Factory Machine Automation Playbook v12

2014 EDITION
FACTORY & MACHINE

AUTOMATION PL AYBOOK
Also inside: Project Management Tips Energy Management Advice Common Project Mistakes Asset Management Guide Safety & Security Tips
HOW TO SUCCESSFULLY IMPLEMENT FACTORY & MACHINE AUTOMATION PROJECTS
Cho advi ck full o f pra ce fo c buil r the ma tical der a chin er y s we end l user l as !
Mac Build hine e
r OE Ms
Hands-on practical advice on selecting and implementing controllers, motion control, drives, HMI, I/O, networking, pneumatics, robotics, sensors, vision, and much more.
OEE & Lean Manufacturing
FACTORY & MACHINE Automation Playbook
2 / 167
SPONSORS
3 / 167
CONTENTS
7
Playbook Advisors
8 Contributors 11 Introduction
Section 1: Planning and implementing an automation project
14 17
12 points to consider before even beginning your automation project Nine tips for automation project managers
20 Automation project management from a machine builders perspective 25 How to justify capital projects: Speaking finance gets results 35 Eight tips for selecting the right automation system components 37 How to properly select and vet a system integrator 43 12 common mistakes people make in automation projects 47 10 ways your automation project can fail and how to prevent it
OEM machine designers (in addition to automation end users) will specifically find useful tips in highlighted articles.
4 / 167
CONTENTS
Section 2: Selecting products to build your automated system
52 16 best practices for specifying PLCs, PACs or PC controllers 58 10 steps to creating the perfect HMI 63 Eight steps to I/O engineering success 65 11 recommendations for selecting motors and drives 70 Four tips for improving motion control systems 72 Seven considerations for applying servo drives, motion controllers and PLCs 75 Seven issues to think about before you develop an industrial network 77 Six things to think about when you get down to the network details 79 Five considerations for implementing Ethernet for an industrial network 82 Four tips for dealing with wireless latency and bandwidth issues 84 How network management systems aid firmware, configuration updates
5 / 167
CONTENTS
86 12 tips for selecting and sizing pneumatic and hydraulic components 89 11 considerations for selecting and deploying industrial robots 93 A role for robots in lean 95 10 secrets to selecting and implementing sensors in industrial applications
1 01
Six critical considerations for successful machine vision applications
Section 3: Applying technologies to improve outcomes
106 Develop a strategy for asset management 107 Five best practices for more reliable asset management 109 Four considerations for monitoring equipment assets 111 Four tips for calibrating equipment 112 Nine strategies for achieving your energy management objectives 116 Nine recommendations for building effective manufacturing IT systems
6 / 167
CONTENTS
119 13 ways to get the most out of OEE and lean manufacturing disciplines 125 Eight ideas for improving product lifecycle management 128 Seven human factors to consider when developing machine safety systems 132 Eight tips for the technical side of safety systems 136 Wiring, safety PLC programming critical to machine safety performance 138 Europe sets standards for safety design 139 Six strategies for creating a secure industrial network 144 Seven details to remember when implementing network security 147 Nine ways to get the most from simulation and CAD/CAM software 149 Five recommendations for implementing workflow systems 151 Vendor Selection Resource Guide
7 / 167
PLAYBOOK ADVISORS
Thomas A. Doney
Senior Research Engineer Nestl
Joe Martin
President Martin CSI
Paul Brinks
COO Koops Inc.
Jeff Miller, PMP

Director of Project Management Interstates Control Systems Inc.
Stephen M. Goldberg
Director - Information Technologies Matrix Technologies Inc.
Howard Skolnik
President/CEO Skolnik Industries
Michael Hake
Senior Facilities Systems Support Technician Data Device Corp.
Arthur C. Smith
Senior Automation Controls Engineer MT&E - Machine & Automation Systems Corning Inc.
Robert Lowe
Executive Director Control System Integrators Association (CSIA)
8 / 167
CONTRIBUTORS
Michael Mikolajczak Bryan Sisler ABB, USA Alex Miller ABB Robotics, USA Mike Berryman Advantech, USA Wendy Jacintha AFLAC, Canada Leslie Crothers Almac, United Kingdom Rob Cotner Anixter, USA Carl Stelling Antaira Technologies, USA Lonnie Purvis Apex Manufacturing Solutions, USA John Coetzee Aristotle Consulting, South Africa Sujata Tilak Ascent Informatics Pvt. Ltd., India Dave Robinson Aurora Industrial Automation, USA Jad Wehbe Automate, Lebanon Germany - Qatar Rafael Arevalo Duque Automatizacion Ingenieros Especialistas sas, Colombia Peter van den Berg Avans University of Applied Science, the Netherlands Stanley Moses Bahwan CyberTek Inc., USA John Malinowski Baldor Electric Company, USA Shawn Day Henry Menke Balluff Inc., USA Jeremy Jones Baumer Ltd., USA Jingxu He Bayer, USA Mike Fahrion B&B Electronics, USA Eric Byres Mike Miklot Belden, Inc., USA Abdulilah Alzayyat Jim Hulman Joaquin Ocampo Bosch Rexroth, USA Larry W. Ostrander CADD Tech Support, USA John F. Wozniak CC-Link Partner Association, USA Johnny Sorensen Chr. Hansen, Denmark John Lewis Cognex Corp., USA Mohbat Tharani COMSTATS Institute of Technology, Pakistan Hernan Gardiazabal ContrALL, Mexico Mike Cerda Control M Automation, Mexico Sanjay Mishra COTMAC Electronics Pvt. Ltd., India Roy Greengrass Del Monte Foods, USA A. Klemptner DTE Energy, USA William Wang DuPont China, China Tim Matheny ECS Solutions Inc., USA Ed Nachel Elobau Sensor Technology Inc., USA Julian Martinez Emerson Network Power, Colombia Roy Adams ERA LLC, USA Vikram Kumar EZAutomation, USA John Holmes Festo Corp., USA Robert L. Fischer Fischer Technical Services, USA Eric Esson Frommelt Safety Products, USA Chris Alexander Givaudan Flavors, USA Dr. Colin Harrison Glasgow Caledonian University, United Kingdom Kurt Wilde Henniges Automotive, USA Satish Samineni Halcrow, Qatar Tianshun Qiu IBM (China) Co. Ltd., China Alexander Pinkham ICONICS, USA Joel Albert Industrial Networking Solutions, USA Josu Bilbao IK4-IKerlan, Spain John Wilson Integrated Automation, Australia Sudhendu Banerjee Instrumentation Ltd., India Majid Takabi JGC Co., Iran Tom England Kollmorgen, USA Pierre Lampron KSH Solutions Inc., Canada Chris Weigmann Lakeside Manufacturing, USA Tom Jensen Lenze, USA Stefano Linari Linari Engineering srl, Italy Dan Perkins LINAK U.S. Inc., USA Jagjeet Paul Little Systems, India Ken Lauer Middough, USA George Hockett II Miniature Plastic Molding LLC, USA Deana Fu Bryan Knight Mitsubishi Electric Automation, USA Stephen Chilton Monozee Ltd., United Kingdom Todd Desso Eddie Lee Mike Werning Moxa Americas, Inc. Nelson South Nelson South Electrical, Australia CONTINUED ON PAGE 9
9 / 167
CONTRIBUTORS
Kenn Anderson Nova Systems Inc., USA Joe Sebastian Diane Trentini Optimation Technology Inc., USA Ben Orchard Opto 22, USA Scott Klages Parsec Automation Corp., USA Jose Gonzalez Valero PEMEX, Mexico Helge Hornis Pepperl+Fuchs, USA Mark Buckley Phoenix Contact, USA Rahul Aggarwal Prekar Services & Solutions, India Rafey Shahid Qanare Engineering, Pakistan Mark Battisti QPoint Robotic Solutions, USA Dennis Sanchez RECOPE, Costa Rica Cheng Xinping Rockwell Automation, China Chris Brogli Paul Brooks Douglas Henderson Jimmy Koh Amy Peters Fatime Ly Seymour Thomas Sugimoto Rockwell Automation, USA Mahendra Dissasekera Ronan Engineering Co., USA Sam Shorer SABMiller, South Africa Andrea Sammartino Saipem Spa, Italy Steve Sarovich Sardee Industries Inc., USA Gilbert Brault Antonio Chauvet Schneider Electric, France Johan Hult Schneider Electric, Sweden Robb Dussault John Boville Schneider Electric, USA Jerry Schultheis Schultheis Automation Control Systems Inc., USA Eder Mathias SEW-Eurodrive, Brazil Nesko Kontic SGS - Wind Energy Technology Centre, China Shamsol Shamus Shamus Technology Ent., Malaysia Dr. Gyan Ranjan Biswal Shiv Nadar University, Noida, India George Pease Show-Me Machine Works, USA Jim Anderson Jill Oertel Aaron Schulke SICK, USA Tom Hoffman Jeff Miller Gregory Richards Siemens, USA Tomaz Vidonja Simplysens, Slovenia Mark A. Erickson Skills Improvement Inc., USA Pat Gallagher Solar Automation Inc., USA Lewis Gordon Tangent Services, USA Peter Hook Tech Innovations LLC, USA Dave Szurek The Mackubin Group, USA Assaf Beckman Tomatic, Israel Matthew T. Seiman Trelleborg Sealing Solutions, USA Ed Novak Trio Motion Technology, USA Pramod Parikh United Phosphorus Ltd., India Fernando Jimenez Universidad de los Andes, Colombia Alejandro Pena Universidad Distrital, Colombia Gary Phillips URS E & C, USA Bill Bobbitt Vans Aircraft Inc., USA Sachin Kumar Vertex Automation System (P) Ltd., India Pradeep Soni VSM Venture Control System P. Ltd., Noida, India Charlie Norz WAGO Corp., USA Nathan Schiavo Wesco, USA Wilfredo Jimenez WJ Automation & Integration Corp., Puerto Rico Karen Leung Worleyparsons, USA Erik Nieves Yaskawa Motoman Robotics, USA Will Zurkan Zurkan Solutions, USA CONTINUED ON PAGE 10
10 / 167
CONTRIBUTORS
Individual Contributors, by Country
Algeria Nesrine Chaouche Bosnia Bojan Djurdjevic Brazil Edson Gonalves de Oliveira Canada Ed Kinakin Guatemala Moises Yac Egypt Mahmoud Abdel Fatah Abo Ahmed India Rajesh Keswani Sarang Kulkarni Senthil Kumar Arunnun Loganathan Mukesh Negi Avinash Patil Naveen Kumar Ramasamy Babu Reddy T Iraq Amer H. Rasheed Ireland Joe Burke Israel Victor Zaltsman Lithuania Genadij Nesterenko Mexico Jorge Loza Netherlands R. Hulsebos Hindrik Koning Nigeria Oladapo Akinbola Iyedupe Norway Rune Saetre Pakistan Faisal Mirzam Saudia Arabia Ghulam Rasul Spain Antonio Anton Miquel Vall Boladeras Sri Lanka Suren Stambo Taiwan Jin-Mu Lin USA Don Baechtel Jim Brastauskas Daniel Bruno Bruce Centofanti Marc Emmerke Greg Fairchild Irene Farquhar Marty Grimes Tony Guzman Daniel Hood Joseph Kolo Rajendera K. Kapoor Michael Kinziger David Lamb Todd LaRoche Hian Yong Leong John Nix Tim OBrien Tony Olivieri Tony Perna Friedrich Purkert Ray Royal Stephen A. Sajewicz William Schmidt Accounties Smith Konstantyn Spasokukotskiy Joe Staples Jim Tennant Suresh Vasan Leonard Walsh Nick Wisniewski Venezuela Juan Nicolaidis
Thanks as well to the many contributors who preferred to remain anonymous.
11 / 167
INTRODUCTION
Manufacturers, machine builders and system integrators have been automating production systems for more than 30 years. But as aging systems become obsolete, technology advances, competition becomes fiercer and priorities change, a new wave of automation is changing the landscape of manufacturing. The drive for cheaper, better, faster has added another elementthe need to become smarter, not just about whats happening on the production floor but about how companies use resources, the skills they require of their workers and how they interact with their customers and supply chains. This edition of Automation Worlds Factory Automation Playbook will explore these themes, sharing guidance from your peers and suppliers about how to plan and manage automation projects, how to justify an automation investment, how to select products, systems and service providers and how to achieve your business and technology objectives. Our thanks to the more than 275 people from 40-plus countriesfrom end-user companies, system integrators, machine builders, educators and automation supplierswho have participated in the development of this playbook. Theyve volunteered to share some of the things theyve learned during their careers as a way to give back to this unique community. In the following pages, well share their ideas about the best practices to follow and common pitfalls to avoid. We hope this information will be useful, whether youve been doing automation projects for more than a decade or are part of the
CONTINUED ON PAGE 12
Share article
Add comment
Return to contents
12 / 167
continued
Introduction
new generation of engineers just entering the field. The goal of this playbook is to help everyone achieve more successful factory and machine automation projects. Just as important, it is to remind all of us why automation adds value to our world. As one of our contributors pointed out, Automation is not about technologyit is about people. Automation is a tool to help people. Keep those people, the stakeholders, in the forefront of your mind as you go about your work.
Jeanne Schweder
Contributing Editor
Share article
Add comment
Return to contents
13 / 167
SECTION ONE:
PLANNING AND IMPLEMENTING AN AUTOMATION PROJECT
14 / 167
12 points to consider before even beginning your automation project

The first step in any automation project is the most critical one: Define your objectives. The more thorough and detailed this definition is, and the earlier in the process it can be achieved, the greater the likelihood that the project will be completed successfully.
3. Helping people. Automation can do many things, but

one must be aware that its purpose is to do real things in a given ecosystem. Keep in mind that the goal is to have systems engineered to serve humans, not the other way around. WHAT DO THEY REALLY WANT, AND WHY?
Its essential to understand each persons expectations before a project starts. There are three parts to this definition process: yy What outcomes or desired results does the project team want to achieve? yy What do they want the project experience to be like (for example, no production line shutdowns during the project or communicate updates by email)? yy How will they define quality, such as on time/on budget or increased production volumes or zero downtime, at the end of the project? Different people will have different expectations and they all have to be satisfied. Return to contents
1. Visualize success. Try to visualize what a project would

look like if it were a stunning success. Take note of how it will affect all the people involved and write down any others you think it might touch. Take all of these people and put them on a spreadsheet column. Now in rows across, write down the attributes they need in the machine/process. Use this when evaluating solutions and communicate shortcomings to those affected. Come up with workarounds or throw out the idea if the results wont be acceptable.
2. Whats driving the project? You need to understand

what is the most important motivation for doing this particular project and use that to guide your decision-making.
Share article Add comment
15 / 167
continued

4. Project definition is critical. Without doing true
engineering work, everything you learned in school and in your career up to this point, you are not doing any project properly or professionally. By creating definition for the project and then verifying that the project will answer the need, you are on your way to successful project management. It is only the start, but without a properly defined starting point, it is difficult to complete (or defend) a meandering, ill-defined project that is meant to resolve a problem, address a challenge or complement your companys engineering resources. TECHNOLOGY COMES LAST
Never start by defining technology-driven objectives. Use the following order: 1. Business objectives. What will the business gain from this project? 2. Operational objectives. How will this project impact operations greater efficiency / better quality / compliance, etc.? 3. Integration objectives. Can data generated by this system be used by other systems? 4. People objectives. Skill development, ease in work pressures. Only when all of these have been defined can you establish the technology objectives.
5. Start with the objectives. Dont even begin to select

suppliers and service providers until youve established a projects objectives. Make sure everyone on the team agrees on what the project needs to achieve before it starts. If you dont know where youre going, youll never get there.
6. Get a second opinion. It pays to get a second opinion

from an informed outsider like a system integrator or machine builder before finalizing project objectivestheyll often
do it for free. If you bring them in at this stage, so that they understand the history of the project, they can contribute to decisions that will improve the chances for a successful project.
7. Set rules for communication. Define what

communications are expected at the start of the project
Return to contents
16 / 167
continued

what is to be communicated, how it is to be communicated, what the milestones of the project will be and how often things should be communicated. the boxes, it becomes a Gantt chart. Putting all your objectives (the completion of functioning subsystems, integration) into one simple chart keeps those objectives clear to the whole team.
8. Talk to everyone. Interview the stakeholders from

various factory disciplines, such as operations, maintenance, quality control, supply chain, shipping and management. They always have a stake in every automation project.
11. Spell everything out. If you want drawings in

portrait vs. landscape mode, for example, or want certain brands to be used, such as for wire or PLCs or other components, state that up front. If a requirement is not written down, then it likely will not happen.
9. Never assume. Dont make assumptions about the

ground rulesspell everything out in advance and define who is responsible for doing what.
12. Scope! Nothing is more important than a scope

that reflects both the well-defined areas of the project and the gray areas of the project. The gray areas should have a general framework put together by the customer and the implementer, with benchmarks that clearly indicate when project reassessment should occur. This way scope creep can be managed to the benefit of both parties.
10. Create a chart to keep objectives clear. Define

the expected performance for each subsystem, and the expected steps to get there. Use Excel to list the task steps, and the hours/$ across a time matrix. Then that becomes a calendar for the schedule, sort of a compressed MS Project. If you color
Share article
Add comment
Return to contents
17 / 167
Nine tips for automation project managers

More than technical skills are required to successfully manage an automation project. It also requires communication and organizational skills, along with the ability to motivate a team of people from a variety of disciplines and different departments. Here are a few practical tips for automation project managers: management skills.
2. Welcome the bad news. Every

automation project has things that go wrong, but the earlier you find out what the problems are, the easier and cheaper they are to fix. Nobody wants to hear or deliver bad news, but its important not to get defensive. Anybody on the team needs to be able to push the stop button if a project has gone off the tracks. Otherwise, youre just gambling that things will come out all right at the end.
Looking for training?

Theres a source to help you learn the ropes of project management or improve your skills. For more information, visit
1. Project management resource. There have been thousands

of words written about project management. If you think you need a refresher course, or expect to be assigned to your first project, theres an organization, Project Management Institute, dedicated to establishing standards, providing training and certifying individuals in project
3. Keep simplicity top-of-mind.

Engineers tend to make systems too complex for non-engineers to deal with. Make sure expectations are established early that will keep the needs of the people who will have to operate and maintain the systems a priority. Include
http://awgo.to/028
Organization: Project Management Institute
people from these functions on the automation team and consult them early in the design and testing stages for new systems and equipment.
Return to contents
18 / 167
continued

4. Be ready to adjust. As with any project, unrealistic
projections, poor execution and just plain bad design can cause a project to fail. What is important is that when you begin a project, understand that there will be modifications necessary along with way. The final result is rarely as exactly planned. This is not considered a failure; its a realistic need to adjust and fine-tune as the project progresses. so that everyone knows exactly what performance measures they need to achieve. Dont rush the testing phase; make sure you leave enough time in the project schedule to accomplish the necessary tests. Its also important to make sure the right people attend the FAT; that includes the lead operator and maintenance tech, not just the manager.
5. Establish testing plans early. It isnt enough to

design a system. You have to test it to prove that it works, not once but twice. Its easy to get started on designing the tests by using a template. Equipment or systems should first be tested at the facilities of the integrator or OEM. This is called FAT (Factory Acceptance Testing), and its goal is to prove that the system design will work. Simulate various scenarios to find out how the system will react. The final testing stage, SAT (Site Acceptance Testing), is done when the system is delivered to the factory floor. Its objective is to prove that the equipment actually does work as designed and is producing product at the level required. Approve the testing plans early in the project
6. Follow programming standards. Make sure that

in-house programmers, system integrators and OEMs use the same PLC programming standards, such as OMAC and PackML. Theres nothing worse than custom code that has to be reworked at the last minute to make it compatible with a plants existing systems. Multiple approaches to programming can cost a company millions of dollars.
7. Communicate often. Dont make decisions without

consulting the team. Unilateral decision-making alienates the team, creates confusion and fails to take advantage of the unique expertise of the team members. Foster open communication and communicate frequently, so that everyone
Return to contents
19 / 167
continued

on the team understands the issues and is aware of any problems that need to be resolved. Establish a communications roadmap for vendors; check with them soon into the project to make sure its working.
9. Make sure you have bench strength. Theres nothing that delays
a project more than a team member who gets assigned to another project and no longer has the time to devote to your project. Identify alternative resources early and have them ready to fill in if needed. That same rule applies to the system integrators team; make sure theyve identified people with equivalent skills who can be assigned to the project if required.
Close Internal Kickoff

Lifecycle Methods Waterfall Agile Spiral Design V Other
Requirements
Development Specification
Site Acceptance Test Factory Acceptance Test

Integration Test Unit/Module Test
Traceability
Design
Subsystem Unit/Module
8. Dont be a roadblock. As
project manager, its your responsibility to respond to information requests and approve various aspects of the project in a timely fashion. Stay involved and be responsive to prevent delays in the projects timeline.
Development
Project management V model, courtesy Control System Integrators Association.
Share article
Add comment
Return to contents
20 / 167
Automation project management from a machine builders perspective

By Paul Brinks, Chief Operating Officer, Koops Inc.
1. Select and build your internal project team. This is an important

first step that should never be skipped. Getting the right people with the right attitude will make the project successful. Work this one through before calling an equipment supplier; it will save precious time and money.
2. Select a Project Manager.

This person will build, execute and monitor the project plan and head up the team throughout the entire process to ensure continuity of understanding and commitments. This person will be the only contact with the system builder or supplier.
General Information
Project name Tech Spec revision level Tech Spec revision date Project description Estimated machine life Target cost
Performance Specifications
Involve departments. Manufacturing,
3. Define your automation goals. The project manager must set the
agenda for the meetings and be persistent. The goal is to develop a Technical Specification (Tech Spec) that lays out the design parameters and the performance expectations for the systems builder. The following list will get you started on a Technical Specification Form:
Quality, Finance, Purchasing, Facilities, Engineering. S elect people for the team with the right combination of skills and attitudes.
Production rate Maximum noise levels Capability Operator duties Number of operators Setup and changeover Repeatability
Return to contents
Share article
Add comment
21 / 167
continued

Machine Definition Project Management
*
Operation sequence Guarding Ergonomics Cycle activation Frame configuration Size footprint Power requirements Quality/Poka-Yoke*
Acceptance Criteria
Timeline development Transportation Installation Warranty Terms

4. Justification. This may be a
challenge. Management and the project team must be committed to the value of the investment. Companies will vary greatly as to how the justification is measured and how quickly a return on investment is required. Many common areas looked at for justification are: Capacity, efficiency, quality, personnel reduction, safety, sales value, etc.
DEFINITION
Runoff requirements Safety review Poka-Yoke verification Training Documentation requirements
Poka-Yoke is a Japanese term that means mistake-proofing. A poka-yoke is any mechanism in a lean manufacturing process that helps an equipment operator avoid mistakes. Its purpose is to eliminate product defects by preventing, correcting or drawing attention to human errors as they occur. More broadly, the term can refer to any behavior-shaping constraint designed into a process to prevent incorrect operation by the user.
Share article
Add comment
Return to contents
22 / 167
continued

Note: It is very useful to narrow it down to three of the major issues and put dollar amounts and specific justification to those issues. You can review the documentation after the automation project has been up and running and compare that to your original thinking.
5. Select a supplier. The best supplier is the one that you

can trust. Start by calling a few companies in for interviews. Use the Technical Specification (Item 3) as reference and ask the hard questions to determine the experience, capacity, capability and thoroughness of the supplier. Pick the supplier with whom you feel most comfortable.
6. The contract. The qualified supplier will be able to

contribute with ideas and concepts that must be reviewed with the project team. Solidify those ideas into a contract with the supplier. The contract should include your commitments and those of the supplier. The supplier will use your Technical Specifications (Item 3) to develop a contract (proposal) that will address the following:
A sign-off on all technical descriptions of the system Production rate of the system Final part drawings from the customer Capability to hold tolerances over a period of time Progress meetings and milestones Statements regarding noise, safety and environment Training for operation and maintenance Recommended spare parts Documentation and manuals Names of selected components Criteria for acceptance of the system at the supplier Criteria for acceptance of the system at your plant Procedure for handling changes after the order Warranty and service policies Delivery date Project price Payment terms
Share article
Add comment
Return to contents
23 / 167
continued

7. Monitor the project. It is highly advisable that project
managers from both the buyer and the supplier stay with the project throughout the entire process. Good communication on all the details between the two is critical throughout the project. The supplier should provide a timeline with all the critical milestones:
8. Training. Select the person from the project team that

will be responsible for the operation and maintenance of the automation system. This key person must take ownership and develop a plan for involving other people from the plant floor and learning as much about the system from the supplier as possible. This is crucial as the transfer of ownership takes place from the supplier to you. The following list should be covered by the training process:
Process planning Design review of electrical, mechanical, and flood power

systems Purchase parts ordered Subassembly Final assembly Debug time Runoff at supplier Runoff at your plant Training Installation and startup
All operational aspects including setup and changeover

procedure PLC, operator interface, and other system programming Interlock and safety systems Troubleshooting and repair service training Preventive maintenance schedule Manual and other documentation
Share article
Add comment
Return to contents
24 / 167
Can your current control platform deliver...

LOGIC MOTION SAFETY ROBOTICS VISION SENSING ENTERPRISE
continued

9. Runoff and acceptance at the supplier. The
intent is that the system, as designed and as stated in the Technical Specification, will be run off at the suppliers plant and that it meets or exceeds the criteria as agreed upon.
ONE CONTROLLER ONE CONNECTION ONE SOFTWARE
10. Installation, final acceptance, and production startup. The acceptance criteria as stated
in the contract will be the standard. This can be a critical time since all the planning done previously must come together at this point. It is now time for the person and company who purchased the system to demonstrate their readiness by putting the system into production. This is usually done with the assistance of the supplier. Notwithstanding warranty and service agreement coverage, most suppliers are eager to have the system running smoothly before leaving the plant.
Koops Inc., Grand Rapids, Michigan, builds assembly and process automation systems and workstations for a broad range of industries. www.koops.com
the performance your customers demand?

One controller through one connection and one software to completely integrate PLC logic, Motion control, Vision processing, Safety guarding, Robot kinematics, and Database connectivity. One great solution to drastically reduce machine tact time and programming complexity while improving performance and speeding development. Learn more about the Sysmac NJ Machine Automation Controller at www.Omron247.com.
Share article
Add comment
Return to contents
25 / 167
How to justify capital projects: Speaking finance gets results

By Gary Mintchell, Founding Editor, Automation World
Note: This article is as relevant today as it was in 2003 when first published. It has been updated several times since then. For technical managers, it seems like a no brainer. Applying new technologies will make the process better, faster and more consistent. Then the inevitable happensthe capital review team, whose members may not know a proximity sensor from a pressure transmitter, say, No money available. Keith Campbell, veteran of Hersheys engineering management team with many years of experience justifying automation expenditures, says, Do it in their language; its easier to convince them. Shrewd managers make capital decisions based on return on investment. You have to show them how your project will impact the bottom line. If you cant show the monetary justification in the language of finance, youll never convince them.
Different languages
This language has terms like cash flow, capital and interest. Campbell, who reveals these definitions later, advises, You must identify the positive cash flows you create with a new system, and then, using your companys method for calculating cash flow, do the math. Even if we are on a solid footing with the language of finance, we may not be so good at seeing our projects through an investors careful eyes. Peter Martin, vice president of Invensys, a Foxborough, Mass., supplier of process controls and software, says, When you are justifying automation, its important to remember that its an accounting problem. It is possible to solve the accounting problem through engineering principles, however. For instance, where is the biggest cost accounting database in manufacturing? It is information from all the sensors in the production process. In other words, tap into the data you have, and translate them into financial numbers.
Return to contents
26 / 167
continued

rewards at the justification stage. This person would be involved in the analysis at all stages of the project, and will be well positioned to translate benefits into the correct numbers. Why is there such an emphasis on financial analysis these days? Steve Loranger, area vice president for Emerson Process Management, an Austin, Texas-based process controls supplier, notes the changing valueof automation over the last 25 years. Automation drivers from the 1950s to 1975 went from pneumatics to electronics by emphasizing speed of operation and labor improvements with limited automation improvements. Drivers from 1975 to 2000 were repeatability and quality. During this time, computers went mainstream, there was improved control, and information integration became essential. Now, drivers are economics and business optimization, due to globally integrated manufacturing and activity-based cost accounting. A new automation project can be designed to solve any of a number of problems in the plant. The sidebar accompanying
Return to contents
Technical managers may be sitting on a gold mine of cost detail that can be used to determine where the manufacturing problems lie, as well as the crucial data that can be used to figure out the best solutionand how to get through the financial maze to approval. This advice directly leads to the conclusion that bringing a finance person into the automation buying team will reap huge
27 / 167
continued

this article provides several areas of improvement that can result from the project. Some of the areas can be hard to quantify, but it is essential to try to cost-justify as many as possible. For example, it may seem hard to quantify safety and ergonomic improvements that result from improved automation. But safety and insurance experts may be able to help document savings that can include anything from avoiding lost workdays to lower insurance premiums. Boston-based Liberty Mutual released its 2003 Fall Workplace Safety Index, and concluded that the financial impact of workplace injuries in the United States is growing faster than the rate of inflation. Insurance premium savings are certainly welcome, but a greater value to an investor is reducing risk to future earnings. Failure Mode Effect and Criticality Analysis is a powerful tool that can be used to demonstrate the risk of
Share article Add comment Return to contents
28 / 167
continued

a catastrophic safety event involving loss of life or limb. More often than not, risk elimination will strengthen the case for capital approval. lead straightness was specified. But the manufacturing of one of the components, a relay, was sent to Mexico in order to save costs. Constant employee turnover in that plant caused quality problems including solder buildup or tape missing over a hole. The problems just couldnt be controlled. This organization clearly suffered because the decision to source in Mexico did not take into account quality tolerances. Compounding the problem, operations and finance folks couldnt team up to demonstrate the cash impact of the scrap and productivity loss. Justification is technology-independent. The same rules apply to buildings, automation systems and computer systems, and to various scopes such as the entire project, just a portion of a project or even when evaluating competing quotes.
Lifecycle costs
Bill Egert, engineering vice president of Addison, Ill.-based integrator Logic One Consulting, and member of the Board of Advisors for the Robotics International division of the Society of Manufacturing Engineers, advises calculating all of the costs associated with the lifecycle of machines. He notes, Check out costs associated with changes. For instance, on robotics, evaluate the tooling changes needed to support product changeover plus auxiliary equipment such as feeders, conveyors and workstations associated with material handling. Dont dismiss employee turnover or morale as a factor that cant be quantified. Egert reveals, We had a printed circuit board assembly machine with robots where the component
Share article
Add comment
Return to contents
29 / 167
continued

Campbell says the fundamentals of justification include these steps: Because projects are expected to pay back funds over several years, it is important to find a way to normalize the amounts in order to keep the analysis in proper perspective.
Identify the base case Identify alternatives to the base case Determine cash flows associated with the alternatives vs. the base case Use your companys financial rules to evaluate the alternatives (payback period, net present value, rate of return, hurdle rate).
Present value
The first step is to determine the present value, which is defined as the value of all future cash flows discounted at the cost of capital, minus the cost of the investment. Discounted means that a future cash flow is worth less (discounted) than a present cash flow. So, $100 received three years from now at 8% cost of capital is the same as receiving $79.38 today. The Net Present Value (NPV) is the present value of all future cash flows discounted at the cost of capital, minus the cost of investment. Cost of capital is a weighted combination of the cost of debt (long-term debt and leases after tax) and the cost of equity (preferred and common stock). All future cash flows means that the PVs are summed over some time horizon, often five or 10 years. Subtract the cost of the initial investment from
Return to contents
The base case is the current state of affairs. Include all the financial data that can be compiled. Then, having identified the correctable problems, document various alternatives to the base case. Quantify all the risk, benefit and loss factors that you can. Take a balanced approach addressing significant pros and cons to demonstrate your thoughtfulness and enhance your credibility. Calculate the numbers and compare to the companys financial rules. Those results can then be compared to determine the best alternative to present to management for funding.

Sleek touchscreen displays | Rugged operator panels Flexible plug-in modules | Available in 8 different models Remote monitoring and control | Converts over 250 protocols
30 / 167
continued

the sum of the PVs to get NPV. The greater the NPV, the better the investment. What if the company just took the funds and invested them? A valuable comparison is the return due to the business investment vs. an anticipated return from automation project investments. The Internal Rate of Return (IRR) is the interest rate that equates the present value of future cash flows to the investment outlay. The IRR assumes that cash flows can be reinvested at a rate equal to the IRR. The hurdle rate is the minimum rate of return to justify an investment. This includes cost of capital, risk premium (which will include analysis of the track record of the group asking for money, type of investment and allowance for overruns), and other factors such as working capital requirements.
Graphite
The next level of HMI is now here.

Sleek. Rugged. Flexible.
Introducing the industrys rst rugged HMI solution. With cast-aluminum construction, Red Lions new Graphite series combines exible plug-in modules with protocol conversion, data logging and webbased monitoring to meet all of your industrial automation needs. From factories to extreme remote locations, Graphite enables customers worldwide to connect, monitor and control processes across a broad range of industries.
Graphite 7 touchscreen
Graphite 9 wide touchscreen
Plug-In Modules
Graphite 12 wide touchscreen
Calculate the cash flows and rates of return for all of the alternatives and then the best solutions will pop out. If
Connect. Monitor. Control.
+1 (717) 767-6511 I info@redlion.net I better.redlion.net

2014 Red Lion Controls Inc. All Rights Reserved.
31 / 167
continued

the numbers dont make the hurdle rate, then reevaluate the benefits. (Microsoft Excel has functions that easily calculate NPV as well as payback and IRR justifications). Emersons Loranger discusses the analysis from a slightly different point of view. The balance sheet is where assets and liabilities are tabulated and the income statement is where income and expenses are calculated. The analysis entails comparing the Return on Invested Capital (operating earnings from income statement divided by invested capital shown on balance sheet) to the weighted average cost of capital, or hurdle rate. The difference is the economic value added. Analysis is good, but often engineers looking at automation projects become infatuated with new technologies and fail to match the project up with business strategies. As Loranger shows in the Business Planning Framework graphic, technology managers find their comfort zones in evaluating automation technology alternatives. The profit zone for the business, however, lies in meeting or exceeding plant, production and
business objectives. So, when looking for projects with the highest probability of approval, make sure that they align with one or more of the objectives in the Profit Zone.
Train managers
Logic Ones Egert offers some additional tips on putting together a justification package. Get management trained on technical aspects, he states. They have lots of knowledge and experience on finance and marketing, but not much on technical aspects. A progressive, smart manager will have those technical people. A manager with technical skills will be able to see some problems coming. Another problem is management embracing new technology with no strategy for implementing, no urgency for training or no technical champion to embrace and learn the new stuff. Its not just a matter of providing training in some cases, but whether the workforce has the basic background skills to make training a practical option.
Return to contents
32 / 167
When EVERY minute of downtime matters...choose Graybar
continued

One approach that might change all of the calculations would be to lease new equipment, rather than purchase it. Paul Frechette, president and chief operating officer of Key Equipment Finance, commercial leasing services, a Superior, Colo. unit of Key Corp., says, 80 percent of American businesses lease equipment. They do it understanding that it is use of equipment, not ownership, which creates profits. Leasing from the vendor or from a lessor experienced in the field often yields the best deal, because they understand the value of the residuals (the value of the equipment after the term of the lease is over). The bigger lessors have been doing this for a long time and want repeat business, so they treat the residuals well. Their goal is to become trusted advisors. Assistance in evaluating leasing options is available from equipment sales people. Another resource close at hand would be people in the companys own finance department. They probably are already leasing equipment and have the process figured out.
Industrial-Grade Wire and Cable
Security
Industrial Networking
OEE Dashboards, DCS and SCADA, Micro Data Center Solutions
Electrical Infrastructure
Electrical Distribution
Industrial Enclosures
Control Panels and Control Panel Cooling Solutions
Automation and Control

Hot-Standby Controllers, Legacy System Migration
Graybar offers dependable automation solutions for all applications. Our network of eld automation specialists are there for you to answer even the simplest of questions on process control, facility automation and industrial networking.
Image Courtesy of Belden
EVERYTHING. Automation, networking, electrical, safety and security EVERYWHERE. 240 locations nationwide EVERY DAY. Since 1925
Thats Graybar. Call us. Well be there.
1-800-GRAYBAR (472-9227) graybar.com/pb-1
33 / 167
continued
Who are you competing with internally for dollars?

Make sure your project proposal appeals to your companys, your business units and your project stakeholders priorities. After all, you are competing for the same capital as everyone else. This isnt political. This is survival. Dont let that green roof win over your lean manufacturing improvements! sustainability officer should like your numbers better.
Will your proposed system save water, compressed air
Sustainable manufacturingwhat will really do the
usage, electricity, and/or floor space that must be lighted, heated and cooled? Most plants today face corporate mandates to hit reductions in all these resources, and every bit helps.
most to reduce your total system carbon footprint Will it be that green roof proposal or your production line improvements that produce less scrap and use less energy? Lean production lines wont make the same photo opp that goats munching turf on your plant roof willbut your chief
Consider distributed drive technologies that reduce the

heat buildup inside electrical cabinets and eliminatethe need for costly air conditioning and filtration, along with reduced floor space. To maximize energy efficiency,
Share article
Add comment
Return to contents
34 / 167
continued
also consider high-efficiency electrical power supplies, regenerative power supplies for servo drives, and a common DC bus between servo drives.
Headcount impactprograms that increase headcount
How easily can your production system be reconfigured

if the intended product line goes away? This is where automation can actually help product marketers and engineers mitigate the risk of their program proposal.
dont fare well during ahiring freeze. Increasing capacity without increasing labor is a good justification. But automation that can efficiently scale throughput up or down with reduced attention from plant personnel sounds like a real winner.
Dont forget the convergence of advanced technologies
How is your company investing in growth markets? Could

your automated line be readily deployed and supported worldwide with little or no modification, following international electrical and safety standards as opposed to the local sites internal standards? That could be a big plus.
and best practices that have a positive impact on seemingly unrelated aspects of operations. For example, implementing integrated safety doesnt just make a production line safer; it means more uptime, which results in measurable Overall Equipment Effectiveness (OEE) improvements. And today, the safety network can be the same network that links machinery together on a line, which also improves OEE.
Share article
Add comment
Return to contents
35 / 167
Eight tips for selecting the right automation system components

Many factors come into play when choosing components or systems for an automation project. Some companies reduce the complexity by limiting the number of suppliers they work with or standardizing on certain features or functionalities. Others want maximum flexibility and the ability to customize solutions or select from multiple vendors. The growing use of components built to industry standards is making both approaches easier to implement. market and not the proprietary product of only one supplier. Components should be easily replaceable with another make when needed at any point in time. The system should have the flexibility to expand in the future and should not become obsolete in the near future. Get a commitment from the OEM about planned system life.
3. Dont forget power. Make sure you have all the needed
power requirements in the locations intended for your new devices for the instrumentation you are using. Dont forget to update all prints to reflect your changes.
1. Flexibility required. The adaptability and flexibility

of components are critical. Make sure that open standards like IEC 61131-3, PLCOpen and overall fieldbus communications are supported. For OEMs, having equipment that communicates with more than one fieldbus is an advantage because they will not have to order different part numbers for different customer requirements.
4. Functionality. Make sure new components have all the

functionalities that will be required, such as asset management, power integration, safety system integration and the load of the CPU.
2. Easy replacement. Ensure that components are

user friendly, maintenance friendly, easily available in the
5. Three considerations. First, make sure new

components will comply with regulations, standards and
Return to contents
36 / 167
continued
Eight tips for selecting the right automation system components

best practices. Second, components must be consistent and compatible with existing systems. Third, anticipate new trends in automation to keep your system sustainable. FIND A PARTNER
Automation project managers need to find partners who they can trust and rely on to be with them through every stage of the project, from planning to implementation, from startup to long-term service and support. If a problem does crop up, a good project manager needs to know that their chosen vendors can be trusted to do the right thing in the heat of the moment to keep the project on track and make it a success. There will be plenty of time later to analyze the cause of and blame for the problem. The important thing is to not let issues get in the way of the project schedule and ultimate success.
6. Systems thinking. Do not fail to think systemically,

including power, grounding, communications, control and environment.
7. Look for support. Make sure to do the research and consider the ease with which a system can be modified if needed. Always evaluate whether support will be available after the project is completed. It does no good if the system will be obsoleted within two years and will no longer be supported. If buying from a machine builder, look at the OEMs track record and see how often it advances to newer generations of equipment.
8. Simplify. Select from a specific and predetermined

list of components during the design phase on any piece of
equipment so you dont need a spare parts room the size of a small plant. Go green wherever possible. Retrofit pneumatics, for example, using electric cylinders instead; restrict the number of stroke lengths to no more than three. Use similar criteria to simplify selection for other product categories, whether its motors, servos or other components.
Share article
Add comment
Return to contents
37 / 167
How to properly select and vet a system integrator

The process of finding a qualified system integrator for your automation project requires effort and attention to the details. Experience, expertise, staff capabilities and financial wherewithal are all crucial factors to consider in finding the right integrator partner. control may not have the expertise to handle a complex SCADA project.
2. Be suspicious of overpromises. If during negotiations and

setting requirements, a system integrator continues saying, No problem. Thats easy. We can do all you want... you can be sure that It will be a problem, it will not be so easy and It will be something that is more complicated than assumed. The integrator should prove that he understood your requirements, didnt underestimate the project and that he has experience with similar projects. Be especially careful if you get a much lower price than expected or than others have quoted.
1. Selection criteria. Search for a

system integrator who has a long list of successful projects in the areas you are looking for. Check out any references they provide and find out how long they have been in the field. They should also have a broad range of products they have worked with and have enough staff to handle all the various areas of a project. People who have done a lot of motion
Integrator source
An excellent source for information useful in selecting a systems integrator is the CSIA (Control System Integrators Association). You can search their membership by expertise, state, certification, etc., to find exactly the right fit for your automation project.
http://awgo.to/027
Organization: Control System Integrators Association
Share article
Add comment
Return to contents
38 / 167
continued

3. Familiarity with standards.
Find out what partners the integrator works with since no one can do it alone. Its also important to see how an integrator manages a project and what their code library looks like. Do they follow S88 and S95 methodologies? They dont need to follow these to the letter, but if they dont have a methodology and arent even aware of the standards, dont even consider them.
5. Expertise. Focus on their

knowledge, techniques and skills. Make sure they have full knowledge of system engineering, as well as sufficient experience to handle your project. A proven track record and references from the projects they have done are essential. DO YOUR HOMEWORK.
Extensive planning is complete, timelines and schedules are determined, budgets and ROI calculated and all the textbook preparations and considerations have been met. What could go wrong? Plenty! Always vet your system integrator. Get references, see a system designed and implemented by them in use, visit their factory and, most important, run credit checks and investigate their financial health. Nothing is more destructive than having an integrator run out of money before the project has been completed.
6. Current experience. Prior

experience in your discipline is key to the selection of your Integrator. Experience keeps the integrator current on new technologies and new hardware and software. As a result of the recent recession, integrators are not as abundant as before, with many unable to survive the economic turmoil. Many integrators have reduced staff, minimized technology education
4. Comfort factor. In addition to

reliability and professional capabilities, choose an integrator you feel comfortable with, who understands your process needs and who has experience in the field. The integrator also needs to have a staff with expertise and domain knowledge in your business area.
opportunities and made other cutbacks. Take the time to assess the strengths and weaknesses of any integrator you consider to ensure that they are capable of delivering the system that you require.
Return to contents

Graphic HMI | PLCs | Panel PCs | OITs
39 / 167
Powerful Industrial HMIs

4.3 to 15 Display Sizes
Connects to over 100 PLCs High Resolution Graphics SD & USB Expandable Storage Cast Aluminum Enclosure Serial, Ethernet, & USB Audio & Video Operating Temp: -20C to 55C
continued
for Every Need...

7. Stay involved. Has your system integrator done
something similar before? Chances are the pool of talent isnt all that big. Can you allocate any resources to working with that integrator on a day-to-day basis? You will have to take ownership of the system, so you will need to know how to modify it and maintain it or you will be tied into a system that might need unallocated cash to make changes. Get involved at the zero level in the planning, simulation, detailed layout, software handling techniques and maintenance requirements as much as you possibly can in order to get the biggest possible benefits and to learn in excruciating detail how it all goes together.
At a fraction of the cost of competing brands!
8. Take a long-term view. Select an integrator

with experience in similar systems, preferably of the same make. Tie payments to project milestones. Make sure his services will be available for upgrades and maintenance by signing a separate contract.
425.745.3229
Every Machine Needs the Human Touch
Call today for a Free Demo
www.maplesystems.com
Share article
Add comment
Return to contents
40 / 167
continued

9. Problem-solvers. Choose an integrator who has
experience in the tasks you need performed. They have probably already solved many of the problems you may face if you choose one whose experience is outside the necessary area of expertise.
12. Smart isnt enough. Choose an integrator as you

would choose an employee. Spend time, talk to references and know that while every firm out there enlists very smart engineers, you dont want them cutting their teeth on your project.
10. Ask questions. Choosing a system integrator is the

hardest and easily the most overlooked part of an automation project. Ask questions about types of projects theyve done, vertical preferences and size of projects. Have them include project details, such as were they on time and on or under budget, and what percentage of the time.
13. Professionalism counts. Make sure an integrator

can confidently provide you with a project plan, with decision points, contingency plans and staffing that will meet your timeline and project goals.
14. Test the team.

Verify the integrators capabilities by giving a test to the personnel who will perform the work on your project. Make sure those people are listed in the contract, including fallback or substitute candidates.
Return to contents
11. Experience has its limits. Be aware that most

integrators have experience either in a vertical industry or with a certain type of project, such as PLC/HMI programming. Either way, they may lack the capabilities needed to do projects outside of that experience. Many HMI/DCS vendors have a list of endorsed or recommended system integrators on their home page. This is a good place to start.
41 / 167
continued
Detail the requirements

1. One of the most important factors in selecting a system integrator is his willingness to develop a good project proposal. Avoid any integrator whose proposal is just one or two pages long. 2. Automation projects must have good system requirements from the customer, and the system integrator must list in his proposal what requirements will be met and what will not. 3. If the requirements and proposal terms are properly defined from the beginning, the result will be a project with no or minimum change orders. 4. Some system integrators take advantage of a poorly written requirements document from a customer and present a very generic proposal, so the price might look attractive at the beginning. When the project is awarded, then the customer has to face a series of change orders because a requirement that might be obvious was not listed in the proposal. The customer ends up paying far more money for the project than originally estimated. 5. Establishing a good project requirement list is not only an essential customer task, but also requires the cooperation of the system integrator.
Share article
Add comment
Return to contents
42 / 167
continued

15. Do they have business skills? Look beyond
technology expertise or project experience to consider an integrators commercial qualifications: Are they CSIA certified? Do they have insurance? How many years have they been in business?
16. Are they open? Select an integrator that is open to

your requests and ideas. Beware of someone that constantly pushes back. If you hear the phrase nobody does it like that or this is how everyone does it, you might want to consider another integrator that is more open minded. You are paying that integrator to get what you want and neednot just what they are willing to build because its easy or they always do it that way. Yes, you hired them for their experience and would like their suggestions, but dont discount your own ideas just because this is your first time. Also allow for the ability to make some changesespecially if your approach is new and unconventional. Be open for changes and tweaks as you go if it makes the end result easier to use and more flexible. You need to stay involved throughout the whole process. Dont pass up the learning opportunity!
43 / 167
12 common mistakes people make in automation projects

In their rush to complete an automation project, people make the same mistakes over and over again. This ready-fire-aim approach to planning and executing an automation project inevitably causes major headaches, cost overruns and delayed schedules. locate the source of the problem.
3. Start with the integrator. Dont select and buy

equipment based on a specific vendors recommendations, then hire an integrator to get it to work. Instead, hire the integrator to do the design and program and start up the system. In the end, it will not cost more. Time spent in the field getting a mix of components to work together is extremely inefficient vs. implementing a system with devices that are designed to work together. An experienced system integrator inherently designs a system to perform to a customers requirements while minimizing the time it takes the integrator to deliver it.
1. Dont limit input. The most common mistake is

limiting the initial input to too few people. Many managers are surprised when they hear an insight from a person in their plant. Its much easier, and less expensive, to build that insight into the project planning from the start.
2. Never assume. Mistakes are most often made during

the definition phase, when you think that everything will be easy to domotors just need to move from point A to B with synchronized speed, for example, and then during the installation phase, when signal cables are routed together with power cables and shielding is simply forgotten. This causes all kinds of strange equipment behavior later, when its hard to
4. Copy and paste. People dont make mistakes when

planning automation projects; the mistakes are planned in. This is because most machines are sold before they are fully developed and rely on the experience of previous projects using a copy and paste approach to get them completed on
Return to contents
44 / 167
continued

time. The consequence of this common strategy is that you automatically give up the perfect solution for one that is good enough. The tragedy is that, with careful accounting, the differential between a white sheet design (starting with a new platform that commonly comes with an App Store) is much quicker than the copy/paste/mop strategy. It also retains more customers because the adoption curve is much quicker for machines with more canned features. downtime. When two machines need to work together, it is critical to use appropriate handshaking signals to avoid any cell or machine damage. Bypassing safety is another cause for problems. Design cells so workers cannot bypass safety measures.
7. Experts inside. In-house expertise is essential to the

success of any project. Integrators build good machines and systems, but when they are deployed in the plant environment, its the in-house expertise that turns a good system into a great system.
5. Failure to communicate. One of the most common

mistakes is not communicating with the end user and technical staff. If a machine does not make their work easier, they will find a way to make your system do what they want even if it causes other problems. If you do not consider the technical staff, the repairs or adjustments will be met with resentment and most likely extended downtime.
8. Plan for changes. When designing, or budgeting for

automation projects, usually there is a clear goal or list of things that need to happen. But you also need to plan for the unforeseen. Something will always come up later on that will need to be added. To cover this, always add 20 percent to the overall project budget. Also, additional checks or sensors may be needed down the line, so make sure you have extra I/O or at least the flexibility to expand the I/O if needed.
Return to contents
6. Handshakes critical. Not paying attention to

handshaking signals and improper use of I/O handling can cause serious damage to equipment, eventually causing more
45 / 167
continued
Seven Automation Donts

1. Dont over-complicate the solution. Keep the solution simple. 2. Dont program the machine first. Always program or storyboard the HMI first. 3. Dont neglect the communication protocols and interface terminals when evaluating control products. 4. Dont waste too much time planning without customer input. That could cause critical planning errors that will need to be corrected at heavy expense and effort. 5. Dont forget the grounding. 6. Dont propose a project without a good understanding of the requirements. That guarantees scope creep. 7. Dont always believe what salesmen tell you. Do your homework and make your own decisions for your application.
Share article
Add comment
Return to contents
46 / 167
continued

9. Do a punch list. After initial implementation, get
agreement from everybody on the punch list of items that need to be updated. That includes operators, technicians and production management. People might disagree on what has been accomplished and what still needs to be done. etc., and use password protection to allow set-point changes only within a specified range. Never allow full access to program changes.
12. Forbid coding from Day 1. Automation engineers

love to puzzle with the problems they get on their table. Forbid any use of coding software until the entire scope is clear and closed, the delivery has been broken down to manageable pieces (Work Breakdown Structure) and everybody knows what the tasks and targets are ahead of them. Also, make sure that the tasks and the targets are properly documented before letting the engineers loose on the coding tasks, because to have them document it afterwards involves twisting their arms to make them do it. Diving right into detailed problem solving and coding is the fastest way to failure in an automation project.
10. Can a machine do the job? If the automation project

is based on replacing labor, you will first need to understand the totality of what is being done manually. You may need to go back to the drawing board if a machine cannot do what an operator has been doing.
11. Limit program access. Always run an information

session after commissioning to familiarize all personnel who may be involved with set-point changes, principles of operation,
Share article
Add comment
Return to contents
47 / 167
10 ways your automation project can fail and how to prevent it

From failure to define requirements to disengaged project managers, changes in direction or employees who lack the skills to do the job, the sources of automation project failures are often easy to identify. Fixing them is usually the bigger challenge.
2. Lack of the right people resources. Too often a

project is running at full throttle, only to come to a complete stop because the person originally tasked to do the PLC engineering or development is busy putting out fires, has inherited another project or is otherwise not available. When developing schedules and project plans, try to gain stakeholder commitment to use contingent resources or assign another skilled resource based upon a scheduled check item.
1. Not getting maintenance and operators involved from the start. Some assembly jobs have been
done by hand for years. The worker who has been on the line for a long time will have seen what has and has not been done in the past. Just because components on paper are all uniform does not mean that they are in tolerance in the real world. Maintenance workers have dealt with more fixes and operator complaints than the design engineer. The key to a new piece of equipment working well is maintenance and operators taking ownership of the system. If they arent on board, the machine may just end up being a big paperweight.
3. Unengaged project managers. When the project

manager is unengaged or unresponsive to requests for information or approvals, you know the project is destined for failure.
4. Lack of scope benchmarks. Without scope

benchmarks in place that are tied to the proposal document, the project manager cant assess programming time for each phase to help detect scope creep. Benchmarks help deter
Share article
Add comment
Return to contents
48 / 167
continued

a giant breakthrough in small readers
project stakeholders from adding capabilities to the process that can lead to both financial and timeline strains, and ultimately to a failed project.
5. Skills mismatch. Many automation projects

are viewed as successful when the system is in the development and testing stage, but it becomes an entirely different scenario when the project is implemented in the field. Errors begin to crop up. This is often due to the different skill levels of the people who develop the project compared to the people who are sent out to execute it in the field.
Meet the DataMan 50L. The tiny barcode reader that brings big performance to the food & beverage industry.
Dont let its size fool you. The DataMan 50L is huge in barcode reading performance. Measuring just 23.5mm x 27mm x 43.5mm and featuring an IP65-rated housing, the DataMan 50L is premium technology designed for 1-D-oriented barcode reading. The DataMan 50L delivers read rates that can surpass 99% through Cognexs proprietary Hotbars image-analysis technology. The new DataMan 50L is a powerful upgrade for applications that use small laser barcode scanner systems. Visit us at www.cognex.com/50L.
6. Poor planning. Most projects fail because of

poor planning. There is a tendency to underestimate the complexity of the project and overestimate the capabilities of the team. Late changes are the worst enemies of any project. The project owner also needs to establish the most important priorities for the team, such
Scan to Learn More
49 / 167
continued

FIVE POINTS FOR FAILURE.
1. Failure to plan for and handle project resource changes. 2. Failure to know or admit that requirements are not well defined. 3. Failure to address requirement definition problems in a timely fashion. 4. Failure to plan and execute design review and approval milestones. 5. Failure to engineer the verification of project deliverables sufficiently, including lack of inspection and test planning.
frequently.
8. Design misalignment. Failure often comes from

a lack of communication on the design of the project, from component selection to the format of I/O tags, networks and programming structure. Provide a scope prior to design that allows all items of the design to be agreed upon. As this document is created, members of the team or the integrator can then point out potential pitfalls, such as using multiple networks or not selecting a common controller.
9. Confusion. An insufficient amount of effort in the frontas cost, quality, maintenance, training, stocking of components, safety, etc. This will assure that decisions are aligned with the projects goals. loading stage, or subsequent budget cuts or direction changes by management, will result in confusion for the project team. Its a standard recipe for failure.
7. Failure to manage expectations. Make sure all

stakeholders understand the trade-off between scope, budget and time frame. Communicate this deliberately, formally and
10. Other reasons for failure.
Unrealistic schedules are set. Potential risks are not calculated and planned for.
Return to contents
Share article
Add comment
50 / 167
continued

E ngineers working on a project lack the necessary skill sets
or experience. Insufficient milestones to measure progress and identify problems. Outdated/incorrect documentation in brownfield projects. Insufficient time in the schedule for third-party communications or for developing a particular section of the system. M ismatch in the requirements of the project and the solution given by the supplier. M issing of the minute details pertaining to engineering and scope of supply. F ailure to establish a clear schedule to finalize process and equipment designs. L ack of training to enable plant personnel to operate and maintain complex systems and new technologies.
Share article
Add comment
Return to contents
51 / 167
SECTION TWO:
SELECTING PRODUCTS TO BUILD YOUR AUTOMATED SYSTEM
52 / 167
16 best practices for specifying PLCs, PACs or PC controllers

The controller is the foundational product for any automated system. Whether its based on PLCs, PACs or PCs or a combination, your control platform must perform reliably for many years. Quality, functionality, cost, ease of programming and maintenance, the ability to communicate and connect with multiple devices on the factory floor, as well as ready availability of support from the manufacturer, all factor into the selection process: only after the initial machine or process automation conceptual design is completed. Far too often an over-specified controller unnecessarily adds to the automation projects costs. Or even worse, an under-specified controller may result in redesign efforts, additional purchases and schedule delays.
3. Clarify interfaces. If multiple people program parts of

the PLC code, spend some time initially to make sure that the interfaces are clear and everyone understands them. Dumping a diagram on someone is not good enough.
1. Bench test. When working with a controller, its important

to know its capabilities and if it meets the needs of your project. Theres nothing worse than being halfway through the project, only to find out that your controller isnt capable of doing something. If the project includes something you havent done before, always bench-test the process before committing it to the project.
4. No canned code. When planning for PLC-based

controls, if your in-house techs will be involved in maintaining and upgrading the new system for future needs, dont bring in canned code. Ensure that your techs have input as to the structure and nomenclature of the program. Bugs and changes are the norm with any new control system, and you will find your facility rebounding much quicker after such a major change in equipment.
Return to contents
2. Dont over-specify. Dont select a specific controller too

soon in the design phase of a project. Selection should occur
53 / 167
continued

FLEXIBILITY, SUPPORT, WARRANTY, TOTAL COST
There are four key factors to consider when selecting a PLC for a project: yy First, the controller must meet your performance needs today, but consider that the system may operate over the next five to 10 years. During this time, changes to the system may require modifications and choosing a flexible system upfront can help reduce costs in the future. yy Second, consider what type of support is available to you if you have questions on the hardware or software. It can be both frustrating and time-consuming if your PLC vendor does not provide in-depth support in a timely manner. Find out what type of telephone support and local support you can leverage from the manufacturer. Be sure you are comfortable with your access to help if needed. yy Third, think about quality. Everyone wants to know that his or her system is reliable. Ask your vendor about the warranty. When vendors are confident about their quality, they stand behind it with lengthy warranties. yy And finally, consider cost. Today every company, large or small, is looking for ways to become more cost-efficient. Consider the total cost of ownership for the PLC. You must always consider hardware and software costs, but think about ancillary costs. Are there annual software licensing fees? Are there annual technical support fees? What is the cost of training? All of these costs can greatly increase the total cost of ownership of a PLC.
5. Can we talk? A primary concern when implementing any

PLC is communications. This has been minimized with the advent of ODVA, but can still be a problem when dealing with some sophisticated sensors or peripherals. Choosing a PLC family that has all the device type communications modules is paramount.
Most PLCs on the market can communicate on device buses, but not all can accommodate every type of Ethernet. Do your homework and choose a PLC that can support all your buses without a lot of pain.
Return to contents
54 / 167
continued

6. Not all controllers or brands are the same.
Consult with people who are knowledgeable in many different hardware platforms before specifying or selecting a certain make and model or even a platform. Too many times what is specified will not perform to the customers expectations. That leaves gaps in what is bid and will require changes in the project. management or closed-loop control.
8. HMI first. When programming your project, its best to

start with the HMI first. If you write your program code first, quite often youll have to rewrite your code to accommodate your HMI.
7. Key check points. Whenever upgrading a system or

changing from one controller to another, always remember to check the controllers power supply, memory, I/O type, size and availability in the panel. Double-check the purpose for which the controller is intended, and always carefully check the model number. Make sure the controller has the basic features you want, such as online bypass, online programming, alarm
9. CPU load. It is important to consider the CPU load if

communication handling is vital to the application. Running at the maximum cyclic load will result in poor capacity and response times for peer-to-peer and OPC Server communication. Peak cyclic load should be kept below 65 percent and static cyclic load below 60 percent under all conditions. Even lower cyclic loads (30-40 percent) are desirable if high communication throughput is important.
Share article
Add comment
Return to contents
55 / 167
continued

WHAT ARE YOUR GOALS?
When selecting a control platform to automate a machine, you should first decide your end goals. Ask yourself: 1. Do I want increased productivity? Better repeatability? More consistent accuracy? 2. Do I need servo or stepper motors? Servomotors will generally have better acceleration and top speed characteristics over a stepper. Stepper motors do better when holding a position without dithering. 3. What type of controller? Will a PLC work or do I need a more dedicated motion and machine controller? For basic material and conveyor control, a PLC is a good choice. If high-speed electronic gearing, product registration or more complex motion is required, a dedicated motion/machine controller is a better choice. If data handling is required, then a more dedicated motion/machine controller would do better. 4. Will the controller do the job? Best to spec in a controller that can handle more axes of control than you expect as you may need to add these capabilities later. Be sure the controller has the processor power to perform all the needed functions. Its common to run out of gas when performing multiple tasks simultaneously. Look for a fast processor, enough user memory and a lot of connectivity.
10. Get out of the code. Ask the people at the plant why
they are running the way they do. Sometimes what you might think is bad programming is really needed to optimally run a
process. On the flip side of the coin, after examining the code, you often find people think a system is running in a particular way, but the reality is that it is not.
Share article
Add comment
Return to contents
56 / 167
continued

11. Document software. Use of programmable controllers
offers significant advantages over analog devices. However, it brings a new set of issues. First, consider the control of multiple function block parameters. It is a good practice to maintain the software configuration control document that summarizes all programmable/tunable parameters in one place. You will use this document for any disaster recovery event, including cybersecurity issues.
14. Prior experience. Do not use a controller for critical

applications in your plant without a successful prior use experience with a like product with the same revision level components, firmware and software.
15. Are micro PLCs an option? Micro PLCs with flexible,

just enough control may enable OEMs to differentiate their equipment, particularly in stand-alone machines. By developing a range of stand-alone machines using the same controller platform, OEMs can reduce design time and lower their costs. Look for micro PLCs that include:
12. Think ahead. Dont go for the cheapest option when

installing a PLC. Think five years ahead to accommodate factory integration, peer-to-peer networking and data exchange between controllers. The modern factory environment is becoming a network of integrated controllers.
Flexible hardware configurations, like USB, up to six serial ports

and Ethernet for communications. Up to three axes of embedded motion. Plug-ins and 2085 expansion for I/O USB. Single programming software package that eases installation, configuration, connectivity and maintenance.
13. Dont overcomplicate your solution. Keep it as

simple as possible. Dont use a PC-based system when all you need is a little advanced I/O control.
Share article
Add comment
Return to contents
57 / 167
continued

16. Single control platform. Customizing your controller
selection for each application may seem like a smart move, but sometimes it pays to narrow down to a single control platform. Survey your requirements and select a platform capable of handling all current and near-future needs, from the simplest to the most complex ones. Selecting a single control platform for all of your automation control requirements, whether it is motion, robotics, numerical control, C program or sequence control, can reduce spare parts inventory, unify programming methods across all machine types and simplify training and maintenance efforts.
Speed up controller response

Shave milliseconds off controller response times by optimizing subroutines, exploiting interrupt programming and leveraging peer-topeer review. See how by viewing this white paper.
http://awgo.to/025
Source: Rockwell Automation
Share article
Add comment
Return to contents
58 / 167
10 steps to creating the perfect HMI

When developing HMI screens, realize that you are attempting to capture the essence of the machine or process, not just posting key automation variables and control mechanisms. Operational feedback is vital for efficient HMI screen layouts. Think of yourself as an artist, commissioned by manufacturing operations to create the HMI screens. success of your system depends on their usage.
3. Design tips. A good design requires careful use of layout,

color and content. If you get it wrong, your operator misses an indication, you lose money, or worse, someone is injured. The bad screen is less than satisfactory: The layout is poor, the plant representation isnt logical and the screen layout makes it difficult to locate the data. Poor selection of colors, excessive use of capitals in a serif font and repetitive use of units with all data values makes this a really difficult screen to readespecially at a glance or from a distance. Avoid colors that could create problems for people with color blindness. Minimize the use of colors to allow actual device state and alarms to stand out. For alarming, choose colors that contrast with the normal process view so the operator will notice the change.
1. Less is more. Its important to keep the HMI simple and

with the operator in mind. Its best when its self-explanatory and easily understood. Also, try to make the pages similar and follow the same page layout throughout. Avoid making the display too technical. Its normal for engineers to try to give the customer everything, but with HMI, less really is more.
2. Right-size displays. Dont try to save money by

selecting an HMI display screen thats too small. Its also important not to cram too much information onto a screen. Size the display according to the amount of information that is most important for the operator to see. Always discuss requirements with the equipments operators well ahead of time, not just with their managers. Operators usually have different needs and the
4. Plant review forum. Hold a design review with a group

of plant personnel to discuss any status notifications, events, alerts and alarms that need to be programmed, both from the perspective of an audio-visual action and an operations response. Step through the intended functional system, once as
Return to contents
59 / 167
continued

the designer, once as the user and then invite at least two levels of users who will be interfacing with the HMI. Doing this prior to specifying equipment helps to identify the features that users will want in the HMI station. It also avoids surprises at point of commissioning.
5. Location, location, location. Real estate can be prime

in a busy production area. Locate the HMI in a practical place, out of heavy traffic areas but accessible. Be aware of near-future projects in the area. Guard the HMI location so others dont park or configure something else on top of the station.
6. Back up work periodically. Backups are especially

important before implementing upgrades or changes. Software such as Nortons Ghost Image can be invaluable to support and maintain HMI systems.
7. Visualize the process. HMI graphics should illustrate the

production process in the plant to provide better visualization to the operators, giving them a sense of the action thats required.
Use hardware that meets minimum requirements and keeps the number of failure points low and assures high availability of the system.
Return to contents
60 / 167
Tightly Integrated Vision System Easy to use Embedded Software Sensor Resolution: VGA to 1600x1200 Factory Communications
Industrial Enclosures 360 Direct Mounting Factory Style Connectors Ideal for Single Point Inspections
continued

8. Only essential data. Make control and monitoring
of the process simpler by selecting only the most essential information from the process database for the historian. This will reduce the load on the system and keep it from stalling or failing. Dont forget the need for maintenance and make sure you schedule periodic backups.
9. Think about flow. It is essential to have a clear

design approach to the HMI. Decide how the display blocks naturally flow and how sections need to be grouped together for the operator. Do not blindly follow P&I diagrams. The S88 functional hierarchy is a good place to start. Make paper-based designs to get a feel for screens, navigation and other requirements, and review with clients prior to designing and making electronic screens.
BOA products are highly integrated vision systems in a tiny smart camera package specifically designed for industrial use. Complete with choice of application software embedded, BOA offers new and experienced users alike, an easy-to-deploy cost effective vision solution.
10. Alarm strategy. Alarming needs to have a wellarticulated strategy. Alarms must be used for conditions that require intervention and must have a clear corrective action associated with each one. Anything else should not be an alarm.
Get more vision.

www.teledynedalsa.com
61 / 167
continued
Alarming guidelines
The key aspect of an HMI display is the dynamic plant data. There are two basic types of dynamic data: Alarms and normal Plant Status data. 1. Alarm status for the overall plant, preferably organized into groups, should be visible on every screen and there should be a simple navigation route to access the screen containing additional details about the alarm. 2. The alarm colors should follow the safety convention: Red = stop, prohibition, danger; Yellow = caution, risk of danger; Green = safe condition; Blue = mandatory action. As one in 12 men have some form of color-blindness, which can affect the perception of red and green, color cannot be used as the sole indicator of alarms. 3. Any color change must be supplemented with a pictorial change and, if the alarm is critical, an audible alert. Pictorial changes could include shape changing, a change in the position of an indicator, having additional text or objects appear on an alarm. Flashing of alarms that have not been accepted is very irritating and stressful and should be avoided.
Share article
Add comment
Return to contents
62 / 167
continued
4. Similarly, automatic changing of displays should be avoidedto have a page disappear when you are working on it is irritating and, in extreme cases, a cascade of alarms can produce so many screen refreshes, an operator can be locked out of the system. 5. Audible alerts can be very useful, especially if the system is able to create multiple tones and pitches. These tones can be used to transmit the importance of an alarm. Research has shown that a high-pitched, fast-pulsing sound automatically conveys urgency; a lower-pitched, slow-pulsing sound is less urgent. 6. Whatever convention is used, alarms should be placed where they can be easily seen, such as along the top of the screen.
Our expertise in automation, both electric and pneumatic, can solve all your motion challenges
Global manufacturer of process control and factory automation solutions
For more information: Call: 1-800-463-3786 www.festo.com/us
Share article
Add comment
Return to contents
63 / 167
Eight considerations for I/O engineering success

The days when every device in an automated system had to be installed using multiple wires are over. While proper system design can still be challenging, technology advances in I/O have greatly reduced engineering and installation time and the wiring errors that once caused frustrating delays in the commissioning of new automated equipment. parts, find out whether they are NPN or PNP, if analog signals are voltage or current, any handshaking requirements and dry contact digital or higher-level communication. It seems simple, but one key component that doesnt match up with the I/O you select can cause big headaches.
1. Motion needs deterministic I/O. Try to have

deterministic data transfer. If motion is I/O-sensitive, then you need deterministic I/O to synchronize to the motion task, so that events happen in the same time interval.
4. Field electronics. Ensure that I/O electronic interfaces

can be implemented directly in the field, allowing you to replace the junction box multi-conductor back to the equipment, rack or MCC room. Field electronics need to be G3 rated per ISA standard (S71.04).
2. Quick connections. When selecting a terminal block for

your control cabinet, look for one that has pre-built jumpers that can be installed quickly. This will save time later.
5. Shorten commissioning. I/O allocation plays a key

role in reducing the commissioning duration of an automation project, followed by appropriate loop testing prior to start of commissioning activities.
3. Match specifications. Its important to know all the

information about any components you are interfacing to when you develop specifications for a project. If others are supplying
6. Delay layouts. The design team working on the project

should not begin the planning and layout drawings for
Return to contents
64 / 167
continued
Eight considerations for I/O engineering success

distributed I/O in the facility until all equipment OEMs have provided general arrangements. Provide the team with an overall scope on what these cabinets are called by name, and what area of the facility each will handle. Timing of this design phase with the upfront engineering will save time and money. REMOTE I/O PITFALLS.
There are many design pitfalls to avoid when developing I/O systems. The options now available to the designer are limited mostly by hardware price point, once you understand the purpose, location and lifecycle issues. Just because a thing can be done, however, does not mean that it should. Remote I/O options, for example, are growing, which can reduce wiring and terminal block needs in some cases by over 50-80 percent compared to what was available just 10 years ago. But serious thought has to be given to proper documentation and training of plant personnel to repair and maintain the system and prevent downtime. The documentation should include troubleshooting methodology in addition to part number, manufacturer, MAC address, etc. The control software should also be integrated with the remote I/O layout to allow for either remote troubleshooting or status information. If these simple things are not properly accounted for and implemented, the actual usage of the remote I/O may not be worth the savings. Return to contents
7. Leave room for expansions. Make sure your new

control cabinets have plenty of room for all I/O points needed in that cabinet. Also allow room for expansions that will be required for unanticipated changes and upgrades In the future. For I/O wiring, plan to label the parts of the circuit wiring that connect to the I/O points from that side of the devices with the program addresses. This will lessen the time needed for your techs to troubleshoot issues with those circuits later on. The rest of the circuit labeling should be based on the print line numbers.
8. Diagnostics. Make use of the built-in diagnostic

information provided by most I/O systems. Good information for the operator can save you a lot of production time.
Share article
Add comment
65 / 167
11 recommendations for selecting motors and drives

Motors and drives are two of the foundation components of any automated system. Here are a few tips and best practices for achieving improved motor control: a hybrid contactor. Now you have the best of both worlds a programmable, intelligent overload that has motor load feedback (alarm back to operator as well as shutdown parameters) with a hybrid contactor. The hybrid contactor extends the time between end-of-life motor switching by a factor of 10. The intelligent overload will remain in service indefinitely.
1. Think system. When doing an equipment upgrade,

think of the drive train as an integrated system and choose components with similar efficiency ratings. It makes no sense to couple a high-efficiency pump to an inefficient worm gear. The motor used to drive the load could be half the horsepower with a more efficient gear reducer because of the reduced energy losses.
4. Proper way to select motors. Selecting a motor

needs a bit more than just calculating the maximum rotational speed and torque. The best way to select a motor is by drawing a speed-torque diagram of the load and the maximal allowed speed-torque diagram of the motor (as defined for continuous operation). If the diagram of the load characteristics is fully enclosed by the diagram of the motor characteristics, the motor is adequate.
2. Matching firmware. When changing a drive, make sure

the firmware of the drive or motion controller matches the one you are replacing.
3. Intelligence improves uptime. When you want

to improve uptime, think about replacing standard IEC electromechanical starters with an intelligent overload with
5. Manual mode. The manual mode, which allows

maintenance to check if one specific motor has a problem or
Return to contents
66 / 167
continued

not, is usually forgotten. If the motor will not run correctly, put the drive into manual and run the motor for a short time. This eliminates the drive from the problem and points to the controller or, if local control does not work, the drive could be suspect. Magnetically coupled drives have the advantage of decoupling of vibration and potential overloading of the motor or driven equipment due to the air gap between the motor shaft and the other shaft, which can reduce costly damage to mechanical seals on equipment.
6. Do your homework. Always check for the proper

rating and proper type of drives or motors for different type of application. Ask the supplier about the fail-safe function of the system and always check for proper grounding of the system. Make sure you inform the supplier about the features you want and the process to be controlled.
8. Economical spares. Try to use the same type of drives to

maintain a common inventory. Also, instead of stocking multiple spare cards for the drive, keep one spare module. This will be an economical solution.
9. Deciding factors. With the sophistication of drives

technologies, it often becomes difficult to decide what to choose as the right technology for positioning applications. In the past, servo systems were the only choice available for achieving reliable positioning performance. Today, however, many applications, excluding CNC machines, can be implemented using AC flux vector drives. The determining factor in the final choice of technology is the positioning accuracy requirements and the ability to deliver full torque at zero speed.
Return to contents
7. Magnetically coupled drives. For variable speed

control of rotating equipment, such as drives for an agitator motor or a chiller compressor, take special care to place the drive in a hardware panel installed in a dust-free location, preferably air-conditioned. A better solution for harsh environments that have maintenance people with minimum skills might be a magnetically coupled drive with variable speed option.
67 / 167
Can your current control platform deliver...

LOGIC MOTION SAFETY ROBOTICS VISION SENSING ENTERPRISE
continued

10. Drive failures. The reliability of the core
components, such as the PLC or a variable frequency drive, in a control system is important. Drive failure may be caused by many factors: PCB calibrating, IC chips failure, mishandling during installation, operating environment, etc. Even though the manuals of some drives claim that using certain technologies, such as MOV, common mode choke, common mode capacity and others, can make the drive more EMI compatible, it can also make them easier to damage.
ONE CONTROLLER ONE CONNECTION ONE SOFTWARE
the performance your customers demand?

One controller through one connection and one software to completely integrate PLC logic, Motion control, Vision processing, Safety guarding, Robot kinematics, and Database connectivity. One great solution to drastically reduce machine tact time and programming complexity while improving performance and speeding development. Learn more about the Sysmac NJ Machine Automation Controller at www.Omron247.com.
11. Good housekeeping. Keep motors and drives

clean and free of foreign contaminants to keep them running for a long period of time.
Share article
Add comment
Return to contents
68 / 167
continued
Performance packed into compact drives

Advancements in todays AC drives, including compact drives, require that engineers more thoroughly review how drives with new, performance-enhancing features can contribute to automation projects. Selecting a compact drive still requires an understanding of the most appropriate control technologyvolts per hertz, sensorless vector, etc.but while those control technologies have remained relatively unchanged over the past decade, there have been dramatic technological leaps in other areas. Similar to trends in consumer electronic products, compact drives now pack more intelligence and user-focused design in smaller sizes. Engineers tasked with implementing an automation project need to understand the latest compact drive features and how the right mix of features can ease data sharing, improve safety, minimize programming and installation time, and, ultimately, lower total overall cost.
Share article
Add comment
Return to contents
69 / 167
continued
To find a compact drive that can do more and maximize value, engineers should examine features in the following four key areas:
Programming. Seek simple local and programmable
Communications. Seek compact drives with multiple
communication options, dual port connectivity supporting ring topologies with device level ring (DLR) functionality, and support for other open industrial networks.
automation controller (PAC)-integrated programming to reduce development time. Features such as descriptive scrolling text on LCD human interface modules (HIMs) and intuitive software with standard connectivity help speed up drive configuration.
Physical size. Seek compact, modular designs that
Safety. Seek embedded safety as a standard feature to
help protect personnel and equipment, meeting ISO 138491 standards with ratings up to and including SIL 2/PLd Cat 3.
allow simultaneous configuration and installation while offering flexible mounting options with small footprints, high ambient operating temperatures and low clearance requirements, saving valuable panel space.
Share article
Add comment
Return to contents
70 / 167
Four tips for improving motion control systems

Technology advances, along with a systems approach to design where all the components are working together in harmony, allow engineers to deliver improved performance in motion control applications. Here are some tips and best practices to get the most out of your motion control solution: running conditions, inertia, braking and deceleration, current dissipation, back driving or on-site drive tuningjust to name a few of the more common issues associated with motioncontrol design. Youre the person responsible for ensuring you have thought of everything when dealing with motion-control concerns. So instead of charging full force into a project, take the time to first identify all the possible scenarios that your project may face before it starts. Its important to document potential trouble spots and anticipate appropriate solutions.
1. Design for system. It is important to understand the

accuracy requirements of the entire electromechanical system when specifying servo drives. The control system, position feedback sensing, the drives and final gears/mechanical links have to be carefully chosen to work together so that the desired resolution of control can be achieved. It is important to work with suppliers who strive to understand your needs and will provide knowledgeable technical support when complex control strategies need to be implemented.
3. Exceed machine specifications. The problem with

motion control is that speed does not necessarily equate to throughput and motor resolution does not equate to system accuracy. You need to design the system to exceed the machine specifications; this means from the drive point back to and including the motor.
2. Plan for surprises. If youve ever designed motion

control systems or served as a project manager, chances are youve run into a few surprises during a project, such as overShare article Add comment
4. Cubic splines. Use cubic splines for motion planning and

for servo interpolation of position, velocity and acceleration.
Return to contents
71 / 167
continued
Four tips for improving motion control systems
Dont forget power, grounding

Proper system design is critical to the long-term success of your manufacturing system. Steps to remember include: 1. Power monitoring for energy management. 2. Balanced and adequate power distribution for immediate needs (in current and voltage range), as well as an allowance for growth. 3. Power supply review for variable frequency drives, inverters and converters to ensure adequate isolation, impedance and grounding. 4. Grounding review for supply to drives, drives to motors, motors to supply for high-frequency mitigation, as well as safety or PE (potential earth) and adequate isolated TE (true earth grounding) for control and communications. 5. Cable selection, routing, management and access design.
Share article
Add comment
Return to contents
72 / 167
Seven considerations for applying servo drives, motion controllers and PLCs
Technology advances in servo drives have made them the workhorses of motion control. Here are some recommendations for implementing servo drives: that can quickly pay for itself, especially for users who run multiple format sizes on the same production line.
1. Dont fear servos. There are many different levels

of positioning and motor controls now. Some basic variable frequency drives can even be used to do what could have been done only with coordinated drive systems in the past. So dont be wary of servo technology. They are now more cost competitive with auto-tuning, which makes them straightforward to implement.
3. Why use motion controllers? Everyone knows some

PLCs can do lots of things, and that includes motion control. However, separate motion controllers persist because they perform combined servo and stepper motion control and are properly coordinated as a high-performance system with the same servo drive supplier. Companies that produce motion controllers design them specifically to increase a machines output with improved accuracy. Trying to use a PLC to address registration or robot-type control, plus handle recipe data, may require additional PLC programming capability and time vs. some motion controllers. Past experience on such applications says its best to use the optimal tool for the job. And with the latest motion/machine controllers with built-in IEC 61131-3 functionality or other straightforward programming capability, you can have the best of both worlds.
2. Quick changeovers. Machine setup and changeovers

lead to lost production time and inefficient production. Changeovers can vary from minutes to hours. Consider using low-voltage servo drives with built-in encoder, controller or removable memory units, specifically designed for auto-format settings and quick changeovers. Using a customer-friendly servo drive for quick changeovers and machine setup is an investment
Return to contents
73 / 167
continued
4. Over-sizing wastes energy, cost and panel space. Some of the biggest energy wasters on a machine are
frequently overlooked. Over-sized servo drive/motor systems, for example, cause machines to consume more energy than necessarysomething that can easily be avoided through proper design. End users often underestimate the returns from energy-efficiency investments, since it costs more up front and may take a few years to achieve payback. As a result, they often inadvertently build in extra long-term, ongoing costs by overlooking details when sizing machine components. When sizing a machine, the entire motion profile is important, not just speed and load. Having a detailed and accurate profile of needed motion can pay dividends. Typically, a less precise profile will lead to an over-sized servomotor. This means that the energy consumption of the system will be higher than needed. The key to getting the motion profile right is properly calculating velocity, continuous vs. peak torques, acceleration, and matching load and motor inertias. Further, refine the profile by accounting for cycle times. How long does the system have to move from one point to the next, and how long can it take to complete the
entire trajectory?
5. Document requirements. When building dedicated

automation with motion control, whether you source it out or not, it is extremely important to understand the system you are building and the functionality that you intend it to have. There are different levels of motion control, especially if using a PLC as the primary logic controller. For example, on an indexing assembly station that used a servo drive to index large assembly pallets from one station to the next, the controls company used an incremental encoding servo drive system rather than an absolute encoding system. This error crept in because the original rationale for using an absolute system was not documented. Consequently, in an emergency stop situation, the indexing system would stop and then want to do a complete index, starting from its current point. Had absolute encoding been used as originally planned, recovery from an e-stop would have been very simple. If the expected functionality had been properly documented, additional complexity would not have been added to what should have been a simple solution.
Return to contents
74 / 167
continued
6. Minimize vibrations. The latest vibration suppression
algorithms in some servo drives can actually minimize vibrations from occurring on overhung loads and in the machine base without additional sensors. These vibration suppression algorithms, combined with auto-tuning and filtering, can allow for high-performance motion without complicated mechanical damping or heavy bracing. LOAD TO MOTOR INERTIA RATIOSIMPROVE RESPONSE TIME
Calculating an inertia ratio is often overlooked by newcomers to servo sizing, but is arguably the most important factor in determining the performance of a servo system. Inertia ratio is calculated by dividing the load inertia by the motor inertia. Lower load-to-motor ratios improve response times, reduce mechanical resonance and minimize power dissipation. An inertia mismatch of greater than 10:1 can produce oscillations and extended settling times. To prevent overshooting and oscillations with very large mismatches, the control gain may have to be reduced. A motion system with a load-to-motor inertia less than 10:1 can reach a set speed or move into position in less time than one with a ratio greater than 10:1. Large inertia mismatches require higher current to drive the motor, thus they dissipate more power. For example, a mismatch of only 5:1 will dissipate six times more power, and it gets worse as the load inertia increases.
7. Reduce wiring, space. By using common DC and/

or multi-axis servo drives, OEMs can reduce wiring, energy consumption and panel space. These systems use regenerative energy to power other axes, rather than wasting this energy as heat in the electrical enclosure. Panel space is reduced by up to 30 percent, while wiring is reduced by up to 50 percent, compared to a traditional single-axis servo system architecture.
Share article
Add comment
Return to contents
75 / 167
Seven issues to think about before you develop an industrial network

Networks provide the framework for any automation project. The issues are complex and require an in-depth understanding of the requirements of your process and the nuances of networking technologies. Here are some suggestions to help you meet the challenges:
1. Multi-vendor problems. If you are connecting devices

from different vendors, try to find out if you are the first to get these devices talking to each other. If yes, plan for a lengthy commissioning process. Communication standards may be fine on paper, but in practice you are likely to have to do a lot of fiddling to get everything working.
Data delivery reliability Future proofing to include scalability Data/network security requirements Current on-site expertise Ease of architecture Total cost of ownership
3. Design for the process. When implementing an
industrial network (be it Ethernet or traditional fieldbus), be sure to get all affected parties involved during the initial design. This could include production workers on the plant floor, IT, engineering and more. One method is to simulate your product going through the entire production phase, see where it goes and who interacts with it, what information it needs and where that information comes from, as well as what information it produces and where that information goes. Getting all the affected parties involved will not only get you the best solution, it will make everyone understand that they have an investment in the project.
Return to contents
2. Selection factors. When choosing the network topology

and protocol you want to use, remember to evaluate and select according to the following factors:
Process time requirements End-to-end distance requirements

76 / 167
continued
Seven issues to think about before you develop an industrial network

4. Functionality varies by vendor. Understand what
functions and performance your network needs to deliver before listening to various sales pitches. The functionality various manufacturers implement, even in standard fieldbus or Ethernet systems, can vary substantially. Never make assumptions about any vendor-specific products. conditions and possible changes in those conditions. Design your network to handle not just current conditions, but also possible changes. This is a particular requirement in hazardous environments like cement and power plants. Dont jump into implementation in the field without prior design, locating equipment and identifying signal paths on plans.
5. Does your team have fieldbus skills? Select a

fieldbus that can be handled by the software team at your disposal. The greatest fieldbus technology in the world will fail if the software team does not understand the integration, implementation or error handling of the selected product.
7. Keep things simple. Industrial automation networking

is great, but remember to keep things simple. If a few discrete I/O handshakes would serve the purpose, it might be the best design. Even if a fieldbus segment could theoretically be loaded to the maximum or use a less-traditional architecture, those designs could reduce system reliability or make it harder to troubleshoot in the future.
6. Plan for future. Give careful consideration to site
Share article
Add comment
Return to contents
77 / 167
Six things to consider when you get down to the network details
It all comes down to the details. Thats as true for networking as it is for every other aspect of an automation project. Here are some tips for making sure the details are covered with your industrial network: fieldbuses and especially proprietary networks, it is critical to test to the point of failure. These failure points can be associated with the number of Ethernet port connections, the size and frequency of data being managed, as well as data addressing in the PLC. The PLC addresses used in data collection, if not contiguous or near contiguous, can cause excess read/write cycles to the PLC. Some PLCs can only provide X number of devices in one read. If that number is 1k (1024 devices) and you attempt to read the values of coils 250, 1400, 5000 and 6500 in one cycle, it can actually create four separate read requests. This results in performance issues and missing data. Think of the impact if you want to read 250 values! FMEA (Failure Modes and Effect Analysis) is a great tool to aid in trying to identify what can go wrong.
1. Keep a list. Networked devices have addresses. It is very

important to keep a list that shows the assigned address, the product this address has been assigned to and the line/plant location where the product has been installed. It is very difficult to troubleshoot many systems because this basic information was not captured, leading to significant equipment downtime. Once installed, these devices need to be labeled accordingly since it is not uncommon to have several identical devices in close proximity. This information should also be part of any electrical and mechanical drawing.
3. Be aware of security issues. You have to be constantly

aware of the security aspects of your control network. Seek cooperation with the IT professionals; you likely have more overlap with office systems than you might know.
2. Test to failure. When developing data collection/data

passing applications (PLC to PLC, PC to PLC, etc.) using Ethernet,
Share article
Add comment
Return to contents
78 / 167
continued
Six things to consider when you get down to the network details
4. Avoid subnetworks. When selecting fieldbus or
network architecture, avoid the use of subnetwork systems or expandability features that require configuration of expansion modules or field devices separately from the PC or PLC. Subnet components add an additional burden for end-user support and complexity in software (re-tagging/programming) when the subnet I/O count or type changes. stand a chance of disproving this. Make sure high-quality network analyzers are available, and the real root cause of the problems will show up very quickly: very often it is application software. A network engineer without a network analyzer is like an electrician without a multimeter: clueless.
6. Everythings networked. Nothing is not in the

network anymore. When you implement a new project or a new system, the networking criteria are a critical consideration. Every device needs a communication port or ports, physical media, communication protocol and tools to configure, display, diagnose, analysis, etc.
5. Need network analyzer. When a system using a

fieldbus/industrial network does not work as expected, somehow the network is always blamed: too slow, too many flipped bits due to EMC (electromagnetic compatibility) issues, etc. Without proper measuring equipment, a network troubleshooter wont
Share article
Add comment
Return to contents
79 / 167
Five considerations for implementing Ethernet for an industrial network

Ethernet is everywhere on the factory floor, but standards for dealing with it may be lacking. Here are some suggestions for updating your practices: technology makes it easy to manage traffic. For a large plant floor, different areas can be zoned for control and monitored independently. Industrial Ethernet can make media redundancy very flexible, and the convergence time is very short, often milliseconds with Resilient Ethernet Protocol (REP) and Device Level Ring (DLR).
1. Need industrial IT strategy. With the rapid growth of

industrial Ethernet devices, the lack of an industrial IT strategy at many companies is becoming a real problem. Its not uncommon to have thousands of Ethernet devices on the plant floor, but strategies for data management, security, redundancy, reliability, etc., are often seriously lacking. Start with a basic industrial networking standards document, just as you have an electrical, controls or HMI strategy. Simple rules for implementing Ethernet networks (wired or wireless) save many problems down the road and support easy expansion in the future.
3. Maintain standard Ethernet frames. Ethernet is

the future of real-time and long-distance industrial networking. It is being adopted for many aspects of automation, including controls and I/Os, servos, safety, configuration and diagnostics, synchronization and motion. To realize the benefits of these technologies, however, requires a good integration of standard Ethernet frames when selecting an industrial Ethernet technology. Users mainly select industrial Ethernet because they want to fully benefit from Ethernet and its higher-level functionality, such as web server, diagnostic, firmware upgrade, etc.
2. Ethernet is fast, flexible. One of the many benefits

of industrial Ethernet is that it can be used to build a very large, widely distributed network compared to many other fieldbus networks. Classless IP address scheming is important here. VLAN
Return to contents
80 / 167
continued

4. Learn Ethernet. Take the time to learn (through courses
or self-taught) the art of Ethernet networking. Its never going to go away. If you can seamlessly work through VPNs, port forward, subnet masks and IP addresses, your job is only going to become more interesting.
5. Get ready for connectivity. It makes sense to

implement all PLCs on Ethernet using protocol converters. This makes your plant ready with data available on Ethernet for future connectivity with MES/ERP systems.
Networking tips for machine builders

OEMs need to understand the big picture when selecting a network for a machine. Does the end user of that machine need secure remote access, will IT be involved, is the machine standalone or will it be networked? How? What are the requirements? In todays factory, departments such as IT, operations and accounting will likely be involved in the project scope. You need to understand their requirements when selecting a network and how to provide value after the machine has been delivered.
Share article
Add comment
Return to contents
81 / 167
continued
Machine builders also need to consider how their equipment will impact the factory LAN once the customer installs the equipment on the factory floor. Many OEMs now use Ethernet as their communication protocol within the machine and provide an Ethernet switch to network the devices in the panel and to provide a link to the factory floor. Several of the industrial protocols on the market today use multicasting between devices in order to streamline communication. This feature can save bandwidth within the machine by allowing a device to send one packet to several
devices at once, but can cause problems with the factory network if not handled properly. If an OEM puts an unmanaged switch on the machine and the customer connects the machine to the factory LAN, this multicast traffic will be broadcast throughout the factory because an unmanaged switch will turn that multicast traffic into broadcast. The solution is to use a managed switch that supports both IGMP and IGMP snooping on the machine. This will prevent the multicast traffic from reaching the factory LAN.
Share article
Add comment
Return to contents
82 / 167
Four tips for dealing with wireless latency and bandwidth issues
More and more, systems engineers are taking advantage of industrial wireless technologies to reduce the amount of cabling in their designs. There are some issues to be aware of, however, when replacing dedicated connections with wireless links: multicast traffic coming from PLCs or producer devices. Multicast traffic is handled differently than unicast traffic by wireless access points. Multiple devices can receive multicast traffic, while unicast is destined for only one device. Wireless access points transmit multicast traffic at a minimal rate to ensure that all listening clients will be able to receive the traffic. This results in low aggregate bandwidth over the wireless AP as it has to lower its transmit rate down from the maximum.
1. Need latency tolerance. Todays wired Ethernet

connections are full duplex. This means that each end device can both transmit and receive at the same time. On the other hand, wireless technologies such as 802.11a/b/g/n are half duplex. This means that when any one device is transmitting, all other devices must wait. Make sure that your application is designed to be tolerant of the latency introduced due to the half duplex nature of wireless.
3. Low bandwidth requirements. Make sure that

your applications bandwidth requirements are low enough to be satisfied by the lower rates. Many designers overlook these points and experience problems when moving to wireless solutions. Being aware of the limitations of wireless technology can ensure that your upfront design will work in a wireless deployment.
2. Control multicast traffic. When implementing wireless

technology in factory automation projects, be aware of any
Share article
Add comment
Return to contents
83 / 167
continued
Four tips for dealing with wireless latency and bandwidth issues
4. Dont take shortcuts with wireless. Consider
the entire system design and the support lifecycle of the system before choosing technology and vendors. Time spent up front on site surveys, path loss calculations and fade margin will pay dividends when it comes time for installation. Design in fade margin. Wireless is very reliable when well designed, but if you dont design in appropriate fade margin youll have problems in the future.
Our expertise in automation, both electric and pneumatic, can solve all your motion challenges
Global manufacturer of process control and factory automation solutions
For more information: Call: 1-800-463-3786 www.festo.com/us
Share article
Add comment
Return to contents
84 / 167
How network management systems aid firmware, configuration updates

As technology advances, automation projects today are becoming more and more complicated. Many times engineers are focused on the design of the end application and fail to spend enough time thinking about the ongoing needs of the network. Todays automation projects are always connected to some sort of network. A reliable network is an integral part of the successful automation project. If you fail to plan for the growth of the network or plan the management aspect of it, the project is bound to run into problems down the line when it is too late to change things. Most network devices contain firmware and need to be updated for security patches or increased functionality over time. Failure to plan for how firmware updates will be accomplished in the running system can lead to misconfiguration and long downtimes. When you only have a few devices deployed, this can be a simple task to accomplish. When you have many deployed, it can become challenging and time-consuming. The order in which the network devices are updated can make a big difference in the connectivity of the network and needs to be planned out as well. Another common problem is failure to plan how configurations of your network devices will be backed up after changes are made. You want to ensure that when a device needs to be swapped out, its configuration can be quickly installed on the replacement device with no ambiguity as to which features to enable. Over time, as new functionality is added to the system, changes may be required to the network topology as new devices are added. Unfortunately, hand-drawn documents of network diagrams are the last thing to get updated and often get overlooked. This can lead to problems later on when new systems engineers are assigned to maintain the project. In
Share article
Add comment
Return to contents
85 / 167
continued
How network management systems aid firmware, configuration updates

addition, the ability to generate an inventory report that details the exact devices on your network can aid in upgrading and maintaining the network. In order to manage these kinds of tasks, include an NMS, or network management system, in your systems design up front. An NMS should be capable of not only managing a single vendors equipment, but should include third-party devices as well. Make sure that your NMS has the capability to discover devices added to the network. It should also be capable of autotopology, which can document the connectivity in the system. Firmware upgrade and device configuration and documentation must also be present to ensure ease of maintenance. Including an NMS also provides for ongoing monitoring of network availability and stability. Having the capability to look at the availability of network links can help to isolate problems in the network before they become critical. Its also important to have the ability to replay network conditions after a problem occurs. This can aid in isolating the root cause. Planning for these tasks up front will help lower the maintenance costs for your system.
Share article
Add comment
Return to contents
86 / 167
12 tips for selecting and sizing pneumatic and hydraulic components

In todays typical manufacturing facility, hydraulic and pneumatic systems serve as the primary means of power for most cylinders, tooling and even some drive systems. They can be operated in high-temperature as well as high-radiation industrial environments where most electronic instruments will not function properly. Volumes of material exist on proper system design, proper sizing of components, circuit design, valve and control technologies, as well as other design considerations. However, here are a few tips you may not find in the textbooks:
2. Use electric actuators. With ever-increasing energy

costs, designers should consider using energy-efficient electric movement, provided the application requirements fall within an electric actuators performance capabilities. This technology has advanced rapidly over the last five to 10 years, with vast improvements in functionality, including more precise movement and even built-in sophisticated controls.
3. Valve sizing. Correct sizing of components, including

piping, valves and actuators, can improve the productive capacity of pneumatic systems. Valve sizing is particularly important. If the flow capacity is too small, it can have a negative impact on production cycles. If you want to improve production cycle time and quality, then proper sizing is critical.
1. Flow vs. pressure. When dealing with pneumatics, it is

critical to understand the difference between pressure and flow. Too often operators compensate for starved flow with increased pressure. It is often best to install oversized supply lines to a process in order to ensure the appropriate volume of air.
4. Align pipelines. If pipelines are not aligned properly at

the correct angle, as indicated in the installation drawings, there
Share article
Add comment
Return to contents
87 / 167
continued

is a great possibility of equipment damage.
8. Use feedback sensors. Dont rely on software interlocks

to control pneumatic devices unless you account for the delay caused by physical actuation. 100 ms is a long time in the computer world. Always back up actuators with electrical feedback sensors, redundant if possible.
5. Choose three-position valves. Wherever operators

will be working near an operation, a three-position valve is a better choice than a two-position valve. This is because a threeposition valve will stop the equipment instantly in the event of an emergency. This is in contrast to a two-position valve, which will first complete the operation before stopping.
9. Parallel air. Make sure you have an adequate air supply

when using pneumatic technology. Costly leaks are often hard to detect in a noisy plant environment. To avoid failure in the supply of compressed air on a network, it is important to verify that the distribution is closed so that the compressed air comes in parallel and not in series. Inspect tubing, ferrule, connection and joints for leakages. Make sure the air being produced is dry. All air filters should be checked periodically for accumulated water drainage.
6. Check temperatures. Be sure to check the surface

temperatures of equipment during preventive maintenance time and make a record. High temperatures could damage the viscosity properties of the hydraulic oil.
7. Built-in flow control. When you are using a pneumatic

cylinder in a project, especially in high cycle count projects, use a fitting that has a flow control valve built in to make the cylinder last longer.
10. Choose quality tubing. To prevent leaks, use nylon

tubing on machines rather than push-on fittings and PE tubing.
Share article
Add comment
Return to contents
88 / 167
continued

The leakage often found with soft tubing is hard to detect in a plant environment.
11. Inlet side flow control. In a pneumatic logic circuit

controlling a double-acting cylinder, place the flow controls on the inlet side of your cylinder depending on the direction of travel. Air is compressible and positioning will float if controlled on the outlet. This will also create back pressure.
Let Graybars team of Industrial customer-focused sales professionals and automation and control technical specialists help you: Increase Output improve throughput with improved process control improve quality with improved process control Reduce Costs select the right automation and control products for lower equipment and system maintenance online monitoring and predictive diagnostics to reduce costs Safety select sensing and signaling solutions to provide a safe production environment intrinsic safety solutions
12. Low fire risk. One of the advantages of pneumatic
Learn more at graybar.com/pb-2
Automation and Control Solutions for the Industrial Customer
technology is that it can operate without using electricity. This minimizes the risk of fire or explosions from sparks or arc flash events. This technology is particularly useful in a plant making edible oils or hydrogenating oils or when using flammable gases in the production process.
Share article
Add comment
Return to contents
89 / 167
11 considerations for selecting and deploying industrial robots

As manufacturers embrace the business case for implementing robots, engineers are challenged to design systems using todays highly complex and increasingly sophisticated robot technology. cell doors have safety interlocks and light curtains as needed, and make sure you make the robot aware of these safety devices so it can do the job better. When it comes to designing your robot cell (electrical and mechanical layout) and programming, always consider safety as your top most priority. This aspect is even more important given all the codes and regulations for robotic safety. For more information on new safety requirements, visit http://awgo.to/026.
1. Redefining robots. Too much focus on humanoid

robotics is a misplaced definition of objectives. A robot is really a modular, autonomous platform combining measuring circuits, active RFID, RF, acoustic, laser and power technologies for insitu data processing and real-time communication. Distributed architectures with this type of robot are revolutionizing industrial automation.
4. Complexity can be barrier. When implementing

robotics, engineers need to ensure the system is scalable, will mitigate safety and security risks, and has built-in energy management. The robotic system must provide personnel at all levels with access to prognostic and diagnostic data in the same way discrete and process automation systems deliver operating data. Unfortunately, the complexity of the design process can often be a barrier to achieving the cost savings and efficiency gains expected with robots.
2. Dont fight the laws of physics. Adjust your

expectations to what the robot is actually capable of doing.
3. Safety first. Pay attention to the cell layout from the

operators perspective. Fence the area so the operator cannot reach into the cell while the robot is in full motion. Make sure all
Share article
Add comment
Return to contents
90 / 167
continued
Tips for robotics integration

Whether youre looking to integrate robotics into existing equipment or scale your control and information platform to accommodate robots, here are some general tips on the three primary options: 1. Use a single control platform that can be scaled to fit a wide range of robotics applications, regardless of size or complexity. This method allows the highest level of integration because it combines kinematic robot control within a machines controller. All configuration, programming, kinematics, troubleshooting and operations are performed within a single control platform, which helps reduce engineering costs, training, maintenance and the overall machine footprint. 2. Use a single network technology and a common control and visualization environment. A networked approach integrates the robot control system with the machine control system. This is the most cost-effective solution for quickly integrating robotics into an existing application. Doing so gives the machines controller access to the robots control system, including diagnostics, necessary automation interlocks, troubleshooting, alarming and reporting. 3. Use a common control engine and development environment to help eliminate the need for separate
Share article
Add comment
Return to contents
91 / 167
continued
controllers and systems. This embedded approach to robotics integration brings the robot module directly into the control platforms chassis. It keeps machine and robot
control separate, but helps drastically reduce the machine footprintby up to 50 percentbecause there are fewer control boxes on a machine.
5. Tooling clearance. It is very important to have a clear,

defined understanding of the type of end effector for your application so that tooling does not damage in-order production parts. Selecting a well thought-out end effector will also help minimize the teach time on the final program to ensure the proper clearance to run the robot at the maximum speed.
emergency maintenance never happens, and temporary, suboptimal, rigging ends up hurriedly being used.
7. Get early feedback. Try and do as detailed a simulation

as early as you can and show it to the workforce involved in the process in order to get feedback on possible operational issues. You may find that there is more going on in the existing process than you knew about and that micro-management is necessary.
6. Plan for maintenance. For large robots, make sure

means for maintenance are included in the original project scope. A monorail hoist designed in at the start of the project, for example, is much cheaper and easier to install than one built years later. Installing a hoist while running requires scheduling, downtime, lost production, etc. Installing a hoist during
8. Zoning for product size. In a robotic pick-and-place

system for thermoformed packaging trays, incorporate zoned suction cups that can be isolated or turned on and off, to allow for various tray sizes.
Share article
Add comment
Return to contents
92 / 167
continued

9. Electronic changeovers. Customization is only a
fraction of the normal line production, but the ability to create electronic changeovers between formats in a small footprint streamlines the customization process. MECHATRONICS FOR OEMS
The perception of robots in the industrial workplace follows a form factor that leads users towards a limited amount of mechanical models. This feels modular, but its not mechatronic. Changing the definition of robotics to coordinated axes synchronized by a single software and processor opens up conventional machine design to modular code and mechanismsor mechatronics. OEMs that have adopted this new outlook make robotic machines that are faster, smoother and more flexible, not by changing their mechanics but by changing their approach. The choice for OEMs is even easier because they need only migrate their control philosophy to those capable of true mechatronics.
10. Error codes. When you are programming a robot, many

lines of code are involved. If you build in your own error codes in the program, it is easier to identify where in the program the error has occurred and to diagnose the issue. If it is a new issue, add it to the list of your error programs.
11. Faster remastering. For a robotic cell, design in a

location datum point into the cell. Having an independent datum point outside of the usual work area (still within the robot work envelop) will allow quick remastering of an axis or robot following maintenance. This is critical for users of just a few robots, who dont typically have a lot of robot axis mastering
experience. Witness marks on joints can fall off, and having an independent means to establish the coordinate system is a major time saver.
Share article
Add comment
Return to contents
93 / 167
A role for robots in lean

Lean manufacturing is a strategy for reducing wastein materials, movement, waiting time, processing and defects. While robots are not innately lean, since they could be used to automate a faster creation of waste, there are a number of ways that their capabilities can support lean manufacturing systems: Traditional production lines are designed to be an effective collaboration between man and machine. While the machines (including robots) can be programmed for optimal performance, people cannot. An efficiently designed automated robotic station must take into account the human variable and not limit the station ahead of time by creating an overly rigid structure. Most important, the decision to use robots must be justified by an ROI analysis. Planning is critical. Robots must be properly incorporated into the overall lean manufacturing environment, in the right applications, to get the desired results. Standard industrial robots have a single tool mounted to a single arm. While more efficient than human labor, the lack of flexibility is limiting. By incorporating tool changers, the robot can perform multiple functions. This improved utilization improves productivity and profitability.
Repeatability and accuracyimproved product quality or
consistency and reduced scrap rates. Robots deliver limited production loss and lower error rates compared to manual operations. Speedincreased production rates and reduced wait time for operators. Robots have negligible downtime in situations where there is high demand for the manufactured product. Flexibilityreduced training and changeover time. Robots can also be set up to multi-task.
Share article
Add comment
Return to contents

Graphic HMI | PLCs | Panel PCs | OITs
94 / 167
Powerful Industrial HMIs

4.3 to 15 Display Sizes
Connects to over 100 PLCs High Resolution Graphics SD & USB Expandable Storage Cast Aluminum Enclosure Serial, Ethernet, & USB Audio & Video Operating Temp: -20C to 55C
continued
for Every Need...
A role for robots in lean

Vision systems empower robots
Another development that can advance lean manufacturing is the combination of vision technology with robots. Vision-generated guidance information allows robots to vary their motion targets. This is particularly useful for operations that require visual distinctions and decisionmaking, such as racking/un-racking of parts, part picking from bins and part inspections. By taking over these once manual activities, robots can deliver higher consistency, accuracy, repeatability and speed. Robots are heavily utilized in inspection applications using flexible measuring systems. Mounted with vision cameras, these robot systems can collect information from multiple locations, dramatically reducing the number of vision cameras and fixtures required to inspect parts. Visionequipped robots can also reduce imperfections and scrap material in finishing operations, such as routering, grinding and sealing.
At a fraction of the cost of competing brands!
425.745.3229
Every Machine Needs the Human Touch
Call today for a Free Demo
www.maplesystems.com
Share article
Add comment
Return to contents
95 / 167
10 secrets to selecting and implementing sensors in industrial applications

The successful application of sensors depends on selecting the right technology for the application, the variables of the product being sensed and the conditions in the operating environment. Ontario and would be susceptible to lake-effect snow. If the ducts filled with snow, it would impair the operation of the air handler and the sensors within the ductwork.
1. Measuring range. When choosing a sensor (pressure,

temperature, analog, etc.), the measuring range should directly correspond with the physical measuring range in order to obtain the most accurate reading and optimum sensor lifespan. For example, to measure 0-10 psi pressure range, a pressure transducer with a sensing range of 0-10 psi is most suitable. Same concept applies for voltage or resistance analog signals.
3. Load cells important. No one gives load cells the credit

they deserve when it comes to level measurement in tanks. They work great for batch measurement applications when using a hinged tripod tank mounting arrangement: two legs with hinges, the third with a load cell in compression. Use a panel meter with discrete output to give an output when the set point is reached. This also works well for providing a low-level alarm in applications. The load cell and controller can make it simple to automate the process in the future.
2. Weather watch. Be aware of environmental conditions

when installing equipment. As an example on one project, the intake air ducts on air handler units were installed facing southwest, with no grating or gooseneck. The ducts faced Lake
4. Need flexibility. When choosing a sensor, consider

whether it provides the flexibility required, such as features that
Share article
Add comment
Return to contents
96 / 167
continued

adapt to changing product. In this case, consider capacitive sensors, which are sensitive to more colors and materials than others, and in many cases are less expensive than ultrasonic sensors.
5. Select for technology, conditions. The

most common mistakes in sensor applications include failing to select the most appropriate sensing principle/ technology for the task, and failing to consider the full range of expected operating conditions. For example, although a capacitive proximity sensor can detect metals, in general an inductive proximity sensor would be a better choice. Ambient light, temperature, dirt, vibrations or other conditions can affect sensor performance. An example of failing to consider operating conditions would be to install a sensor rated for a maximum temperature of 70 degrees C in an area where temperatures can reach 85 degrees C or higher. In this case, the sensor may experience premature failure or may exhibit unstable operation, such as locking
97 / 167
continued

on or locking off. Additionally, sensor life can be extended in harsh environments when used with accessories that are designed to protect the sensor. Depending on the cost of the sensor being replaced, this can be a pretty costly situation when, in fact, a relatively inexpensive replacement connector cable could have solved the problem in the first place.
6. Digital lowers costs. If linear or proportional output

sensor devices are needed, avoid analog field devices to minimize cost and support issues for shielded cables and grounding. When available, digital output equivalents are usually worth the additional purchase price for overall lower cost of ownership.
8. Intelligent sensors. Consider adopting intelligent

sensors that can be scaled, calibrated or configured remotely in order to shorten changeover time, automate sensor reconfiguration and facilitate remote sensor diagnostics.
7. Faulty cables. When replacing a bad sensor in an

existing field application, be sure to also check the condition of the quick-disconnect cable or cord set. In many cases, the pins or sockets are weakened or corroded, leading to intermittent operation. Replacing only the sensor may temporarily restore electrical contact, but it will certainly fail again because the root cause, a faulty mating connector, has not been corrected.
9. Advance warning. An important trend in sensors is to

upgrade or augment discrete on-off sensors with sensors that provide a continuously variable output signal, either analog or digital. Continuous sensor output signals enable much higher levels of operational sophistication, such as fault prediction and statistical process control. Through analysis of sensor data, machine controllers can alert operators of impending problems
Share article
Add comment
Return to contents

All Gigabit modular design | Up to 24 port connections Robust remote monitoring | DIN rail and rackmount models Smart plug-and-play operations | Hot-swappable modules
98 / 167
continued

before they actually become a problem. An optical analog sensor, for example, may measure the bend angle on a stamped part. If the bend angle begins to drift beyond a given +/- tolerance, the sensor will detect the change and the machine controller tolerance limits can alert the production team before bad parts are produced.
NT24k
The next level of switching is here.

Gigabit. Modular. Extreme.
Introducing the ultimate in network exibility. With all Gigabit and versatile connectivity options, Red Lions new N-Tron NT24k modular switch series delivers the conguration exibility to meet all of your industrial networking needs. From factories to extreme remote environments, NT24k enables customers to connect, monitor and control across a broad range of industries.
10. More sensor tips. If changes are required, ensure

NT24k Rackmount Gigabit Ethernet Switch NT24k-DR16 DIN Rail Gigabit Ethernet Switch
NT24k-DR24 DIN Rail Gigabit Ethernet Switch
Mix and Match Copper, Fiber, Fast Ethernet and Gigabit Modules
proper calibration and document it in the software changes in the DCS. A built-in display unit for local monitoring of process data is recommended. Follow selection guides and material. Install the sensor in a proper rack/enclosure if the dust level is high. Put proper tags at the site to guide servicing. After commissioning, put the instrument on continuous monitoring/trending to make sure readings are correct and the calibration is accurate before handing it off to operations personnel.
Connect. Monitor. Control.
+1 (717) 767-6511 I info@redlion.net I better.redlion.net

2014 Red Lion Controls Inc. All Rights Reserved.
Share article
Add comment
Return to contents
99 / 167
continued
Operating environment critical factor

Dont overlook critical details about environmental conditions when choosing a photoelectric sensor. Typical selection criteria include sensing range, electrical output, connection type, etc. However, in order to get the best results, sometimes users need to go beyond these basic criteria and include other critical details. These factors often end up as some of the most important considerations: 1. Are there sudden temperature changes? Condensation can build up on the lens. Some sensors are more immune to internal condensation than others. 2. Is it an extremely dusty environment? This can be particularly challenging if the sensor is mounted looking up. Consider mounting the sensor to look down. Another option would be to select an infrared LED sensor, which is better at seeing through dust and fog than a standard red LED sensor. Sometimes users will even direct an air purge at the lens to prevent accumulation of dust or particles.
Share article
Add comment
Return to contents
100 / 167
continued
3. Are the sensors mounted outdoors? It is important to know the maximum and minimum temperatures to which the sensor will be exposed. For extreme environments, an internal or external heating or cooling unit may be necessary. Sometimes a heating unit is advantageous to reduce frost or fog buildup on the exterior of the lens. 4. Will the sensor be exposed to wash-down conditions? Choose an enclosure with the appropriate NEMA/IP
enclosure rating. Consider hygienic requirements in sensor selection, since these are becoming more popular in the food and beverage industry. 5. Is the sensor exposed to direct sunlight? During sunset or sunrise, for example, the sun might shine directly into the receiver of a sensor and give a false output. Reduce the risk of this happening by using a hooded bracket to minimize interference.
Share article
Add comment
Return to contents
101 / 167

As anyone who has been involved in a machine vision project knows, approximately 80 percent of the success of a vision system is related to illumination. Other considerations important to the success of a vision project include camera selection, ease of programming, availability of technical support and project definition. Some tips to get the most out of your machine vision system: reflections and direct sunlight potential. No matter the camera attributes or software tools, if the illumination is not right, the project will fail. Before establishing a proposal for a project, make sure you understand the illumination needs. Otherwise, you might end up incurring additional hardware costs that were not considered in the proposal.
1. Choose the right light. Choosing the right light (LED,

halogen, etc.) plus the right color (blue, white, red, IR) and the illumination technique (dark field, ring light, spot light, bright field, coaxial) are key for project success. Sometimes you have to think outside the box when selecting lighting, like using a different color light to bring out different features based not only on color, but the wavelength of illumination. For instance, finer detail can be seen better with blue illumination than with red. You can play this to your advantage when you want to enhance or reduce contrast. Consider all lighting conditions including
2. Modifications required. Software quality control and

quality assurance are essential to project success. Software control is more important than hardware control. Off-the-shelf vision software programs will need to be modified to fit each unique application.
3. Plan for the future. Before the design and build of

a vision inspection system, consider how to make it easy to reprogram and use for future applications. Find out whether support is readily available for the camera and lighting. Get hands-on programming experience first, then get the
Share article
Add comment
Return to contents
102 / 167
continued

programming training. Otherwise you may have trouble keeping up with the training. The camera resolution and software are absolutely critical. Dont purchase a lower-cost, lower-resolution camera just because it works on this part. Think of the future. One camera and software manufacturer has an online users discussion group. Thats very helpful, with answers often available within minutes of posting. instead of custom, lower-cost pick-and-place systems. The cost may be higher, but the versatility and ability to program different parts is well worth the added cost.
5. Match environment. Vision hardware must be chosen

precisely for the environment. Optics must match the desired field of view. Illumination must be robust. Tested software libraries help keep the complexities to a minimum.
4. Versatility required. Dont purchase a system designed

for specific parts (like O-rings) that must be programmed to do your different parts (such as grommets or seals). There are systems just for O-rings, for example, that fail miserably on nonO-ring parts. Consider a four- to six-axis robot to handle parts
6. Prepare for upgrades. When considering a vision

system, always bear in mind the effects of Windows upgrades on the future of the system. A complete backup image system will give the vision system an additional five years of life.
Share article
Add comment
Return to contents
103 / 167
continued
10 questions to ask
Whether you are new to machine vision or an experienced user, consider the following 10 questions when selecting a stand-alone vision system: 1. Does the vision system make it easy to set up applications, create custom operator interfaces and administer vision system networks? 2. What is the importance of part location tools, and how can you assess their performance? 3. Does the vision system have a complete set of image preprocessing tools? 4. What should you look for in character reading and verification capabilities? 5. How can you determine the repeatability of a vision systems gauging tools? 6. How do you evaluate industrial code reading tools and what are some specific features to look for? 7. What networking and communications features are available? 8. What should you know about vision system accessories? 9. Does the vendor offer a wide range of hardware options? Are they rugged enough for your environment? 10. Does the supplier provide the support and learning services you need?
Share article
Add comment
Return to contents
104 / 167
continued
Test read rate performance

To evaluate industrial code reading tools, start by measuring the vision systems reading speed. To do this, present a wellmarked code to the vision system and have it read the code hundreds of times under pristine conditions to determine the number of reads per minute. Make sure you have a 100% read rate under these optimized conditions, or you may face problems later when conditions might be less than ideal. For example, at a production line speed of 2,000 parts per hour, a read rate of 99.7 percent would fail to read the ID codes on 48 parts in just one eighthour shift. After establishing the systems reading speed, you should run a more challenging read rate test to determine the impact of factors such as line vibration, variable lighting conditions and extremely high line speeds on the vision systems reading performance in your application. To test this, present a large sample of codes of good, bad and marginal quality to the vision system. At the same time, simulate vibration and motion blur by shaking the part and sliding it back and forth beneath the camera as it acquires an image. This test will provide a good initial assessment of how well the vision systems read rate will hold up under real-world production conditions.
Share article
Add comment
Return to contents
105 / 167
SECTION THREE:
APPLYING TECHNOLOGIES TO IMPROVE OUTCOMES
106 / 167
Develop a strategy for asset management

When beginning an asset management process, go slowly and deliberately with the understanding that it is a process rather than an event. Ensure, by free trial runs if possible or in-depth research or observation, that the software you purchase for tracking, generating work orders, inventory control and lifecycle costs are what you will actually use and not too much or too little. After that hurdle has been crossed, you are just beginning a true asset management program. Reliability is related to predictive, proactive maintenance and knowing when and how to run to end of life. This understanding can rarely be obtained quickly or simply. Set yourself up for success by using the boots on the ground as a primary source of input for what works and doesnt work. Track, report and verify constantly and consistently. If the people who make the financial decisions are not onboard, your program will fail. Cost things correctly, comparing the cost of maintenance vs. the purchase of new equipment. Make sure to include all the factors, such as operator and maintenance training, ease of repair and usage of equipment, which will affect throughput of product, cost of product and cost of using the asset. Develop a program to demonstrate that proper purchasing, operating and maintenance practices are a revenue-generating process. This will help management realize that ROI is much more than simply purchase price, labor and materials.
Share article
Add comment
Return to contents
107 / 167
Five best practices for more reliable asset management

Effective asset management requires operating and maintaining equipment at optimum efficiency. While software is now widely used to monitor plant systems, human knowledge and a commitment to following best practices are still the foundation for achieving the benefits of asset management programs. (SOPs), the asset has become unsupported. As is often said, its not over until all the paperwork is in the system. Having proper PMs with good procedures is one of the most important aspects of this. Service technicians, whether in-house or contracted, vary in skill level. By having the testing procedure in hand with a proper frequency, confidence is established; someone is taking care of the system. Evidence of service is a requirement these days and this PM procedure is the foundation of that evidence. Documented service completes the evidence, but a system that is producing efficiently and effectively is the best indication that the system is well maintained.
1. Automate data collection. Data collection is the key to

success for asset management. Automating the data collection is a must vs. relying on manual data collection methods such as paper-based logs on clipboards. If data is coming primarily from people logging data manually, data will suffer as well as the goal of improving the equipment.
2. Catalog capital purchases. If anything is purchased in

capital fashion, it only makes sense to catalog the asset properly. Without cataloging the asset into a maintenance program, with all the technical detail and corresponding preventive maintenance (PM) requirements, recording it properly into the plants drawing system or into the active operating instructions
3. People, not just software. Asset management

software has extensive functionality, but to get real benefits from it requires dedicated human resources. Those resources also need to be well educated (engineer or high-grade tech), motivated and have the power to drive maintenance resources accordingly. It takes management commitment to providing the proper resources to make asset management programs work.
Return to contents
108 / 167
continued
Five best practices for more reliable asset management

4. Take a balanced approach. There are many
approaches to asset management. The difficulty comes in how to balance these approaches. An engineer looks at a machine and its capacities. An accountant looks at a machine and its worth. There are many software packages available that will assist in combining both perspectives. What is very important is how you track items like downtime. From a technicians point of view, its about keeping a machine running, not about doing the paperwork. For the engineer and accountant, its about having data that can be used to justify replacement or upgrading of equipment on the floor. The bigger the company, the more important this becomes.
BETTER ASSET MANAGEMENT DATA

There are a number of ways to improve data collection and access to information from operating equipment: 1. Enable real-time condition monitoring for a wide range of assets, including descriptions of possible causes and suggested corrective actions for each condition. 2. Create one single-user interface, where maintenance can access all types of asset-related information and systems. 3. Integrate CMMS to enable seamless access to work orders, work order history, etc. from all DCS work places. 4. Enable real-time, in-situ asset management during operations along the entire operational process vs. prescribed, a posteriori asset management.
5. Clean sensing lines. Always blow down transmitter

sensing lines on a yearly basis, especially steam. This small tip can avoid transmitter manifold blocking.
Share article
Add comment
Return to contents
109 / 167
Four considerations for monitoring equipment assets

Monitoring and diagnostics are critical factors in asset management programs. Here are four recommendations for creating more effective monitoring systems: halt production. The rapid rate of technology evolution makes it nearly impossible to stay current with all the options that engineers and designers have today. Technology now allows real-time monitoring of machine status, error conditions, the temperature of vital components, speed, current draw and a wealth of other data that an engineer can provide via an HMI or other device. With so much information potentially available, designers need to assist end users in determining exactly what information is critical to their operation and the best way to present the information. Interaction with the end user is vital. The engineer must have a thorough understanding of the customers performance criteria, diagnostics requirements and problem resolution procedures. Time spent obtaining this information lays the foundation on which the rest of the project is often based.
1. Phase in implementation. If you are connecting

several pieces of equipment to a remote monitoring system, first connect a few strategic ones and run for several days to understand issues in the environment or with connectivity, user expectations, usage patterns, etc. Once you get this feedback and fine-tune the system, scaling is not that difficult. But if you start directly with all the assets, this would just multiply any problems.
2. Identify diagnostic priorities. Gone are the days

when automation included diagnostic systems that were solely driven using binary code triggered by I/O. Todays manufacturing environment demands real-time status monitoring and diagnostics. Trial-and-error diagnostics will no longer suffice for problem identification when it comes to resolving issues that
3. Monitor system. If you are going to collect data from

machines using PLCs, you need to include some level of system monitoring. It may be as simple as a ping test to the PLC or a
Return to contents
110 / 167
continued
Four considerations for monitoring equipment assets

bit toggle where the application sets or resets a bit. In any case, the communications link should be monitored and alerts created when they fail. The alert can be as simple as a line-side machine alarm or sending an alert email to a group email for IT and technicians, or even to a centralized operations center monitor. Monitoring and notification do not need to be complex to be effective. motor may not be required. In most applications it is acceptable to monitor one rotating asset for a short period of time, say for 5 minutes, and then use the same transmitter to monitor several other motors or pumps. With this arrangement you will still need sensors on each piece of equipment, but they can share one transmitter, reducing costs. A system can be engineered to use several tandem piezo acceleration sensors wired through relays so that the transmitter monitors one device at a time. Data collection can be simplified by using a PLC with the transmitter and relays in one node. The controller can switch the relays and collect the vibration information from the corresponding pumps or motors.
4. Shared transmitters. Using real-time vibration

monitoring on large or critical rotating equipment can provide maintenance staff with valuable information on the health of their assets. However, continuous monitoring of one pump or
Share article
Add comment
Return to contents
111 / 167
Four tips for calibrating equipment

Good calibration practices are an essential part of managing your equipment assets. Here are four tips on proper calibration techniques: over time in using equipment and their inability to use it properly causes a lot of equipment damage.
1. Secure connections. When completing calibrations on

thermocouples, pressure transducers and other devices, if you have to unwire the device to put it in a hotwell, make sure you get the connections back correct and secure.
3. Match transmitter output. When calibrating the

instrument loop connected to a digital read-out device, it is a good idea to fix the read-out measured value and match the transmitter output, or call it output-vs.-input calibration.
2. Calibration expertise. Verify values of actual process

data before making calibrations. Calibration should be provided by trained personnel with very accurate equipment. To maintain calibration, it is essential that the operator be fully trained on the use of the equipment. Many individuals have learned bad habits
4. Calibration reminders. An easy way to keep up with

calibration and monitoring systems is via software designed for this purpose (for example, Gage Track). By having a master gauge for every item, when calibration is due you can send it out to be recertified per ISO standard.
Share article
Add comment
Return to contents
112 / 167
Nine strategies for achieving your energy management objectives

Whether your primary goal is to reduce operating costs or achieve your companys sustainability goals, finding ways to reduce energy consumption requires good tools and good information. often cover all or part of the cost of those improvements, which makes it easier to get management and financial support for adding energy reduction activities to automation projects.
1. Choose the right tools. A comprehensive energy

management program is quite challenging, since every aspect of a manufacturing facility is an energy consumer (processing, packaging, warehousing, utilities and even the building itself). A common mistake is to expect a traditional process or machine automation system to be pressed into service for energy management applications (EMS). Instead, purpose-built EMS systems are designed to provide the right tools for energy analysis and reporting.
3. Involve production, not just facilities management. Involve people responsible for production
processes in energy management activities, since up to 90 percent of energy is consumed by production equipment. They will help you ensure that proper steps are taken to understand how process energy consumption can be reduced without affecting the productivity of expensive production assets. The primary reason most companies focus their energy-saving activities on the facility is that facility management personnel are often given the responsibility for reducing energy costs. Not only is the facility in their comfort zone, but its often the only area where they have the institutional authority to make changes. By involving production, you can address all the areas of your operation that consume energy.
2. Side benefit. Energy management programs that achieve

the most significant savings are typically those whose original goal was to improve control of production processes. The energy savings achieved as a result of improved production processes
Return to contents
113 / 167
continued

FIVE WAYS TO MANAGE ENERGY COSTS
Reducing energy costs from production processes requires managing the five most important factors that determine both utility charges and total energy consumption: 1. Energy event management. Detection and analysis of process changes that cause consumption to exceed forecast. 2. Peak demand management. Minimizing peak demand, which triggers higher utility rates or penalties. 3. Scheduled demand management. Minimizing costs by shifting demand to lower-cost time periods. 4. Idle state management. Minimizing energy draw during idle process conditions. 5. Demand/response management. Offering energy capacity back to the grid on request in exchange for incentives.
4. Use interns to collect data. Its fairly simple to

identify viable energy management projects, but it takes real engineering to develop the business case. Use interns from local universities to collect the actual data points needed to develop a well-founded business case.
5. Avoid duplication. Many motor control devices now

have network connections that pass along energy data. Theres no need to duplicate these data-generating capabilities by installing power monitors over the top of intelligent motor control devices.
6. Take advantage of incentives. It can often be difficult

to find the funds to invest in projects that will reduce energy consumption by your plant. Federal, state and local governments offer a range of incentive and rebate programs for energy saving projects and using alternative energy sources.
Share article
Add comment
Return to contents
114 / 167
continued
Audits provide holistic energy assessment

Energy assessments and audits can help companies identify a wide range of changes they can make to help reduce their consumption. Audits can be simple, such as a walkthrough of a building or facility to identify quick-hit opportunities, or much more detailed efforts. These are not one-time projects, but rather ongoing efforts to identify variables, such as how seasons might affect production costs and whether previously implemented improvements are continuing to perform as planned. Such assessments can help to establish the scope of an effort to reduce energy consumption, define key metrics and put resources in place that can take a holistic view of energy for the organization. Recommendations may include low-investment modifications, such as shifting maintenance operations to non-peak times, or may be more involved, such as programming changes to equipment. Evaluation and prioritization of capital improvement opportunities can also be included in the analyses. An assessment, regardless of scale or scope, should help answer the following key questions:
Where am I likely to find quick returns? What key metrics should I put in place? How can I encourage ongoing improvements?
Share article
Add comment
Return to contents
115 / 167
continued

7. Be prepared. Before planning for any energy
management purchase, its important to first gather your data. It must cover the entire usage pattern of the equipment. Based on the requirements, choose the technology (hardware and software) that will help in analyzing a combination of parameters instead of a single parameter. Monitor the results and associate operational conditions with energy consumption. always correct, it is the key to cost savings as it is the perfect metric for measurement.
9. Track big consumers.

Always make sure you have the means Energy-saving incentives to track the energy For information on the energy incenperformance of large tive programs available in your state or energy consumers. region, go to The term large can be http://awgo.to/021 determined by using a Source: U.S. Department of Energy simple Pareto analysis. Make a list of all of your energy users and section off the top 20 percent. This will identify a large portion of your energy usage, as well as the focus of your maintenance activities.
8. Start with your power bill. Look for peak demand

charges or power factor charges. If you have a shift come in and get the facility running from a dead stop, this can create a big grid load for a short time and lead to additional kw/hour charges due to the short period amp draw. Work with your facilities to stagger the starting of equipment and lights. When possible, use soft starts or VFDs on large-horsepower motors to reduce large startup currents. Utilize lighting vendors and not just an integrator or electrical contractor to create ROIs based on the real-world numbers you can give them from your power bill and a walk-through of your facility. Although the power bill is not
Share article
Add comment
Return to contents
116 / 167
Nine recommendations for building effective manufacturing IT systems

Information technologies are giving manufacturers powerful tools for improving their processes, productivity and profitability. Here are some ideas for making manufacturing IT systems more flexible and reliable.
3. Virtual redundancy. Look to redundancy through

virtualization. It is not just a concept that holds for office IT; it is very well suited to manufacturing IT. Backup, recovery, simulation, external support (shipping the machine setup to a supplier or specialist support) processes can all be improved with server virtualization.
1. Data model. Most of these technologies are dependent

upon a rigorous data model. So putting that model in place first, and understanding the source, importance and use of the data, is critical. For manufacturing IT systems, its setting expectations about what the product can and cannot do, how it can scale, what performance and refresh rates should be, and what data types and databases it can interface with.
4. Build a wall. It is imperative to separate production

networks from office networks. This is because production systems do not need access to the Internet and the office environment does. If a connection must exist, it should be only through a firewall gateway system.
2. Common structure. When implementing a multi-site

MES it is very important to identify common business processes and standardize them across all sites (as far as possible). This will ensure a common data structure and reporting at a central level.
5. System requirements. It is crucial that developers

meet and actually listen to the stakeholders. Depending upon scope and complexity, a number of meetings may be required. You generally cannot expect people to be able to convey all of their thoughts and gain a clear understanding in one sitting. As
Share article
Add comment
Return to contents
117 / 167
continued

a requirements document is being developed, keep end-user priorities in mind. Too often, functional and design requirements creep into what should be a straightforward requirements document. If the requirements document is developed by the system integrator, make sure you fully understand, own and sign off whats in it. integrators understand the plant floor, but can miss the scale and scope of the user requirements and scalability requirements. The issues are typically cultural, not technical. BEFRIEND IT
Develop strong relationships with your IT department. When they know where you are coming from and you know where they are coming from, implementation can be considerably easier. Be patient and explain your production needs in terms IT people can understand. Its often surprising how helpful IT can be once they understand the constraints of a production environment and how email isnt a part of the system or how an isolated control system does not need the same level of virus protection as a desktop in the office. Without this relationship, you are most likely going to run into brick walls throughout your entire project. Often, having the right relationships can make it easier to use temporary solutions until best practices can be implemented.
6. Start slow. If you are implementing a manufacturing

intelligence product and are able to create customizable reports, dont go out and develop all reports in advance. Implement only a few and start collecting data. Let users get a feel for what is possible and then sit with them to collect report requirements.
7. Cultural barriers. Data is worthless. Information is

invaluable. Converting data to actionable information is the goal. When developing an information project, you have to consider the entire scope. IT consulting firms do an awesome job of building the user requirements, but can miss the connections to the plant floor equipment and processes. Automation
Share article
Add comment
Return to contents

Tightly Integrated Vision System Easy to use Embedded Software Sensor Resolution: VGA to 1600x1200 Factory Communications Industrial Enclosures 360 Direct Mounting Factory Style Connectors Ideal for Single Point Inspections
118 / 167
continued

8. Programming languages. Focus on flexibility,
expandability and the opportunity to choose what highlevel programming language meets your companys needs. The industry has evolved to where manufacturing programming languages are no longer the only solution for automation. High-level languages such as C++, C#, Visual Basic and MatLab, for example, can now accomplish this.
9. Powerful cellular. Many companies dont

fully understand the capabilities of Industrial Cellular technology. New cellular routers include standard features such as I/O control, protocol converters, seamless network integration, routing, NAT, firewall and cloud interface, all with LTE speed. The major commercial hurdle is that cellular carriers dont have solid relationships with control engineers, so major decision-makers are just ignorant of the capabilities. Wireless Ethernet or wireless serial radios certainly have their place, but a deeper knowledge of cellular applications could be an industry changer.
BOA products are highly integrated vision systems in a tiny smart camera package specifically designed for industrial use. Complete with choice of application software embedded, BOA offers new and experienced users alike, an easy-to-deploy cost effective vision solution.
Get more vision.

www.teledynedalsa.com
119 / 167
13 ways to get the most out of OEE and lean manufacturing disciplines
Overall equipment effectiveness (OEE) and lean manufacturing have won many converts. These two disciplines are frequently linked because they provide a systematic way to design manufacturing processes, measure their efficiency and identify problems. Here are some tactics to get the most out of your lean and OEE initiatives: rework, thereby increasing throughput in quality. Before building a lean cell, talk to your operators, quality people, manufacturing engineers and process engineers. Get their input, hold meetings and keep them in the loop throughout the project. They are the main stakeholders who will eventually approve of your cell.
1. Accessing data. One of the great challenges when

executing a project to gather and report OEE metrics is easy access to manufacturing equipment status. The obstacles may include islands of automation or even equipment thats not automated. Dont expect that all equipment information is available via existing automation systems. Be prepared to install simple data acquisition systems to gather the necessary data to track OEE.
3. Lean management. Lean manufacturing is a powerful

concept when employed correctly. The problem is that with lean, along with other methodologies, one size does not fit all. Managers can get caught up in how it improved this company or industry, and then try to implement it internally. What they fail to do is penetrate the details of why it worked, what support structure is required and how that translates to their internal business. Lean is as much about management engagement in daily operations as it is about the methodology.
2. Stakeholder input. Lean manufacturing is critical in

todays global economy because it helps you drive your output (product efficiency) higher while maintaining low defects and
4. Measure the right things. Nothing is worse than the

wrong input. OEE is not always a KPI metric in batch operations. If you speed up the drying process, for example, the OEE goes
Return to contents
120 / 167
continued
down, but you will be making more product in a shorter period of time. fine-tune the flow of your product.
5. Visual management. Visual management, including

large display screens on the factory floor, are an effective tool for OEE programs, letting both managers and workers easily monitor the metrics of production lines and track KPIs. Displays harness natural human competitiveness. In one experience, once data was displayed it started a race between shifts to drive up OEE. Without any management intervention there was a 20 percent increase in productivity. Among the most useful KPIs to display: count (good or bad), reject ratio, operating speeds, takt (cycle) time, downtime and OEE (availability multiplied by performance and quality) for determining resource utilization.
7. Too lean? If you operate with vendors that are stationed in

areas with a high potential for natural disasters, think carefully about being too lean with your supplies. Youll need to plan for alternative routes and suppliers. Another area that has to be monitored is the amount of time for production to meet customer need. Sometimes manufacturing is too lean and when theres a sudden demand, the slow ramp to manufacture can cost more money than producing stock.
8. Business support. Make sure the business has

adopted and fully understands OEE. This can be a huge change management nightmare if not well-entrenched prior to the project (or as part of the project execution). Lean manufacturing can also be applied to service disciplines, not just product manufacturing, mostly with only minor adaptations. Look to these techniques and principles to streamline your own processes and eliminate waste.
6. Increase uptime. Lean manufacturing is a very important

factor in a production plant. Just by placing materials at the point of use within the production floor area, you can increase production uptime. This is just one small adjustment that will
Share article
Add comment
Return to contents
121 / 167
continued
Calculating OEE
As described in World Class OEE, the OEE calculation is based on three factors: availability, performance and quality. Heres how each of these factors is calculated: Time / Total Pieces). Ideal Cycle Time is the minimum cycle time that your process can be expected to achieve in optimal circumstances. It is sometimes called Design Cycle Time, Theoretical Cycle Time or Nameplate Capacity. Since Run Rate is the reciprocal of Cycle Time, Performance can also be calculated as: Performance = (Total Pieces / Operating Time) / Ideal Run Rate. Performance is capped at 100 percent, to ensure that if an error is made in specifying the Ideal Cycle Time or Ideal Run Rate, the effect on OEE will be limited.
Availability
Availability takes into account Down Time Loss, and is calculated as: Availability = Operating Time / Planned Production Time.
Performance
Performance takes into account Speed Loss, and is calculated as: Performance = Ideal Cycle Time / (Operating
Share article
Add comment
Return to contents
122 / 167
continued
Quality
Quality takes into account Quality Loss, and is calculated as: Quality = Good Pieces / Total Pieces.
OEE
OEE takes into account all three OEE factors, and is calculated as: OEE = Availability x Performance x Quality. It is very important to recognize that improving OEE is not the only objective.
OEE = Availability x Performance x Quality OEE = B x D x F A C E
Availability
A = Total Operative Mode Time B = Run Time Time Losses

Performance
C = Normal Speed D = Actual Speed dr

Quality
UNO-2362G
AMD Dual Core T40E Small-Size Automation Computer w/ 1x GbE, 2x mPCIe, HDMI/DP
Speed Losses
UNO-2483G
Intel Core i7/i3/ Celeron RegularSize Automation Computer w/ 4x GbE, 3x mPCIe, HDMI/VGA
FieldBus iDoor
PCM-26D1PB
DI/DO iDoor
PCM-27D24DI
Communication iDoor
PCM-24D2R2/PCM-24D2R4
E = Product Output F = Actual Good Product

Scrap Losses
Hilscher netX100 FieldBus, ProfiBus, 1x DB9

PCM-26D2CA
Digital I/O, isolated 16 DI/8 DO, 1x DB37
OXPCIe-952 Isolated RS-232, 2x DB9, isolated RS-422/485

PCM-24D4R2 / PCM-24D4R4
SJA1000 CANBus, CANOpen, 2x DB9
OXPCIe-954 UART, NonIsolated RS-232, 1x DB37, Non-isolated RS-422/485
Share article
Add comment
Return to contents
123 / 167
continued
9. Meaningful reports. Data
capture is quite easy. Reporting the data in a manner that helps implement change can be challenging. Dont assume a single report is sufficient. Different users need different data. And that data must be presented to each user in a manner that is meaningful. Software selection plays only a small part in the OEE process, but that is where customers spend the most time upfront. Operator involvement, the quality of the integration partner and the ability of the controls hardware to collect data are what truly make an OEE project successful.
10. Improvement tool. OEE can be

a very valuable tool to identify problems within a process. Ensure that everyone understands what the three elements are that make up OEE: availability, speed and quality, and how to calculate each. Once processes are stabilized, use OEE to drive improvement.
12. Efficiency tool. OEE has to be automated to be successful. The data needs to be driven from machine status, not humans inputting the status. Any manually derived OEE system can be fiddled with to produce the expected 85 percent efficiency rate. Improving systems and automating OEE measurements may bring into question the accuracy of historical OEE data. To avoid internal politics, put an amnesty in place and promote automated
OEE in-depth
For a detailed discussion on calculating Overall Equipment Effectiveness, go to
http://awgo.to/022
Source: Automation World
11. Software less important.
data as a new way of measuring OEE. On the other hand, the only reason to use OEE is to help drive an improvement process to increase operational efficiency.
Share article
Add comment
Return to contents
124 / 167
continued
If that isnt a widely embraced priority, then save yourself lots of time, money and effort.
13. Improving uptime. OEE can help you identify opportunities to improve your total uptime. First, understand the categories that OEE represents. Next, determine what things you want to track and how specific you want to be. There isnt a set rule as to what that may be. An example may be that under your performance efficiency category, you list specific pieces of equipment in an assembly line to track. By breaking down your categories you will have better opportunities to make improvements. The last hurdle is how to capture the data used to calculate OEE. Keep it simple and train your people in how to capture the data you need, what it is and why its important.
usa.siemens.com/tia-portal
Up to 30% reduction in engineering effort for faster time to market.

Experience a more intuitive and efficient way of working using the TIA Portal integrated automation software a single engineering framework that allows you to combine PLC, PC-based control, HMI, Network configuration, Drives, and Safety in a single, proven engineering environment. Request a trial license today! usa.siemens.com/tia-portal-trial-license
Answers for industry.
Share article
Add comment
Return to contents
125 / 167
Eight ideas for improving product lifecycle management

Product Lifecycle Management (PLM) has been described as an information strategy that allows organizations to work as a single team to design, produce, support and retire the products they make, while capturing best practices and lessons learned along the way. Its goal is to improve the quality of products and processes. Here are some suggestions for selecting and using PLM systems: not a bad idea to look at tool features to begin with, to make sure that you are aware of best practices and capabilities that can be leveraged, but dont let a tool dictate a process. lifecycle costs in the equation. In most capital equipment situations, the upfront
2. Fostering collaboration. The

most important function of a PLM system is to foster collaboration among people with different functional responsibilities. It allows them to work in a parallel rather than linear fashion by creating a shared information resource of product and process knowledge. This can encourage innovation, improve quality and shorten time to market for new products.
1. Dont let tools dictate process. Project teams implementing

PLM can get lost in the weeds. Have clear results and improvement goals in mind. Dont let the tools dictate your process; get your process defined first, with any known gaps resolved. Then look at tools and map them to your requirements. Its
Working with PLM software

For more information about using PLM software to facilitate collaborative work, download an ARC white paper at
3. Lifecycle costs. When evaluating

equipment options, always include
http://awgo.to/023
Source: Siemens
Return to contents
126 / 167
continued

cost of the equipment is 2-5 percent of the lifecycle costs, while the rest is the cost to run and maintain the equipment. PLM software that is able to validate the production system in a simulated threedimensional environment. This allows the risks of failure to be identified in different parts of the process or equipment. The software can also be used to determine the best way to lay out production lines in order to move material through the factory floor.
4. Keep it basic. Remember that

hardware and software designs have a direct impact on industrial productivity. The most elegant and complex system design does not help a customer unless it is faster, easier to maintain, uses less energy and, above all, can be understood by plant maintenance personnel. Sometimes it is better to sacrifice elegant and complex for basic and simple if the result is a faster, easier-to-maintain manufacturing line. Those who care about manufacturing productivity will appreciate it.
6. Is there a payback? Dont be

afraid to tell others when a system is at its end of life. Just because an outdated system is running today is no guarantee it will be running tomorrow. Strive to educate operations and management that its important to upgrade as needed. But dont upgrade just to have the latest technology if there is no real payback.
Modernizing manufacturing
To learn more about the digital manufacturing initiative sponsored by the National Center for Manufacturing Sciences and other resources for modernizing American manufacturing, visit
http://awgo.to/024
Source: National Center for Manufacturing Sciences
5. Validation essential. Choose

Return to contents
127 / 167
continued

7. Track equipment. If you are looking at new maintenance
software, make sure that downtime, maintenance hours and material costs can be easily tracked to each major piece of equipment. This will help you make informed decisions about whether to replace, upgrade or leave alone each piece. It is also possible with some software providers to use the information to evaluate your techs.
8. Digital manufacturing. One element of PLM is

digital manufacturing, an integrated, computer-based system comprised of simulation, three-dimensional visualization, analytics and collaboration tools. Its used to create product and manufacturing process definitions simultaneously. By enabling product-related information to be shared between design and manufacturing groups, it can reduce the expensive changes often experienced when faulty product designs reach the manufacturing stage.
Share article
Add comment
Return to contents
128 / 167
Seven human factors to consider when developing safety systems

People will do whatever they have to do to get the job done, even if that means evading systems designed to keep them safe. Engineers who design safety systems need to keep that fact top of mind. Here are some tips for dealing with the human variable: more robust machine safety systems that will still allow for efficiency as well as protect your workforce.
2. Dont invite overrides. When

designing a safety system, its essential to understand how an operator or maintenance technician needs to interact with a machine. It you make the safety system too extreme or complex to deal with, youre actually inviting them to override the safety system in order to get their jobs done. End users should make sure they see a new machine operate with all the safety features functioning before they accept the machine.
1. Understand human nature.

It is not enough to rely on industry standards to develop machine safety. You must work with the manufacturing crews. They have so much insight into what people are actually going to do to improve their throughput and efficiencies, even if it requires them to work around safety systems. Its just human nature. By communicating and observing your workforce, you will be able to develop
Machine safety standards

There are many organizations dedicated to improving machine safety. For links to them, a glossary of safety terms and a discussion of machine safety standards, download a white paper at
http://awgo.to/017
Source: Siemens
3. Safety education. Machine

safety is primarily an education issue.
Return to contents
129 / 167
continued

Convincing the end customer about the advantages of safety is difficult, but not impossible. Most end users view safety systems as a detriment to production, when the opposite is the case. Good safety principles and finding a vendor who has the products and expertise to assist is 90 percent of the battle. the adjacent equipment in manual mode before adjusting his machines setting.
5. Get real feedback. Arrange

cross-functional meetings. This means real meetings that have a purpose, where everyone contributes and that result in good documentation. This is key to having a safe approach when integrating controls, interfaces and other automation gear that enhance the workplace. It is easy to create a negative condition when upgrading, especially when its a poorly supported or poorly organized project. Without representatives assembled to discuss every interacting departments needs (such as training, maintenance, service, emergency conditions, etc.), the projects purpose will not be properly communicated, the buy-in for the
4. Operator safety. Wherever

operator safety is required, you need to ensure that it is a foolproof and mistakeproof system. Theres no room for a safety failure because of operator mistake or negligence or bypassing of a few sensors. Also, while interlocking equipment, always consider the adjacent equipment if it is sequence-related to the equipment. There have been many incidents of hand injury because the operator forgot to put
$afety Pays
The OSHA website has an application designed for small businesses called $afety Pays that can help make the case for implementing safety systems. It gives scenarios based on lost time (litigation is not included) from the insurance industry, which can demonstrate the effect of severe injuries on sales and profits.
http://awgo.to/015
Source: Occupational Safety and Health Administration
Return to contents
130 / 167
continued

change will be seriously impaired and, even worse, unsafe conditions may arise. Bringing their viewpoints into the design review process will help eliminate costly surprises during the testing or rollout phases. By conducting proper meetings and maintaining clear communication with all impacted personnel, project management is demonstrated and confidence is instilled in the management of change. production due to an injury or downtime from faulty equipment.
7. Is it needed? Make sure you are on

the same page as the machine builder or system integrator when making design decisions about machine safety. A lot of money can go towards guarding, only to find that the machine will be in a secure area that cannot be accessed during operation. On the other side, the end user should not cut costs by eliminating machine safety features just because they dont understand the need for implementing safety systems.
openSAFETY
Looking for a safety solution that supports more than one TUV-approved protocol for industrial Ethernet? Consider using vendors that support the openSAFETY standard, which is vendor neutral with regards to fieldbus and supports safe operations with interoperable technologies. For more information, visit
6. Pay now, or pay later. Saving

someone from injury by paying for training courses is better than losing
http://awgo.to/019
Source: Ethernet Powerlink Standardization Group Source: Ethernet Powerlink Standardization Group
Share article
Add comment
Return to contents
131 / 167
continued
Safety standards online

Be proactive and try to stay ahead of regulation before changes are mandated. The Internet is a great source of information about current regulations and standardsand what might be coming next.
Community Emergency Response Plant Emergency Response Physical Protection (Dikes) Physical Protection (Relief Devices) Automatic Action SIS or ESD Critical Alarms, Operatior Supervision and Manual Intervention Basic Controls, Process Alarms and Operator Supervision Process Design
Apply LOPA for risks

Deep dive into Process Hazard Analysis (PHA) to identify the risks underlying a process. Apply LOPA (layer-of-protection) analysis to rate the SIL level and guide the SIF design according to IEC 61508/61511. Understand all aspects of the safety lifecycle before proceeding with design and implementation.
LOPA chart courtesy of ABS Consulting, awgo.to/018
Share article
Add comment
Return to contents
132 / 167
Eight tips for the technical side of safety systems

From new standards for functional safety to making sure that an e-stop will actually stop everything on a machine, these practical recommendations address the details of a safety system:
2. Validate the safety code.

Determine each failure mode and validate that it fails to a safe state. Just because the logic tells you to turn an output on or off when running, does not necessarily mean it will return to the correct state if there is a fault. It needs to be verified.
1. Functional safety. Functional

safety, as defined in IEC 61508, is a totally new methodology in automation. Its based on two main principles: 1. Its a systems approach. Sensor - controller actuator, every component should have the same SIL/PL. Otherwise, it makes no sense. 2. System/product lifecycle idea. Todays safety does not mean tomorrows safety. Functional safety needs a procedure to implement it continuously.
3. Key features for safety systems. Low PFD (probability of failure

on demand), equivalent to the longaccepted TMR (triple modular redundant) benchmark standards, in either simplex or redundant configurations. Low STR (steps to reproduce) that meets or exceeds the TMR standard when implemented in dual configuration. Exceptional hardware fault tolerance in dual configurations.
IEC 61508 explained

For a comprehensive look at functional safety and the IEC 61508 standard, visit
http://awgo.to/016
Source: International Electrotechnical Commission
Safety modules independent from the logic solvers. By choosing safety systems with these features, availability has been estimated as high as 99.9999 percent.
Share article
Add comment
Return to contents
133 / 167
continued

4. Identify risks. Deep dive into Process Hazard Analysis
(PHA) to identify the risks underlying a process. Apply LOPA (layer-of-protection) analysis to rate the SIL level and guide the SIF design according to IEC 61508/61511. Understand all aspects of the safety lifecycle before proceeding with design and implementation. pos values or set them to zero once you make it to the home position. Now the main program can be run from the beginning, without any worries.
6. Consider magnetic locks. Magnetic lock systems

have come a long way and they really simplify the way you can design and safeguard a machine. Interlocks are built in and they are a little harder to bypass than previous generations of the technology. They can be very useful for maintenance and for troubleshooting because they can be installed in a manner that will satisfy everyone, from the operator to OSHA.
5. Send robots home. When programming a robot that

has the potential for a crash situation and relies on an operator to manually move the robot out of position, program in flags or position steps. Then create a program called home. After each critical move/step of your robot in the program, to avoid other machinery or tooling, use a variable, such as pos, and assign it a numeric or other value like zero as the home value. When you create the home program, you can run it and have a series of if statements. For example, if pos = 10, then do this. Now you know where the robot was positioned when it crashed and you can provide a safe route automatically to exit its current position and into a safe home position. Make sure to clear your
7. Discharge capacitors. On older AC and DC drives, even

when locked out, make sure capacitors are fully discharged before removing the front panels and working within the drive.
8. Stop everything. Dont allow OEMs to place e-stop

buttons on their consoles if they do not stop all equipment in the immediate vicinity.
Share article
Add comment
Return to contents
134 / 167
continued
Dont overlook safety distance calculations

The safety of a machine is not guaranteed by simply using a safety laser scanner in an application. A safety distance calculation needs to be considered to ensure the correct use and functionality of the scanner device. The safety distance calculation will help determine the size of the safety field or the distance a scanner plane is mounted from a hazard. How will the device be mounted? Will it be scanning vertically or horizontally? If it is vertical, the scanner plane may have to be mounted farther from the hazard, similar to a light curtain. More commonly, if it is mounted with a horizontal plane, there may be a chance for reach-over, which would require a larger-sized safety field. These two possibilities are called the Depth of Penetration and are a part of the safety distance calculation.
Share article
Add comment
Return to contents
135 / 167
continued
Consider also the stop time of the entire system. Realize that the stop time may include more than just the stopping of the machine. The time it takes for the scanner to react, for the stop signal to travel to the machine, for the machine to actually come to a stop and any other delays must be considered. These delays may be small, but can have an impact on the overall size required for the safety field.
The stop time of the machine will also be used in calculating the safety distance. By implementing this calculation into your design of a safety laser scanner, you will be on your way to properly complying with standards and achieving greater employee safety.
Share article
Add comment
Return to contents
136 / 167
Wiring, safety PLC programming critical to machine safety performance

Some common pitfalls in machine safety have to do with not wiring devices correctly. Many devices today can cover a range of safety levels, such as SIL 1 through SIL 3, but have different wiring methods. Diagnostic coverage is extremely important with safety and incorrect wiring or an incomplete understanding of the wiring requirements could lead to a lower safety level or a system that does not work at all. Be sure to follow the manufacturers recommended wiring practices and understand the diagnostics that are performed on the circuit. Having two devices that perform diagnostics of the same type may cause the system to not work. An example would be cross-wire detection where the PLC card checks the circuit by sending out a pulse on the wire and detecting that pulse back on the input. If the device that it is wired to the PLC card does not pass the pulse through, then the I/O module may fault. This could be corrected by selecting the right devices or a simple hardware setup change. Either way, you need to understand how safety works. Once you have designed your system, you must program it. Pay special attention to what the controller allows you to do in the safety code. A safety PLC can add many benefits that can help the system be more flexible and increase production. On the other hand, it has to be programmed and must be tested for correct operation during the machines commissioning phase. This is a very important step and is often overlooked. Be sure to inject faults into the safety system to ensure that your configuration and code give you the desired response. A safety PLC can add great benefits to the automation project, but it also can add scan time that may affect the response time of the safety system. It is important to understand this and to select the right hardware. The response time is very important
Share article
Add comment
Return to contents
137 / 167
continued
Wiring, safety PLC programming critical to machine safety performance

a giant breakthrough in small readers
in safety and could make a machine that appears to have all its safety bases covered not respond fast enough to a person working in a highly dangerous area. Make sure you document your safety system, from risk assessment to the testing and checkout phase. Integrated safety is very flexible and can give great benefits, but pay attention to the wiring and configuration of the devices. And remember, time is distance and the scan time may affect the response of your system on a high-speed machine with close approach boundaries.
Meet the DataMan 50L. The tiny barcode reader that brings big performance to the food & beverage industry.
Dont let its size fool you. The DataMan 50L is huge in barcode reading performance. Measuring just 23.5mm x 27mm x 43.5mm and featuring an IP65-rated housing, the DataMan 50L is premium technology designed for 1-D-oriented barcode reading. The DataMan 50L delivers read rates that can surpass 99% through Cognexs proprietary Hotbars image-analysis technology. The new DataMan 50L is a powerful upgrade for applications that use small laser barcode scanner systems. Visit us at www.cognex.com/50L.
Scan to Learn More
Share article
Add comment
Return to contents
138 / 167
Europe sets standards for safety design

The European Union has defined required safety methods for machines, which are standard in all European nations and now accepted worldwide. New and improved safety strategies offer manufacturers a way to improve productivity and competitiveness in the market. Some examples: standstill. When executing a safety function, such as monitoring a crawl speed that deviates from the expected value (such as too fast), the safety system detects this deviation and actively returns machine operation to a safe state by stopping the machine safely and removing the torque from the motor shaft.
1. Restoring a safe state. Functional safety in machinery

usually means systems that safely monitor and, when necessary, override the machine applications to ensure safe operation. A safety-related system thus implements the required safety functions by detecting hazardous conditions and bringing operation to a safe state, ensuring that a desired action, such as safe as stopping, takes place.
3. Human response required. In a hydraulic press

machine, as another example, human safety was achieved by using a light curtain at the job presss work area to hold the press for any human interrupt. The press can only resume operation when the operator comes out of the working area and acknowledges the action.
2. Detecting deviations. Safety system monitoring can

include machine speed, direction of movement, stopping and
4. Safety modules. Safety inputs are monitored with special

modules that detect input discrepancies and they are processed in a safety controller, which generates safety code.
Share article
Add comment
Return to contents
139 / 167
Six strategies for creating a secure industrial network

Security and safety are the same word in many languages. You cant have a secure system unless you know whos running the equipment and what theyre doing. Theres an incredible overlap between safety and security. Theyre both about identifying the bad things that can happen, and finding ways to minimize the chances that they will. In the IT world, its about information confidentiality. On the plant floor, its all about the safety of people and the process. Here are some ideas for improving security in an industrial environment: managed network with a good IT strategy as a starting point for network security.
2. Collaboration rules. Keep a logical separation between

enterprise and control networks, including the addition of a firewall between. The policies for the enterprise network cannot be the same for control networks. The two systems have different performance requirements, reliability requirements, operating systems and applications, risk management goals, security architectures, security goals and different assumptions about security. By discussing these differences and gaining an understanding of each groups expectations and priorities, IT and control engineers within an organization can develop a solid foundation for communication and cooperation. IT and control engineers should define a role list to avoid misunderstandings. Collaboration should be the rule, not the exception. On the plant
1. Pay attention to the basics. Network security can be a

complex topic. Most IT security experts say the implementation of basic security features available on network devices solves over 90 percent of concerns. Basic tools such as port security, VLANs, routed interfaces and simple firewall features can stop the majority of malware and intrusions. As a simple practice, use a
Share article
Add comment
Return to contents
140 / 167
continued

floor, use network equipment designed specifically for industrial applications. accessibility, lockable PLC panels, server rooms), hazard protection (fire, floods, EMI, etc.), a disaster recovery plan and other features as appropriate to the needs and concerns of your business.
3. Be on your guard. As with functional safety, the objects

involved in security are not only devices or equipment. There are human factors as well. Security is more challenging than safety, because its always in a state of dynamic change. New malware, viruses, worms and tools arise every day. Defenders need to be awake all the time. In an industrial environment, its more difficult than in an office environment. The plant is not allowed to shut down its process. So policy, procedures and cooperation are very important in implementing an industrial security strategy.
5. Defense-in-depth. In the past, industrial network security

was accomplished through air gaps. Essentially, this relied on having physically separated or isolated systems to protect plant equipment and networks from the rest of the world. This type of security resulted in industrial systems with software that wasnt kept up-to-date with the latest security patches, as well as pockets of unsecured networking equipment. Now these systems are slowly becoming connected to public networks for the purposes of remote administration, programming and monitoring, making them vulnerable to many threats. In order to protect these networks, a defense-in-depth strategy should be deployed. This type of defense protects in several places, such that bypassing a single security device does not provide unfettered access to the
4. Develop a security policy. In addition to malware

issues, implementation of a security policy should also include: an authentication mechanism, data backup procedures, offsite backup of electronic media, physical protection (such as
Share article
Add comment
Return to contents
141 / 167
continued

rest of the network. A defense-in-depth strategy should provide secure remote access through the use of VPN gateways to provide encrypted access at the external boundaries. The internal zone boundaries should employ firewall and network address translation. This can limit the scope of access by an internal action such as a phishing or a virus introduced by a trusted device inside the network, such as accessing a malicious external website. It can also provide critical device protection by isolating malfunctioning devices from broadcasting packets to the entire network and creating a denial of service. Employing an industrial VPN/NAT/firewall/router at multiple places in your network can provide an in-depth defense against many attacks aimed at industrial systems. Protect your network at the site level, internal zone and cell levels.
6. Prioritize your efforts. Every

control system has one or more assets that would seriously impact production, safety or the environment if successfully attacked. These might be the SIS (safety integrated system) in a refinery, the PLC controlling chlorine levels in a water filtration plant or the RTU in an electrical substation. Plant personnel know what really matters in an operation. If these assets are aggressively protected, the chance of a truly serious cyber incident is massively reduced.
Protecting control systems

For more information about protecting industrial control and SCADA systems from security threats, download the white paper at
http://awgo.to/020
Source: Tofino Security
Share article
Add comment
Return to contents
142 / 167
continued
Security threats confront every manufacturing plant

Network security is becoming a more important issue. With manufacturing facilities becoming more wired and automated, as well as accessible from outside the facility, external security is becoming an issue that in the past was typically not even a consideration. Security, from both outside and from within the facility must now be incorporated as part of any automation project. Consider how much cost is involved when the production facility is shut down for standard maintenance operations, which are planned and intentional. Now consider the cost impact if the facility was maliciously shut down, or if only one operation in the facility was disrupted. The cost could be devastating. With all of the eavesdropping and international espionage in the news, it is becoming more important to secure the automated facility and protect operations from outside interests (including foreign governments). Cost is becoming less an issue when compared to the potential damage that
Share article
Add comment
Return to contents
143 / 167
continued
could be caused by a breakdown in security. Dont skimp by using cheap security software. A hack or virus in a system can cause the entire business to be compromised. External access is only one security consideration. What if an outside interest gained access to your operation solely for the purpose of accessing your information without your knowledge? Gaining access to your product manufacturing process, your supply chain and other aspects of your production could provide invaluable information to an unscrupulous competitor. All of these factors and potential threats should more than justify the cost of implementing a security plan for your facility.
In addition, there are security threats from within the facility. These can be as innocent as an accidental modification to a production program or as intentional as a disgruntled employee. While many security issues can be solved by better human behavior, theres no way to guarantee that the behaviors threatening your facility will actually change. Take all of these threats into account when developing a security plan. Considering the risks to your business, it shouldnt be difficult to justify implementing a security plan for your facility.
Share article
Add comment
Return to contents
144 / 167
Seven details to remember when implementing network security

Network security is absolutely necessary for todays industrial networks. Failure to restrict access can be disastrous. Access to your network by untrained persons can lead to misconfigured network devices. Access to unsecured ports can lead to network loops being accidentally created. Here are a few security details to keep in mind when constructing your network: the production network into three sectionsPLCs, HMI users and serversto reduce traffic where it is not required. Access to the management interface of your network switches can also be controlled. Utilize an accessible IP list to limit administrative access to your network devices. This list will only allow connections to the management interface of a switch from a list of pre-selected IP addresses. To further prevent access to the management interface, a separate management VLAN can be created for this purpose as well. However, many industrial networks operate in a single VLAN with a flat IP scheme. Creating separate VLANs can introduce a bit more complexity into the average system, but the accessible IP list can often provide just the right amount of protection along with the desired simplicity.
1. Keep production running. Recovery and uptime are

the critical priorities on the factory floor. Make sure security systems function in a familiar way so that people on the plant floor who are used to dealing with control systems can understand them. For example, dont create a security system that shuts down the equipment if a panicked operator enters the wrong password in an emergency situation.
2. Divide VLANs. Separate your production floor assets

from the management functions (office computers, reception door locks, etc.) using different VLANs. Its often useful to divide
3. Use managed switches. Design your network with

managed switches, which allow data flow control and reduce loads on the network. These devices contain a management interface that will give you great control over their operation, as
Share article
Add comment
Return to contents
145 / 167
continued

well as limit access to the network. Unmanaged switches do not provide any type of control and allow any device to be plugged into the network. Managed switches also allow the network designer to disable any unused ports. This prevents unauthorized devices from gaining access to the network. The ports can either be disabled or be configured to use a central RADIUS server, which can control access to them using 802.1X. This requires a bit more configuration, but allows for all your network devices to have a single user database that is centrally administrated, rather than have to manage user names and passwords on individual switches. Make sure you change the default admin password of the switch. It typically comes set to a default and many fail to change it. It goes without saying that this is a big problem and it should always be changed. protocols, any port can be connected with an Ethernet cable back into another port on a switch and create a broadcast storm. This can cripple the switch as well as the network. This kind of problem can also be tricky to track down and flush out of a network. Loop prevention protocols include the spanning tree variations such as rapid spanning tree. For industrial applications, these can be too slow, but optimized solutions such as TurboChain and broadcast storm prevention (BSP) can provide response time in milliseconds to prevent network loops from occurring. These features can be used to prevent a malicious denial of service outage from occurring as well as prevent an accidental Ethernet cable loopback.
5. Look for redundancy and robustness. Having

equipment that is easy to disrupt makes an attackers job easier. All network components, including cabling, cabinets and active equipment, need to be industrially hardened, resilient and have high mean-time-between-failure (MTBF) ratings because of the harsh environments found in an industrial facility. Active
4. Guard against network loops. Many industrial

networks are designed with redundant paths in the system and already employ a redundancy/loop prevention mechanism. This is also a feature of a managed switch. Without loop prevention
Share article
Add comment
Return to contents
146 / 167
continued

components in an industrial network, such as switches and routers, need to support industrial redundancy technologies and the level of redundancy required for your production needs. This will keep operations going in the event of malware or other network intrusions. Plant personnel need to be immediately alerted if a read-only remote operator station suddenly tries to program a PLC. Waiting for the IT team to analyze the event the next day is too late.
6. Early network warning system. Integrating security

with industrial control systems is critical for both support and security event monitoring in a network. Using such a system will facilitate the detection of unusual activity on the network, an area that is typically poorly done in the industrial automation world.
7. Optimize firewalls to protect the right protocols. Firewalls should be optimized to secure SCADA
protocols such as Modbus and OPC, rather than email or web traffic, which have no place on a plant floor system. Products that inspect email and web traffic simply add cost and complexity to the security solution. Design your security system to handle very wide power ranges, since the plant floor often has dirty power.
Share article
Add comment
Return to contents
147 / 167
Nine ways to get the most from simulation and CAD/CAM software
Simulation software and CAD/CAM systems have helped transform the design of machines and automated systems by reducing design engineering time and costs. Here are some tips for getting the biggest bang from your software investment: anyone said, We performed too much simulated testing.
3. Integration simulation. You can increase productivity

for automated systems using pneumatic, hydraulic, electric control, electro-pneumatic, electro-hydraulic, PLC ladder programming or function block diagram by simulating the entire integration of these technologies into a new project. Using soft technologies as support for projects allows you to analyze the behavior of the entire system, see how a design works or compare different design options and technologies. Simulation software has become an essential tool for successful automation projects.
1. Find a user group. For any software, it is useful to find

out if theres a software user group or online community that shares problems and solutions or good and bad examples. White papers and a few application examples in the manual cannot compare with real experiences shared by users. This is especially important if the software supplier provides only paid help or support.
2. Test and test again. Simulate industrial control systems

on the bench to the greatest extent possible and practical. Experience suggests that theres never been a startup where
4. Start with a database. Study software concepts

well and avoid going too far before creating a full, consistent components database.
Share article
Add comment
Return to contents
148 / 167
continued
Nine ways to get the most from simulation and CAD/CAM software
5. Verify performance. CAD/CAM simulation helps the
programmer and engineer to know about the working of a machine before its built and for troubleshooting as well. Its also useful for research. Before applying any hardware ideas, a programmer or engineer can simulate to verify the results to the nearest real-world values. simulation give you a good image of the problem to solve. Have a mental model to make sure digital version mimics the real world.
8. Keep it simple. CAD/CAM is one of those tools that quietly

revolutionized low-volume production. But it is easy to get caught up in adding features because it is so easy to do. Keep it as simple as it needs to be and little more. This is as true in design as it is in cutting metal. Drive for simplicity; save a lot of headaches.
6. Talk to those who did a project. Its worth researching

similar projects and simulations. Try to visit the sites where the work took place. The published version that emerges from a project is usually a pale imitation of the blood, sweat and tears that actually went into a particular software system. If you can get a word with those who were actually on the front line of the system, they tend to be the most truthful about its benefits or limitations.
9. Is it real? Models can be very powerfulor very misleading.

The challenge in creating a useful model is validating that the output is actually predictive. We are conditioned to believe what we see. In simulation, what we see may not be real. While simulation can save time and money, just make sure you are modeling with the correct variables. Mathematical modeling is the first step in simulation, yet the most critical step to success. Always validate against real-world conditions.
7. Design with modeling. Make sure modeling and
Share article
Add comment
Return to contents
149 / 167
Five recommendations for implementing workflow systems

Workflow software is a useful tool in many applications, from enforcing standards and compliance to feeding into an MES. Here are some suggestions for implementing workflow software: PHASE IT IN
Its a good idea to implement workflow automation software in two planned projects. Plan and execute the first workflow project within a limited domain, where the systems, responsibility and authority reside in one group. Once there is proven success with this project, the bigger projects that span groups can be tackled with knowledge and confidence in the workflow tool. The challenge on a bigger project that spans domains is selecting a project team and leader with the authority to make decisions and trade-offs efficiently, with buy-in from all.
1. Define your objectives. For workflow software,

you need to first discuss what you want to use the workflow software to do. Do you want it to enforce compliance, for example, or build a corrective action solution or provide offshoot functionality for an MES? Are you using it to interface plant-to-business applications? Workflow software needs to enforce a standard procedure or series of procedures. If you have processes that change all the time, workflow may be too structured for you to benefit. But to facilitate standard responses to activities or events, workflow software is a good solution.
be specific when discussing and documenting software requirements, methods and objectives.
2. Define subsets. Recognize and define the expanding

subsets of workplace software (for example, fixed programming, limited variability programming, full variability programming, utility software, embedded software, firmware, etc.) and
3. Document standard work. Ensure that the real

production workflow is accurately documented and understood for all products and all variations before you start the project. And make sure you get the operators to agree and quantify the standard work (if its available). If you dont do this up front and
Return to contents
150 / 167
continued
Five recommendations for implementing workflow systems

get everything documented, agreed on and the future state well understood, then you will end up running in circles.
4. Improving code. When you ask for additional product

flexibility that will require workflow software code changes, allow sufficient time for your programmer or integrator to make the changes. Pushing them beyond their work capacity with unrealistic schedules can result in mistakes and project delays.
Use templates to save a lot of time. Use IEC 61131-3 for programming machine behavior. Be sure to enlist the experience of all those who will come
in contact with the workflow that you are trying to model or diagram. Ensure proper channels of workflow. A proper design is essential to avoid delays in a workflow project.
5. More workflow tips.
Do not be overly analytical and make it unnecessarily

complicated.
Share article
Add comment
Return to contents

VENDOR SELECTION RESOURCE GUIDE
151 / 167
Advantech
Advantech, a pioneer in Intelligent Automation Technology

With more than 30 years of experience in providing a full range of products to different vertical markets, the Industrial Automation Group of Advantech is a pioneer in intelligent Automation technology. By combining connectivity, flexibility, ruggedness and being at the leading-edge of Internet of Things technology, Advantechs Industrial Automation Group is proving to be a global leading Automation Product and Services provider. Major product lines include:
Automation Controllers
Advantechs Programmable Automation Controllers (PAC) combine a PLCs ruggedness with PC-based technology, an open architecture, high performance CPU, rich I/O modules and power software.
Automation Software
Advantechs automation software lineup includes SCADA software, SoftLogic programming tools, OPC WEB RESOURCES Server, and other user-friendly VIDEO programming tools and utilities.
Embedded Automation Computers

Advantech offers complete line of embedded automation computers with rugged and cableless designs, including fanless box PCs and industrial control devices. With compact and multiple IOs, multiple expansion solutions and multiple mounting methods,
Advantech Now and Beyond
Intelligent HMI Platforms

With a complete range of intelligent operator panels, touch panel computers, industrial automation panel PCs, and industrial monitors, Advantech offers a wide range of human machine interface (HMI) products for industrial automation panel needs. In addition, an integrated I/O and control feature with HMI/SCADA software enables efficient integration.
COMPANY: Advantech Corporation
awgo.to/200
WHITE PAPER
How has the recent strides in automation changed the factory floor? awgo.to/201
PRODUCT
ADDRESS: 11380 Reed Hartman Hwy, Cincinnati, OH 45241 WEB: www.advantech.com
Multi-touch wide screen monitor with waterproof M12 connectors.
awgo.to/202
PHONE: (800) 800-6889
Share article
Add comment
Return to contents

each embedded automation platform is suitable for a wide variety of automation applications in a wide range of environments.
152 / 167
Advantech
With more than 6,000 talented people, Advantech operates an extensive support, sales and marketing network in over 20 countries worldwide. In addition, we cooperate closely with our partners to help provide complete solutions for a wide array of applications across a diverse range of industries.The Advantech Industrial Automation Groups Intelligent Automation, Seamless Integration mission statement looks forward to the contribution that Advantech, together with its partners, can make to this new era of intelligent automation. Whether in public safety, building energy efficiency, environmental monitoring, industrial monitoring, smart transportation, smart grids, smart homes and other areas with our expertise and experience we can provide the best solution to create better tomorrow.
Distributed I/O Modules

While the Internet-of-Things is rapidly becoming a reality, customers can take advantage of Advantechs machine-to-machine I/O modules (ADAM-2000 series), RS-based I/O Modules (ADAM-4000 series), and Ethernet-based I/O Modules (ADAM-6000 series) to monitor and manage field sites easily.
Data Acquisition and Control

Advantech offers wide range of industrial data acquisition and control devices with various interfaces and functions. Based on PC technology, from ISA to USB, and signal conditioning to graphical software tools, Advantechs industrial I/I products are reliable, accurate, affordable, and suitable for many industrial automation applications.
Industrial Communication Solutions

Advantechs Industrial Communication products provide reliable wired and wireless communication for mission critical applications. Products include Industrial Ethernet Switches, Industrial Wireless AP/CPE, Media Converters, Serial Device Servers, Cellular IP Gateways, Modbus Gateways, and Serial Communication Cards.
COMPANY: Advantech Corporation
ADDRESS: 11380 Reed Hartman Hwy, Cincinnati, OH 45241 WEB: www.advantech.com Return to contents
PHONE: (800) 800-6889
Share article
Add comment

153 / 167
Festo
Pneumatic and Electric Drive Technology for Factory & Process Automation
Festo is a leading global manufacturer of pneumatic and electromechanical systems, components and controls for process control and factory automation solutions, with more than 55 national headquarters serving more than 180 countries. With over 40 years of innovation in the United States and over 80 years globally, Festo has continuously elevated the state of manufacturing with innovations and optimized motion control solutions that deliver higher performing, more profitable automated manufacturing and processing equipment. Our dedication to the advancement of automation extends beyond technology to the education of current and future automation and robotic designers with simulation tools, teaching programs, and on-site services. Festo is globally recognized as a symbol of expertise in factory automation and process control. We can help decrease process costs by engaging Festo as an extended workbench and benefitting from our expertise with regard to pre-assembled pneumatics, customized product designs, and system solutions. Festo enables its partners to obtain more intelligent automation
COMPANY: FESTO
solutions from a single source. In addition to tried and tested pneumatic drive units, Festo also provides both servo-pneumatic and electric drive units. Our intelligent systems for status monitoring and machine diagnosis (condition monitoring solutions) are made up of sensors, software, controllers, and visualization. These solutions can greatly reduce maintenance and servicing costs. With a comprehensive line of automation components, custom components and complete WEB RESOURCES electromechanical and pneumatic motion controlled multi-axis systems. For more information about Festo Corporation: Festo can support your most complex automation requirements. FESTO ull Range of Standard and F Customized Products With a comprehensive line of more than 30,000 automation products, Festo can support the most complex automation requirements.
CORPORATE OVERVIEW
awgo.to/138
NEW PRODUCT HIGHLIGHTS
awgo.to/139
SOCIAL MEDIA
PHONE: 1 800 99 FESTO WEB: www.festo.com/us
awgo.to/140 Return to contents
Share article
Add comment

Pneumatic Drives Servo Pneumatic Technology Handling & Vacuum Technology Air Preparation, Pneumatic Connections and Tubing Valve and Valve Manifolds Sensors and Machine Vision Control Technology Electromechanical Components Industry Specific Expertise Whether designing new machinery or modernizing existing systems, Festo can provide the resources you need to meet your unique requirements in every stage of industrial production and manufacturing. Automotive Biotech/Pharmaceutical Electronics/Light Assembly Flat Panel/Solar Food & Beverage Lab Automation Printing, Paper & Converting Water/Wastewater Complete System Solutions Our experienced engineers provide complete support at every stage of your development process, including: conceptualization, analysis,
COMPANY: FESTO
154 / 167
Festo
engineering, design, assembly, documentation, validation, and production. Engineering & Design Handling & Custom Assembly Control Systems
Training & Consulting
Our dedication to the advancement of automation extends beyond technology to the education of current and future automation and robotic designers with simulation tools, teaching programs and on-site services. Festo Didactic is the knowledge and learning division of Festo Corporation. Didactics charter is to provide automation technology training for manufacturing employees at our industrial customers worldwide. From basic training packages to the planning, control and handling of complex networked CIM systems and complete, fully equipped learning centers we can create a customized offer to suit your personal requirements for efficient learning and guaranteed results.
PHONE: 1 800 99 FESTO WEB: www.festo.com/us Return to contents
Share article
Add comment

155 / 167
Graybar
GRAYBAR: Your nationwide resource for automation, networking, electrical, safety and security solutions.
Graybar has high quality electrical, automation and control products common to the factory floor or automation processes. Graybars experience and alliances in automation and control products can provide a value to help your company get critical data from the shop floor to the top floor. Let Graybars team of Industrial customer-focused sales professionals and automation and control technical specialists help you boost output, reduce costs and increase safety. Graybar is uniquely positioned to provide the solutions needed from the factory floor to the corporate boardroom, including:
Software
A wide range of easy-to-use software programs that will help you easily migrate to newer platforms.
Operator Interfaces
The latest technologies in the human-machine dialogue field to help machine builders and industrial users meet new control system standards.
Industrial Networking
Ruggedized industrial Ethernet products designed specifically to network in tough environments, support the industrial protocols transmitted across these networks, and accommodate the environmental rigors of the location.
Enclosures
Industrial enclosures and enclosure solutions that isolate critical controls from harsh environments and help ensure reliable performance in a range of extreme conditions.
Wireless
Wireless data communication solutions for indoor and outdoor applications that offer reliable transmission, low maintenance and increased system availability.
PLCs and I/O

User-friendly PLCs providing secure industrial connections.
COMPANY: Graybar
Power Supplies
Industrial-grade power supplies for demanding applications and harsh environments.
PHONE: 1-800-GRAYBAR (472-9227) WEB: graybar.com/industrial Return to contents
Share article
Add comment

AC Drives and Soft Starts
Technical assistance to help you commission your variable frequency drive (VFD) and provide the control for a more energy-efficient operation. Graybars automation specialists are certified by Schneider Electric for VFD stat-up and commissioning.
156 / 167
Graybar
Power Monitoring
Power management systems designed to help manage real-time conditions, isolate problems, study trends, and control loads and generators.
Sensors
Technical specialists to help you select the right sensor for your application, including proximity sensors, electronic pressure sensors, photoelectric sensors and limit switches.
Industrial Cables and Connectors

A wide range of industrial data cabling solutions for all of your harsh environment needs that will help you avoid transmission errors that can lead to downtime or safety issues.
Services
A wide variety of services to support our customers facility needs in power, lighting, networking, energy management, security and more. Our technical specialists help customers in all these areas today and continually expand their knowledge and skills to master new technologies.
Terminal Blocks and Interface Products

A comprehensive line of DIN-rail mounted products to choose from, featuring an array of termination methods that save time, space and money.
Safety
Plant-wide safety audit provisions, lockout/tagout provisions, arc flash analysis, and personal protective equipment (PPE) to help avoid electrical hazards that can result in serious injury or death.
KEY COMPANY CONTACT Brett Felton, National Marketing Manager PHONE: (314) 573-9200 LOCATION: St. Louis, MO EMAIL: brett.felton@graybar.com
COMPANY: Graybar
PHONE: 1-800-GRAYBAR (472-9227) WEB: graybar.com/industrial Return to contents
Share article
Add comment

157 / 167
Omron Automation & Safety
We help customers build superior automated machines that are easy to use, install and integrate.
Omron Automation and Safety is a leading global supplier of automation systems serving industrial customers for more than 80 years. Our comprehensive product lines and application expertise are delivered via a well-trained distribution channel. They work with you to solve demanding automation challenges and apply the advanced technology built into Omron products. WEB RESOURCES We support machine builders and OEMs across the United States, Canada Find Omron Automation & Safety on and Latin America with sensing and control technologies that help you deliver more capable and profitable machines in less time. We strive to be your trusted partner in automation. Leverage our industry expertise and powerful yet simple solutions in your next project.
LINKED IN
http://www.linkedin.com/ company/omron-electronics
FACEBOOK
https://www.facebook.com/ OmronAutomationSafety?ref=hl
TWITTER
https://twitter.com/ OmronProduct
YOUTUBE
COMPANY: Omron Automation and Safety PHONE: (847) 843-7900
ADDRESS: One Commerce Drive, Schaumburg, IL 60173
http://www.youtube.com/user/ OmronAutomationTech Return to contents
Toll-free: (800) 556-6766 WEB: www.omron247.com
Share article
Add comment

158 / 167
Omron Automation & Safety
Primary Industries Served Automotive Food/Beverage Semiconductor Electronics and Small Parts Assembly Pharmaceutical/Cosmetics Automation Expertise Packaging & Material Handling Measurement & Gauging Inspection Track & Trace Quality Improvement
Omron Facts 80 years in the controls business, founded in 1933 $6.5 billion sales (USD, April 2012) 40% of our sales come from industrial automation; electronic components, social systems, automotive electronics and healthcare make up the balance 35,411 employees worldwide
COMPANY: Omron Automation and Safety PHONE: (847) 843-7900
KEY COMPANY CONTACT

PHONE: (847) 843-7900 Toll-free: (800) 556-6766 LOCATION: Schaumburg, IL EMAIL: salesnet@omron.com
ADDRESS: One Commerce Drive, Schaumburg, IL 60173 Return to contents
Toll-free: (800) 556-6766 WEB: www.omron247.com
Share article
Add comment

159 / 167
Opto 22
Three Reasons To Call Opto 22 for Your Automation Application

Simple-to-build groov mobile operator interfaces, industrial SNAP PAC System with guaranteed-for-life I/O, and a 40-year history of engineers responding to your monitoring and control needs: three reasons your automation project and youdeserve to work with Opto 22. groov: Your system on your mobile. groov is all you need to build mobile operator interfaces for your system and securely view them from virtually any smartphone or tablet. Mobility. What would you like to be able to see or control from your smartphone? Machine status? Factory production? Energy usage? Facility security? Key performance indicators? Now you can. Your
COMPANY: Opto 22
groov interface works on virtually any authorized, web-enabled device regardless of manufacturer or screen size: smartphones, tablets, and more. Gauges, buttons, labels, even live video all scale to match the device youre using, but never become too small to use. Simplicity. With groov, all you need to build interfaces is a web browser. No plugins; no extra software. And theres no coding or programming. Just drag and drop WEB RESOURCES touchscreen-ready indicators and controls onto the screen, then tag them VIDEO from your own tag database. Interface Simplify your job with a groov mobile interface. updates are simple, too. No user or device keys; no reinstallations. Just have http://awgo.to/166 users refresh their screens. WHITE PAPER Connectivity. What system do you 14 ways to build an operator interface have: Allen-Bradley, Modbus, Siemens, that works. Yokogawa, ABB? Now it doesnt matter. http://awgo.to/167 With groov, you can build mobile PRODUCT interfaces to all of these and many groov makes http://awgo.to/168 Return to contents
mobile simple. Get your free trial.
ADDRESS: 43044 Business Park Drive, Temecula, CA 92590 WEB: www.opto22.com
PHONE: (800) 321-6786
Share article
Add comment

more. Your authorized users have a secure mobile interface that lets them monitor and control equipment from anywhere. Get your groov free trial today. Find out more at groov.com. SNAP PAC System: Automation simplified. The SNAP PAC System simplifies the typically complex process of choosing, buying, and applying an automation system. Four flexible componentscontrollers, brains, I/O, and softwareform a system that can handle any application from basic equipment monitoring to complete factory automation. Distributed control. Program SNAP programmable automation controllers (PACs) with easy-to-use flowchart-based software and optional scripting for complex tasks. Intelligent brains (I/O processors) free the controller and make system expansion easy by providing latching, counting, pulsing, totalizing, thermocouple linearization, scaling, ramping, and even PID loop control all at the local level. Guaranteed-for-life I/O. We manufacture all our own products at our company headquarters in Temecula, California. With this close association between engineering and manufacturing, we have
COMPANY: Opto 22
160 / 167
Opto 22
complete control over quality. We do no statistical testing: each I/O module or solid state relay is tested twice before its shipped to you. Thats why we can afford to guarantee most I/O and SSRs for life. About Opto 22. Founded in 1974 by engineers who designed a better solid-state relay, Opto 22 has built reliable controllers, I/O, SSRs, and automation software for 40 years. With our flat structure, we can respond quickly to customers needs and develop cuttingedge products fast. All our products are based on open standards; all products are manufactured and supported in the U.S.A.
Easy-to-use software, reliable hardware, and people you can talk to: thats the Opto 22 difference. Call today: 1-800-321-6786 or 951-695-3000 KEY COMPANY CONTACT Selam Shimelash Systems Engineer PHONE: (800) 321-6786 ext. 3085 LOCATION: Temecula, CA EMAIL: systemseng@opto22.com
ADDRESS: 43044 Business Park Drive, Temecula, CA 92590 WEB: www.opto22.com Return to contents
PHONE: (800) 321-6786
Share article
Add comment

161 / 167
Red Lion Controls
Red Lion Controls

As the global experts in communication, monitoring and control for industrial automation and networking, Red Lion Controls has been delivering innovative solutions for over forty years. Our awardwinning technology enables companies worldwide to gain realtime data visibility that drives productivity. The following industrial automation products collect, present and process data anywhere, anytime:
Controllers: PID controllers, signal conditioners and data

acquisition devices for machine and process control Protocol Conversion: extensive protocol library connects otherwise incompatible devices on wired or wireless networks HMIs: combine protocol conversion, data logging and web server capabilities with visualization functionality for PLCs, motor drives and more Panel Meters: a wide range of models and sizes with expansion capabilities that easily adapt to changing requirements
COMPANY: Red Lion Controls PHONE: (717) 767-6511
Visual Management: enables the display of real-time KPI data

and Andon messages on large televisions to drive productivity RTUs & I/O Modules: provide a simple yet powerful monitoring and control system for remote sites
ADDRESS: 20 Willow Springs Circle York, PA, 17406 USA
FAX: (717) 764-0839
WEB: www.redlion.net
E-MAIL: info@redlion.net
Share article
Add comment
Return to contents

162 / 167
Red Lion Controls
In addition, Red Lion now offers an industrial networking portfolio that includes:
Unmanaged Switches: compact IEEE 802.3 Layer 2 industrial

switches with automatic speed, duplex and cable sensing Monitored Switches: enable Layer 2 network performance monitoring via N-View software Managed Switches: provide Layer 2 and Layer 3 networking in a rugged package PoE Solutions: designed to transmit power and/or data over an Ethernet network Wi-Fi Radios: IEEE 802.11a,b,g,n hardened radios support data bandwidths up to 300 Mb/s Cellular M2M Routers: provide uninterrupted, secure communication for remote sites
To learn more, call +1 (717) 767-6511 or visit www.redlion.net/together.
COMPANY: Red Lion Controls PHONE: (717) 767-6511
ADDRESS: 20 Willow Springs Circle York, PA, 17406 USA
FAX: (717) 764-0839
WEB: www.redlion.net
E-MAIL: info@redlion.net
Share article
Add comment
Return to contents

163 / 167
Siemens
The worlds leading supplier of innovative and environmentally friendly products, solutions and services for industrial customers.
The Siemens Industry Automation Division supports the entire value chain of its industrial customers from product design to production and services with an unmatched combination of automation technology, industrial control technology and industrial software. With its software solutions, the division can shorten the time-to-market of new products by up to 50 percent. www.usa.siemens.com/automation The Siemens Drive Technologies Division is the worlds leading supplier of products, systems, applications, solutions and services for the entire drive train, with electrical and gear motors components. With its products and solutions, the division enables its customers to achieve productivity, energy efficiency and reliability. www.usa.siemens.com/drivetechnologies The Siemens Customer Services Division provides product-related services as well as services to improve the availability, reliability and productivity of industrial processes. A wide-ranging portfolio of environmental solutions helps industrial companies to use energy, water and equipment efficiently, reduce emissions and
COMPANY: Siemens Industry, Inc
comply with environmental guidelines. www.usa.siemens.com/services Industry Automation Portfolio Process and Batch Control Strategies SCADA, Process Controllers, HMI, Fieldbuses and Networks Discrete/Machine Control Strategies PLC, Motion Control, Logic and Programming Software, Discrete I/O, Sensors, HMI, Networks Asset Management Asset Optimization, Maintenance, Fieldbuses, Instrumentation, Power Supplies Information Management Networking, Ethernet Safety Strategies Process, Machine Energy Management Sustainability, Energy Management Software, Variable Frequency Drives, Motors, Motion Control Operations Management Production Management, Performance Management, Security
ADDRESS: 3333 Old Milton Parkway, Alpharetta, GA 30005 EMAIL: info.us@siemens.com Return to contents
WEB: www.usa.siemens.com/industry
Share article
Add comment

Efficient automation starts with efficient engineering Totally Integrated Automation: Efficiency driving productivity Efficient engineering is the first step towards better production: faster, more flexible, and more intelligent. Totally Integrated Automation (TIA) saves time in engineering as a result of the efficient interoperability of PLCs, HMIs, safety, and drives.
The result:
164 / 167
Siemens
An extensive infrastructure of local expertise and global support ensures you benefit fully from Totally Integrated Automation along the entire production process. Additional TIA productivity benefits are accomplished through common system characteristics across the entire Automation System: Integrated Engineering Industrial Data Management Industrial Communication Industrial Security Safety Integrated Our revolutionary TIA Portal engineering software provides the framework! TAKE A TEST DRIVE!
Request a trial copy of TIA Portal software and experience first-hand a single engineering framework that allows you to combine all automation tasks in one environment, reducing engineering costs up to 30% usa.siemens.com/tia-portal-trial-license
Lower cost in design, commissioning & maintenance Reduced downtime Faster time-to-market Greater flexibility
COMPANY: Siemens Industry, Inc
ADDRESS: 3333 Old Milton Parkway, Alpharetta, GA 30005 EMAIL: info.us@siemens.com Return to contents
WEB: www.usa.siemens.com/industry
Share article
Add comment

165 / 167
Teledyne DALSA
Teledyne DALSA High Performance Digital Imaging Solutions

Teledyne DALSA is an international leader in high performance digital imaging and semiconductors with approximately 1000 employees world-wide. Established in 1980, and acquired by Teledyne Technologies in 2011, Teledyne DALSA delivers industry-leading technology for digital imaging and specialized semiconductor fabrication. With core competencies in CCD and CMOS imagers, high-performance electronic cameras, image processing hardware and software, Teledyne DALSA is committed to enabling industry and exploration through innovative technology. Teledyne DALSAs industrial vision solutions are designed to meet the diverse needs of industry and end users alike. Designed specifically for factory floor deployment and usability, our innovative vision systems offer scalable solutions that satisfy a wide range of application needs from positioning robotic handlers to complete assembly verification. These products are easy enough for novices, powerful enough for professionals. Designed for single point inspection, Teledyne DALSAs BOA products are highly integrated vision systems in a tiny smart camera package specifically designed for industrial use. Complete with choice of application software embedded, BOA offers manufacturers a robust and flexible automated inspection system that is easy to integrate and deploy on the factory floor. For applications requiring multicamera inspection, Teledyne DALSAs embedded machine vision systems are comprised of a centralized camera controller that delivers low deployment cost with high performance processing. These vision systems are available with choice of application software and camera interface to suit a range of application needs.
WEB RESOURCES
VIDEO
BOA Smart Camera Demonstration
awgo.to/155
ON DEMAND WEBINAR
Machine Vision for Factory Automation
awgo.to/156
PRODUCT
COMPANY: Teledyne DALSA
ADDRESS: 700 Technology Park Drive, Billerica, MA 01821 WEB: www.teledynedalsa.com
BOA Vision System Small, Smart and Flexible
PHONE: 978-670-2000
awgo.to/155
Share article
Add comment
Return to contents

Teledyne DALSAs vision systems are available in a range of costeffective models to satisfy a broad variety of user requirements. These include single 640 x 480 standard camera configurations to high-performance multi-camera models with 1600 x 1200 color resolution. They support line scan technology to address challenging large format or cylindrical unwrapping applications. Vision solutions are equipped with two distinct styles of application interface to accommodate the differing needs and experience of end users: iNspect Express software allows experienced users and 1st time adopters alike to setup and deploy solutions with little or no prior machine vision knowledge. iNspect Express logical setup is built from the experience and algorithms that have been put to the test over the course of many years. Sherlock software offers experienced vision integrators additional flexibility, together with a rich suite of capabilities and options that can be applied to the most challenging applications. Sherlock provides advanced functionality in terms of scripting, customization and support for 3rd-party tools.
166 / 167
Teledyne DALSA
Teledyne DALSA vision solutions provide a full suite of vision tools and capabilities for performing the following inspection tasks: Positioning Guide robotic handlers or adjust vision tools for part movement Identifying Identify product for verification or traceability Verifying Verify parts for correctness, assembly or packaging Measuring Measure parts for dimensional accuracy Flaw Detection Check part surfaces for scratches and other defects
COMPANY: Teledyne DALSA
ADDRESS: 700 Technology Park Drive, Billerica, MA 01821 WEB: www.teledynedalsa.com Return to contents
PHONE: 978-670-2000
Share article
Add comment
167 / 167
Thank you for downloading Automation World's Factory & Machine Automation Playbook! Now that you've had a chance to review it, we'd love your feedback. Share your thoughts!
Post your comments

Factory Machine Automation Playbook v12

Загружено:

Сведения о документе

Исходное описание:

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Factory Machine Automation Playbook v12

Загружено:

Авторское право:

Доступные форматы

2014 EDITION

FACTORY & MACHINE

HOW TO SUCCESSFULLY IMPLEMENT FACTORY & MACHINE AUTOMATION PROJECTS

Mac Build hine e

OEE & Lean Manufacturing

FACTORY & MACHINE Automation Playbook

FACTORY & MACHINE Automation Playbook

FACTORY & MACHINE Automation Playbook

FACTORY & MACHINE Automation Playbook

Six critical considerations for successful machine vision applications

Section 3: Applying technologies to improve outcomes

FACTORY & MACHINE Automation Playbook

FACTORY & MACHINE Automation Playbook

Jeff Miller, PMP

FACTORY & MACHINE Automation Playbook

FACTORY & MACHINE Automation Playbook

FACTORY & MACHINE Automation Playbook

Thanks as well to the many contributors who preferred to remain anonymous.

FACTORY & MACHINE Automation Playbook

FACTORY & MACHINE Automation Playbook

PLANNING AND IMPLEMENTING AN AUTOMATION PROJECT

FACTORY & MACHINE Automation Playbook

12 points to consider before even beginning your automation project

3. Helping people. Automation can do many things, but

1. Visualize success. Try to visualize what a project would

2. Whats driving the project? You need to understand

FACTORY & MACHINE Automation Playbook

12 points to consider before even beginning your automation project

5. Start with the objectives. Dont even begin to select

6. Get a second opinion. It pays to get a second opinion

7. Set rules for communication. Define what

FACTORY & MACHINE Automation Playbook

12 points to consider before even beginning your automation project

8. Talk to everyone. Interview the stakeholders from

11. Spell everything out. If you want drawings in

9. Never assume. Dont make assumptions about the

12. Scope! Nothing is more important than a scope

10. Create a chart to keep objectives clear. Define

FACTORY & MACHINE Automation Playbook

Nine tips for automation project managers

2. Welcome the bad news. Every

Looking for training?

1. Project management resource. There have been thousands

3. Keep simplicity top-of-mind.

FACTORY & MACHINE Automation Playbook

Nine tips for automation project managers

5. Establish testing plans early. It isnt enough to

6. Follow programming standards. Make sure that

7. Communicate often. Dont make decisions without

FACTORY & MACHINE Automation Playbook

Nine tips for automation project managers

Close Internal Kickoff

Site Acceptance Test Factory Acceptance Test

Project management V model, courtesy Control System Integrators Association.

FACTORY & MACHINE Automation Playbook

Automation project management from a machine builders perspective

1. Select and build your internal project team. This is an important

2. Select a Project Manager.

Involve departments. Manufacturing,

FACTORY & MACHINE Automation Playbook

Automation project management from a machine builders perspective

Timeline development Transportation Installation Warranty Terms

Runoff requirements Safety review Poka-Yoke verification Training Documentation requirements

Involve departments. Manufacturing,

Process planning Design review of electrical, mechanical, and flood power

All operational aspects including setup and changeover