dioxide, Temperature and Humidity


The TR-76Ui-H is a three-channel recorder designed to simultaneously measure and record CO2 concentration, temperature and humidity. Temperature measurement accuracy is 0.3 C between 10 and 40 C, and 0.5 C at all other temperatures. The overall range is -30 to 80 C. The unit has a CO2 range up to 9999 ppm with accuracy of (50 ppm + 5% of reading) (at 5000 ppm or less), with automatic atmospheric pressure adjustment for the measurement location. Humidity measurements range from 0 to 99% with accuracy of 2.5% RH (at 25 C, 10 to 85% RH) 4.0% RH (at 25 C, 0 to 10% or 85 to 99% RH). At temperatures other than 25 C and = 0 C, add 0.1% RH per degree of difference from 25. Humidity hysteresis: 1.5% RH or less. The unit can store up to 8000 data sets and is supplied with software which enables the user to download recorded data to a PC via USB connection, whereby data from all three channels can be simultaneously viewed in graph or table form.
TandD Corporation www.tandd.com 518.669.9227

Cable Planning Software Works from Controller to Field Level


FieldSys software allows cable laying routes to be configured exactly to scale, and includes routing, database-assisted management of cable routes, and automatic data analysis to accelerate processes, simplify assembly and servicing, and ensure highly efficient system planning. The new software is a field cabling add-on module for EPLAN Platform 2.2. It is based on a 2D machine/plant layout, which can be read into the software in DWG or DXF format, for example. Within the platform, the system can add a to-scale network of routes to this layout and display the possible cable laying routes. This means connections between controller and field components can be planned efficiently and permanently documented. Based on routing information, the software generates comprehensive cable reports.
EPLAN Software & Services LLC www.eplanusa.com 888.375.2668

Products

Monitoring System for Nuclear Power Plants


The 1E qualified CL86 Plus spent fuel pool (SFP) multi-monitor system integrates continuous level, point level and temperature measurements into a multi-variable solution. The system features integrated continuous water level, multiple point level wet/dry indication and alarms, and water temperature sensors, and provides discrete and independent outputs of each measurement for interface with the plant control room and alarm systems. Sensors operate independently from one another to aid in the reliability and accuracy. Designed for both new and retrofit SFP installations, the system consists of a unified probe assembly that is immersed in the SFP and manufactured to the exact length specified for the depth of the application. The sensor uses thermal dispersion technology, and the sensor wires and electronics interface junction box are housed in a rugged metal enclosure that is water-tight and resistant to falling debris. The electronics are remote mounted up to 1000 feet (300 m) away in a stainless steel NEMA rated enclosure for installation wire-up to power and to provide the outputs to the control room.
Fluid Components International www.fluidcomponents.com 800.854.1993

Capacitive Touch Sensor


KT Series capacitive touch sensitive sensors are designed to be used as machine start/stop buttons in the industrial automation, mobile and building automation industries. Sensors use capacitive technology for start and stop actuation, and are available with one of two sensing principles: dynamic and static. Models with the dynamic capacitive measuring principle detect a hand or finger for actuation; the output signal is actuated for 300 ms. This principle allows the sensor to ignore build-up on the sensing face. Dynamic touch sensors suppress interference such as water, layers of ice, or particles that can stick to the sensor face. Even if the operator is wearing a glove, the sensor will trigger. Static touch sensors detect hands and objects for as long as the sensing face is damped. This is particularly useful in twohand control or anti tie-down applications. Static touch sensors also work through glass. Switching status LEDs provide optical feedback. The polycarbonate housing is durable, oil resistant, impact and scratch resistant and carries an IP69K NEMA rating.
ifm efector inc. www.ifm.com/us 800.441.8246

Power Supplies for Charging Secondary Batteries


The HWS-L/BAT series of supplies are designed to charge secondary batteries-Li Ion, lead acid, etc.-used in emergency power backup systems. The units are intended for small to medium emergency backup systems that use rechargeable batteries with a nominal voltage of 24 V or 48 VDC. They can also be used in applications that require a constant current source such as UPS battery charging, wastewater treatment, electrolysis, etc. The units are CE marked and the 600-W unit carries UL, CSA, EN60950-1 and EN50178 safety approvals, while the 1000-W unit carries additional safety certifications per the medical EN60601-1 specifications. Both power levels comply with MIL-STD-810F for vibration and shock. All models conform to EN55011-B, EN55022-B and FCC-B for conducted and radiated EMI as well as EN61000-4 immunity and EN61000-3-2 Class A power factor and harmonic distortion specifications.
TDK-Lambda www.us.tdk-lambda.com 800.526.2324

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Products

Servo Drives with AC Servo Motor


The HD Series servo system solution features a highperformance digital servo drive with a high-precision AC servo motor. The combined servo drive and motor are optimized for performance, offering advanced functionality, high power density, and seamless commissioning in a cost-effective package. The series incorporates a new current loop design that achieves a frequency response of up to 3 kHz, and an auto-tuning function that performs optimal configurations and minimizes position error and settling time. In addition, an active nonlinear anti-vibration algorithm eliminates vibration in highly flexible resonant systems. Additional features include STO (Safe-Torque-Off), 16 bit analog input, fault relay, secondary feedback, encoder simulation, adaptive feed forward feature, PWM manipulation and more. The series comes with ServoStudio GUI software, which includes a setup wizard for simple drive-motor configuration. Connectivity to controller is through analog command, Pulse & Direction, CANopen, and EtherCAT; Profinet connectivity is planned. Torque ratings range from 0.16 N-m to 28 N-m, max speed to 6,000 rpm, and motor power rating of 50 W to 4.5 kW. Input voltage can be 120/240 VAC, single or three phase, to 400/480V three phase.
Servotronix Motion Control www.servotronix.com 866.561.7554

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Exchange CAD Design Data


Briefcase Browser aids information exchange for product design and validation by globally dispersed teams. Part of the companys Teamcenter product lifecycle management (PLM) software, this package enables OEMs to efficiently share CAD design data with suppliers who do not have the same software package, allows fast onboarding of suppliers for design data exchange to minimize lead times, reduces costs to the supplier base by providing a low install, low overhead tool for CAD design data sharing with OEMs, and reduces administration overhead at OEMs thanks to automatic import and export of product data. The software enables companies to efficiently manage and exchange product and cost data with their supply chains, even with suppliers that dont use this software. The platform provides a single source of data and streamlined processes across the extended enterprise.
Siemens PLM Software www.siemens.com/plm 800.498.5351
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Products

RFID Processors Combine Low, High Frequency


Using a new generation of RFID processors, the BIS V RFID system maximizes flexibility by providing a single device for both low frequency 125 KHz and high frequency 13.56 MHz read/write heads with an IO-Link master port. Combining up to four-head capability on both frequencies with local analog, valve manifold or I/O access/control provides a solution for many types of RFID applications. The BIS V system also allows users to draw on a single processor family with a wide array of read/write head and RFID tag options for both manufacturing and logistics solutions. It provides a functional display, status LEDs and a USB service interface. The BIS V offers these additional functions: four asynchronous 125 KHz and 13.56 MHz read/write antenna channels; LCD display with control buttons for setting and displaying the network address and data carrier/tags UID; an integrated IO-Link master port for connecting discrete or analog I/O, or valve manifolds; industrial IP 65 rated metal housing; intelligent power plug option for saving parameters on the device; flexible mounting options for hard-point or DIN rail.
Balluff, Inc. www.balluff.com 800.543.8390

Smart Displacement Sensors


The Gocator 1100 and 1300 series are aimed at automating non-contact distance measurement processes and real-time closed loop control. The sensors perform high speed dimensional measurements, such as height and thickness or surface roughness with scan rates up to 32 kHz (10 kHz for the 1100 series), which make them suitable for real-time closed loop control. They measures at high resolution over ranges up to 2 m. Scalable to a multi-sensor system, they connect to PLCs using industry standard protocols, while an open source SDK provides user specific custom application development software development is not required, and the units use web based interface found in the companys Gocator Profile Sensors. Units are pre-calibrated, and integrated laser and optics that deliver measurement out of the box. They provide laser measurement and data processing in one unit, with no additional hardware required to generate decisions. Class 2m, 3R, 3B laser options are optimized for different types of applications The housings are rated IP67 for industrial environments.
LMI Technologies www.lmi3d.com 604.636.1011

Wireless Sensor
The SureCross Q45 Remote Device (RD) model operates with isolated dry contacts. The latest addition to the companys line of wireless sensors, this unit is capable of interfacing with isolated dry contacts or PNP outputs, allowing the unit to interface with almost any digital sensor. It also features a mode in which it interfaces directly with NAMUR inductive proximity sensors. In addition, the unit delivers the longest lifetime in this series of sensors, using less than 100 A of current for battery life of five or more years depending on the application. The sensors operate in the 2.4 GHz ISM Band radio and meet world-wide standards, with a range of 3,000 ft (1 km).
Banner Engineering www.BannerEngineering.com 888.373.6767

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IT VIew

Industrial Software: Buying Versus Building


The question of whether to purchase commercial of f -the-shelf (COTS) sof tware or to build a custom solution often arises. In the late 1970s through early 1980s, the idea of developing software packages to address the needs of common commercial applications across industries started to take hold. Prior to that, only large-scale enterprises could af f ord the cost of custom developing systems to support standard business applications. In those days, small armies of computer programmers needed access to large data centers in order to deliver what are now standard business applications. Then, software packages for accounting/financial, inventory, purchasing, sales order entry and other commercial applications
l What

Organizations that make their choices of suppliers/partners based on completeness of vision and overall commitment are experiencing success.
were available on just about every mainf rame or minicomputer out there. And the world changedinstead of custom development as the norm, the trend changed to buy rather than build, if the needs could be met. Marketplace rationalization took place and a company out of Germany f ounded by five former IBM engineers called Systemanalyse und Programmentwicklung (System Analysis and Program Development)better known as SAPbecame the market leader in enterprise software. The difference today with enterprise resource planning (ERP) and manuf acturing execution system (MES) sof tware is that one all-encompassing automation and/or MES solution does not exist. With no dominant player in the MES space, making choices becomes difficult and certainly not obvious. So when it comes to choosing between buying versus building an MES solution, the answer (as you would expect) is it depends. It comes down to how an organization would respond to the following questions: ON THE WEB
Multiple MES Systems This case study examines how to harmonize disparate MES systems after a merger or acquisition. Visit http://bit.ly/awapp006

is your MES strategy? What is your roadmap? What is the timing for delivery? l Is there an enterprise standard that the organization is following? l Is the application under consideration strategic? Unique? If so are the resources (financial and people) available to provide support/enhancements over the long term? l Are there collaboration opportunities with existing partners/ vendors? If so, do they see broader marketplace value? l Are your requirements going to remain static or change in the future? Scalability, standardization and roll-out requirements need to factor into the decision. l And, I know it sounds simple but are there solutions commercially available; better yet, are there choices? Organizations that make their choice of suppliers/partners based on completeness of vision and overall commitment are experiencing success. They realize that COTS MES software is an evolution and is not fully baked. Influencing outcome is key. But, how should you evaluate whether to go custom or COTS? My advice is to clearly understand what is available in the marketplace before embarking on a custom development effort. To me it boils down to a few basic criteria: l Is what you are doing from an MES perspective truly unique, or do you achieve value on how the system is used as opposed to how you get it? l Are you prepared to divert resources from your core business to the development and maintenance effort (and it isnt just technology peoplethe business must be fully engaged)? l Have you analyzed the total cost of ownership of custom vs. COTS? l Does building a custom solution give your organization a competitive advantage? Be practical in your evaluationalthough COTS MES is much f urther along than years past in terms of reliability and multifunctionality, products are still evolving. If COTS is the route you choose, be prepared to stay engaged with your selected partner and to drive your program toward success. MES will never be implemented by checking a tick-box or through simple configuration; your manufacturing operation will still need to be modeled against your MES requirements, and its important that you are committed to guiding the process with your partners.
John Southcott, jsouthcott@brocksolutions.com, is Chairman

of the MESA International Board and co-CEO of Brock Solutions, Kitchener, Ontario, Canada.
November 2012 l Automation World

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Integrator

VIew

Test Stand Replicates Extreme Personnel Conditions


Firefighters and fighter pilots lives depend on

ON THE WEB
Integrator Insights Find more integrator view columns on the changing role of integrators in todays manufacturing environment. Visit http://bit.ly/slant103

the temperature control systems built into the protective clothing that makes working in extreme conditions possible. When a developer of personal cooling systems needed an automated test stand to test their products in harsh environments, it turned to Viewpoint Systems. Aspen Thermal develops microclimate conditions systems, including miniature cooling systems that circulate water inside protective clothing and keep the bodys core temperature within saf e limits during exposure to extreme temperatures. Aspen Thermals miniature cooling system, based on a vapor compression cycle and a miniature rotary compressor, contains a small DC motor for variable operation of the compressor to meet the load demand. The miniature refrigeration unit chills a heat transfer liquid (usually water), which is circulated to a tube-lined garment worn by the user. A custom digital control system maintains the circulating liquid temperature at the user-specif ied setpoint by varying the compressor speed.

Range of conditions

Aspen Thermal needed an automated test stand f or its personal cooling system f luid conditioning module (FCM) that would demonstrate the actual performance of each FCM at the rated load over a range of operating conditions. A fluid conditioning module must maintain the desired water output temperature at multiple setpointsregardless of the ambient temperature or the actual cooling load. The FCM test stand is designed to gather cooling perf ormance, at the rated load, over a range of operating conditions. A thermal test enclosure provides the stable, repeatable ambient temperature environment f or the FCM. A liquid circulating loop (LCL) provides the variable cooling load f or the test stand. Sof tware proportional-integral-derivative (PID) control loops maintain the enclosure temperature at the desired ambient setpoint by controlling the pulse-width modulation (PWM) and maintaining actual heat load at the desired setpoint. Viewpoint Systems built a custom application using National Instruments LabView and its own toolkits to perform automated sequencing, control, measurement, analysis and reporting. The test

Setpoint profiles can be quickly created, edited, and deployed to support changing test requirements or experimental testing.

application starts the LCL pump and heater, energizes the FCM condenser fan, turns on the FCM, and starts the PID controllers. A setpoint sequencer begins the test sequence, waits for each setpoint to stabilize, and gathers the test results. At the end of the sequence, the test application shuts down the PID controllers, the FCM, the LCL, and prints the final test report. The application was developed and implemented by using NI LabView and a layered model view controller (MVC) architecture f ramework was tailored to Aspens specif ic test stand requirements. A tab-delimited text file drives the setpoint auto sequencer. Setpoint prof iles can be quickly created, edited, and deployed to support changing test requirements or experimental testing. Viewpoint Systems dBaser database toolkit reads test stand configuration data from a Microsof t Excel worksheet, directly into native LabView data types. This file contains all the specif ic inf ormation while allowing for a high degree of application flexibility. Complete snapshots of all test results are time-stamped and written to the Excel results file using the dBaser toolkit. The final hardcopy test report with a graph is created by Excel and shipped with each completed FCM. When the client decided to switch from thermocouples to resistance-temperature detector (RTD) sensors, the conversion was quickly implemented: change the sensors, swap hardware I/O modules, and reconfigure the device and channel model parameters in the Excel worksheet. No code changes were required. Aspen is now able to test a completed FCM automatically under all desired operating conditions to ensure compliance with performance specifications. The MVC architecture provides the necessary perf ormance, saf ety and f lexibility required f or demanding test applications.

Jim Campbell, jac@viewpointusa.com, is president of Viewpoint Systems, which specializes in automation and control of measurements and is a member of the Control System Integrators Association. Visit www.AutomationWorld.com

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Automation World l November 2012

Ent Erpris E ViEw

Overall Equipment Effectiveness: Benchmark Data by Industry


OEE, or overall equipment effectiveness, is an important metric for many companies initiatives in operational excellence. There are many different definitions of OEE, but it is largely understood to be a composite metric based on three different areas of a particular assets performance. These three areas are: Availability, Efficiency, and Quality, resulting in the OEE formula of Availability % x Efficiency % x Quality% = OEE The dif f erences between OEE f ormulas lie in how each of these three terms are measured, so it is important to be precise in this regard. At a high level, it is helpful to think and talk about OEE in the following way: l First, OEE measures how often an asset is available when it should be producing product for a customer. l Second, when an asset is producing product f or a customer, OEE measures how close the asset is producing to its theoretical maximum. l Third, for those products that are produced, OEE measures the percentage of products that are produced within quality specifications. At LNS Research, we have been collecting data f rom our industrial client base on people, process, metrics and technology. As of September 10, 2012 we have now benchmarked over 350 companies across a number of different strategic objectives, metrics and operational excellence capabilities. Our goal is to benchmark over 1,000 companies by the end of the year and make this data available to our clients through an interactive benchmark data web portal. Through this portal,

clients will be able to compare their performance to their peers using metrics such as OEE, On Time and Complete Shipments, Successful New Product Introductions, and Cost of Quality. For now, the chart on this page shows the distribution of performance in OEE across a number of different discrete manufacturing industries. Here are a few important observations by industry: Aerospace and Defense has the lowest median performance but also has a broad distribution, with performance well above the median in the middle two quartiles. There is lots of room for improvement on average, but also some impressive performance out of the top quartile. Semiconductor also has a low median but a much tighter distribution. As an asset-intensive industry, all semiconductor companies could improve profits by improving asset utilization in OEE. Automotive performance with regard to OEE is surprisingly low compared to all respondents, as well as to some of the other performers. There is also an impressive distribution of performers well into the top and bottom tails in performance. As with aerospace and def ense companies, there is lots of room f or improvement among some automotive companies. Electronics is dead even with the median for the overall population. However there arent a lot of companies performing at the median; rather there are large groupings around 90 percent and 70 percent. Industrial Equipment is a leading industry in OEE and it impressively outperforms other discrete industries like aerospace and automotive. An impressive share of respondents is in the top two quartiles and is performing above 90 percent. Medical Devices is the real surprise This shows the distribution of performance in OEE across a number of different discrete of this analysis. Many people assume manufacturing industries. Source: LNS Research since it is a highly regulated industry with high margins that ef f iciency is low. Our analysis shows otherwise. More analysis is needed to determine why performance is so strong, but our guess is that it has to do with maturity around systems managing quality and change control. Companies in this industry are at a severe competitive disadvantage if performance isnt well above the overall average.
Matthew Littlefield, matthew. littlefield@lnsresearch.com, is president and principal analyst for LNS Research based in Brookline, Massachusetts, which has issued a research report on Taking Overall Equipment Effectiveness beyond the Plant Floor. November 2012 l Automation World

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Industry

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Wireless Sensing Benefits from New Technology and Standards


Wireless sensing is the most important new technology

in process measurement to appear in decades. For this reason alone it has attracted the sustained attention of ARC Advisory Group and other industry analyst organizations. While growth of wireless measurements in industrial applications has proven to be slower than most forecasts, wireless communication continues to grow much faster than the overall automation market. Looking at the changes in wireless sensor networking (WSN) during the past year, ARC is most impressed by the greater maturity of the industry along with significant new technical achievements. We believe that both will spur market growth because they

published f or years, most commercial WSN applications have used non-standard medium access (MAC) rules to optimize the performance of their own networks. WirelessHART, ISA100.11a, ZigBee and IPv6 sensor networks all depended on a customized MAC layer to achieve low power consumption and reliable endto-end message delivery. This limits the value of the IEEE standard, because applications needed their own specialized MACs. IEEE 802.15.4e makes important changes to the def ined MAC layer. It creates a standard and fully defined MAC that can support diverse types of networks. This includes 6LoWPANcompressed IPv6 networks. It also supports the synchronized

Using a chipset that conforms to IEEE 802.15.4e is a big benefit for industrial customers, since it helps drive down power consumption by roughly 50 percent with each new generation.
enable a much larger set of customers to be well served. Recent events help illustrate how these developments have changed (and will continue to change) the wireless sensing market. Greater WSN industry maturity has come through a steady series of acquisitions. At present, almost all the pioneering sensor-networking ventures have been acquired by much larger companies. Most of the acquirers are well-established semiconductor suppliers, and virtually all the f abless WSN firms have now been snapped up. Hayward, Calif .-based Dust Networks has become one of the most recent, acquired in late 2011 by specialist Linear Technology Corp. of Manhasset, N.Y. Fortune 1000 companies must carefully manage the technologies they employ if they are to meet their customer expectations. A technology that is sourced from a group of venture-stage fabless semiconductor firms represents a major supply chain risk to global firms whose customers expect product support for many years going forward. Today, the list of WSN suppliers no longer represents an exceptional risk to the supply chain of global giants like Emerson, GE, Honeywell and Siemens. WSN has also grown technically during the past year. The most important development is the completion of the e revision to the IEEE 802.15.4 standard. Though the 15.4 standard has been ON THE WEB
Technology Trends From Wireless Sensor developments to the future of industrial computing, stay informed on the latest technology developments. Visit http://bit.ly/awinnovation

TDMA network properties used in industrial low-power applications (e.g., WirelessHART and ISA100.11a). Finally, 15.4e accommodates extensions, so that these diverse networks (as well as future ones) can extend the standard MAC without violating the standard itself. This decouples WSN development f rom the three- to f our-year-long IEEE standards development process. It will give the IEEE standard greater value and a much longer lif e, enable greater interoperability among WSN silicon and network stacks, and enable future WSN technologies to leverage an existing and fully standard MAC. The new standard was developed largely from Dust Networks technology, with extensive and enthusiastic contributions from many major suppliers, notably including Siemens. Dust now employs its most recent chip design (which conf orms to 15.4e) in both WirelessHART and IPv6 products. Using the latest chipset is a big benefit for the WirelessHART (industrial) customers, since it helps drive down power consumption by roughly 50 percent with each new generation. In battery-powered industrial devices, this provides an energy surplus, enabling devices to have longer life and/or to serve in applications that previously consumed too much battery power. Another area to watch may be energy harvesting. Though energy harvesting represents an ongoing technical challenge, it is a very active development area within Linear Technology Corp.
Harry Forbes, hforbes@arcweb.com, is senior analyst at ARC

Advisory Group in Dedham, Mass.


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Automation World l November 2012

November 2012

Supplement to Automation World

Tablets and Smart Phones Poised to Makea Big Impact

Industry Interrupted

Building a Better HMI Industrial Networking Desires Revealed Products

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Mobility Disruptive to the Way We Operate


I
m sitting at another industry technology conference. Speaker asks, How many of you have a smart phone? Almost everyone. How many have a tablet? About two-thirds. About eight years ago, Tony Perkins started a Website/company dubbed AlwaysOn predicated on the supposition that people were always on the Internet. He was early. But now, most of us are always on. We can check email, flight status, Twitter, Facebook, LinkedIn, messaging, sports scores at almost any time, any place. These devices are migrating into our plants and factories whether management and information technology departments endorse it or not. Like many technologies, people are doing it, so management is better served figuring out how to make best use of the phenomenon than trying to bar the doors. The same thing happened with PCs in the mid 80s and throughout the 90s. The enabling factor in the enterprise is WiFia technology that connects devices to the Ethernet network wirelessly. The other enabling factor is cellularmobile phone technology. Combine those, and workers are more empowered with information than ever before. And they can get out of the control room or maintenance building and into where the action is. That can only make things better for productivity.

Gary Mintchell Co-founder and Editor In Chief

Recipe for Ethernet | This feature article surveys the basics of an Ethernet TCP/IP network and whets your appetite for further learning. Visit http://bit.ly/awfeat070

Devices are migrating into our plants and factories whether management and information technology departments endorse it or not.

Contents

5 Industry Interrupted: Tablets and Smart Phones Poised to


Make a Big Impact 10 Building a Better HMI 12 Industrial Ethernet Products Desires Revealed

14 An Automation World Survey: Industrial Networking

supplement to automation world

November 2012

INdustrIal EthErNEt rEvIEw

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Industry Interrupted:
Tablets and Smart Phones Poised to Make a Big Impact

Industrial IT teams are likely to rail against the use of mobile devices, but many equipment makers feel they are fighting against the tide to ignore them. Productivity will ultimately determine which side will win.
By Terry Costlow, Automation World Contributing Editor

pple isnt likely to become a player in harsh industrial environments, but its reach is extending into many factories. Tablets and smart phones are becoming a part of the control and monitoring technologies in a growing number of plants. Whether theyre from Apple, the many Android suppliers or other manufacturers, these handheld devices are expected to continue the trend that began when users started toting laptops around. The latest generation of handhelds makes it even easier for operators and technicians to gather data when theyre right next to the equipment. Companies that embrace the use of tablets and smart phones feel theyre continuing a trend that took off when companies started using Ethernet. Automation companies that adopt consumer electronics technologies early will have an edge, says Erik Nieves, technology director at the Motoman Robotics Division of Yaskawa America,
supplement to Automation world

Miamisburg, Ohio. The robotics industry isnt large enough to drive technology, we have to use advances made in other areas. Suppliers throughout the industrial automation field predict that handhelds will see significant growth. Many predict that equipment operators and technicians will hasten the advance by using their own devices instead of waiting for management to acquire tablets or phones. Bring your own device has become a hot topic, says Ben Orchard, systems engineer at Opto 22, Temecula, Calif. Its inevitable that people will bring these devices in, so companies need a set of programs and rules so this can happen without creating big problems. Many information technology teams are likely to rail against the use of personal devices. But many equipment makers feel they will be fighting against the tide. Productivity will ultimately determine which side will win. whether tablets will advance beyond data collection to take over control of equipment remains uncertain. If someone spills solvent on one, its done. And if you add enough protection, you might as well start with an hMI that has a factory-grade IP rating, comments one machine builder. Photo source: Phoenix Contact
INdusTrIAl EThErNET rEvIEw

November 2012

Rather than discouraging personal devices, companies should encourage it, says Paul Brooks, Rockwell Automations business development manager for networks in Milwaukee. If its banned, people will say they cant be as productive as theyd like. It will be hard for IT people to win that argument. The latest generation of handhelds will augment existing systems, not displace them. Human machine interfaces will continue as the mainstay of controls, and notebooks should continue to see use in applications that demand more capabilities than tablets can provide. We do not expect smartphones and tablets to completely replace traditional mobile computers, as some companies will need a more robust solution, says Lisa London, senior product marketing manager at Honeywell Scanning & Mobility. We foresee mixed environments, where some applications will stick with a traditional mobile computer/handheld device and other applications will use a tablet coupled with additional software and enterprise sleds that provide protection and added durability.

To be in the field using the tablet as a calibration device and check the wiring is very helpful. Tablets and smart phones can bring many benefits, but they also bring additional challenges. One is to deal with an almost inevitable occurrence, the loss or theft of a tablet thats been connected to the corporate network. Potential loss of a device can be a big concern, Orchard says. Many products have remote wipe and remote lock if theyre lost. Many also have ways to track the device if its

Wireless networks with uninterrupted coverage will have to be linked tightly with the Ethernet backbone.
lost. It will be interesting to see if something like two-way authentication happens in industrial environments. One way to avoid problems like this is to ensure that users cant download information that could cause problems if it is stolen. One technique is to dedicate handhelds only to data monitoring. Sometimes, these changes may require some upgrades to the existing network infrastructure. One way to protect this data is through virtualization, Brooks says. Instead of a device being a thick device, make it a thin device that can only display information, not store it. Thats doable because most portables have a virtual client. Very frequently, we find that employing virtualization requires an upgrade to the infrastructure, for example fault tolerant wireless LANs with no dropouts. Whether tablets will advance beyond data collection to take over control of equipment remains uncertain. Some proponents feel that it will be difficult to use the latest handhelds in harsh environments unless or until a company figures out how to ruggedize equipment without adding much cost. You need something with an ingress protection (IP) rating. Even if you put a tablet in a nice case, its not IP protected, says Nieves. If someone spills solvent on one, its done. If you add enough protection, you might as well start with an HMI that has a factory-grade IP rating.

Changes to networks and poliCies

o realize productivity gains, network designers and plant managers will have to make changes to their networks as well as their corporate policies. Wireless networks with uninterrupted coverage will have to be linked tightly with the Ethernet backbone. Companies will also have to figure out how to let employees work freely to improve their efficiency. Tablets and smart phones work very well as a dashboard so people can look at live data remotely, Nieves says. Im very bullish on the role apps can play. Any time you can increase access to information about the production system, you get a lot of benefits. These apps democratize data and let users do anything they like with that data. Some apps will come from suppliers, others will be written by employees. Companies will probably want to establish some vetting for programs from individuals. Its

security policies must be expanded when employees use their personal equipment.
likely that app stores that focus on industrial environments will pop up soon, providing a way for companies to pick software that has gone through some testing. Some equipment vendors are already offer apps written for automation engineers and technicians. Weve created an Android app that helps with wiring, says Benson Hougland, vice president at Opto 22. In the past, someone would wire something in a panel, then run back to the controller to see if everything was working right.

proteCting the network


henever new devices come into industrial environs, data security comes into the picture. Tablets and smart phones have many of the conventional security issues related to wireless networking and portable devices. Other threats, such as the employee who is angry and wants to get back at his boss, warrant attention. Password rotation, MAC address filtering, and a sane security policy in the environment should mitigate the risks, says Dan Fenton, control and software marketing specialist at Phoenix Contact.
November 2012
supplement to automation World

INdusTrIal EThErNET rEvIEW

These security policies must be expanded when employees use their personal equipment. These devices bring a much different challenge. Privately-owned handhelds typically wont be authorized nor will they run only companysanctioned software. Perhaps even more importantly, these devices can easily be removed from the facility without any safeguards to protect information thats going outside corporate walls. Security is a huge issue, Brooks says. Not so much virus protection, its more security of intellectual property. If someone uses a personal tablet, you lose the security that comes with a company-owned laptop thats equipped with security. Companies need to figure out how to control information going into and out of the facility. Network developers must integrate security plans for tablets into existing security systems. Of paramount importance is to ensure that these personal devices cant get into the network unless they are carried by authorized users. Once these users are in the network, they must be governed by the protective schemes that prevent users from straying into areas that are outside their purview.

Companies will have to figure out how to let employees work freely to improve their efficiency.
The need for and importance of failsafe authentication is more important than ever, London says. Passwords have become only a part of the security process. Firewalls, multiple device management software and signature tokens are important to the security of mobile devices. Those steps must be taken even when handhelds are used only to monitor devices. When tablets are used to actually control equipment on the floor, managers must ratchet up the level of protection. At the same time, network developers need to make sure that their wireless links meet all the requirements necessary for devices that manage equipment. For tablets to take control of equipment, you first need a mission critical wireless infrastructure so you can be confident that a critical message will arrive in a timely manner, Brooks says. You also need security. Typically, if youre not employing encryption and other security steps at all times, you shouldnt let tablets and smart phones take command. Building in the necessary security isnt something to be taken lightly. In this era of open networks that go throughout

ON THE WEB
Future of Industrial Computing In this video, Gary Mintchell, Co-founder and Editor in Chief, ponders industrial computing and thin clients. Visit http://bit.ly/awvids080

the enterprise, its increasingly important that IT departments get in on the act. IT personnel have typically been involved in wireless communications and handheld devices for a fair while, so they will usually have a fair amount of experience and knowledge in these areas. Industrial folks often create their own networks so IT is not involved, Orchard says. When youre putting industrial information into the ether with wireless, security is always a potential stumbling block. It takes a different set of skills to put together a secure wireless network, so its important to get IT involved. Once employees start using tablets and phones inside the facility, theyll doubtless want to use them when theyre in other areas. Managers who are traveling or at home can easily tap into corporate networks to check on things or troubleshoot problems. But it takes some planning to grant access only over secure connections. One of the best situations you can have is to provide security by using a virtual private network (VPN), Hougland says. That provides a single point of entry and it provides secure http traffic. While developers stress the need for high levels of security, many note that the job may not be as daunting as it can sound. Many aspects of security are already built into network schemes, so users dont have to do a lot beyond setting up their parameters. Thats beneficial for network designers who might look at the many facets of protection and decide its easier to just skip it completely. Theres a lot of security built into wireless networks, Hougland says. Its not absolutely bulletproof but most include protocols like Wi-Fi Protected Access 2 (WPA2). Another thing people can do is to use https if youre going to use http at all. That prevents snooping. The necessary level of security can also be lowered by limiting the access level of tablets. These handhelds can be set up so they are limited to viewing data, not changing any parameters on the equipment. When theyre only used as monitors, the security requirements are far lower. If the tablet is simply providing insight into published data, security is not an issue, assuming companies dont make public information they dont want seen, Nieves says. If you use tablets in the HMI, security plays a major role in the design considerations. Others note that phones and tablets usually use their own operating systems, so many viruses and other maladies wont move onto industrial architectures. Viruses written for Apple or Android platforms generally wont impact other operating systems. But thats a general rule, and it may change as tablets and PCs begin sharing more technologies. Many of the threats from common mobile devices wont transfer to PC operating systems, due to different architectures. Whether this will change as the two combine, such as the case of Windows 8, will have to be watched closely, Fenton says. Regardless of what happens there, some sort of training for operators to prevent social engineering attacks will have to be undertaken. o
November 2012
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INdustrIal EthErNEt rEvIEw

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Building a Better HMI


Web-based technologies and interface design are just two areas in which consumer electronics technology is driving changes in industrial machine interfaces.

ortable equipment is transforming the way industrial workers monitor equipment and gather data. But for the foreseeable future, these handhelds will augment, not replace, the human machine interfaces (HMI) that are tightly linked to industrial machines. These HMIs are advancing rapidly, using color displays, touch input, enhanced programmability and other technologies to make it easier for operators to set up and use complex machines. One of the most dominant trends in these controls is their utilization of commercial technologies. As theyve done with the Ethernet communications that link systems together, developers are utilizing the huge volumes and vast knowledge base of electronics used by consumers, students and businesses.

displays have been overused. If there are too many options or too much information on the screen, it can create confusion instead of simplifying operation. When HMIs and portable equipment use imagery that isnt identical, it can be even more confusing. HMI screens have gotten so colorful and complex that theyre difficult to use, says Benson Hougland, vice president at Opto 22, in Temecula, Calif. Were working on techniques that make it easier for engineers to create screens that have different targets, like PCs, smart phones and tablets. Its kind of like an app store. Making an HMI thats easier to use is Opto 22s number one R&D project. One way to reduce confusion is to let operators set up functions that are specific to their jobs. Developers are taking many different paths to help operators create these shortcuts.The code that works behind the scenes lets them make changes without impacting reliability. The software engineers who work on this code understand both the need for personalization and the requirement for reli-

software engineers who work on this code understand both the need for personalization and the requirement for reliability.
Were seeing a lot more Web-based technologies, says Gordon Daily, product marketing manager at Rockwell Automation, Milwaukee. Many HMIs offer shortcuts, navigation history and other elements people are familiar with from Web browsing. HMIs also utilize commercial hardware, ranging from the microprocessors that work in the background to displays and inputs that operators see whenever they use the machine. Improvements in low-cost flat screen displays continue to help operators get more input without sacrificing readability. High brightness, high contrast, and multi-touch displays are certainly making operators lives easier. Higher resolution displays make reading and fitting a higher level of detail in graphs and images much easier, says Dan Fenton, control and software marketing specialist at Phoenix Contact, Harrisburg, Pa. However, some developers feel that the capabilities of these

ON THE WEB
All About HMI Find the latest news, trends, case studies and all things HMI here. http://bit.ly/findhmi

ability, Fenton says. Hiding a button because it clutters your screen might not be possible, but changing how the button looks sure is. This makes certain the operator can always use that button if need be, as opposed to hiding it and then being unable to find it just when its needed. HMI creators are also following another industry trend, the move to develop all aspects of a system simultaneously. Many companies are working on the controls while the equipment is being designed. This ensures that the HMI operates with maximum efficiency. Companies need to focus on the back end code, so that the HMI is more tightly integrated into the system, rather than tacked on at the end, Fenton says. There is, of course, the drive to connect the mobile market, but I think what is holding this back more than anything is the knowledge of how to create a solid, reliable, and secure connection between the user and the machine the user is controlling.o
Terry Costlow is a Contributing Editor to Automation World, www.automationworld.com November 2012
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Profinet Coupler for APAX I/O

the aPaX-5071 Profinet Coupler enables the popular Profinet networking interface to be used with aPaX series I/O modules in remote and distributed applications. It features an integrated 2-port Ethernet switch, allowing for a daisy-chain style of Ethernet networking between multiple distributed couplers. In addition, the flexible nature of the aPaX series I/O allows for high-speed communication backplane to be extended over Ethernet. this allows for I/O nodes to be connected in a line (bus) topology, instead of a traditional star topology, therefore reducing the effort required for wiring and saving installation costs. Most importantly, a single aPaX-5071 coupler can be used to interface aPaX I/O for multiple distributed locations into the Profinet network, thus requiring only one IP address on the network. Advantech www.advantech.com/ea 800.800.6889

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Unmanaged Industrial Switches with M12 Connectors

the companys newest 8-port unmanaged switch models are the lNX800-M12, with eight 10/100tX ports, and the lNP-800-M12, with eight 10/100tX ports and four IEEE 802.3af compliant PoE (Power-over-Ethernet) ports. the switches come with M12 screw-in type connectors instead of the traditional rJ45 connectors. this design is appropriate for applications such as railway, heavy industries, or other mobile applications that require tight and secure connections in order to overcome high vibration and shock while sustaining reliable network service. the switches are compliant with EN50155/50121-3-2/50121-4 (railway applications), can be offered as wide temperature models (-40 C to 70 C) and are enclosed in a rugged IP30 aluminum case for harsher environments, making them suitable for a variety of industrial applications. Aaxeon www.aaxeon.com 877.229.3665

the sEr-3200 enhances electrical power monitoring systems in missioncritical facilities. the latest update (version 2.0) adds major new features and enhancements: up to 32 GB of user-accessible onboard flash memory, operations counters for all 32 high-speed digital inputs, support for dCF77 time-sync protocol, 16 data-log groups to facilitate required test reports for emergency power systems, and more. the units integral web server presents a detailed record of all events, time-stamped to 1-ms resolution-all available over an Ethernet network using a standard web browser. the unit also ensures easy integration into supervisory systems through Modbus tCP, sQl database and web technologies. Cyber Sciences, Inc. www.cyber-sciences.com 615.890.6709

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13

Industrial Networking Desires Revealed


In the last few years, we at Automation World have seen a noticeable shift in attitude among industrial automation professionals about Ethernet and wireless network technologies.
e first started seeing demonstrable proof of this in the Automation World Innovation survey conducted in late 2011 (See the January 2012 issue for results.) In that survey, nearly half of respondents said the incorporation of Ethernet into plant floor systems was the most innovative advance to occur in automation over the past decade. With so many readers citing this development as being more innovative than any other, Ethernets advance onto the factory floor was recognized as the clear innovation winner, in readers opinions. Recently, we conducted another survey to obtain insight into current engineering and management applications and opinions surrounding the use of Ethernet and wireless networks across industry. Nearly 1,000 readers from a variety of industriesranging from automotive, chemicals, and electronics to food & beverage, oil & gas, and machinery/ equipment OEMsresponded to this survey, co-sponsored by industrial network vendor Moxa. In addition to quantifying our belief that plant managers and engineers are not only open to the use of Ethernet, but actively evaluating and installing it for specific applications (see charts), one open-ended question caught our eye. We asked respondents to identify their unfulfilled industrial networking desires. Heres what they had to say: l Connecting to the factory with a smart phone; l Converting process control operator stations to Ethernet; l Connecting work cells and machines to form a SCADA/ MES system; l Remote switching of power distribution networks; l Increased support for Power over Ethernet by more vendors; l Real-time instrument data feeds over Ethernet; l Connecting dedicated safety controllers with Ethernet; l Development of a complete wireless network connecting plant cameras, voice, data and control systems; l Connecting servo drives with Ethernet; and l Implementing IEEE 1588 precision time control. Full results will be published in the December 2012 issue of Automation World and online at www.automationworld.com. o
By David Greenfield, Automation World Media and Events Director

14

INdustrIal EthErNEt rEvIEW

November 2012

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The New Control System Integrator


The Future of the Integration Field and How to Stay Ahead of the Curve

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The New Control System Integrator

The Future of the Integration Field and How to Stay Ahead of the Curve
Integrators are the human face of the industrial automation industry but if you look closer, youll see how their face has changed in light of the ever-changing landscape of information technology.
Control system integrators have long served the automation industry as the technical and mechanical specialists who bridge the gap between people and the machines, devices and software they use. For process manufacturers, the machines, devices and automation software packages are all essential to a successful process but it is the integrator who gets everything to work together. Modern information technologies have transformed how integrators get things done on a daily basis and has even affected the kinds of things they do. Technology is progressing at such a rapid pace that its almost impossible to keep track of it all. Modern information technologies have affected virtually every part of our everyday life from how we communicate, how we relax, how we socialize and especially how The Internet ..................................... page 5 SQL Databases ......................... page 6, 12 OPC-UA ............................................ page 7 Mobile Devices ............................... page 8 Server-Centric Applications .......... page 9 MES ................................................. page 11 PLC Programming ........................ page 11 Networking ................................... page 13 Software Programming ............... page 13 SCADA System Security ............... page 14 we work. Those who cant keep pace are in danger of being left behind.

New World, New Challenges for Manufacturing Companies


The world has changed in terms of how readily we accept new technologies. It took close to 50 years before half of American households had a functional telephone, but it only took about 10 years for the Internet to be in 50% of U.S. homes.

Consumption Spreads Faster Today


Percent of U.S. Households

The graph to the left (from The New York Times, designed by Nicholas Felton) shows the rate of consumption of technologies in U.S. households from 1900 to 2005.

nytimes.com. 2008. The New York Times. 10 Feb. 2008 http://www.nytimes.com/imagepages/2008/02/10/opinion/10op.graphic.ready.html

800.266.7798 www.inductiveautomation.com

It seems that much of the world has simply gotten used to the rapid change of technology and has even come to expect it. One of the major catalysts for technological change has been the Internet because of the way it facilitates the rapid distribution of data around the worldwide community. For businesses, the Internet has made the world both a smaller and bigger place at the same time. Smaller because its so much quicker to communicate with a global audience and bigger because it has opened up entirely new markets that never would have been within reach before. This kind of connection can be a boon for businesses, but it comes at a cost steeper competition. The new business world is more competitive now than ever, and that makes the cost of not staying ahead of the curve for new technology and trends that much higher. The highly competitive manufacturing industry is especially affected by this new global business landscape. Manufacturers have to look for every competitive edge they can get and often have to do more with less in order to compete on a global scale. Top quality control system integrators can be a huge part of helping manufacturers stay ahead of their competition; in fact, they can be the key difference. A forward-thinking control system integrator doesnt only give their clients the control system they need that moment they give them the system that can take their client into the next decade and beyond. A top quality integrator is one who keeps their feet firmly rooted in the solid foundations of their disciplines past, but with an eye fixed on the future.

consider when choosing a control system integrator to hook up their machines, devices and software. For integrators, this paper will help inform them on the latest technologies and trends that are shaping the future of the integration field.

We Asked the Experts


To get this information we went right to the experts themselves. We surveyed a pool of more than 6,000 integrators from various industries around the world. The pool was comprised of a wide cross-section of integration firms, ranging from smaller operations to some of the largest and most successful integration firms in the world.

We asked them two basic questions: 1. Which new technology has most changed the role of control system integrators in the industry today? 2. What skill set will be the most valuable in the future for control system integrators? We found the results of our survey to be informative, insightful, and even surprising. For your benefit the results and responses of our survey have been analyzed and summarized in the form of this paper. Our hope is that this information can be a help to you in making informed decisions moving forward into the future.
The New Control System Integrator 2 | 3
2012 Inductive Automation

Manufacturers & Integrators


With so much riding on successfully charting a manufacturing companys course for the future, its important to know what to look for in a control system integrator, and what the future holds for the industry. At Inductive Automation, part of our mission is to inform and educate in ways that will help move the industrial automation market into a productive future. As part of that effort we have investigated this topic to help prepare manufacturers in knowing what to

The New Control System Integrator

Question 1: What Technology has Most Changed Control System Integration?

In order to know where you are going you have to know where you have been. Its vitally important to understand what technologies have most changed and continue to change the field of control system integration in order to see what direction the field is moving.

For this reason we asked our pool of integrators the question: Which new technology has most changed the role of control system integrators in the industry today? The results and the analysis of each answer are below.

1: The Internet 2: SQL Databases 3: OPC UA 4: Mobile Devices 15% 14% 13%

49%

5: Server Centric Applications 9%


% = Represents what percentage of integrators responded to the question with that answer.

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1: The Internet 49%


Is there anything the Internet didnt change? Clearly the expert respondents of our survey felt that the Internet has had a vast transformative effect on the field of control system integration. At 49%, the Internet was the overwhelming choice by integrators as the technology that has most changed the field today. So what have those changes been, and why are those changes important? Wide Area Networks Wide area networks or WANs were around before the Internet, but they were much more difficult and expensive to create. A WAN is made up of connected local area networks (LANs). These LANs consist of computers and devices that have been networked together on a local level, such as an office. When several LANs are connected across a large area they form a WAN. For most companies, data is the lifeblood of their business; without it, decisions cant be made and things dont get done. The most efficient and secure way to share data across multiple sites is a WAN, but before the Internet, WANs were reserved for only the wealthiest and most technically savvy companies. However today because of the Internet setting up a WAN is easy. You just need to plug into the Internet, adhere to security protocols and get connected. The ease at which this can be done has literally changed the way most companies do business. Its now a standard for companies to have connected networks that facilitate the rapid sharing of data, communications and ideas around the company, no matter where they are. The Web makes it possible for integrators to link multiple sites together into a WAN, even if they are on opposite sides of the world. An operations manager in California can check the status of a production line in a facility in India through a secure WAN right from his desk and see data in real time. Thats a game changer. Remote Access Easy remote access is another major reason the Internet changed the integration field. The ability to remotely access a supervisory control and data acquisition (SCADA) system through Internet technologies such as virtual private networks (VPNs) have opened up new possibilities to integrators. Having the ability to connect from anywhere means that integrators can now develop a new SCADA project, update old ones and even troubleshoot systems for customers around the world all while sitting in their own office. Remote access allows any integrator to offer customers real-time assistance, regardless of location. It has also greatly widened the reach of integration firms, regardless of their size. The Internet also gave integrators the ability to offer remote access to clients. Giving them the ability to access their control systems from another facility, their home or the field. Customers have come to expect this kind of access to their data, and as a result, it is an essential skill for integrators to know how to provide remote access to clients. Fortunately the Internet has also made it easier for integrators to search for support topics and immediately connect with vendors, which makes it easier to find solutions for their customers. Thanks to the Internet, having a huge in-house library of user manuals is no longer necessary because it is fast and easy to find support documentation for new and old products. The Cloud The cloud is a concept entirely born out of the Internet. Its the idea of using large arrays of remote Internet-based servers to store and handle data and server applications. The cloud concept is that a company has its server applications and data saved off-site, on the servers of a third-party hosted cloud service, and then that data can be accessed by connecting to the cloud server through an Internet connection. The cloud is one of the buzziest of buzzwords in business today, in large part because of the potential it holds. Its unclear what the future of the cloud will be in the industrial automation market and how it will affect things, but one thing does seem clear: For better or worse, the handling of more and more data and software is heading into the cloud. The cloud is an Internet technology that integrators simply must be aware of because of its potential impact on the industry and because many of their customers are moving their information to the cloud.

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The New Control System Integrator


2: SQL Databases 15%
Coming in with 15% of the vote, a significant number of the integrators we surveyed felt that SQL databases have had a big effect on their role and the field at large. SQL-compatible databases are the most popular databases in the world, used to store information of all types in every industry you can imagine. SQL is not a type or brand of database; SQL is a standardized structured query language for databases. SQL databases are relational databases, which are structured like a large spreadsheet with rows, columns and cells, but are much more powerful and accessible to multiple users at the same time. SQL databases are popular for their simplicity, ease of connectivity, flexibility and most of all their ability to quickly query related data. Data Analysis SQL was created with the specific intent to make it easy to ask questions of data. The primary function of SQL is to create a query (or question) and run it against your data to retrieve an answer. Simply put, SQL was built to quickly answer complex questions about large amounts of data. The real power of SQL for analyzing data is in its ability to relate data together across multiple tables and multiple databases. The ability to ask questions of your data is extremely empowering, and it can be used endlessly to find important answers that can positively affect the profitability of a company. There are any number of facts that can come to light when data is questioned facts that can inform important decisions that affect a companys bottom line. Having controls data easily accessible in a SQL database makes it easier to ask and answer important questions of data. Logging Historical Data Traditionally, time-series data has been stored in a process historian, but relational SQL databases offer a compelling alternative. SQL databases compare favorably to process historians and even offer the major advantage of making historical data more accessible to other enterprise systems. SQL databases are less expensive, easily accessible and more easily scalable than storing historical data in a dedicated historian. A process historian is an application specifically created to deal with time-series data. A historian is made for the storage and analysis of time-series data and as such is designed with an emphasis on the compression and speedy retrieval of large amounts of data. Most historians use proprietary technology to compress and store data, which can make it difficult for other systems to easily communicate with them. As a result, time-series data is often kept totally separate and detached from the rest of the enterprise data; not because it has to be, but because historians make it difficult for other systems to work with. Using an SQL database allows integrators to break away from the use of expensive proprietary process historians and use a solution that any IT department can easily support.

Connecting to Enterprise Systems The business world on the whole has fully embraced SQL databases and as a result most standard enterprise systems use SQL databases. This is especially true for enterprise resource planning (ERP) systems. According to the integrators we surveyed, one of the most common requests they receive from their customers is to connect the data from their SCADA systems to their ERP systems. Before SQL databases, connecting SCADA systems with other manufacturing execution systems (MES) was a real challenge. It could take multiple applications, running on multiple operating systems and an untold amount of hours and support just to get data to and from the plant floor and back to corporate planners. Now, if you use SCADA software that utilizes SQL databases, getting it to work with the databases of other MES applications is a simple process because both systems speak the same language. Since SQL is so widely used, it is very well supported so troubleshooting isnt nearly as time-consuming.
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3: OPC-UA 14%
Coming in right behind SQL databases, OPC-UA was selected as the next technology that has had a great effect on the integration field. Its easy to see why. OPC is the method used to connect with devices like programmable logic controllers (PLCs) and programmable automation controllers (PACs), which are the foundation for most industrial automation systems. In the automation industry, OPC functions similarly to how printer drivers function on a personal computer. Without it, devices just arent able to understand each other and work together. Any change to OPC has a large effect in how integrators connect the plant floor to the rest of the enterprise. Interoperability OPC-UA is a unified architecture for OPC. Its the next generation of OPC standards created to provide a more uniform and reliable framework for accessing real-time and historical data. The focus of OPC-UA is interoperability, to make it easier to connect to more diverse types of devices as well as different brands of them. OPC-UA was also designed to work with older devices and new state-of-the-art ones, creating a bridge from legacy products to new devices. Unlike the OPC technology of the past, OPC-UA is not dependent on DCOM, a proprietary Microsoft technology that has become deprecated. This means that control systems that utilize UPC-UA no longer have to be tied to a specific brand of device or operating system, which has opened the field for new products and software. This has increased the choices and flexibility for integrators when putting in new control systems. The result is that integrators now have more options to choose from in order to create the systems their clients need. Fast Implementation One of the major benefits of OPC-UA for integrators is that it has greatly simplified the process of connecting devices. Instead of having to install different drivers for each type of PLC to get everything connected, an OPC-UA server can be used to connect to any PLC or PAC. This can be a real time-saver and allow integrators to focus on other parts of the system. OPC-UA is also open and platform independent, which gives integrators a great deal more freedom
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to put a system together how they want, instead of being locked into a specific setup by proprietary technology. It also means that control systems dont have to be tied to a specific type of operating system because of the PLCs. Connecting to the Enterprise An underlying benefit to all of this is that OPC-UA makes it easier and more secure to connect data coming from PLCs on the plant floor to other systems in the rest of the enterprise. Integrators are always asked to make controls data more accessible and more available. Integrators who help their clients do this effectively are a huge asset to manufacturing companies. Manufacturers that employ integrators who can do this will reap the benefits of having real-time process and analytics of the data from their plant floor. OPC-UA is one of the key technologies that allow the modern integrator to do accomplish this.

The New Control System Integrator


4: Mobile Devices 13%

Smartphones and mobile devices seem to be taking over the world. All you have to do is walk down a crowded street or step into a restaurant to notice people swiping, clicking, listening and sometimes even making a call on their smartphone. People use their phones all the time, and they have become accustomed to getting information on-demand in the palm of their hand. It seems that expectations for instantly-accessible data havent gone unnoticed in the industrial automation field. 13% of the integrators we surveyed said that mobile devices have a huge effect on them and on the demands of their customers. Customer Demand The effect that mobile devices are having on integrators is pretty easily summed up in two words: customer demand. Integrators overwhelmingly told us that the request they hear most from their customers is the ability to access their SCADA systems with their mobile device. In some ways its like the Internet boom all over again, but this time with mobile devices. Customers want to be connected to their data, and they want that connection on-the-go. With the success of smartphones it has become commonplace to access information ranging from social media sites, banks, cloud services and enterprise systems so why not control systems? The fact is that people have begun to see it as a requirement, not a convenience, to access their data from their mobile device, and integrators and SCADA software vendors have struggled to keep up with the demand.

Access Data Anywhere The demand from companies to access their control system data from mobile devices doesnt just come from higher expectations based on other industries. Its based out of the very real need to compete. In todays economy, manufacturing companies are especially in need of getting every advantage possible. This means that manufacturers are often forced to do more with less. To do this, the workforce today needs to be mobile in order to cover more ground effectively. Todays companies need access to their data from anywhere and at any time from the field, from their home. Often in the field, the only Internet access that can be achieved is through the network of a mobile device. Using a mobile device to connect to HMI / SCADA systems can be a valuable asset in these instances and can even be the difference in averting a serious problem. Dynamic Data Presentation Another change for integrators with the rise of mobile device popularity is the shift in how their customers see and interact with their data. Smaller screen sizes and touchscreen technology have a largely affected how HMI screens are seen and used when accessed on a mobile device. People interact with their systems differently on a touchscreen device than on a desktop computer. Quite literally, mobile devices are changing the way HMI screens look as integrators are designing screens that are more effectively formatted to device requirements.

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5: Server-Centric Applications 9%
With 9% of the vote, server-centric applications came in last, but certainly not least, in our list of the most transformative technologies on the field of integration. Traditionally software is installed on local machines and runs only where it is installed, but servercentric applications are different. Server-centric applications are installed on a server, and application clients can be launched to any machine connected to the server without individual installations. Server-centric applications have caused a shift in how SCADA software is deployed across an enterprise and have greatly affected the way in which integrators go about installing SCADA software. With SCADA software being a major piece of the puzzle in the job of integrators, a technology like server-centric applications has made a big difference in how integrators get the job done. No Installation One of the biggest benefits that server-centric applications offer is how greatly they reduce the work and time needed to install SCADA software. Instead of the time-consuming task of installing software on every machine that needs it, application clients can be deployed from the server in a matter of seconds via the network or Internet. This can save hours, days, even weeks of time for integrators, giving them time to focus on other things such as developing new HMI / SCADA projects. Another huge benefit of server-centric applications is the ability to launch an unlimited number of clients. This makes it easy for integrators to give access to people who need it and facilitates the effective flow of data throughout the enterprise. Instant Updates Since the application is located in one place the server the process of making updates to SCADA systems has been greatly streamlined. Instead of updating each installation of the software, updates can be made at the server level and instantly deployed across entire networks in seconds. This is also a huge advantage when developing new HMI / SCADA projects. New projects can now be concurrently developed by multiple people at the same time. The process is seamless because Reliability Server-centric applications also have the advantage of being more stable. This is due in part to the fact that its easier to set up redundancy. Since everything is stored in one place, its a fairly straightforward process to back up the information with another redundant server or in the cloud. Fault-tolerant systems can be created by joining two servers together via a gateway, so if one goes down the other keeps running and users dont even notice a difference.
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development all happens in the same place on the server. This can save an untold amount of time, making development much quicker.

The New Control System Integrator

Question 2: What Skills Will Be the Most Valuable for Integrators in the Future?
All of the technologies discussed in this paper have had a big effect on both the role of integrators and the kinds of services they can offer their customers. With the speed of technological advancement showing no signs of slowing down, it is important to keep up with all of these changes in order to stay relevant and prosperous as an integrator today. Like technology, integrators must continue to change and grow in order to keep up with the demands of their customers and stay one step ahead of the competition. A huge part of this growth is continuing to learn the skills that will allow integrators to keep pace with the industry. In an effort to help you stay ahead of the curve we asked the integrators we surveyed the following question: What skill set will be the most valuable in the future for control system integrators? The results and the analysis of each answer are below.

1: MES

2: PLC Programming

3: SQL Databases

24% 4: Networking

23% 5: Software Programming

20% 6: SCADA System Security

16%

12%

5%

% = Represents what percentage of integrators responded to the question with that answer.

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1: MES 24%
A manufacturing execution system (MES) is an information technology for the monitoring and management of work-in-process on a factory floor as well as historical production data. MES software is designed to bridge the communication gap between the plant floor and the management and executive levels. It is used to keep track of real-time data in the manufacturing process as well as analyze and present it in the form of actionable information. MES software is used for tracking and improving such things as unplanned downtime, quality, recipe management, track and trace, scheduling, genealogy and many more functions. Customers Are Demanding It There are some people who may be surprised that the ability to work with MES came up in our survey as the number one essential skill for integrators to know in the future. However, its no surprise to those integrators we surveyed for one specific reason: their customers are continuing to demand more integration between their control system and MES and ERP systems. Improving Processes With MES MES solutions offer manufacturers the tools necessary for continued improvement of their processes to make them more efficient and ultimately more profitable. In a challenging economy many companies have been forced to do more with less. Making their process more efficient is a cost-effective way of doing that.

ERP systems is enticing because the cross-analysis of all that data can result in immediate and impactful insights into whats actually happening in each system, how they affect each other, and how they can be improved. Huge Potential for Growth Integrators who have the knowledge and expertise to integrate MES software with SCADA and ERP have a real opportunity to set themselves apart from the pack by offering their clients something that they really need, and its likely something that they dont already have. MES is a large area for growth for integrators because many manufacturers are still stuck in the past when it comes to MES data; many often track MES data manually on paper. Automated data collection is much faster, more accurate and can give manufacturers the edge theyre looking for. Being able to offer that service greatly increases an integrators value to their customers and its a great setup for growth in the future. In a sense MES can be the gift that keeps on giving because it can increase efficiency, which is the equivalent of finding free money right on the plant floor. Companies can become more profitable by using MES tools to become more efficient. For integrators who offer MES services, they have the potential to deliver their clients a huge return on investment, which can greatly increase the profitability of the client and the integrator.

2: PLC Programming 23%


A PLC or PAC is a digital computer used for the automation of electromechanical processes. PLCs are used to capture data and control machinery, usually on a factory floor. PLCs are relatively simple computers, designed with reliability and durability in mind. Most PLCs are programmed with basic ladder logic because of its apparent simplicity.

Of course you cant improve a process unless you track it, and MES software offers that solution. MES gives manufacturers the chance to really see what is happening with their process, and it facilitates a sense of accountability for making the process better. The potential of integrating MES, control and

Still a Foundational Skill PLC programming is a foundation skill for integrators because it serves as the basis for most control systems. For this reason its not surprising at all to see PLC programming come in as the second most important integration skill to know.

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2012 Inductive Automation

The New Control System Integrator


In order for a SCADA system to be of much use, data has to get from the plant floor to a database, and PLCs are the best devices suited to this task. Simple PLC logic is still the language of choice for interfacing with machines and has proven to be a solid time-tested solution for industrial controls. That is not likely to change anytime soon, which makes PLC programming an indispensable skill for integrators now and in the future. Integrators who have strong PLC programming skills will continue to be valuable in the future, even as new technologies emerge. The reasons for this are twofold. The first reason is that PLCs are at the heart of control systems for almost all manufacturers and even if that changes, it wont change quickly. Manufacturers value reliability above all and are slow to make changes to new technologies until they are proven. This means that PLCs will be around a long time, and even if the industry does migrate to a new technology, it will be a slow process that will still require the expertise of integrators with strong PLC programming skills. A Skill Only Integrators Possess The second reason is that while IT (information technology) departments already handle many of the other skills on this list, PLC programming is still foreign to most of them. Since PLC programming isnt used much outside the manufacturing industry, most IT professionals dont have to deal with it and dont know much about it. This makes an integrator with deep knowledge of how to work with PLCs totally essential. made up of rows, columns, and cells. You can think of it like a big spreadsheet, just way more flexible and powerful. Relational databases are extremely popular, so much so that they pretty much define what the word database means. When you think of a database, you are more or less thinking of a relational database, and SQL is the most common query language for relational databases. SQL databases are the most commonly used database in the world and are already in use by most MES and ERP systems. SQL is also being increasingly used to manage the data in SCADA systems. As a result of the wide use of SQL and its increasing prominence in the industrial automation field, it has become more important than ever for integrators to broaden their skills in working with SQL databases. The integrators we surveyed told us that their clients are always asking them to get more data into the hands of more people. Most of the data that companies have is stored in SQL databases, which requires integrators to know SQL in order to work effectively with that data. Databases Are Friends of IT Departments Integrators who know SQL also have the added advantage of being able to communicate more effectively with IT departments, which can make a huge difference, especially when trying to win new clients. IT departments are much more likely to give their seal of approval to SCADA systems that use standard information technologies like SQL than those that are built on proprietary technology. SQL Skills Open a New World Possessing a SQL skill set also increases the kind of work an integrator can do. This skill set opens a new potential for greater growth in the future, especially because many companies already have a SCADA system in place. While most integrators just update and maintain a previously-installed SCADA system, the modern integrator can offer more services to customers by leveraging the data that customers already have and relate it to data from other enterprise systems. This service offers a higher value to a manufacturing company. SQL is perfect for this application, and integrators who can add SQL to their toolkit will be able to offer a more complete package of services to their clients in the future.

3: SQL Databases 20%


As mentioned earlier in this paper, SQL is a standardized structured query language for relational databases. A database is a central clearinghouse for information. It digitally stores any variety of information you can imagine. Databases are not defined by what kind of information they store, but rather the structure in which they store data. Every true database requires a database management system (DBMS), and a relational DBMS is the most widely used. A relational database is one that stores information in the basic structure of tables

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4: Networking 16%
A network is a collection of interconnected computers, network servers and other devices. The components of a network are connected together by communication channels governed by communication protocols that facilitate the sharing of resources and information.

5: Software Programming 12%


Software programming is a broad term that generally describes the process of writing, testing, debugging and maintaining the source code for software programs. Integrators who know how to write custom code are highly valuable. A huge part of integration is getting all the different systems and pieces of software to talk with each other. Having knowledge of some of the more common programing languages gives integrators more flexibility when working with a SCADA system. They can often extend the usefulness of a given piece of SCADA software. SCADA Software is Not Enough One thing many of the integrators we surveyed told us was that customers were always asking for more functionality from their existing SCADA software. Many companies are often unsatisfied with the outof-the-box functionality of their SCADA software package, and they want a customized solution to fit their customized process. This makes sense, especially for manufacturing companies that have spent years refining their process to work for them. Companies often have to change how they do things to fit the way their software is preconfigured. They want integrators to make the software conform to their processes and ways of doing things, instead of the other way around. Integrators with software programming skills can offer clients custom-made solutions, which often eliminate the need for more add-on software and can increase the functionality of existing SCADA systems. This kind of skill can make an integrator endlessly valuable to their clients because they can offer innovative new solutions to problems that other integrators cant. Integrators with this skill will be able to say yes to clients requests much more than saying no. That could make all the difference in winning new jobs in the future. Coding for the Future There are many programing languages out there, but many integrators we surveyed stressed the importance of using programming languages like Java and Python that are based on open standards and are easily supported.

Often classified by size, networks can range from a local area network that can consist of as few as two connected computers, to a wide area network that can consist of thousands of computers spanning the globe. The Internet is itself a network made up of the connection of millions of other networks. Simply put, a network is how information gets from point A to point B through standard communication protocols. Networking is important to integrators because without communication there is little integration. Networks connect people with data, which is an essential role of an integrator. As the network of the World Wide Web grows larger and companies expand their reach even further, they will need to deliver data to the right people, no matter where they are. Strong networking skills are important in delivering scalable solutions that will grow with companies as they expand. An Ever-Growing Skill Communication technologies have continually improved over the years, and networks have become larger and more complex. There are more ways now to set up system architectures than ever before, which have given integrators more possible solutions to communication problems. This also means that there are also more variables to consider than ever before, and this will likely increase in the future. Integrators who have developed their networking skills will be better equipped to handle new challenges moving forward.

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The New Control System Integrator


Integrators who offer custom code based on open standards are looking out for the best interests of their customers. Open standard languages dont trap a company into using only the original code author to maintain and update the code over the longhaul. This is important to manufacturers because they need to know that if for some reason their original integrator is no longer available moves, retires, etc. they can maintain their system without too much hassle.

Who is the New Control System Integrator?


A new integrator has emerged. He is a champion of the latest technologies. The Internet, SQL databases, mobile devices and other changes have not held him back, but have propelled him forward to greater heights in service to his customers.

6: SCADA System Security 5%


The term system security in our survey referred to the safeguards, protocols and procedures that ensure the safety of the controls and data of a SCADA system. The subject of SCADA system security is growing more important every day as the Internet continues to further connect everything together. A lack of security can open a system up to virus attacks that can cripple processes, potentially costing a company a lot of time and money. With so many devices going online, even machinery on the plant floor is being connected to the Internet. The reality for todays manufacturers is that even if a piece of plant equipment is in the dark depths of a facility, it doesnt mean its not easily accessible electronically. Security Isnt Just For IT Departments While network security is well within the realm of IT departments, integrators should take an active role in SCADA system security. Many IT departments are unfamiliar with SCADA, and may not give it the time and attention needed to ensure its security. Integrators need to have enough security knowledge to bridge that gap. Strong system security expertise can set an integrator apart from the competition. An integrator with these skills is an attractive choice to manufacturers, especially those with highly-sensitive processes and data. With the Internet came great technological changes, but also increased risk. Security threats to SCADA systems posed by the Internet only seem to be increasing, making system security an important skill for modern integrators now, and even more essential for the future.

He can offer solutions to his customers that were never possible before, because he has leveraged these new technologies to benefit his customers. As customers continue to demand more connectivity for their data and systems, this new integrator is rising to meet the challenge. But the new integrator has not forgotten his foundation. He has merely added to it. Foundation skills such as PLC programming remain as important as ever, and lay the groundwork for building newer skills such as working with MES and SQL databases as these technologies have grown in importance. As customer demands continue to evolve and technology advances, integrators must be ever prepared to help facilitate the success of their clients with the latest tools and a rock-solid basis of past experience. Modern technologies and associated customer needs have changed the role of integrators, and will continue to shape their future. Embracing the Future Steve Hechtman, the founder and CEO of Inductive Automation has more than 30 years of experience as a control system integrator and is a widely respected innovator in the field. Steves frustrations with the limitations of legacy SCADA software led him to start Inductive Automation in order to create SCADA software solutions for the future. A big part

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of Steves success has been to embrace new technologies and the possibilities they offer in solving todays problems. There are some integrators who just stick with what they know; theyre old-school so they just stay away from technology thats unfamiliar to them, said Steve. These guys are encountering a glass ceiling they think they cant get through. What they dont know is that the ceiling isnt really there. You can walk right through it if you are willing to expand your comprehension and learn new things. The future has all kinds of new possibilities, but you have to be willing to embrace it. New, modern web-based SCADA software that fully utilizes SQL databases opens up new possibilities for integrators that would have been impossible before. Steve explained: The Internet is amazing. On one project we used a corporate WAN to combine sites all across the country. They were all linked together and all logging data to a central server from which reports from any of the sites could be generated. This was all possible by virtue of the fact that we could put the PLCs on the Ethernet along with all the servers; everything on the same WAN. We can also maintain everything remotely; it really is amazing. Its a real thrill as an integrator to be able to do that, to see it all come together and to be able to offer that value to your customers. Something like this just wasnt possible before the Internet. We just wouldnt have been able to do it without these new technologies. Grounded in the Past As exciting and as bright as the future may be, it is important for integrators to remember how they got to where they are in the first place. It would be foolish to throw out the wisdom of the past for the promise of the future. For this reason its important to remember the foundation that makes integrators special, and makes them a valuable and essential part of the automation industry. Steve explained what skills integrators must never lose: No matter how technology changes, there will always be a place of the plant floor for guys who can fix stuff and make it run always, always, always. You need to have that sense, that skill for how to get the job done, for how to make things work.

You can never lose that, no matter what new tools are invented, you can never replace that common sense and intuition that a good integrator can bring to the table. You have to remember that at its core, the job of integration is to work with people, not machines. You have to be able to be one-on-one with your customers. They need to see you and talk with you in order to build a relationship of trust. The trust is so important, you cant fake it.

The Internet is great, but you cant let it become a crutch. Remote connectivity is no replacement for human connection. We have these great tools, but your skill as an integrator to solve peoples problems and to give their control system a human face one they can trust that skill is invaluable. It will always be the most important one to have as an integrator, you can never lose it. If you give your customers the service they are entitled to, what they deserve, then you will be a good integrator now and in the future. The new control system integrator should embrace the future, but also have their feet firmly grounded in the past. This really defines who the new control system integrator is and what qualities companies should look for when choosing an integrator that will stand the test of time. Integrators who have a solid foundation of problem-solving and an open mind for future technological advancements in the field will position themselves for success today and for many, many tomorrows to come.

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November 2012 l Automation World

63

Pintos Prose

Industrial Automation and the Cloud


Jim Pinto

jim@jimpinto.com

improved the perf ormance, quality and productivity of manuf acturing and process systems. But perf ormance remains at a plateau. Further improvements demand more data in real-time, which is beyond the capability of existing systems. In the last issue of Automation World (October 2012), I discussed how the Internet of Things (IoT) would generate the next huge leap in industrial productivity. But IoT certainly wont bear fruit without ways to analyze all the data. Cloud computing is the enabler, the catalyst for that inflection point. Use of the cloud is a transformative approach that provides more than just the conventional data center model. It fundamentally changes how masses of data can be stored for interaction. It offers services on demand at the infrastructure, platform and software levels. Big data, the cloud and analytics combine to offer breakthrough productivity solutions. Also in the October issue, David Greenf ield wrote, Databases are the ref rigerators of the industrial world. They store

Over the past two decades, automation has

ON THE WEB
Cloud Meets Manufacturing Find more articles on how accessible cloud computing is becoming to manufacturing operations. Visit http://bit.ly/awcloud

Already in industrial automation, were seeing applications of cloud computing to f acilitate preventive and predictive maintenance, a major change-driver. This requires every possible machine parameter to be collected historically and analyzed to drive intelligent decisionmaking; this is not possible with only real-time analysis.

Integrate the cloud

Cloud/IoT restructuring will overthrow many assumptions about who the industrys leaders will be and how they will establish and maintain leadership.
information that is important, but only some of the data is used. Without a way to utilize accumulated data, it becomes outdated and useless. The problem is that it is not truly exploited. The cloud is the missing link. Cloud-computing technology is now at a maturing phase. Development of both private and public cloud systems has become a priority across a broad spectrum of commercial suppliers and users. Cloud services are becoming inexpensive and widely available, and enterprises can move or migrate workloads within and between their own data centers. Data center management still remains somewhat manual, but automated systems are becoming available to dynamically allocate resources for optimization in a wide range of applications. The cloud pushes away from fixed client-server architectures to a distributed architecture with local and global intelligence. In industrial applications, clear targets are manufacturing execution and production planning systems. There is minimal need for discrete servers that perform functions for only a few manufacturing processes when those can be operated more effectively as cloud services.

Automation suppliers can simplify the integration of cloud services into their products and systems in several ways: eliminate complex and/or proprietary architectures; use open communication standards; think in terms of services and not discrete products; and make sure that systems architecture properly scales into the cloud. Software architectures and tools created in previous decades will no longer f it the new cloud inf rastructure. For example, with production plant monitoring, the ability to share development of application sof tware with a distributed team f rom many locations was previously possible only in very f ew systems. Now distributed access and versioning should be built-in, and as easy to setup as accessing remote email. For cloud-based IoT systems, block-storage architectures that cannot provide instant snapshots of machine images will be prone to all sorts of failures. Those failures will grow more pronounced in the industrial automation world when a five-second failure could result in the loss of many millions of dollars worth of time-specific information. In addition to creating new markets and opportunities, cloud/ IoT restructuring will overthrow many assumptions about who the industrys leaders will be and how they will establish and maintain leadership. The insightf ul Jeremy Pollard writes: Def inite-purpose devices have populated our software and hardware toolboxes for decades. The cloud might change it all. As the saying goes, you aint seen nothin yet.

Jim Pinto is an industry analyst and commentator, writer,

technology futurist and angel investor. You can e-mail him at: jim@jimpinto.com. Or review his prognostications and predictions on his Web site: www.jimpinto.com
Visit www.AutomationWorld.com

64

Automation World l November 2012

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