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

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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

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SPONSORS

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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 builder’s 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.

FACTORY & MACHINE Automation Playbook 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 OEM machine designers (in addition to automation end users) will specifically find useful tips in highlighted articles.

.FACTORY & MACHINE Automation Playbook 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 OEM machine designers (in addition to automation end users) will specifically find useful tips in highlighted articles.

.FACTORY & MACHINE Automation Playbook 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 OEM machine designers (in addition to automation end users) will specifically find useful tips in highlighted articles.

FACTORY & MACHINE Automation Playbook 7 / 167 PLAYBOOK ADVISORS Thomas A. Stephen M. Howard Skolnik President/CEO Skolnik Industries Michael Hake Senior Facilities Systems Support Technician Data Device Corp. Doney Senior Research Engineer Nestlé Joe Martin President Martin CSI Paul Brinks COO Koops Inc.Machine & Automation Systems Corning Inc. Goldberg Director . PMP Director of Project Management Interstates Control Systems Inc.Information Technologies Matrix Technologies Inc. Jeff Miller. Smith Senior Automation Controls Engineer MT&E . Robert Lowe Executive Director Control System Integrators Association (CSIA) . Arthur C.

USA Johnny Sorensen Chr. Mexico Mike Cerda Control M Automation. Mexico Sanjay Mishra COTMAC Electronics Pvt. Italy Dan Perkins LINAK U.. India Ken Lauer Middough. Ostrander CADD Tech Support. USA Eric Byres Mike Miklot Belden.. USA Mike Fahrion B&B Electronics. Canada Chris Weigmann Lakeside Manufacturing. Pakistan Hernan Gardiazabal ContrALL. USA Ed Nachel Elobau Sensor Technology Inc. Canada Leslie Crothers Almac. Spain John Wilson Integrated Automation. USA John F. Colombia Peter van den Berg Avans University of Applied Science. Klemptner DTE Energy. USA Josu Bilbao IK4-IKerlan. USA Stefano Linari Linari Engineering srl. USA Deana Fu Bryan Knight Mitsubishi Electric Automation... Wozniak CC-Link Partner Association. USA Robert L. USA Lonnie Purvis Apex Manufacturing Solutions. Fischer Fischer Technical Services.. India Dave Robinson Aurora Industrial Automation. the Netherlands Stanley Moses Bahwan CyberTek Inc. USA Joel Albert Industrial Networking Solutions... USA George Hockett II Miniature Plastic Molding LLC. Ltd. USA John Holmes Festo Corp. USA Julian Martinez Emerson Network Power. USA Chris Alexander Givaudan Flavors. United Kingdom Todd Desso Eddie Lee Mike Werning Moxa Americas. Australia Sudhendu Banerjee Instrumentation Ltd. Inc. United Kingdom Kurt Wilde Henniges Automotive. USA Larry W..FACTORY & MACHINE Automation Playbook 8 / 167 CONTRIBUTORS Michael Mikolajczak Bryan Sisler ABB. China Alexander Pinkham ICONICS. Lebanon Germany . Qatar Tianshun Qiu IBM (China) Co. India Roy Greengrass Del Monte Foods. USA Tom Jensen Lenze. Colombia Roy Adams ERA LLC.S. Colin Harrison Glasgow Caledonian University.. USA Wendy Jacintha AFLAC. USA Eric Esson Frommelt Safety Products. South Africa Sujata Tilak Ascent Informatics Pvt. USA Dr.. USA Stephen Chilton Monozee Ltd. Iran Tom England Kollmorgen.. USA A. Ltd. Ltd... USA Alex Miller ABB Robotics. USA Mohbat Tharani COMSTATS Institute of Technology. USA Satish Samineni Halcrow. USA Shawn Day Henry Menke Balluff Inc. USA Abdulilah Alzayyat Jim Hulman Joaquin Ocampo Bosch Rexroth. USA John Malinowski Baldor Electric Company. Inc. Denmark John Lewis Cognex Corp. USA Jagjeet Paul Little Systems.. USA Mike Berryman Advantech. USA Vikram Kumar EZAutomation... USA John Coetzee Aristotle Consulting. Hansen.Qatar Rafael Arevalo Duque Automatizacion Ingenieros Especialistas sas. USA Jad Wehbe Automate. USA Jeremy Jones Baumer Ltd. USA Pierre Lampron KSH Solutions Inc. USA William Wang DuPont China. USA Carl Stelling Antaira Technologies. Australia » CONTINUED ON PAGE 9 . India Majid Takabi JGC Co. Nelson South Nelson South Electrical. USA Jingxu He Bayer. China Tim Matheny ECS Solutions Inc. United Kingdom Rob Cotner Anixter. Inc.

USA Tom Hoffman Jeff Miller Gregory Richards Siemens... Italy Steve Sarovich Sardee Industries Inc. Slovenia Mark A.. India Rafey Shahid Qanare Engineering. Brazil Nesko Kontic SGS . USA Dennis Sanchez RECOPE. USA Jerry Schultheis Schultheis Automation Control Systems Inc. USA Jim Anderson Jill Oertel Aaron Schulke SICK. Noida. Gyan Ranjan Biswal Shiv Nadar University. China Chris Brogli Paul Brooks Douglas Henderson Jimmy Koh Amy Peters Fatime Ly Seymour Thomas Sugimoto Rockwell Automation. Erickson Skills Improvement Inc. India Fernando Jimenez Universidad de los Andes. USA Sam Shorer SABMiller. USA Ed Novak Trio Motion Technology. Costa Rica Cheng Xinping Rockwell Automation. USA Ben Orchard Opto 22.... USA Dave Szurek The Mackubin Group. USA » CONTINUED ON PAGE 10 . USA Joe Sebastian Diane Trentini Optimation Technology Inc. USA Wilfredo Jimenez WJ Automation & Integration Corp.. Mexico Helge Hornis Pepperl+Fuchs. Noida. USA Sachin Kumar Vertex Automation System (P) Ltd.. USA Assaf Beckman Tomatic. USA Tomaz Vidonja Simplysens. Israel Matthew T. USA Pramod Parikh United Phosphorus Ltd. USA Mark Buckley Phoenix Contact. USA Lewis Gordon Tangent Services. USA Bill Bobbitt Van’s Aircraft Inc. Sweden Robb Dussault John Boville Schneider Electric. USA Scott Klages Parsec Automation Corp.. USA Pat Gallagher Solar Automation Inc. USA Nathan Schiavo Wesco. USA Peter Hook Tech Innovations LLC.. Colombia Alejandro Pena Universidad Distrital.FACTORY & MACHINE Automation Playbook 9 / 167 CONTRIBUTORS Kenn Anderson Nova Systems Inc. USA Will Zurkan Zurkan Solutions. Seiman Trelleborg Sealing Solutions. USA Gilbert Brault Antonio Chauvet Schneider Electric. Ltd. India George Pease Show-Me Machine Works. USA Jose Gonzalez Valero PEMEX. USA Eder Mathias SEW-Eurodrive. China Shamsol Shamus Shamus Technology Ent. Puerto Rico Karen Leung Worleyparsons. India Pradeep Soni VSM Venture Control System P.Wind Energy Technology Centre.. Pakistan Mark Battisti QPoint Robotic Solutions. Colombia Gary Phillips URS E & C.. USA Erik Nieves Yaskawa Motoman Robotics... Malaysia Dr. France Johan Hult Schneider Electric. USA Rahul Aggarwal Prekar Services & Solutions. USA Mahendra Dissasekera Ronan Engineering Co. South Africa Andrea Sammartino Saipem Spa.. India Charlie Norz WAGO Corp.

by Country Algeria Nesrine Chaouche Bosnia Bojan Djurdjevic Brazil Edson Gonçalves 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. 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. 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. Rasheed Ireland Joe Burke Israel Victor Zaltsman Lithuania Genadij Nesterenko Mexico Jorge Loza Netherlands R.FACTORY & MACHINE Automation Playbook 10 / 167 CONTRIBUTORS Individual Contributors. . Kapoor Michael Kinziger David Lamb Todd LaRoche Hian Yong Leong John Nix Tim O’Brien Tony Olivieri Tony Perna Friedrich Purkert Ray Royal Stephen A.

They’ve volunteered to share some of the things they’ve learned during their careers as a way to give back to this unique community.FACTORY & MACHINE Automation Playbook 11 / 167 INTRODUCTION Manufacturers. better. we’ll share their ideas about the best practices to follow and common pitfalls to avoid. This edition of Automation World’s Factory Automation Playbook will explore these themes. But as aging systems become obsolete. the skills they require of their workers and how they interact with their customers and supply chains. We hope this information will be useful. Our thanks to the more than 275 people from 40-plus countries—from end-user companies. educators and automation suppliers—who have participated in the development of this playbook. systems and service providers and how to achieve your business and technology objectives. machine builders and system integrators have been automating production systems for more than 30 years. not just about what’s happening on the production floor but about how companies use resources. how to justify an automation investment. system integrators. whether you’ve 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 » . a new wave of automation is changing the landscape of manufacturing. faster has added another element—the need to become smarter. In the following pages. machine builders. The drive for cheaper. sharing guidance from your peers and suppliers about how to plan and manage automation projects. how to select products. competition becomes fiercer and priorities change. technology advances.

Just as important. The goal of this playbook is to help everyone achieve more successful factory and machine automation projects.FACTORY & MACHINE Automation Playbook 12 / 167 continued Introduction new generation of engineers just entering the field. the stakeholders.“  Jeanne Schweder Contributing Editor Share article » Add comment » Return to contents » . Automation is a tool to help people. Keep those people. “Automation is not about technology—it is about people. As one of our contributors pointed out. it is to remind all of us why automation adds value to our world. in the forefront of your mind as you go about your work.

13 / 167 SECTION ONE: PLANNING AND IMPLEMENTING AN AUTOMATION PROJECT .

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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?
It’s essential to understand each person’s 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 won’t be acceptable.

2. What’s 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.
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continued

12 points to consider before even beginning your automation project
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 company’s 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. Don’t even begin to select
suppliers and service providers until you’ve established a project’s objectives. Make sure everyone on the team agrees on what the project needs to achieve before it starts. If you don’t know where you’re going, you’ll 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 objectives—they’ll often
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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—
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continued

12 points to consider before even beginning your automation project
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. Don’t make assumptions about the
ground rules—spell 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

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Project Management Institute.FACTORY & MACHINE Automation Playbook 17 / 167 Nine tips for automation project managers More than technical skills are required to successfully manage an automation project. 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. Return to contents » . Looking for training? There’s a source to help you learn the ropes of project management or improve your skills. Anybody on the team needs to be able to push the stop button if a project has gone off the tracks. Include http://awgo. Nobody wants to hear or deliver bad news. For more information. dedicated to establishing standards. or expect to be assigned to your first project. but it’s important not to get defensive.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. Here are a few practical tips for automation project managers: management skills. there’s an organization. Project management resource. the easier and cheaper they are to fix. Engineers tend to make systems too complex for non-engineers to deal with. It also requires communication and organizational skills. Keep simplicity top-of-mind. Otherwise. There have been thousands of words written about project management. but the earlier you find out what the problems are. 2. along with the ability to motivate a team of people from a variety of disciplines and different departments. Every automation project has things that go wrong. visit 1. If you think you need a refresher course. Welcome the bad news. you’re just gambling that things will come out all right at the end. providing training and certifying individuals in project Share article » Add comment » 3.

such as OMAC and PackML. Unilateral decision-making alienates the team. Equipment or systems should first be tested at the facilities of the integrator or OEM. Make sure that in-house programmers. The final testing stage. understand that there will be modifications necessary along with way. Approve the testing plans early in the project Share article » Add comment » 6. What is important is that when you begin a project. 5. As with any project.FACTORY & MACHINE Automation Playbook 18 / 167 continued Nine tips for automation project managers 4. Don’t rush the testing phase. 7. The final result is rarely as exactly planned. not once but twice. Multiple approaches to programming can cost a company millions of dollars. not just the manager. Don’t make decisions without consulting the team. It’s easy to get started on designing the tests by using a template. system integrators and OEMs use the same PLC programming standards. It’s also important to make sure the right people attend the FAT. Its objective is to prove that the equipment actually does work as designed and is producing product at the level required. unrealistic projections. make sure you leave enough time in the project schedule to accomplish the necessary tests. poor execution and just plain bad design can cause a project to fail. so that everyone knows exactly what performance measures they need to achieve. Simulate various scenarios to find out how the system will react. and its goal is to prove that the system design will work. creates confusion and fails to take advantage of the unique expertise of the team members. Communicate often. Establish testing plans early. There’s nothing worse than custom code that has to be reworked at the last minute to make it compatible with a plant’s existing systems. SAT (Site Acceptance Testing). It isn’t enough to design a system. is done when the system is delivered to the factory floor. This is called FAT (Factory Acceptance Testing). Follow programming standards. that includes the lead operator and maintenance tech. so that everyone Return to contents » . This is not considered a failure. You have to test it to prove that it works. Be ready to adjust. Foster open communication and communicate frequently. it’s a realistic need to adjust and fine-tune as the project progresses.

 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. Don’t be a roadblock. courtesy Control System Integrators Association. That same rule applies to the system integrator’s team. check with them soon into the project to make sure it’s working. Identify alternative resources early and have them ready to fill in if needed. As project manager. There’s 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. Share article » Add comment » Return to contents » . Stay involved and be responsive to prevent delays in the project’s timeline. Make sure you have bench strength. 9. Establish a communications roadmap for vendors.FACTORY & MACHINE Automation Playbook 19 / 167 continued Nine tips for automation project managers on the team understands the issues and is aware of any problems that need to be resolved. it’s your responsibility to respond to information requests and approve various aspects of the project in a timely fashion. make sure they’ve identified people with equivalent skills who can be assigned to the project if required. Development Project management “V” model.

Purchasing. This is an important first step that should never be skipped. General Information  Project name  Tech Spec revision level  Tech Spec revision date  Project description  Estimated machine life  Target cost Performance Specifications  Involve departments. Getting the right people with the right attitude will make the project successful. Facilities. Finance. Manufacturing. Work this one through before calling an equipment supplier.  Production rate  Maximum noise levels  Capability  Operator duties  Number of operators  Setup and changeover  Repeatability Return to contents » Share article » Add comment » . 2. Chief Operating Officer. Koops Inc. S  elect people for the team with the right combination of skills and attitudes. 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. The goal is to develop a Technical Specification (Tech Spec) that lays out the design parameters and the performance expectations for the system’s builder. The following list will get you started on a Technical Specification Form: Quality. Select and build your internal project team. Define your automation goals. The project manager must set the agenda for the meetings and be persistent. 3. 1. Select a Project Manager.FACTORY & MACHINE Automation Playbook 20 / 167 Automation project management from a machine builder’s perspective By Paul Brinks. it will save precious time and money. Engineering. This person will build.

Justification. safety. Share article » Add comment » Return to contents » . the term can refer to any behavior-shaping constraint designed into a process to prevent incorrect operation by the user.” 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. More broadly. quality. personnel reduction. etc. correcting or drawing attention to human errors as they occur. Companies will vary greatly as to how the justification is measured and how quickly a return on investment is required. sales value. DEFINITION  Runoff requirements  Safety review  Poka-Yoke verification  Training  Documentation requirements Poka-Yoke is a Japanese term that means “mistake-proofing. Management and the project team must be committed to the value of the investment.FACTORY & MACHINE Automation Playbook 21 / 167 continued Automation project management from a machine builder’s perspective 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. This may be a challenge. Many common areas looked at for justification are: Capacity. efficiency.

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 » . capability and thoroughness of the supplier. The qualified supplier will be able to contribute with ideas and concepts that must be reviewed with the project team.FACTORY & MACHINE Automation Playbook 22 / 167 continued Automation project management from a machine builder’s perspective 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. 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. Start by calling a few companies in for interviews. The contract. Pick the supplier with whom you feel most comfortable. Solidify those ideas into a contract with the supplier. The best supplier is the one that you can trust. The contract should include your commitments and those of the supplier. Select a supplier. You can review the documentation after the automation project has been up and running and compare that to your original thinking. Use the Technical Specification (Item 3) as reference and ask the hard questions to determine the experience. 6. 5. capacity.

It is highly advisable that project managers from both the buyer and the supplier stay with the project throughout the entire process. Select the person from the project team that will be responsible for the operation and maintenance of the automation system. The supplier should provide a timeline with all the critical milestones: 8. Good communication on all the details between the two is critical throughout the project. 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. operator interface. 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. mechanical. Monitor the project.FACTORY & MACHINE Automation Playbook 23 / 167 continued Automation project management from a machine builder’s perspective 7. 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 » . This is crucial as the transfer of ownership takes place from the supplier to you. Training. The following list should be covered by the training process:  Process planning  Design review of electrical.

ONE CONTROLLER ONE CONNECTION ONE SOFTWARE 10.. Learn more about the Sysmac NJ Machine Automation Controller at www.  Koops Inc.com the performance your customers demand? One controller through one connection and one software to completely integrate PLC logic. Vision processing. and Database connectivity. www. Grand Rapids. Share article » Add comment » Return to contents » . final acceptance. The intent is that the system. Michigan. Safety guarding. Notwithstanding warranty and service agreement coverage.koops. It is now time for the person and company who purchased the system to demonstrate their readiness by putting the system into production. builds assembly and process automation systems and workstations for a broad range of industries. Runoff and acceptance at the supplier.com. LOGIC MOTION SAFETY ROBOTICS VISION SENSING ENTERPRISE continued Automation project management from a machine builder’s perspective 9. Robot kinematics. Motion control. Installation. and production startup. This is usually done with the assistance of the supplier... most suppliers are eager to have the system running smoothly before leaving the plant. The acceptance criteria as stated in the contract will be the standard. One great solution to drastically reduce machine tact time and programming complexity while improving performance and speeding development.Omron247. as designed and as stated in the Technical Specification.FACTORY & MACHINE Automation Playbook 24 / 167 Can your current control platform deliver. will be run off at the supplier’s plant and that it meets or exceeds the criteria as agreed upon. This can be a critical time since all the planning done previously must come together at this point.

” Applying new technologies will make the process better. supplier of process controls and software. advises. Return to contents » . you’ll never convince them. “Do it in their language. say. veteran of Hershey’s engineering management team with many years of experience justifying automation expenditures. Campbell. Automation World Note: This article is as relevant today as it was in 2003 when first published. Mass. we may not be so good at seeing our projects through an investor’s careful eyes.” Keith Campbell. Share article » Add comment » Different languages This language has terms like cash flow.FACTORY & MACHINE Automation Playbook 25 / 167 How to justify capital projects: Speaking finance gets results By Gary Mintchell. says. using your company’s method for calculating cash flow. and translate them into financial numbers. You have to show them how your project will impact the bottom line. where is the biggest cost accounting database in manufacturing? It is information from all the sensors in the production process. It has been updated several times since then. faster and more consistent. vice president of Invensys. tap into the data you have. For technical managers.. “No money available. capital and interest. it’s easier to convince them. do the math. who reveals these definitions later. “You must identify the positive cash flows you create with a new system. it’s important to remember that it’s an accounting problem. says. Founding Editor. however. If you can’t show the monetary justification in the language of finance.” In other words. It is possible to solve the accounting problem through engineering principles. For instance.” Even if we are on a solid footing with the language of finance. Then the inevitable happens—the capital review team. and then. Peter Martin. it seems like a “no brainer.” Shrewd managers make capital decisions based on return on investment. “When you are justifying automation. whose members may not know a proximity sensor from a pressure transmitter. a Foxborough.

During this time. drivers are economics and business optimization. “Automation drivers from the 1950s to 1975 went from pneumatics to electronics by emphasizing speed of operation and labor improvements with limited automation improvements. notes the changing value
of automation over the last 25 years.” A new automation project can be designed to solve any of a number of problems in the plant. This advice directly leads to the conclusion that bringing a finance person into the automation buying team will reap huge Share article » Add comment » . Why is there such an emphasis on financial analysis these days? Steve Loranger. there was improved control. due to globally integrated manufacturing and activity-based cost accounting. and will be well positioned to translate benefits into the correct numbers. computers went mainstream. an Austin. as well as the crucial data that can be used to figure out the best solution—and how to get through the financial maze to approval. Now. 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.FACTORY & MACHINE Automation Playbook 26 / 167 continued How to justify capital projects: Speaking finance gets results rewards at the justification stage. This person would be involved in the analysis at all stages of the project. and information integration became essential. Texas-based process controls supplier. Drivers from 1975 to 2000 were repeatability and quality. area vice president for Emerson Process Management.

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. 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 » . but it is essential to try to cost-justify as many as possible. it may seem hard to quantify safety and ergonomic improvements that result from improved automation.FACTORY & MACHINE Automation Playbook 27 / 167 continued How to justify capital projects: Speaking finance gets results this article provides several areas of improvement that can result from the project. Boston-based Liberty Mutual released its 2003 Fall Workplace Safety Index. Some of the areas can be hard to quantify. but a greater value to an investor is reducing risk to future earnings. For example. But safety and insurance experts may be able to help document savings that can include anything from avoiding lost workdays to lower insurance premiums.

” This organization clearly suffered because the decision to source in Mexico did not take into account quality tolerances.FACTORY & MACHINE Automation Playbook 28 / 167 continued How to justify capital projects: Speaking finance gets results a catastrophic safety event involving loss of life or limb. He notes. evaluate the tooling changes needed to support product changeover plus auxiliary equipment such as feeders. “We had a printed circuit board assembly machine with robots where the component Share article » Add comment » Return to contents » . But the manufacturing of one of the components. “Check out costs associated with changes. Compounding the problem. just a portion of a project or even when evaluating competing quotes. and member of the Board of Advisors for the Robotics International division of the Society of Manufacturing Engineers. on robotics.” Don’t dismiss employee turnover or morale as a factor that can’t be quantified. engineering vice president of Addison. was sent to Mexico in order to save costs. The problems just couldn’t be controlled. The same rules apply to buildings. a relay. and to various scopes such as the entire project. Constant employee turnover in that plant caused quality problems including solder buildup or tape missing over a hole. operations and finance folks couldn’t team up to demonstrate the cash impact of the scrap and productivity loss. automation systems and computer systems. risk elimination will strengthen the case for capital approval. advises calculating all of the costs associated with the life
cycle of machines. Justification is technology-independent. Lifecycle costs Bill Egert. Ill. lead straightness was specified. Egert reveals. For instance. conveyors and workstations associated with material handling. More often than not.-based integrator Logic One Consulting.

FACTORY & MACHINE Automation Playbook 29 / 167 continued How to justify capital projects: Speaking finance gets results Campbell says the fundamentals of justification include these steps: Because projects are expected to pay back funds over several years. net present value. Calculate the numbers and compare to the company’s financial rules. The Net Present Value (NPV) is the present value of all future cash flows discounted at the cost of capital. the  base case Use your company’s financial rules to evaluate the alternatives  (payback period. Discounted means that a future cash flow is worth less (discounted) than a present cash flow. 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. hurdle rate). minus the cost of the investment. Take a balanced approach addressing significant pros and cons to demonstrate your thoughtfulness and enhance your credibility. document various alternatives to the base case. often five or 10 years. Include all the financial data that can be compiled. minus the cost of investment. Present value The first step is to determine the present value. it is important to find a way to normalize the amounts in order to keep the analysis in proper perspective. Quantify all the risk.38 today. Those results can then be compared to determine the best alternative to present to management for funding. which is defined as the value of all future cash flows discounted at the cost of capital. Subtract the cost of the initial investment from Return to contents » The base case is the current state of affairs. So. rate of return.     Identify the base case Identify alternatives to the base case Determine cash flows associated with the alternatives vs. benefit and loss factors that you can. having identified the correctable problems. Then. Share article » Add comment » . $100 received three years from now at 8% cost of capital is the same as receiving $79.

net © 2014 Red Lion Controls Inc. Monitor. If Share article » Add comment » Return to contents » Connect. From factories to extreme remote locations. With cast-aluminum construction. +1 (717) 767-6511 I info@redlion. risk premium (which will include analysis of the track record of the group asking for money. Sleek. the better the investment. All Rights Reserved. Graphite enables customers worldwide to connect. Control. The IRR assumes that cash flows can be reinvested at a rate equal to the IRR. Graphite The next level of HMI is now here. Red Lion’s new Graphite™ series combines flexible plug-in modules with protocol conversion. Graphite 7” touchscreen Graphite 9” wide touchscreen Plug-In Modules Graphite 10” touchscreen Graphite 12” wide touchscreen Graphite 15” touchscreen Calculate the cash flows and rates of return for all of the alternatives and then the best solutions will pop out. and other factors such as working capital requirements. Introducing the industry’s first rugged HMI solution. data logging and webbased monitoring to meet all of your industrial automation needs. an anticipated return from automation project investments.FACTORY & MACHINE Automation Playbook 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 How to justify capital projects: Speaking finance gets results the sum of the PVs to get NPV. This includes cost of capital. monitor and control processes across a broad range of industries. The Internal Rate of Return (IRR) is the interest rate that equates the present value of future cash flows to the investment outlay. The greater the NPV. type of investment and allowance for overruns). Flexible. What if the company just took the funds and invested them? A valuable comparison is the return due to the business investment vs. Rugged.net I better. The hurdle rate is the minimum rate of return to justify an investment.redlion. .

Analysis is good. however. So. Emerson’s Loranger discusses the analysis from a slightly different point of view. The profit zone for the business. Train managers Logic One’s Egert offers some additional tips on putting together a justification package. when looking for projects with the highest probability of approval. but often engineers looking at automation projects become infatuated with new technologies and fail to match the project up with business strategies. The difference is the economic value added. “Get management trained on technical aspects. A progressive. As Loranger shows in the Business Planning Framework graphic. It’s not just a matter of providing training in some cases. 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. production and Share article » Add comment » business objectives. lies in meeting or exceeding plant. then reevaluate the benefits. (Microsoft Excel has functions that easily calculate NPV as well as payback and IRR justifications). make sure that they align with one or more of the objectives in the Profit Zone.FACTORY & MACHINE Automation Playbook 31 / 167 continued How to justify capital projects: Speaking finance gets results the numbers don’t make the hurdle rate. A manager with technical skills will be able to see some problems coming. no urgency for training or no technical champion to embrace and learn the new stuff. smart manager will have those technical people. but whether the workforce has the basic background skills to make training a practical option.” he states. technology managers find their comfort zones in evaluating automation technology alternatives. “They have lots of knowledge and experience on finance and marketing. Return to contents » . but not much on technical aspects. The balance sheet is where assets and liabilities are tabulated and the income statement is where income and expenses are calculated.” Another problem is management embracing new technology with no strategy for implementing. or hurdle rate.

Call us. which creates profits.” Assistance in evaluating leasing options is available from equipment sales people. 240 locations nationwide EVERY DAY. president and chief operating officer of Key Equipment Finance. so they treat the residuals well. DCS and SCADA. networking. says. Their goal is to become trusted advisors. Image Courtesy of Belden EVERYTHING. Colo. not ownership.  Share article » Add comment » Return to contents » Industrial-Grade Wire and Cable Security Industrial Networking OEE Dashboards. Micro Data Center Solutions Electrical Infrastructure Electrical Distribution Industrial Enclosures Control Panels and Control Panel Cooling Solutions Automation and Control Hot-Standby Controllers. commercial leasing services. Leasing from the vendor or from a lessor experienced in the field often yields the best deal.FACTORY & MACHINE Automation Playbook 32 / 167 When EVERY minute of downtime matters. “80 percent of American businesses lease equipment. We’ll be there. They probably are already leasing equipment and have the process figured out. Legacy System Migration Graybar offers dependable automation solutions for all applications. Paul Frechette. unit of Key Corp. safety and security EVERYWHERE..com/pb-1 . Our network of field automation specialists are there for you to answer even the simplest of questions on process control.. because they understand the value of the residuals (the value of the equipment after the term of the lease is over). electrical. Another resource close at hand would be people in the company’s own finance department. Since 1925 That’s Graybar. The bigger lessors have been doing this for a long time and want repeat business. a Superior. They do it understanding that it is use of equipment.choose Graybar continued How to justify capital projects: Speaking finance gets results One approach that might change all of the calculations would be to lease new equipment. Automation.. rather than purchase it. facility automation and industrial networking. 1-800-GRAYBAR (472-9227) graybar.

electricity. you are competing for the same capital as everyone else. and/or floor space that must be lighted. After all. » CONTINUED ON PAGE 34 Share article » Add comment » Return to contents » . This isn’t political. your business unit’s and your project stakeholder’s priorities. and every bit helps. To maximize energy efficiency. Don’t let that “green roof” win over your lean manufacturing improvements! sustainability officer should like your numbers better. This is survival. heated and cooled? Most plants today face corporate mandates to hit reductions in all these resources.FACTORY & MACHINE Automation Playbook 33 / 167 continued How to justify capital projects: Speaking finance gets results Who are you competing with internally for dollars? Make sure your project proposal appeals to your company’s. 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 won’t make the same photo opp that goats munching turf on your plant roof will—but your chief  Consider distributed drive technologies that reduce the heat buildup inside electrical cabinets and eliminate
the need for costly air conditioning and filtration.  Will your proposed system save water. compressed air  Sustainable manufacturing—what will really do the usage. along with reduced floor space.

don’t fare well during a
hiring freeze. which also improves OEE. it means more uptime. following international electrical and safety standards as opposed to the local site’s internal standards? That could be a big plus. and a common DC bus between servo drives. implementing integrated safety doesn’t just make a production line safer. regenerative power supplies for servo drives.  Don’t 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. But automation that can efficiently scale throughput up or down with reduced attention from plant personnel sounds like a real winner. and best practices that have a positive impact on seemingly unrelated aspects of operations.  Headcount impact—programs 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.  Share article » Add comment » Return to contents » . which results in measurable Overall Equipment Effectiveness (OEE) improvements.FACTORY & MACHINE Automation Playbook 34 / 167 continued How to justify capital projects: Speaking finance gets results also consider high-efficiency electrical power supplies. the safety network can be the same network that links machinery together on a line. For example. And today. Increasing capacity without increasing labor is a good justification.

First. The system should have the flexibility to expand in the future and should not become obsolete in the near future. standards and Return to contents » . Make sure that open standards like IEC 61131-3. market and not the proprietary product of only one supplier. such as asset management. Don’t forget to update all prints to reflect your changes. Make sure new components have all the functionalities that will be required. 3. Make sure you have all the needed power requirements in the locations intended for your new devices for the instrumentation you are using. 1. maintenance friendly. Don’t forget power. 2. The adaptability and flexibility of components are critical. Flexibility required. power integration. Some companies reduce the complexity by limiting the number of suppliers they work with or standardizing on certain features or functionalities. easily available in the Share article » Add comment » 5. Easy replacement. Components should be easily replaceable with another make when needed at any point in time.FACTORY & MACHINE Automation Playbook 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. Get a commitment from the OEM about planned system life. 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. For OEMs. Ensure that components are user friendly. Three considerations. make sure new components will comply with regulations. The growing use of components built to industry standards is making both approaches easier to implement. PLCOpen and overall fieldbus communications are supported. safety system integration and the load of the CPU. Others want maximum flexibility and the ability to customize solutions or select from multiple vendors. 4. Functionality.

8. components must be consistent and compatible with existing systems.  Share article » Add comment » Return to contents » . look at the OEM’s track record and see how often it advances to newer generations of equipment. Second. using electric cylinders instead.FACTORY & MACHINE Automation Playbook 36 / 167 continued Eight tips for selecting the right automation system components best practices. Systems thinking. If buying from a machine builder. Simplify. Make sure to do the research and consider the ease with which a system can be modified if needed. Third. from planning to implementation. Do not fail to think systemically. including power. Always evaluate whether support will be available after the project is completed. for example. control and environment. Use similar criteria to simplify selection for other product categories. It does no good if the system will be obsoleted within two years and will no longer be supported. The important thing is to not let issues get in the way of the project schedule and ultimate success. There will be plenty of time later to analyze the cause of and blame for the problem. servos or other components. Look for support. 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 startup to long-term service and support. 6. 7. Retrofit pneumatics. restrict the number of stroke lengths to no more than three. Select from a specific and predetermined list of components during the design phase on any piece of equipment so you don’t need a spare parts room the size of a small plant. communications. 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. Go green wherever possible. anticipate new trends in automation to keep your system sustainable. whether it’s motors. If a problem does crop up. grounding.

expertise. to find exactly the right fit for your automation project. http://awgo. If during negotiations and setting requirements.FACTORY & MACHINE Automation Playbook 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. state. control may not have the expertise to handle a complex SCADA project. etc. “No problem. Check out any references they provide and find out how long they have been in the field. Selection criteria. Be suspicious of overpromises.to/027 Organization: Control System Integrators Association Share article » Add comment » Return to contents » . didn’t underestimate the project and that he has experience with similar projects. it will not be so easy and It will be something that is more complicated than assumed. 2. a system integrator continues saying. Search for a system integrator who has a long list of successful projects in the areas you are looking for.. 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. Experience. certification. staff capabilities and financial wherewithal are all crucial factors to consider in finding the right integrator partner. The integrator should prove that he understood your requirements.. you can be sure that It will be a problem. That’s easy. We can do all you want”.. Be especially careful if you get a much lower price than expected or than others have quoted. 1. 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.

It’s also important to see how an integrator manages a project and what their code library looks like. most important. In addition to reliability and professional capabilities. Current experience. choose an integrator you feel comfortable with. 6. Expertise. Make sure they have full knowledge of system engineering. Return to contents » . As a result of the recent recession. but if they don’t have a methodology and aren’t even aware of the standards. techniques and skills. The integrator also needs to have a staff with expertise and domain knowledge in your business area. as well as sufficient experience to handle your project. What could go wrong? Plenty! Always vet your system integrator. budgets and ROI calculated and all the textbook preparations and considerations have been met. Prior experience in your discipline is key to the selection of your Integrator. run credit checks and investigate their financial health. who understands your process needs and who has experience in the field. Focus on their knowledge. Experience keeps the integrator current on new technologies and new hardware and software. Find out what partners the integrator works with since no one can do it alone. Extensive planning is complete. Comfort factor. 5. DO YOUR HOMEWORK. Share article » Add comment » opportunities and made other cutbacks. integrators are not as abundant as before. see a system designed and implemented by them in use. visit their factory and. Do they follow S88 and S95 methodologies? They don’t need to follow these to the letter. Many integrators have reduced staff. Get references. A proven track record and references from the projects they have done are essential. with many unable to survive the economic turmoil. Nothing is more destructive than having an integrator run out of money before the project has been completed. 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. timelines and schedules are determined. minimized technology education 4. Familiarity with standards. don’t even consider them.FACTORY & MACHINE Automation Playbook 38 / 167 continued How to properly select and vet a system integrator 3.

Tie payments to project milestones. Select an integrator with experience in similar systems..FACTORY & MACHINE Automation Playbook Graphic HMI | PLCs | Panel PCs | OITs 39 / 167 Powerful Industrial HMIs 4. 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.com Share article » Add comment » Return to contents » . Make sure his services will be available for upgrades and maintenance by signing a separate contract.3229 Every Machine Needs the Human Touch Call today for a Free Demo www. At a fraction of the cost of competing brands! 8. 425.3” to 15” Display Sizes • Connects to over 100 PLCs • High Resolution Graphics • SD & USB Expandable Storage • Cast Aluminum Enclosure • Serial. detailed layout. preferably of the same make.maplesystems.745. How to properly select and vet a system integrator 7. 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. Stay involved. Get involved at the zero level in the planning.. Ethernet. 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. simulation. & USB • Audio & Video • Operating Temp: -20°C to 55°C continued for Every Need. Has your system integrator done something similar before? Chances are the pool of talent isn’t all that big. Take a long-term view.

Problem-solvers. Share article » Add comment » . Make sure those people are listed in the contract. you don’t want them cutting their teeth on your project. Choose an integrator who has experience in the tasks you need performed. 12. 14. Many HMI/DCS vendors have a list of endorsed or recommended system integrators on their home page.FACTORY & MACHINE Automation Playbook 40 / 167 continued How to properly select and vet a system integrator 9. Choosing a system integrator is the hardest and easily the most overlooked part of an automation project. 13. Verify the integrator’s capabilities by giving a test to the personnel who will perform the work on your project. they may lack the capabilities needed to do projects outside of that experience. Professionalism counts. such as were they on time and on or under budget. Have them include project details. 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. Ask questions. Test the team. such as PLC/HMI programming. and what percentage of the time. contingency plans and staffing that will meet your timeline and project goals. talk to references and know that while every firm out there enlists very smart engineers. Be aware that most integrators have experience either in a vertical industry or with a certain type of project. 10. This is a good place to start. including fallback or substitute candidates. Make sure an integrator can confidently provide you with a project plan. Choose an integrator as you would choose an employee. Spend time. with decision points. Either way. Return to contents » 11. Ask questions about types of projects they’ve done. Experience has its limits. Smart isn’t enough. vertical preferences and size of projects.

3. 4. then the customer has to face a series of change orders because a requirement that might be obvious was not listed in the proposal. 5. the result will be a project with no or minimum change orders. but also requires the cooperation of the system integrator. When the project is awarded. Avoid any integrator whose proposal is just one or two pages long. Automation projects must have good system requirements from the customer. If the requirements and proposal terms are properly defined from the beginning. 2.FACTORY & MACHINE Automation Playbook 41 / 167 continued How to properly select and vet a system integrator Detail the requirements 1. The customer ends up paying far more money for the project than originally estimated.  Share article » Add comment » Return to contents » . and the system integrator must list in his proposal what requirements will be met and what will not. so the price might look attractive at the beginning. Establishing a good project requirement list is not only an essential customer task. Some system integrators take advantage of a poorly written requirements document from a customer and present a very generic proposal. One of the most important factors in selecting a system integrator is his willingness to develop a good project proposal.

Beware of someone that constantly pushes back. You are paying that integrator to get what you want and need—not just what they are willing to build because it’s easy or they “always do it that way. but don’t discount your own ideas just because this is your first time. Do they have business skills? Look beyond technology expertise or project experience to consider an integrator’s 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. you hired them for their experience and would like their suggestions. You need to stay involved throughout the whole process. If you hear the phrase “nobody does it like that” or “this is how everyone does it. Be open for changes and tweaks as you go if it makes the end result easier to use and more flexible. Also allow for the ability to make some changes—especially if your approach is new and unconventional.FACTORY & MACHINE Automation Playbook 42 / 167 continued How to properly select and vet a system integrator 15.” Yes.” you might want to consider another integrator that is more open minded. Don’t pass up the learning opportunity!  Share article » Add comment » Return to contents » .

Mistakes are most often made during the definition phase. when you think that everything will be easy to do—motors just need to move from point A to B with synchronized speed. An experienced system integrator inherently designs a system to perform to a customer’s requirements while minimizing the time it takes the integrator to deliver it. it will not cost more.FACTORY & MACHINE Automation Playbook 43 / 167 12 common mistakes people make in automation projects In their rush to complete an automation project. This causes all kinds of strange equipment behavior later. People don’t make mistakes when planning automation projects. The most common mistake is limiting the initial input to too few people. Instead. Never assume. Many managers are surprised when they hear an insight from a person in their plant. implementing a system with devices that are designed to work together. Start with the integrator. Time spent in the field getting a mix of components to work together is extremely inefficient vs. hire the integrator to do the design and program and start up the system. cost overruns and delayed schedules. Don’t select and buy equipment based on a specific vendor’s recommendations. Don’t limit input. people make the same mistakes over and over again. when signal cables are routed together with power cables and shielding is simply forgotten. 2. to build that insight into the project planning from the start. and then during the installation phase. the mistakes are planned in. Copy and paste. In the end. This “ready-fire-aim” approach to planning and executing an automation project inevitably causes major headaches. when it’s hard to Share article » Add comment » 4. 1. then hire an integrator to get it to work. for example. 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 » . locate the source of the problem. 3. and less expensive. It’s much easier.

5. 8. In-house expertise is essential to the success of any project. The tragedy is that. they will find a way to make your system do what they want even if it causes other problems. downtime. it’s the in-house expertise that turns a good system into a great system. the repairs or adjustments will be met with resentment and most likely extended downtime. If you do not consider the technical staff. Also. One of the most common mistakes is not communicating with the end user and technical staff. To cover this. It also retains more customers because the adoption curve is much quicker for machines with more “canned” features. 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. 7. Experts inside. additional checks or sensors may be needed down the line.FACTORY & MACHINE Automation Playbook 44 / 167 continued 12 common mistakes people make in automation projects time. But you also need to plan for the unforeseen. Something will always come up later on that will need to be added. or budgeting for automation projects. with careful accounting. Integrators build good machines and systems. Failure to communicate. usually there is a clear goal or list of things that need to happen. Plan for changes. Bypassing safety is another cause for problems. but when they are deployed in the plant environment. If a machine does not make their work easier. Not paying attention to handshaking signals and improper use of I/O handling can cause serious damage to equipment. it is critical to use appropriate handshaking signals to avoid any cell or machine damage. Handshakes critical. Return to contents » 6. eventually causing more Share article » Add comment » . always add 20 percent to the overall project budget. so make sure you have extra I/O or at least the flexibility to expand the I/O if needed. Design cells so workers cannot bypass safety measures. When two machines need to work together. When designing. The consequence of this common strategy is that you automatically give up the perfect solution for one that is good enough.

Don’t neglect the communication protocols and interface terminals when evaluating control products. That guarantees scope creep. Don’t propose a project without a good understanding of the requirements.  Share article » Add comment » Return to contents » . 6. 3. Don’t always believe what salesmen tell you. Always program or storyboard the HMI first. That could cause critical planning errors that will need to be corrected at heavy expense and effort. Don’t waste too much time planning without customer input. Don’t program the machine first. 2. 7.FACTORY & MACHINE Automation Playbook 45 / 167 continued 12 common mistakes people make in automation projects Seven Automation Don’ts 1. Don’t forget the grounding. Do your homework and make your own decisions for your application. Keep the solution simple. 5. Don’t over-complicate the solution. 4.

Limit program access. principles of operation. Always run an information session after commissioning to familiarize all personnel who may be involved with set-point changes.  10. Forbid any use of coding software until the entire scope is clear and closed. Diving right into detailed problem solving and coding is the fastest way to failure in an automation project. Do a punch list. After initial implementation. the delivery has been broken down to manageable pieces (Work Breakdown Structure) and everybody knows what the tasks and targets are ahead of them. because to have them document it afterwards involves twisting their arms to make them do it. People might disagree on what has been accomplished and what still needs to be done.FACTORY & MACHINE Automation Playbook 46 / 167 continued 12 common mistakes people make in automation projects 9. That includes operators. 11. you will first need to understand the totality of what is being done manually. Can a machine do the job? If the automation project is based on replacing labor.. make sure that the tasks and the targets are properly documented before letting the engineers loose on the coding tasks. Never allow full access to program changes. etc. Automation engineers love to puzzle with the problems they get on their table. and use password protection to allow set-point changes only within a specified range. You may need to go back to the drawing board if a machine cannot do what an operator has been doing. get agreement from everybody on the punch list of items that need to be updated. Forbid coding from Day 1. technicians and production management. 12. Also. Share article » Add comment » Return to contents » .

you know the project is destined for failure. 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. When the project manager is unengaged or unresponsive to requests for information or approvals. Fixing them is usually the bigger challenge. try to gain stakeholder commitment to use contingent resources or assign another skilled resource based upon a scheduled “check” item. the sources of automation project failures are often easy to identify. has inherited another project or is otherwise not available.FACTORY & MACHINE Automation Playbook 47 / 167 10 ways your automation project can fail and how to prevent it From failure to define requirements to disengaged project managers. 1. only to come to a complete stop because the person originally tasked to do the PLC engineering or development is busy putting out fires. Too often a project is running at full throttle. Just because components on paper are all uniform does not mean that they are in tolerance in the real world. If they aren’t on board. The key to a new piece of equipment working well is maintenance and operators taking ownership of the system. Benchmarks help deter Share article » Add comment » Return to contents » . When developing schedules and project plans. Without scope benchmarks in place that are tied to the proposal document. 4. Not getting maintenance and operators involved from the start. 3. Unengaged project managers. Some assembly jobs have been done by hand for years. 2. the machine may just end up being a big paperweight. Maintenance workers have dealt with more fixes and operator complaints than the design engineer. the project manager can’t assess programming time for each phase to help detect scope creep. changes in direction or employees who lack the skills to do the job. Lack of the right people resources. Lack of scope benchmarks.

Don’t let its size fool you. Skills mismatch. Poor planning. 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. Many automation projects are viewed as successful when the system is in the development and testing stage. Measuring just 23. Errors begin to crop up. the DataMan 50L is premium technology designed for 1-D-oriented barcode reading. Most projects fail because of poor planning. The DataMan® 50L is huge in barcode reading performance. 5. The DataMan 50L delivers read rates that can surpass 99% through Cognex’s proprietary Hotbars™ image-analysis technology. The tiny barcode reader that brings big performance to the food & beverage industry.5mm and featuring an IP65-rated housing. and ultimately to a failed project.cognex. Visit us at www.5mm x 27mm x 43. such Share article » Add comment » Return to contents » Scan to Learn More . Late changes are the worst enemies of any project.com/50L.FACTORY & MACHINE Automation Playbook 48 / 167 continued 10 ways your automation project can fail and how to prevent it a giant breakthrough in small readers project stakeholders from adding “capabilities” to the process that can lead to both financial and timeline strains. 6. The project owner also needs to establish the most important priorities for the team. but it becomes an entirely different scenario when the project is implemented in the field. The new DataMan 50L is a powerful upgrade for applications that use small laser barcode scanner systems. There is a tendency to underestimate the complexity of the project and overestimate the capabilities of the team.

frequently. Make sure all stakeholders understand the trade-off between scope. Failure to manage expectations. Provide a scope prior to design that allows all items of the design to be agreed upon.  Potential risks are not calculated and planned for. Failure to plan for and handle project resource changes. stocking of components. Failure to know or admit that requirements are not well defined. loading stage. members of the team or the integrator can then point out potential pitfalls. Return to contents » Share article » Add comment » . safety. Design misalignment.  Unrealistic schedules are set. 3. quality. Failure to engineer the verification of project deliverables sufficiently. 8. will result in confusion for the project team. 1. 7. such as using multiple networks or not selecting a common controller. 9. 5. budget and time frame. As this document is created. Failure to plan and execute design review and approval milestones. maintenance. Other reasons for failure. Communicate this deliberately. formally and 10. or subsequent budget cuts or direction changes by management. networks and programming structure.FACTORY & MACHINE Automation Playbook 49 / 167 continued 10 ways your automation project can fail and how to prevent it FIVE POINTS FOR FAILURE. from component selection to the format of I/O tags. including lack of inspection and test planning. Failure often comes from a lack of communication on the design of the project. It’s a standard recipe for failure. An insufficient amount of effort in the frontas cost. 2. 4. Confusion. This will assure that decisions are aligned with the project’s goals. Failure to address requirement definition problems in a timely fashion. etc. training.

 Share article » Add comment » Return to contents » . L  ack of training to enable plant personnel to operate and maintain complex systems and new technologies.FACTORY & MACHINE Automation Playbook 50 / 167 continued 10 ways your automation project can fail and how to prevent it E  ngineers working on a project lack the necessary skill sets or experience. F  ailure to establish a clear schedule to finalize process and equipment designs.  Insufficient time in the schedule for third-party communications or for developing a particular section of the system.  Insufficient milestones to measure progress and identify problems.  Outdated/incorrect documentation in brownfield projects. M  issing of the minute details pertaining to engineering and scope of supply. M  ismatch in the requirements of the project and the solution given by the supplier.

51 / 167 SECTION TWO: SELECTING PRODUCTS TO BUILD YOUR AUTOMATED SYSTEM .

” Ensure that your techs have input as to the structure and nomenclature of the program. the ability to communicate and connect with multiple devices on the factory floor. cost. Don’t over-specify. always bench-test the process before committing it to the project. There’s nothing worse than being halfway through the project. 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. Or even worse. Quality. Far too often an over-specified controller unnecessarily adds to the automation project’s costs. 1. PACs or PC controllers The controller is the foundational product for any automated system. if your in-house techs will be involved in maintaining and upgrading the new system for future needs. Clarify interfaces. Bugs and changes are the norm with any new control system. Dumping a diagram on someone is not good enough. Selection should occur Share article » Add comment » . Whether it’s based on PLCs. 4. Return to contents » 2. 3. spend some time initially to make sure that the interfaces are clear and everyone understands them. additional purchases and schedule delays. an under-specified controller may result in redesign efforts. When working with a controller. ease of programming and maintenance. If the project includes something you haven’t done before. and you will find your facility rebounding much quicker after such a major change in equipment. functionality. only to find out that your controller isn’t capable of doing something. Don’t select a specific controller too soon in the design phase of a project.FACTORY & MACHINE Automation Playbook 52 / 167 16 best practices for specifying PLCs. If multiple people program parts of the PLC code. PACs or PCs or a combination. When planning for PLC-based controls. don’t bring in “canned code. Bench test. your control platform must perform reliably for many years. No canned code. it’s important to know its capabilities and if it meets the needs of your project.

large or small. Return to contents » . yy Second. but think about ancillary costs. yy Third. PACs or PC controllers FLEXIBILITY. During this time. changes to the system may require modifications and choosing a flexible system upfront can help reduce costs in the future. 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. SUPPORT. Be sure you are comfortable with your access to help if needed. is looking for ways to become more cost-efficient. Can we talk? A primary concern when implementing any PLC is communications. Do your homework and choose a PLC that can support all your buses without a lot of pain. but not all can accommodate every type of Ethernet. WARRANTY. think about quality. the controller must meet your performance needs today. Share article » Add comment » Most PLCs on the market can communicate on device buses. When vendors are confident about their quality. they stand behind it with lengthy warranties. Choosing a PLC family that has all the device type communications modules is paramount. TOTAL COST There are four key factors to consider when selecting a PLC for a project: yy First. It can be both frustrating and time-consuming if your PLC vendor does not provide in-depth support in a timely manner. but can still be a problem when dealing with some sophisticated sensors or peripherals. consider cost. consider what type of support is available to you if you have questions on the hardware or software. yy And finally. Find out what type of telephone support and local support you can leverage from the manufacturer. You must always consider hardware and software costs. Ask your vendor about the warranty.FACTORY & MACHINE Automation Playbook 53 / 167 continued 16 best practices for specifying PLCs. Consider the total cost of ownership for the PLC. but consider that the system may operate over the next five to 10 years. This has been minimized with the advent of ODVA. Everyone wants to know that his or her system is reliable. 5. Today every company.

online programming. I/O type. always remember to check the controller’s power supply. HMI first. It is important to consider the CPU load if communication handling is vital to the application. Consult with people who are knowledgeable in many different hardware platforms before specifying or selecting a certain make and model or even a platform. Even lower cyclic loads (30-40 percent) are desirable if high communication throughput is important. size and availability in the panel. Whenever upgrading a system or changing from one controller to another. quite often you’ll have to rewrite your code to accommodate your HMI. Share article » Add comment » Return to contents » . 7. Make sure the controller has the basic features you want. CPU load. alarm 9. If you write your program code first. Too many times what is specified will not perform to the customer’s expectations. Key check points. That leaves gaps in what is bid and will require changes in the project. Running at the maximum cyclic load will result in poor capacity and response times for peer-to-peer and OPC Server communication. it’s best to start with the HMI first.FACTORY & MACHINE Automation Playbook 54 / 167 continued 16 best practices for specifying PLCs. such as online bypass. Not all controllers or brands are the same. Peak cyclic load should be kept below 65 percent and static cyclic load below 60 percent under all conditions. memory. management or closed-loop control. 8. PACs or PC controllers 6. Double-check the purpose for which the controller is intended. and always carefully check the model number. When programming your project.

Be sure the controller has the processor power to perform all the needed functions. a dedicated motion/machine controller is a better choice. It’s common to “run out of gas” when performing multiple tasks simultaneously. you should first decide your end goals. Look for a fast processor. Share article » Add comment » Return to contents » . product registration or more complex motion is required. then a more dedicated motion/machine controller would do better. Stepper motors do better when holding a position without dithering. Ask the people at the plant why they are running the way they do. 3. Do I want increased productivity? Better repeatability? More consistent accuracy? 2. If high-speed electronic gearing. Get out of the code. Do I need servo or stepper motors? Servomotors will generally have better acceleration and top speed characteristics over a stepper. 10. a PLC is a good choice. Ask yourself: 1. but the reality is that it is not.FACTORY & MACHINE Automation Playbook 55 / 167 continued 16 best practices for specifying PLCs. On the flip side of the coin. enough user memory and a lot of connectivity. 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. If data handling is required. 4. PACs or PC controllers WHAT ARE YOUR GOALS? When selecting a control platform to automate a machine. you often find people think a system is running in a particular way. Sometimes what you might think is bad programming is really needed to optimally run a process. 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. after examining the code.

configuration.  Single programming software package that eases installation. 14. By developing a range of stand-alone machines using the same controller platform. peer-to-peer networking and data exchange between controllers. Think five years ahead to accommodate factory integration.  Up to three axes of embedded motion. particularly in stand-alone machines. OEMs can reduce design time and lower their costs. 13. Don’t go for the cheapest option when installing a PLC. Look for micro PLCs that include: 12. firmware and software. Keep it as simple as possible. Think ahead. connectivity and maintenance. up to six serial ports and Ethernet for communications. it brings a new set of issues. including cybersecurity issues. It is a good practice to maintain the software configuration control document that summarizes all programmable/tunable parameters in one place.  Flexible hardware configurations. The modern factory environment is becoming a network of integrated controllers. “just enough” control may enable OEMs to differentiate their equipment. Don’t overcomplicate your solution. PACs or PC controllers 11. First. 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. Share article » Add comment » Return to contents » . consider the control of multiple function block parameters. Prior experience. like USB.FACTORY & MACHINE Automation Playbook 56 / 167 continued 16 best practices for specifying PLCs.  Plug-ins and 2085 expansion for I/O USB. You will use this document for any disaster recovery event. Are micro PLCs an option? Micro PLCs with flexible. Don’t use a PC-based system when all you need is a little advanced I/O control. 15. Use of programmable controllers offers significant advantages over analog devices. Document software. However.

unify programming methods across all machine types and simplify training and maintenance efforts. Selecting a single control platform for all of your automation control requirements.  Speed up controller response Shave milliseconds off controller response times by optimizing subroutines.FACTORY & MACHINE Automation Playbook 57 / 167 continued 16 best practices for specifying PLCs. http://awgo. exploiting interrupt programming and leveraging peer-topeer review.to/025 Source: Rockwell Automation Share article » Add comment » Return to contents » . Survey your requirements and select a platform capable of handling all current and near-future needs. numerical control. but sometimes it pays to narrow down to a single control platform. can reduce spare parts inventory. PACs or PC controllers 16. C program or sequence control. whether it is motion. See how by viewing this white paper. from the simplest to the most complex ones. Single control platform. Customizing your controller selection for each application may seem like a smart move. robotics.

not just with their managers. For alarming. Right-size displays. the plant representation isn’t logical and the screen layout makes it difficult to locate the data. Hold a design review with a group of plant personnel to discuss any status notifications. Less is more. Don’t try to save money by selecting an HMI display screen that’s too small. Minimize the use of colors to allow actual device state and alarms to stand out. Avoid making the display too technical. choose colors that contrast with the normal process view so the operator will notice the change. realize that you are attempting to capture the essence of the machine or process. not just posting key automation variables and control mechanisms. once as Return to contents » . your operator misses an indication. The ”bad” screen is less than satisfactory: The layout is poor. try to make the pages similar and follow the same page layout throughout. excessive use of capitals in a serif font and repetitive use of units with all data values makes this a really difficult screen to read—especially at a glance or from a distance. Operators usually have different needs and the Share article » Add comment » 4. 2. Plant review forum. 3. both from the perspective of an audio-visual action and an operations response. Size the display according to the amount of information that is most important for the operator to see. Avoid colors that could create problems for people with color blindness. commissioned by manufacturing operations to create the HMI screens. It’s also important not to cram too much information onto a screen. or worse. Also. It’s best when it’s self-explanatory and easily understood. less really is more. Step through the intended functional system. success of your system depends on their usage. Operational feedback is vital for efficient HMI screen layouts. but with HMI. Think of yourself as an artist. 1. Design tips. Always discuss requirements with the equipment’s operators well ahead of time. color and content.FACTORY & MACHINE Automation Playbook 58 / 167 10 steps to creating the perfect HMI When developing HMI screens. someone is injured. Poor selection of colors. It’s important to keep the HMI simple and with the operator in mind. It’s normal for engineers to try to give the customer everything. alerts and alarms that need to be programmed. A good design requires careful use of layout. If you get it wrong. events. you lose money.

Backups are especially important before implementing upgrades or changes. Guard the HMI location so others don’t park or configure something else on top of the station. Be aware of near-future projects in the area. 6. Doing this prior to specifying equipment helps to identify the features that users will want in the HMI station. Real estate can be prime in a busy production area. 5. out of heavy traffic areas but accessible. Visualize the process. Software such as Norton’s Ghost Image can be invaluable to support and maintain HMI systems. It also avoids surprises at point of commissioning. Locate the HMI in a practical place. 7. HMI graphics should illustrate the production process in the plant to provide better visualization to the operators. Location.FACTORY & MACHINE Automation Playbook 59 / 167 continued 10 steps to creating the perfect HMI the designer. location. once as the user and then invite at least two levels of users who will be interfacing with the HMI. Back up work periodically. Return to contents » . Share article » Add comment » Use hardware that meets minimum requirements and keeps the number of failure points low and assures high availability of the system. location. giving them a sense of the action that’s required.

Alarms must be used for conditions that require intervention and must have a clear corrective action associated with each one. 9. Do not blindly follow P&I diagrams.FACTORY & MACHINE Automation Playbook 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 10 steps to creating the perfect HMI 8. www. Don’t forget the need for maintenance and make sure you schedule periodic backups. BOA products are highly integrated vision systems in a tiny smart camera package specifically designed for industrial use. Make control and monitoring of the process simpler by selecting only the most essential information from the process database for the historian. Complete with choice of application software embedded. Alarm strategy. Make paper-based designs to get a feel for screens. This will reduce the load on the system and keep it from stalling or failing. 10. It is essential to have a clear design approach to the HMI. and review with clients prior to designing and making electronic screens. Alarming needs to have a wellarticulated strategy. Only essential data. Decide how the display blocks naturally flow and how sections need to be grouped together for the operator. Anything else should not be an alarm. BOA offers new and experienced users alike. The S88 functional hierarchy is a good place to start.  Share article » Add comment » Return to contents » Get more vision. Think about flow.teledynedalsa.com . an easy-to-deploy cost effective vision solution. navigation and other requirements.

The alarm colors should follow the safety convention: Red = stop. Alarm status for the overall plant. if the alarm is critical. 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. prohibition. 2. an audible alert. 3.FACTORY & MACHINE Automation Playbook 61 / 167 continued 10 steps to creating the perfect HMI Alarming guidelines The key aspect of an HMI display is the dynamic plant data. risk of danger. 1. color cannot be used as the sole indicator of alarms. preferably organized into groups. a change in the position of an indicator. Blue = mandatory action. which can affect the perception of red and green. As one in 12 men have some form of color-blindness. Pictorial changes could include shape changing. Any color change must be supplemented with a pictorial change and. should be visible on every screen and there should be a simple navigation route to access the screen containing additional details about the alarm. danger. » CONTINUED ON PAGE 62 Share article » Add comment » Return to contents » . Yellow = caution. Green = safe condition. There are two basic types of dynamic data: Alarms and normal Plant Status data.

com/us Share article » Add comment » Return to contents » .festo. especially if the system is able to create multiple tones and pitches.FACTORY & MACHINE Automation Playbook 62 / 167 continued 10 steps to creating the perfect HMI 4. an operator can be locked out of the system. can solve all your motion challenges Global manufacturer of process control and factory automation solutions For more information: Call: 1-800-463-3786 www. a cascade of alarms can produce so many screen refreshes. Research has shown that a high-pitched. in extreme cases. automatic changing of displays should be avoided—to have a page disappear when you are working on it is irritating and. These tones can be used to transmit the importance of an alarm. Audible alerts can be very useful. alarms should be placed where they can be easily seen. 6. such as along the top of the screen. Whatever convention is used. 5.  Our expertise in automation. a lower-pitched. Similarly. slow-pulsing sound is less urgent. both electric and pneumatic. fast-pulsing sound automatically conveys urgency.

then you need deterministic I/O to synchronize to the motion task. 5. Match specifications. Field electronics need to be G3 rated per ISA standard (S71. so that events happen in the same time interval. parts. While proper system design can still be challenging. This will save time later.04). It seems simple. I/O allocation plays a key role in reducing the commissioning duration of an automation project. if analog signals are voltage or current.FACTORY & MACHINE Automation Playbook 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. find out whether they are NPN or PNP. allowing you to replace the junction box multi-conductor back to the equipment. followed by appropriate loop testing prior to start of commissioning activities. It’s important to know all the information about any components you are interfacing to when you develop specifications for a project. 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. but one key component that doesn’t match up with the I/O you select can cause big headaches. Ensure that I/O electronic interfaces can be implemented directly in the field. The design team working on the project should not begin the planning and layout drawings for Return to contents » . Motion needs deterministic I/O. look for one that has pre-built jumpers that can be installed quickly. 1. Try to have deterministic data transfer. If others are supplying Share article » Add comment » 6. Delay layouts. Shorten commissioning. 4. rack or MCC room. 2. When selecting a terminal block for your control cabinet. Quick connections. If motion is I/O-sensitive. any handshaking requirements and dry contact digital or higher-level communication. 3. Field electronics.

the actual usage of the remote I/O may not be worth the savings. however. But serious thought has to be given to proper documentation and training of plant personnel to repair and maintain the system and prevent downtime. once you understand the purpose.  Share article » Add comment » . REMOTE I/O PITFALLS. etc. Also allow room for expansions that will be required for unanticipated changes and upgrades In the future. for example. MAC address. The rest of the circuit labeling should be based on the print line numbers. If these simple things are not properly accounted for and implemented. Good information for the operator can save you a lot of production time. 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. 8. Diagnostics. are growing. The options now available to the designer are limited mostly by hardware price point. Timing of this design phase with the upfront engineering will save time and money. and what area of the facility each will handle. location and lifecycle issues. Make sure your new control cabinets have plenty of room for all I/O points needed in that cabinet. Remote I/O options. Leave room for expansions. does not mean that it should. The documentation should include troubleshooting methodology in addition to part number. The control software should also be integrated with the remote I/O layout to allow for either remote troubleshooting or status information. This will lessen the time needed for your techs to troubleshoot issues with those circuits later on. Just because a thing can be done. Return to contents » 7. manufacturer. Provide the team with an overall scope on what these cabinets are called by name. 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. For I/O wiring.FACTORY & MACHINE Automation Playbook 64 / 167 continued Eight considerations for I/O engineering success distributed I/O in the facility until all equipment OEMs have provided general arrangements. Make use of the built-in diagnostic information provided by most I/O systems. There are many design pitfalls to avoid when developing I/O systems.

When you want to improve uptime. When doing an equipment upgrade. think about replacing standard IEC electromechanical starters with an intelligent overload with Share article » Add comment » 5. Manual mode. 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 motor is adequate. If the diagram of the load characteristics is fully enclosed by the diagram of the motor characteristics.FACTORY & MACHINE Automation Playbook 65 / 167 11 recommendations for selecting motors and drives Motors and drives are two of the foundation components of any automated system. 1. The manual mode. 3. think of the drive train as an integrated system and choose components with similar efficiency ratings. 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). Here are a few tips and best practices for achieving improved motor control: a hybrid contactor. Think system. make sure the firmware of the drive or motion controller matches the one you are replacing. 2. When changing a drive. The motor used to drive the load could be half the horsepower with a more efficient gear reducer because of the reduced energy losses. which allows maintenance to check if one specific motor has a problem or Return to contents » . 4. It makes no sense to couple a high-efficiency pump to an inefficient worm gear. Matching firmware. Proper way to select motors. The intelligent overload will remain in service indefinitely. Selecting a motor needs a bit more than just calculating the maximum rotational speed and torque. Intelligence improves uptime. The hybrid contactor extends the time between end-of-life motor switching by a factor of 10.

servo systems were the only choice available for achieving reliable positioning performance. The determining factor in the final choice of technology is the positioning accuracy requirements and the ability to deliver full torque at zero speed. Try to use the same type of drives to maintain a common inventory. Share article » Add comment » . the drive could be suspect. many applications. take special care to place the drive in a hardware panel installed in a dust-free location. With the sophistication of drives technologies. Also. Today. however. can be implemented using AC flux vector drives. 9. it often becomes difficult to decide what to choose as the right technology for positioning applications. 8. keep one spare module. instead of stocking multiple spare cards for the drive. preferably air-conditioned. Return to contents » 7. is usually forgotten. Magnetically coupled drives. Do your homework. Make sure you inform the supplier about the features you want and the process to be controlled. excluding CNC machines. Always check for the proper rating and proper type of drives or motors for different type of application. Economical spares. 6. which can reduce costly damage to mechanical seals on equipment. A better solution for harsh environments that have maintenance people with minimum skills might be a magnetically coupled drive with variable speed option. This eliminates the drive from the problem and points to the controller or. such as drives for an agitator motor or a chiller compressor.FACTORY & MACHINE Automation Playbook 66 / 167 continued 11 recommendations for selecting motors and drives not. If the motor will not run correctly. In the past. For variable speed control of rotating equipment. Ask the supplier about the fail-safe function of the system and always check for proper grounding of the system. 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. This will be an economical solution. if local control does not work. Deciding factors. put the drive into manual and run the motor for a short time.

such as the PLC or a variable frequency drive. Learn more about the Sysmac NJ Machine Automation Controller at www. common mode capacity and others.com. such as MOV.FACTORY & MACHINE Automation Playbook 67 / 167 Can your current control platform deliver. it can also make them easier to damage. One great solution to drastically reduce machine tact time and programming complexity while improving performance and speeding development. can make the drive more EMI compatible. Robot kinematics. Drive failure may be caused by many factors: PCB calibrating. etc.. operating environment. ONE CONTROLLER ONE CONNECTION ONE SOFTWARE the performance your customers demand? One controller through one connection and one software to completely integrate PLC logic. Drive failures.. Keep motors and drives clean and free of foreign contaminants to keep them running for a long period of time. Vision processing. Safety guarding. common mode choke. LOGIC MOTION SAFETY ROBOTICS VISION SENSING ENTERPRISE continued 11 recommendations for selecting motors and drives 10.  Share article » Add comment » Return to contents » . and Database connectivity.Omron247. Even though the manuals of some drives claim that using certain technologies. The reliability of the core components. 11. IC chips failure. Good housekeeping. Motion control. mishandling during installation. in a control system is important.

require that engineers more thoroughly review how drives with new.FACTORY & MACHINE Automation Playbook 68 / 167 continued 11 recommendations for selecting motors and drives Performance packed into compact drives Advancements in today’s AC drives. improve safety. lower total overall cost. and. compact drives now pack more intelligence and user-focused design in smaller sizes. minimize programming and installation time. Selecting a compact drive still requires an understanding of the most appropriate control technology—volts per hertz.—but while those control technologies have remained relatively unchanged over the past decade. 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. sensorless vector. ultimately. » CONTINUED ON PAGE 69 Share article » Add comment » Return to contents » . including compact drives. there have been dramatic technological leaps in other areas. etc. performance-enhancing features can contribute to automation projects. Similar to trends in consumer electronic products.

FACTORY & MACHINE Automation Playbook

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11 recommendations for selecting motors and drives

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. 

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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 tuning—just to name a few of the more common issues associated with motioncontrol design. You’re 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. It’s 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 you’ve ever designed motion
control systems or served as a project manager, chances are you’ve 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. 
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Four tips for improving motion control systems

Don’t 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. 

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some motion controllers.FACTORY & MACHINE Automation Playbook 72 / 167 Seven considerations for applying servo drives. Using a customer-friendly servo drive for quick changeovers and machine setup is an investment Share article » Add comment » Return to contents » . There are many different levels of positioning and motor controls now. especially for users who run multiple format sizes on the same production line. Past experience on such applications says it’s best to use the optimal tool for the job. Why use motion controllers? Everyone knows some PLCs can do lots of things. 3. Don’t fear servos. Quick changeovers. may require additional PLC programming capability and time vs. And with the latest motion/machine controllers with built-in IEC 61131-3 functionality or other straightforward programming capability. Companies that produce motion controllers design them specifically to increase a machine’s output with improved accuracy. and that includes motion control. which makes them straightforward to implement. you can have the best of both worlds. motion controllers and PLCs Technology advances in servo drives have made them the workhorses of motion control. Some basic variable frequency drives can even be used to do what could have been done only with coordinated drive systems in the past. Trying to use a PLC to address registration or robot-type control. Changeovers can vary from minutes to hours. Machine setup and changeovers lead to lost production time and inefficient production. Consider using low-voltage servo drives with built-in encoder. They are now more cost competitive with auto-tuning. 1. 2. 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. controller or removable memory units. specifically designed for auto-format settings and quick changeovers. However. So don’t be wary of servo technology. plus handle recipe data. Here are some recommendations for implementing servo drives: that can quickly pay for itself.

not just speed and load. especially if using a PLC as the primary logic controller. Over-sizing wastes energy. since it costs more up front and may take a few years to achieve payback. it is extremely important to understand the system you are building and the functionality that you intend it to have. When building dedicated automation with motion control. motion controllers and PLCs 4. recovery from an e-stop would have been very simple. The key to getting the motion profile right is properly calculating velocity. 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. whether you source it out or not. Further. in an emergency stop situation. refine the profile by accounting for cycle times. Document requirements. on an indexing assembly station that used a servo drive to index large assembly pallets from one station to the next. and matching load and motor inertias. for example. This means that the energy consumption of the system will be higher than needed. they often inadvertently build in extra long-term. the indexing system would stop and then want to do a complete index. For example. the entire motion profile is important. Return to contents » . Typically. acceleration. Some of the biggest energy wasters on a machine are frequently overlooked. Having a detailed and accurate profile of needed motion can pay dividends. a less precise profile will lead to an over-sized servomotor. If the expected functionality had been properly documented. and how long can it take to complete the Share article » Add comment » entire trajectory? 5. There are different levels of motion control. End users often underestimate the returns from energy-efficiency investments. starting from its current point. Over-sized servo drive/motor systems. cost and panel space. As a result. How long does the system have to move from one point to the next. ongoing costs by overlooking details when sizing machine components. Had absolute encoding been used as originally planned. cause machines to consume more energy than necessary—something that can easily be avoided through proper design. peak torques. When sizing a machine. Consequently. continuous vs.FACTORY & MACHINE Automation Playbook 73 / 167 continued Seven considerations for applying servo drives. additional complexity would not have been added to what should have been a simple solution.

These vibration suppression algorithms. Reduce wiring.  Share article » Add comment » Return to contents » . can allow for high-performance motion without complicated mechanical damping or heavy bracing. and it gets worse as the load inertia increases. Minimize vibrations. 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.FACTORY & MACHINE Automation Playbook 74 / 167 continued Seven considerations for applying servo drives. For example. energy consumption and panel space. space. Panel space is reduced by up to 30 percent. Lower load-to-motor ratios improve response times. but is arguably the most important factor in determining the performance of a servo system. LOAD TO MOTOR INERTIA RATIOS—IMPROVE RESPONSE TIME Calculating an inertia ratio is often overlooked by newcomers to servo sizing. By using common DC and/ or multi-axis servo drives. while wiring is reduced by up to 50 percent. motion controllers and PLCs 6. To prevent overshooting and oscillations with very large mismatches. OEMs can reduce wiring. the control gain may have to be reduced. a mismatch of only 5:1 will dissipate six times more power. 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. rather than wasting this energy as heat in the electrical enclosure. Large inertia mismatches require higher current to drive the motor. 7. reduce mechanical resonance and minimize power dissipation. compared to a traditional single-axis servo system architecture. thus they dissipate more power. An inertia mismatch of greater than 10:1 can produce oscillations and extended settling times. combined with auto-tuning and filtering. These systems use regenerative energy to power other axes. Inertia ratio is calculated by dividing the load inertia by the motor inertia.

try to find out if you are the first to get these devices talking to each other. engineering and more. it will make everyone understand that they have an investment in the project. When implementing an industrial network (be it Ethernet or traditional fieldbus).FACTORY & MACHINE Automation Playbook 75 / 167 Seven issues to think about before you develop an industrial network Networks provide the framework for any automation project. Design for the process. When choosing the network topology and protocol you want to use. If yes. Return to contents » 2. remember to evaluate and select according to the following factors:  Process time requirements  End-to-end distance requirements Share article » Add comment » . be sure to get all affected parties involved during the initial design. what information it needs and where that information comes from. plan for a lengthy commissioning process. This could include production workers on the plant floor. The issues are complex and require an in-depth understanding of the requirements of your process and the nuances of networking technologies. Communication standards may be fine on paper. One method is to simulate your product going through the entire production phase. IT. as well as what information it produces and where that information goes. Selection factors. but in practice you are likely to have to do a lot of fiddling to get everything working. Multi-vendor problems. Here are some suggestions to help you meet the challenges: 1. see where it goes and who interacts with it. Getting all the affected parties involved will not only get you the best solution.  Data delivery reliability  Future proofing to include scalability  Data/network security requirements  Current on-site expertise  Ease of architecture  Total cost of ownership 3. If you are connecting devices from different vendors.

Keep things simple. conditions and possible changes in those conditions. Industrial automation networking is great. Never make assumptions about any vendor-specific products. 5. those designs could reduce system reliability or make it harder to troubleshoot in the future. Design your network to handle not just current conditions. Plan for future. Does your team have fieldbus skills? Select a fieldbus that can be handled by the software team at your disposal. Functionality varies by vendor. but remember to keep things simple. Understand what functions and performance your network needs to deliver before listening to various sales pitches. implementation or error handling of the selected product. The functionality various manufacturers implement. even in standard fieldbus or Ethernet systems.  6. Even if a fieldbus segment could theoretically be loaded to the maximum or use a less-traditional architecture. can vary substantially. Don’t jump into implementation in the field without prior design. locating equipment and identifying signal paths on plans. The greatest fieldbus technology in the world will fail if the software team does not understand the integration. This is a particular requirement in hazardous environments like cement and power plants. Give careful consideration to site Share article » Add comment » Return to contents » . If a few discrete I/O handshakes would serve the purpose. 7. but also possible changes.FACTORY & MACHINE Automation Playbook 76 / 167 continued Seven issues to think about before you develop an industrial network 4. it might be the best design.

It is very difficult to troubleshoot many systems because this basic information was not captured. 3. if not contiguous or near contiguous. 2. Keep a list. That’s as true for networking as it is for every other aspect of an automation project. Test to failure. It is very important to keep a list that shows the assigned address. Some PLCs can only provide X number of devices in one read. 1400. These failure points can be associated with the number of Ethernet port connections.) using Ethernet. If that number is 1k (1024 devices) and you attempt to read the values of coils 250.” 1. Seek cooperation with the IT professionals. 5000 and 6500 in one cycle. Once installed. the size and frequency of data being managed. You have to be constantly aware of the security aspects of your control network. When developing data collection/data passing applications (PLC to PLC. This results in performance issues and missing data. Share article » Add comment » Return to contents » . Be aware of security issues.FACTORY & MACHINE Automation Playbook 77 / 167 Six things to consider when you get down to the network details It all comes down to the details. Networked devices have addresses. PC to PLC. it is critical to test to the point of failure. the product this address has been assigned to and the line/plant location where the product has been installed. you likely have more overlap with office systems than you might know. Here are some tips for making sure the details are covered with your industrial network: fieldbuses and especially proprietary networks. leading to significant equipment downtime. can cause excess read/write cycles to the PLC. as well as data addressing in the PLC. This information should also be part of any electrical and mechanical drawing. these devices need to be labeled accordingly since it is not uncommon to have several identical devices in close proximity. etc. The PLC addresses used in data collection. 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. it can actually create four separate read requests.

too many flipped bits due to EMC (electromagnetic compatibility) issues. analysis. communication protocol and tools to configure. Nothing is not in the network anymore. a network troubleshooter won’t Share article » Add comment » Return to contents » . 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. Make sure high-quality network analyzers are available. When you implement a new project or a new system. When a system using a fieldbus/industrial network does not work as expected. stand a chance of disproving this. 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. and the real root cause of the problems will show up very quickly: very often it is application software. Avoid subnetworks. A network engineer without a network analyzer is like an electrician without a multimeter: clueless. Need network analyzer. display. physical media. 6. etc. somehow the network is always blamed: too slow.  5. Every device needs a communication port or ports. etc. the networking criteria are a critical consideration. Everything’s networked. Without proper measuring equipment. diagnose.FACTORY & MACHINE Automation Playbook 78 / 167 continued Six things to consider when you get down to the network details 4.

3. Need industrial IT strategy.. often milliseconds with Resilient Ethernet Protocol (REP) and Device Level Ring (DLR). servos. security. and the convergence time is very short. widely distributed network compared to many other fieldbus networks. It’s not uncommon to have thousands of Ethernet devices on the plant floor. Start with a basic industrial networking standards document. 1. firmware upgrade. redundancy. Users mainly select industrial Ethernet because they want to fully benefit from Ethernet and its higher-level functionality. 2. controls or HMI strategy. but standards for dealing with it may be lacking. just as you have an electrical. different areas can be zoned for control and monitored independently. are often seriously lacking. requires a good integration of standard Ethernet frames when selecting an industrial Ethernet technology. One of the many benefits of industrial Ethernet is that it can be used to build a very large. however. VLAN Share article » Add comment » Return to contents » . With the rapid growth of industrial Ethernet devices. Classless IP address scheming is important here. Simple rules for implementing Ethernet networks (wired or wireless) save many problems down the road and support easy expansion in the future. diagnostic. but strategies for data management. Industrial Ethernet can make media redundancy very flexible. etc. Here are some suggestions for updating your practices: technology makes it easy to manage traffic. reliability. For a large plant floor. configuration and diagnostics. such as web server. It is being adopted for many aspects of automation. safety. synchronization and motion. Ethernet is the future of real-time and long-distance industrial networking. Ethernet is fast. including controls and I/Os. Maintain standard Ethernet frames. flexible. the lack of an industrial IT strategy at many companies is becoming a real problem. To realize the benefits of these technologies. etc.FACTORY & MACHINE Automation Playbook 79 / 167 Five considerations for implementing Ethernet for an industrial network Ethernet is everywhere on the factory floor.

operations and accounting will likely be involved in the project scope.  Networking tips for machine builders OEMs need to understand the big picture when selecting a network for a machine. Take the time to learn (through courses or self-taught) the art of Ethernet networking. It’s never going to go away. your job is only going to become more interesting. If you can seamlessly work through VPNs. Does the end user of that machine need secure remote access.FACTORY & MACHINE Automation Playbook 80 / 167 continued Five considerations for implementing Ethernet for an industrial network 4. You need to understand their requirements when selecting a network and how to provide value after the machine has been delivered. » CONTINUED ON PAGE 81 Share article » Add comment » Return to contents » . 5. is the machine standalone or will it be networked? How? What are the requirements? In today’s factory. Learn Ethernet. This makes your plant ready with data available on Ethernet for future connectivity with MES/ERP systems. will IT be involved. port forward. subnet masks and IP addresses. Get ready for connectivity. departments such as IT. It makes sense to implement all PLCs on Ethernet using protocol converters.

 Share article » Add comment » Return to contents » .FACTORY & MACHINE Automation Playbook 81 / 167 continued Five considerations for implementing Ethernet for an industrial network Machine builders also need to consider how their equipment will impact the factory LAN once the customer installs the equipment on the factory floor. 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. Several of the industrial protocols on the market today use multicasting between devices in order to streamline communication. 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. 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.

When implementing wireless technology in factory automation projects. 3. Multiple devices can receive multicast traffic. Wireless access points transmit multicast traffic at a minimal rate to ensure that all listening clients will be able to receive the traffic. Multicast traffic is handled differently than unicast traffic by wireless access points.FACTORY & MACHINE Automation Playbook 82 / 167 Four tips for dealing with wireless latency and bandwidth issues More and more. Need latency tolerance. however. 2. 1. Make sure that your application is designed to be tolerant of the latency introduced due to the half duplex nature of wireless. Control multicast traffic. This results in low aggregate bandwidth over the wireless AP as it has to lower its transmit rate down from the maximum. Many designers overlook these points and experience problems when moving to wireless solutions. There are some issues to be aware of. Low bandwidth requirements. Being aware of the limitations of wireless technology can ensure that your upfront design will work in a wireless deployment. Today’s wired Ethernet connections are full duplex. Make sure that your application’s bandwidth requirements are low enough to be satisfied by the lower rates. when replacing dedicated connections with wireless links: multicast traffic coming from PLCs or producer devices. wireless technologies such as 802. be aware of any Share article » Add comment » Return to contents » . This means that each end device can both transmit and receive at the same time. all other devices must wait.11a/b/g/n are half duplex. while unicast is destined for only one device. On the other hand. This means that when any one device is transmitting. systems engineers are taking advantage of industrial wireless technologies to reduce the amount of cabling in their designs.

 Our expertise in automation. Wireless is very reliable when well designed. path loss calculations and fade margin will pay dividends when it comes time for installation. but if you don’t design in appropriate fade margin you’ll have problems in the future.festo. Time spent up front on site surveys. Design in fade margin. Don’t take shortcuts with wireless. both electric and pneumatic.FACTORY & MACHINE Automation Playbook 83 / 167 continued Four tips for dealing with wireless latency and bandwidth issues 4.com/us Share article » Add comment » Return to contents » . can solve all your motion challenges Global manufacturer of process control and factory automation solutions For more information: Call: 1-800-463-3786 www. Consider the entire system design and the support lifecycle of the system before choosing technology and vendors.

the project is bound to run into problems down the line when it is too late to change things. In Share article » Add comment » Return to contents » . 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. Today’s automation projects are always connected to some sort of network. Failure to plan for how firmware updates will be accomplished in the running system can lead to misconfiguration and long downtimes.FACTORY & MACHINE Automation Playbook 84 / 167 How network management systems aid firmware. 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. as new functionality is added to the system. You want to ensure that when a device needs to be swapped out. automation projects today are becoming more and more complicated. Unfortunately. If you fail to plan for the growth of the network or plan the management aspect of it. When you only have a few devices deployed. this can be a simple task to accomplish. Most network devices contain firmware and need to be updated for security patches or increased functionality over time. 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. When you have many deployed. Another common problem is failure to plan how configurations of your network devices will be backed up after changes are made. its configuration can be quickly installed on the replacement device with no ambiguity as to which features to enable. configuration updates As technology advances. changes may be required to the network topology as new devices are added. A reliable network is an integral part of the successful automation project. it can become challenging and time-consuming. Over time.

It should also be capable of autotopology. In order to manage these kinds of tasks. An NMS should be capable of not only managing a single vendor’s equipment. configuration updates addition. Make sure that your NMS has the capability to discover devices added to the network. but should include third-party devices as well. Having the capability to look at the availability of network links can help to isolate problems in the network before they become critical. in your systems design up front. This can aid in isolating the root cause. or network management system. Planning for these tasks up front will help lower the maintenance costs for your system.  Share article » Add comment » Return to contents » . include an NMS. the ability to generate an inventory report that details the exact devices on your network can aid in upgrading and maintaining the network. It’s also important to have the ability to replay network conditions after a problem occurs. Including an NMS also provides for ongoing monitoring of network availability and stability. which can document the connectivity in the system. Firmware upgrade and device configuration and documentation must also be present to ensure ease of maintenance.FACTORY & MACHINE Automation Playbook 85 / 167 continued How network management systems aid firmware.

However. Too often operators compensate for starved flow with increased pressure. can improve the productive capacity of pneumatic systems. Align pipelines. Flow vs. valves and actuators. provided the application requirements fall within an electric actuator’s performance capabilities. If pipelines are not aligned properly at the correct angle. valve and control technologies. They can be operated in high-temperature as well as high-radiation industrial environments where most electronic instruments will not function properly. When dealing with pneumatics. as indicated in the installation drawings. here are a few tips you may not find in the textbooks: 2. Correct sizing of components.FACTORY & MACHINE Automation Playbook 86 / 167 12 tips for selecting and sizing pneumatic and hydraulic components In today’s typical manufacturing facility. 4. with vast improvements in functionality. tooling and even some drive systems. If you want to improve production cycle time and quality. it is critical to understand the difference between pressure and flow. then proper sizing is critical. 3. It is often best to install oversized supply lines to a process in order to ensure the appropriate volume of air. circuit design. If the flow capacity is too small. Use electric actuators. it can have a negative impact on production cycles. pressure. This technology has advanced rapidly over the last five to 10 years. 1. there Share article » Add comment » Return to contents » . hydraulic and pneumatic systems serve as the primary means of power for most cylinders. With ever-increasing energy costs. Volumes of material exist on proper system design. as well as other design considerations. including piping. including more precise movement and even built-in sophisticated controls. proper sizing of components. Valve sizing. Valve sizing is particularly important. designers should consider using energy-efficient electric movement.

6. 100 ms is a long time in the computer world. Built-in flow control. a three-position valve is a better choice than a two-position valve. Be sure to check the surface temperatures of equipment during preventive maintenance time and make a record. To avoid failure in the supply of compressed air on a network. Check temperatures. use nylon tubing on machines rather than push-on fittings and PE tubing. All air filters should be checked periodically for accumulated water drainage. Inspect tubing. 9. Wherever operators will be working near an operation. To prevent leaks. Always back up actuators with electrical feedback sensors. Don’t rely on software interlocks to control pneumatic devices unless you account for the delay caused by physical actuation. Share article » Add comment » Return to contents » . Choose three-position valves. High temperatures could damage the viscosity properties of the hydraulic oil. 5. Make sure you have an adequate air supply when using pneumatic technology. 7. This is because a threeposition valve will stop the equipment instantly in the event of an emergency. redundant if possible. Choose quality tubing.FACTORY & MACHINE Automation Playbook 87 / 167 continued 12 tips for selecting and sizing pneumatic and hydraulic components is a great possibility of equipment damage. 8. connection and joints for leakages. Costly leaks are often hard to detect in a noisy plant environment. especially in high cycle count projects. ferrule. Make sure the air being produced is dry. Parallel air. use a fitting that has a flow control valve built in to make the cylinder last longer. which will first complete the operation before stopping. it is important to verify that the distribution is closed so that the compressed air comes in parallel and not in series. This is in contrast to a two-position valve. When you are using a pneumatic cylinder in a project. Use feedback sensors. 10.

Inlet side flow control. Let Graybar’s 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.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. Air is compressible and positioning will float if controlled on the outlet. This will also create back pressure.  Share article » Add comment » Return to contents » . place the flow controls on the inlet side of your cylinder depending on the direction of travel. 11. Low fire risk. In a pneumatic logic circuit controlling a double-acting cylinder. This technology is particularly useful in a plant making edible oils or hydrogenating oils or when using flammable gases in the production process.FACTORY & MACHINE Automation Playbook 88 / 167 continued 12 tips for selecting and sizing pneumatic and hydraulic components The leakage often found with soft tubing is hard to detect in a plant environment. One of the advantages of pneumatic Learn more at graybar.

Fence the area so the operator cannot reach into the cell while the robot is in full motion. This aspect is even more important given all the codes and regulations for robotic safety. and has built-in energy management. Don’t fight the laws of physics. the complexity of the design process can often be a barrier to achieving the cost savings and efficiency gains expected with robots. engineers are challenged to design systems using today’s highly complex and increasingly sophisticated robot technology. When implementing robotics. Pay attention to the cell layout from the operator’s perspective. For more information on new safety requirements. acoustic. will mitigate safety and security risks. 4. Complexity can be barrier. autonomous platform combining measuring circuits. always consider safety as your top most priority.to/026. active RFID. visit http://awgo. Unfortunately.FACTORY & MACHINE Automation Playbook 89 / 167 11 considerations for selecting and deploying industrial robots As manufacturers embrace the business case for implementing robots. laser and power technologies for insitu data processing and real-time communication. 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. 3. Redefining robots. Safety first. Too much focus on humanoid robotics is a misplaced definition of objectives. Distributed architectures with this type of robot are revolutionizing industrial automation. Adjust your expectations to what the robot is actually capable of doing. 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. RF. 2. engineers need to ensure the system is scalable. 1. A robot is really a modular. Make sure all Share article » Add comment » Return to contents » . cell doors have safety interlocks and light curtains as needed.

Use a common control engine and development environment to help eliminate the need for separate » CONTINUED ON PAGE 91 Share article » Add comment » Return to contents » . here are some general tips on the three primary options: 1. alarming and reporting.FACTORY & MACHINE Automation Playbook 90 / 167 continued 11 considerations for selecting and deploying industrial robots Tips for robotics integration Whether you’re looking to integrate robotics into existing equipment or scale your control and information platform to accommodate robots. This method allows the highest level of integration because it combines kinematic robot control within a machine’s controller. troubleshooting. All configuration. regardless of size or complexity. 2. programming. troubleshooting and operations are performed within a single control platform. A networked approach integrates the robot control system with the machine control system. Use a single control platform that can be scaled to fit a wide range of robotics applications. kinematics. which helps reduce engineering costs. 3. maintenance and the overall machine footprint. This is the most cost-effective solution for quickly integrating robotics into an existing application. including diagnostics. Use a single network technology and a common control and visualization environment. Doing so gives the machine’s controller access to the robot’s control system. necessary automation interlocks. training.

Share article » Add comment » Return to contents » . Installing a hoist while running requires scheduling. make sure means for maintenance are included in the original project scope. This embedded approach to robotics integration brings the robot module directly into the control platform’s chassis. emergency maintenance never happens. to allow for various tray sizes. incorporate zoned suction cups that can be isolated or turned on and off. Zoning for product size. 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. For large robots. 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. A monorail hoist designed in at the start of the project. and temporary. Plan for maintenance. for example.FACTORY & MACHINE Automation Playbook 91 / 167 continued 11 considerations for selecting and deploying industrial robots controllers and systems. 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. etc. 6.  5. lost production. It keeps machine and robot control separate. You may find that there is more going on in the existing process than you knew about and that micro-management is necessary. In a robotic pick-and-place system for thermoformed packaging trays. rigging ends up hurriedly being used. Tooling clearance. downtime. Installing a hoist during 8. suboptimal. Get early feedback. is much cheaper and easier to install than one built years later. 7. but helps drastically reduce the machine footprint—by up to 50 percent—because there are fewer control boxes on a machine.

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. Customization is only a fraction of the normal line production. it is easier to identify where in the program the error has occurred and to diagnose the issue. Error codes. The choice for OEMs is even easier because they need only migrate their control philosophy to those capable of true mechatronics. OEMs that have adopted this new outlook make robotic machines that are faster. add it to the list of your error programs. Faster remastering. who don’t typically have a lot of robot axis mastering experience. but the ability to create electronic changeovers between formats in a small footprint streamlines the customization process. many lines of code are involved. This feels modular. and having an independent means to establish the coordinate system is a major time saver. not by changing their mechanics but by changing their approach. 11. If it is a new issue. smoother and more flexible. Changing the definition of robotics to coordinated axes synchronized by a single software and processor opens up conventional machine design to modular code and mechanisms—or mechatronics.  Share article » Add comment » Return to contents » . Witness marks on joints can fall off. Electronic changeovers.FACTORY & MACHINE Automation Playbook 92 / 167 continued 11 considerations for selecting and deploying industrial robots 9. If you build in your own error codes in the program. When you are programming a robot. For a robotic cell. This is critical for users of just a few robots. design in a location datum point into the cell. 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. but it’s not mechatronic. 10.

This improved utilization improves productivity and profitability. people cannot. the robot can perform multiple functions. Robots deliver limited production loss and lower error rates compared to manual operations. Robots have negligible downtime in situations where there is high demand for the manufactured product. Robots can also be set up to multi-task. By incorporating tool changers.  Flexibility—reduced training and changeover time. Planning is critical. 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. waiting time. the lack of flexibility is limiting. Share article » Add comment » Return to contents » .  Repeatability and accuracy—improved product quality or consistency and reduced scrap rates. in the right applications.FACTORY & MACHINE Automation Playbook 93 / 167 A role for robots in lean Lean manufacturing is a strategy for reducing waste—in materials. While the machines (including robots) can be programmed for optimal performance.  Speed—increased production rates and reduced wait time for operators. to get the desired results. While robots are not innately lean. 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. the decision to use robots must be justified by an ROI analysis. Most important. Standard industrial robots have a single tool mounted to a single arm. movement. processing and defects. since they could be used to automate a faster creation of waste. Robots must be properly incorporated into the overall lean manufacturing environment. While more efficient than human labor.

maplesystems. Mounted with vision cameras. repeatability and speed.com Share article » Add comment » Return to contents » . By taking over these once manual activities. Robots are heavily utilized in inspection applications using flexible measuring systems.3” to 15” Display Sizes • Connects to over 100 PLCs • High Resolution Graphics • SD & USB Expandable Storage • Cast Aluminum Enclosure • Serial. This is particularly useful for operations that require visual distinctions and decisionmaking. robots can deliver higher consistency..745. Vision-generated guidance information allows robots to vary their motion targets.3229 Every Machine Needs the Human Touch Call today for a Free Demo www. such as racking/un-racking of parts. dramatically reducing the number of vision cameras and fixtures required to inspect parts.FACTORY & MACHINE Automation Playbook Graphic HMI | PLCs | Panel PCs | OITs 94 / 167 Powerful Industrial HMIs 4. part picking from bins and part inspections. Ethernet. 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. these robot systems can collect information from multiple locations.  At a fraction of the cost of competing brands! 425. such as routering.. accuracy. grinding and sealing. Visionequipped robots can also reduce imperfections and scrap material in finishing operations. & USB • Audio & Video • Operating Temp: -20°C to 55°C continued for Every Need.

etc. Use a panel meter with discrete output to give an output when the set point is reached. When choosing a sensor. with no grating or gooseneck. Be aware of environmental conditions when installing equipment. the variables of the product being sensed and the conditions in the operating environment. analog. it would impair the operation of the air handler and the sensors within the ductwork. Same concept applies for voltage or resistance analog signals. a pressure transducer with a sensing range of 0-10 psi is most suitable. Weather watch. to measure 0-10 psi pressure range.FACTORY & MACHINE Automation Playbook 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. 1. The ducts faced Lake 4. For example. Load cells important. the intake air ducts on air handler units were installed facing southwest. When choosing a sensor (pressure. No one gives load cells the credit they deserve when it comes to level measurement in tanks. Need flexibility. the third with a load cell in compression. Ontario and would be susceptible to lake-effect snow. If the ducts filled with snow. consider whether it provides the flexibility required. As an example on one project. 3. They work great for batch measurement applications when using a hinged tripod tank mounting arrangement: two legs with hinges. 2.). the measuring range should directly correspond with the physical measuring range in order to obtain the most accurate reading and optimum sensor lifespan. This also works well for providing a low-level alarm in applications. Measuring range. such as features that Share article » Add comment » Return to contents » . temperature. The load cell and controller can make it simple to automate the process in the future.

conditions. and in many cases are less expensive than ultrasonic sensors. such as locking Share article » Add comment » Return to contents » . vibrations or other conditions can affect sensor performance. dirt.FACTORY & MACHINE Automation Playbook 96 / 167 continued 10 secrets to selecting and implementing sensors in industrial applications adapt to changing product. although a capacitive proximity sensor can detect metals. 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. Select for technology. For example. in general an inductive proximity sensor would be a better choice. and failing to consider the full range of expected operating conditions. consider capacitive sensors. In this case. the sensor may experience premature failure or may exhibit unstable operation. 5. temperature. which are sensitive to more colors and materials than others. The most common mistakes in sensor applications include failing to select the most appropriate sensing principle/ technology for the task. Ambient light.

Advance warning. sensor life can be extended in harsh environments when used with accessories that are designed to protect the sensor. has not been corrected. leading to intermittent operation. this can be a pretty costly situation when. 8. the pins or sockets are weakened or corroded. Replacing only the sensor may temporarily restore electrical contact. calibrated or configured remotely in order to shorten changeover time. 7. either analog or digital. Consider adopting intelligent sensors that can be scaled. in fact. be sure to also check the condition of the quick-disconnect cable or cord set. avoid analog field devices to minimize cost and support issues for shielded cables and grounding. Through analysis of sensor data. digital output equivalents are usually worth the additional purchase price for overall lower cost of ownership. Faulty cables.FACTORY & MACHINE Automation Playbook 97 / 167 continued 10 secrets to selecting and implementing sensors in industrial applications on or locking off. When available. 6. If linear or proportional output sensor devices are needed. Additionally. In many cases. 9. An important trend in sensors is to upgrade or augment discrete on-off sensors with sensors that provide a continuously variable output signal. a relatively inexpensive replacement connector cable could have solved the problem in the first place. a faulty mating connector. such as fault prediction and statistical process control. When replacing a “bad” sensor in an existing field application. machine controllers can alert operators of impending problems Share article » Add comment » Return to contents » . automate sensor reconfiguration and facilitate remote sensor diagnostics. Digital lowers costs. but it will certainly fail again because the root cause. Depending on the cost of the sensor being replaced. Continuous sensor output signals enable much higher levels of operational sophistication. Intelligent sensors.

Gigabit. All Rights Reserved. may measure the bend angle on a stamped part. Control.FACTORY & MACHINE Automation Playbook 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 10 secrets to selecting and implementing sensors in industrial applications before they actually become a problem.net © 2014 Red Lion Controls Inc. Fiber. Red Lion’s new N-Tron NT24k modular switch series delivers the configuration flexibility to meet all of your industrial networking needs. Monitor. Fast Ethernet and Gigabit Modules proper calibration and document it in the software changes in the DCS. More sensor tips. Extreme. With all Gigabit and versatile connectivity options. 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. From factories to extreme remote environments. for example. Put proper tags at the site to guide servicing. Introducing the ultimate in network flexibility. Follow selection guides and material. After commissioning.tolerance. 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. If changes are required.net I better. Share article » Add comment » Return to contents » . 10. If the bend angle begins to drift beyond a given +/.redlion. ensure NT24k Rackmount Gigabit Ethernet Switch NT24k-DR16 DIN Rail Gigabit Ethernet Switch NT24k-DR24 DIN Rail Gigabit Ethernet Switch Mix and Match Copper. Modular. +1 (717) 767-6511 I info@redlion.  Connect. monitor and control across a broad range of industries. A built-in display unit for local monitoring of process data is recommended. NT24k enables customers to connect. An optical analog sensor. Install the sensor in a proper rack/enclosure if the dust level is high.

Another option would be to select an infrared LED sensor. However. which is better at seeing through dust and fog than a standard red LED sensor. 2. » CONTINUED ON PAGE 100 Share article » Add comment » Return to contents » . sometimes users need to go beyond these basic criteria and include other critical details. Sometimes users will even direct an air purge at the lens to prevent accumulation of dust or particles.FACTORY & MACHINE Automation Playbook 99 / 167 continued 10 secrets to selecting and implementing sensors in industrial applications Operating environment critical factor Don’t overlook critical details about environmental conditions when choosing a photoelectric sensor. Is it an extremely dusty environment? This can be particularly challenging if the sensor is mounted looking up. Typical selection criteria include sensing range. Some sensors are more immune to internal condensation than others. connection type. These factors often end up as some of the most important considerations: 1. in order to get the best results. electrical output. Consider mounting the sensor to look down. etc. Are there sudden temperature changes? Condensation can build up on the lens.

since these are becoming more popular in the food and beverage industry. Is the sensor exposed to direct sunlight? During sunset or sunrise. 5. 4.FACTORY & MACHINE Automation Playbook 100 / 167 continued 10 secrets to selecting and implementing sensors in industrial applications 3. an internal or external heating or cooling unit may be necessary. Will the sensor be exposed to wash-down conditions? Choose an enclosure with the appropriate NEMA/IP enclosure rating. Reduce the risk of this happening by using a hooded bracket to minimize interference. Consider hygienic requirements in sensor selection. 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.  Share article » Add comment » Return to contents » . the sun might shine directly into the receiver of a sensor and give a false output. for example. Sometimes a heating unit is advantageous to reduce frost or fog buildup on the exterior of the lens.

No matter the camera attributes or software tools. make sure you understand the illumination needs. ring light. you might end up incurring additional hardware costs that were not considered in the proposal. Software control is more important than hardware control. approximately 80 percent of the success of a vision system is related to illumination. Choosing the right light (LED. Before establishing a proposal for a project. Other considerations important to the success of a vision project include camera selection. Before the design and build of a vision inspection system. 3. the project will fail. Get hands-on programming experience first. Modifications required. like using a different color light to bring out different features based not only on color. ease of programming. etc. Find out whether support is readily available for the camera and lighting.FACTORY & MACHINE Automation Playbook 101 / 167 Six critical considerations for successful machine vision applications As anyone who has been involved in a machine vision project knows. You can play this to your advantage when you want to enhance or reduce contrast. Sometimes you have to think outside the box when selecting lighting. spot light. IR) and the illumination technique (dark field. red. Plan for the future. Consider all lighting conditions including 2. availability of technical support and project definition. consider how to make it easy to reprogram and use for future applications. Software quality control and quality assurance are essential to project success. Some tips to get the most out of your machine vision system: reflections and direct sunlight potential. Off-the-shelf vision software programs will need to be modified to fit each unique application. 1. For instance. if the illumination is not right. finer detail can be seen better with blue illumination than with red. bright field.) plus the right color (blue. coaxial) are key for project success. then get the Share article » Add comment » Return to contents » . halogen. Otherwise. white. but the wavelength of illumination. Choose the right light.

The cost may be higher. That’s very helpful.to six-axis robot to handle parts 6.  Share article » Add comment » Return to contents » . 5. lower-resolution camera just because it works on this part. Don’t purchase a system designed for specific parts (like O-rings) that must be “programmed” to do your different parts (such as grommets or seals). always bear in mind the effects of Windows upgrades on the future of the system. When considering a vision system. A complete backup image system will give the vision system an additional five years of life. Think of the future. One camera and software manufacturer has an online users discussion group. 4. that fail miserably on nonO-ring parts. The camera resolution and software are absolutely critical. but the versatility and ability to program different parts is well worth the added cost. Optics must match the desired field of view. Match environment. Consider a four. Tested software libraries help keep the complexities to a minimum. for example. Prepare for upgrades. Otherwise you may have trouble keeping up with the training. Vision hardware must be chosen precisely for the environment. lower-cost pick-and-place systems. Illumination must be robust.FACTORY & MACHINE Automation Playbook 102 / 167 continued Six critical considerations for successful machine vision applications programming training. with answers often available within minutes of posting. Don’t purchase a lower-cost. instead of custom. There are systems just for O-rings. Versatility required.

Does the vision system make it easy to set up applications. How can you determine the repeatability of a vision system’s gauging tools? 6. consider the following 10 questions when selecting a stand-alone vision system: 1. create custom operator interfaces and administer vision system networks? 2. Does the vendor offer a wide range of hardware options? Are they rugged enough for your environment? 10. What networking and communications features are available? 8. What is the importance of part location tools. Does the vision system have a complete set of image preprocessing tools? 4. How do you evaluate industrial code reading tools and what are some specific features to look for? 7. and how can you assess their performance? 3. What should you look for in character reading and verification capabilities? 5. What should you know about vision system accessories? 9.FACTORY & MACHINE Automation Playbook 103 / 167 continued Six critical considerations for successful machine vision applications 10 questions to ask Whether you are new to machine vision or an experienced user. Does the supplier provide the support and learning services you need?  Share article » Add comment » Return to contents » .

at a production line speed of 2.FACTORY & MACHINE Automation Playbook 104 / 167 continued Six critical considerations for successful machine vision applications Test read rate performance To evaluate industrial code reading tools. After establishing the system’s reading speed. This test will provide a good initial assessment of how well the vision system’s read rate will hold up under real-world production conditions. bad and marginal quality to the vision system.7 percent would fail to read the ID codes on 48 parts in just one eighthour shift. present a large sample of codes of good. start by measuring the vision system’s reading speed. For example. 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 system’s reading performance in your application. a read rate of 99. simulate vibration and motion blur by shaking the part and sliding it back and forth beneath the camera as it acquires an image. Make sure you have a 100% read rate under these optimized conditions.  Share article » Add comment » Return to contents » . 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. To do this. To test this. or you may face problems later when conditions might be less than ideal. At the same time.000 parts per hour.

105 / 167 SECTION THREE: APPLYING TECHNOLOGIES TO IMPROVE OUTCOMES .

If the people who make the financial decisions are not onboard.  Share article » Add comment » Return to contents » . Make sure to include all the factors. you are just beginning a true asset management program. inventory control and lifecycle costs are what you will actually use and not too much or too little. generating work orders. by free trial runs if possible or in-depth research or observation. ease of repair and usage of equipment. go slowly and deliberately with the understanding that it is a process rather than an event. labor and materials. that the software you purchase for tracking. which will affect throughput of product. Reliability is related to predictive. After that hurdle has been crossed. Develop a program to demonstrate that proper purchasing. Ensure. report and verify constantly and consistently. operating and maintenance practices are a revenue-generating process. cost of product and cost of using the asset. Cost things correctly. Set yourself up for success by using the boots on the ground as a primary source of input for what works and doesn’t work. the purchase of new equipment. This understanding can rarely be obtained quickly or simply. This will help management realize that ROI is much more than simply purchase price.FACTORY & MACHINE Automation Playbook 106 / 167 Develop a strategy for asset management When beginning an asset management process. such as operator and maintenance training. proactive maintenance and knowing when and how to run to end of life. comparing the cost of maintenance vs. your program will fail. Track.

but a system that is producing efficiently and effectively is the best indication that the system is well maintained. Documented service completes the evidence. recording it properly into the plant’s drawing system or into the active operating instructions Share article » Add comment » 3. motivated and have the power to drive maintenance resources accordingly. While software is now widely used to monitor plant systems. Those resources also need to be well educated (engineer or high-grade tech). As is often said. it’s not over until all the paperwork is in the system. (SOPs). someone is taking care of the system. vary in skill level. Asset management software has extensive functionality. Service technicians. relying on manual data collection methods such as paper-based logs on clipboards. not just software. Automating the data collection is a must vs. Evidence of service is a requirement these days and this PM procedure is the foundation of that evidence. it only makes sense to catalog the asset properly. 1. confidence is established. the asset has become unsupported. Return to contents » . Catalog capital purchases. Data collection is the key to success for asset management.FACTORY & MACHINE Automation Playbook 107 / 167 Five best practices for more reliable asset management Effective asset management requires operating and maintaining equipment at optimum efficiency. Having proper PMs with good procedures is one of the most important aspects of this. with all the technical detail and corresponding preventive maintenance (PM) requirements. 2. People. If anything is purchased in capital fashion. By having the testing procedure in hand with a proper frequency. data will suffer as well as the goal of improving the equipment. whether in-house or contracted. It takes management commitment to providing the proper resources to make asset management programs work. If data is coming primarily from people logging data manually. Automate data collection. but to get real benefits from it requires dedicated human resources. Without cataloging the asset into a maintenance program. human knowledge and a commitment to following best practices are still the foundation for achieving the benefits of asset management programs.

An accountant looks at a machine and its worth. the more important this becomes. Integrate CMMS to enable seamless access to work orders. Create one single-user interface. in-situ asset management during operations along the entire operational process vs. From a technician’s point of view. work order history. prescribed. 4. 5. it’s about keeping a machine running. For the engineer and accountant. Always blow down transmitter sensing lines on a yearly basis. not about doing the paperwork. a posteriori asset management. Clean sensing lines. it’s about having data that can be used to justify replacement or upgrading of equipment on the floor. where maintenance can access all types of asset-related information and systems. The bigger the company. The difficulty comes in how to balance these approaches.FACTORY & MACHINE Automation Playbook 108 / 167 continued Five best practices for more reliable asset management 4.  Share article » Add comment » Return to contents » . What is very important is how you track items like downtime. There are many approaches to asset management. 3. from all DCS work places. 2. etc. There are many software packages available that will assist in combining both perspectives. Take a balanced approach. This small tip can avoid transmitter manifold blocking. Enable real-time condition monitoring for a wide range of assets. Enable real-time. including descriptions of possible causes and suggested corrective actions for each condition. especially steam. BETTER ASSET MANAGEMENT DATA There are a number of ways to improve data collection and access to information from operating equipment: 1. An engineer looks at a machine and its capacities.

etc. Once you get this feedback and fine-tune the system. The engineer must have a thorough understanding of the customer’s performance criteria. the temperature of vital components. Here are four recommendations for creating more effective monitoring systems: halt production. first connect a few strategic ones and run for several days to understand issues in the environment or with connectivity. current draw and a wealth of other data that an engineer can provide via an HMI or other device. If you are connecting several pieces of equipment to a remote monitoring system. With so much information potentially available.FACTORY & MACHINE Automation Playbook 109 / 167 Four considerations for monitoring equipment assets Monitoring and diagnostics are critical factors in asset management programs. diagnostics requirements and problem resolution procedures. error conditions. Gone are the days when automation included diagnostic systems that were solely driven using binary code triggered by I/O. usage patterns. Phase in implementation. Monitor system. The rapid rate of technology evolution makes it nearly impossible to stay current with all the options that engineers and designers have today. 2. speed. Technology now allows real-time monitoring of machine status. this would just multiply any problems. user expectations. scaling is not that difficult. Trial-and-error diagnostics will no longer suffice for problem identification when it comes to resolving issues that Share article » Add comment » 3. If you are going to collect data from machines using PLCs. Time spent obtaining this information lays the foundation on which the rest of the project is often based. Today’s manufacturing environment demands real-time status monitoring and diagnostics. But if you start directly with all the assets. designers need to assist end users in determining exactly what information is critical to their operation and the best way to present the information. It may be as simple as a “ping” test to the PLC or a Return to contents » . Interaction with the end user is vital. 1. Identify diagnostic priorities. you need to include some level of system monitoring.

The controller can switch the relays and collect the vibration information from the corresponding pumps or motors.FACTORY & MACHINE Automation Playbook 110 / 167 continued Four considerations for monitoring equipment assets bit toggle where the application sets or resets a bit. reducing costs. 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.  4. continuous monitoring of one pump or Share article » Add comment » Return to contents » . the communications link should be monitored and alerts created when they fail. Using real-time vibration monitoring on large or critical rotating equipment can provide maintenance staff with valuable information on the health of their assets. but they can share one transmitter. However. With this arrangement you will still need sensors on each piece of equipment. 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. Monitoring and notification do not need to be complex to be effective. In any case. Shared transmitters. motor may not be required. or even to a centralized operations center monitor. 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.

2. or call it output-vs.FACTORY & MACHINE Automation Playbook 111 / 167 Four tips for calibrating equipment Good calibration practices are an essential part of managing your equipment assets. Gage Track). 1. it is essential that the operator be fully trained on the use of the equipment. Many individuals have learned bad habits 4. An easy way to keep up with calibration and monitoring systems is via software designed for this purpose (for example.-input calibration.  Share article » Add comment » Return to contents » . pressure transducers and other devices. 3. Match transmitter output. Calibration reminders. Verify values of actual process data before making calibrations. When calibrating the instrument loop connected to a digital read-out device. Calibration should be provided by trained personnel with very accurate equipment. To maintain calibration. 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. When completing calibrations on thermocouples. Calibration expertise. Secure connections. if you have to unwire the device to put it in a hotwell. By having a master gauge for every item. make sure you get the connections back correct and secure. it is a good idea to fix the read-out measured value and match the transmitter output. when calibration is due you can send it out to be recertified per ISO standard.

A common mistake is to expect a traditional process or machine automation system to be pressed into service for energy management applications (EMS). since every aspect of a manufacturing facility is an energy consumer (processing. purpose-built EMS systems are designed to provide the right tools for energy analysis and reporting. By involving production. A comprehensive energy management program is quite challenging. utilities and even the building itself). Not only is the facility in their comfort zone. Involve production. warehousing. Side benefit. packaging. often cover all or part of the cost of those improvements. Energy management programs that achieve the most significant savings are typically those whose original goal was to improve control of production processes.FACTORY & MACHINE Automation Playbook 112 / 167 Nine strategies for achieving your energy management objectives Whether your primary goal is to reduce operating costs or achieve your company’s sustainability goals. finding ways to reduce energy consumption requires good tools and good information. 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. The energy savings achieved as a result of improved production processes Share article » Add comment » Return to contents » . Instead. 2. 3. since up to 90 percent of energy is consumed by production equipment. Choose the right tools. not just facilities management. but it’s often the only area where they have the institutional authority to make changes. Involve people responsible for production processes in energy management activities. which makes it easier to get management and financial support for adding energy reduction activities to automation projects. 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. you can address all the areas of your operation that consume energy. 1.

5. There’s no need to duplicate these data-generating capabilities by installing power monitors over the top of intelligent motor control devices. Take advantage of incentives. It’s fairly simple to identify viable energy management projects. Minimizing energy draw during idle process conditions. Share article » Add comment » Return to contents » . Minimizing costs by shifting demand to lower-cost time periods. 2. 4. Many motor control devices now have network connections that pass along energy data. Demand/response management. Idle state management. It can often be difficult to find the funds to invest in projects that will reduce energy consumption by your plant. 6. which triggers higher utility rates or penalties. Use interns from local universities to collect the actual data points needed to develop a well-founded business case.FACTORY & MACHINE Automation Playbook 113 / 167 continued Nine strategies for achieving your energy management objectives 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. state and local governments offer a range of incentive and rebate programs for energy saving projects and using alternative energy sources. Offering energy capacity back to the grid on request in exchange for incentives. 4. Detection and analysis of process changes that cause consumption to exceed forecast. Federal. Minimizing peak demand. 5. Use interns to collect data. Avoid duplication. 3. Peak demand management. but it takes real engineering to develop the business case. Scheduled demand management. Energy event management.

Recommendations may include low-investment modifications. Such assessments can help to establish the scope of an effort to reduce energy consumption. 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 » . such as programming changes to equipment. such as a walkthrough of a building or facility to identify quick-hit opportunities. An assessment. such as how seasons might affect production costs and whether previously implemented improvements are continuing to perform as planned. but rather ongoing efforts to identify variables. Audits can be simple. define key metrics and put resources in place that can take a holistic view of energy for the organization. Evaluation and prioritization of capital improvement opportunities can also be included in the analyses. regardless of scale or scope. such as shifting maintenance operations to non-peak times. These are not one-time projects. or may be more involved. or much more detailed efforts.FACTORY & MACHINE Automation Playbook 114 / 167 continued Nine strategies for achieving your energy management objectives 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.

Be prepared. It must cover the entire usage pattern of the equipment.S. Look for peak demand charges or power factor charges. Based on the requirements. Make a list of all of your energy users and section off the top 20 percent. 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.to/021 determined by using a Source: U. it is the key to cost savings as it is the perfect metric for measurement. Start with your power bill. 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. Monitor the results and associate operational conditions with energy consumption. go to The term “large” can be http://awgo. region. it’s important to first gather your data. Department of Energy simple Pareto analysis. Before planning for any energy management purchase.  8. Work with your facilities to stagger the starting of equipment and lights. use soft starts or VFDs on large-horsepower motors to reduce large startup currents. choose the technology (hardware and software) that will help in analyzing a combination of parameters instead of a single parameter. If you have a shift come in and get the facility running from a dead stop. Although the power bill is not Share article » Add comment » Return to contents » . Track big consumers. This will identify a large portion of your energy usage. always correct.FACTORY & MACHINE Automation Playbook 115 / 167 continued Nine strategies for achieving your energy management objectives 7. 9. as well as the focus of your maintenance activities. 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. When possible.

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). simulation. is critical. It is imperative to separate production networks from office networks. 5. external support (shipping the machine setup to a supplier or specialist support) processes can all be improved with server virtualization. Most of these technologies are dependent upon a rigorous data model. For manufacturing IT systems. and understanding the source. It is crucial that developers meet and actually listen to the stakeholders. recovery. what performance and refresh rates should be. This will ensure a common data structure and reporting at a central level. 2. importance and use of the data. 3. Common structure. 1. This is because production systems do not need access to the Internet and the office environment does. Data model. Look to redundancy through virtualization. Backup. As Share article » Add comment » Return to contents » . Virtual redundancy. how it can scale. System requirements. Here are some ideas for making manufacturing IT systems more flexible and reliable. it should be only through a firewall gateway system. productivity and profitability. Build a wall. 4. a number of meetings may be required.FACTORY & MACHINE Automation Playbook 116 / 167 Nine recommendations for building effective manufacturing IT systems Information technologies are giving manufacturers powerful tools for improving their processes. If a connection must exist. it’s setting expectations about what the product can and cannot do. It is not just a concept that holds for office IT. So putting that model in place first. You generally cannot expect people to be able to convey all of their thoughts and gain a clear understanding in one sitting. and what data types and databases it can interface with. Depending upon scope and complexity. it is very well suited to manufacturing IT.

Be patient and explain your production needs in terms IT people can understand. but can miss the scale and scope of the user requirements and scalability requirements. When they know where you are coming from and you know where they are coming from. When developing an information project. Cultural barriers. The issues are typically cultural. Data is worthless. Converting data to actionable information is the goal. It’s often surprising how helpful IT can be once they understand the constraints of a production environment and how email isn’t 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. BEFRIEND IT Develop strong relationships with your IT department. Without this relationship. Start slow. not technical. but can miss the connections to the plant floor equipment and processes. having the right relationships can make it easier to use temporary solutions until best practices can be implemented. If the requirements document is developed by the system integrator. Too often. Information is invaluable. 7. “own” and sign off what’s in it. you have to consider the entire scope. integrators understand the plant floor. If you are implementing a manufacturing intelligence product and are able to create customizable reports.FACTORY & MACHINE Automation Playbook 117 / 167 continued Nine recommendations for building effective manufacturing IT systems a requirements document is being developed. keep end-user priorities in mind. you are most likely going to run into brick walls throughout your entire project. don’t go out and develop all reports in advance. IT consulting firms do an awesome job of building the user requirements. Implement only a few and start collecting data. Automation Share article » Add comment » Return to contents » . 6. Often. make sure you fully understand. Let users get a feel for what is possible and then sit with them to collect report requirements. implementation can be considerably easier. functional and design requirements creep into what should be a straightforward requirements document.

9. expandability and the opportunity to choose what highlevel programming language meets your company’s needs.  Share article » Add comment » Return to contents » BOA products are highly integrated vision systems in a tiny smart camera package specifically designed for industrial use.teledynedalsa. Visual Basic and MatLab. all with LTE speed. NAT. Complete with choice of application software embedded. can now accomplish this. C#. so major decision-makers are just ignorant of the capabilities. seamless network integration. Powerful cellular. Get more vision. firewall and cloud interface. New cellular routers include standard features such as I/O control. protocol converters. Focus on flexibility.com . but a deeper knowledge of cellular applications could be an industry changer. routing. BOA offers new and experienced users alike. The major commercial hurdle is that cellular carriers don’t have solid relationships with control engineers. High-level languages such as C++. www. Many companies don’t fully understand the capabilities of Industrial Cellular technology. Wireless Ethernet or wireless serial radios certainly have their place.FACTORY & MACHINE Automation Playbook • 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 Nine recommendations for building effective manufacturing IT systems 8. for example. The industry has evolved to where manufacturing programming languages are no longer the only solution for automation. an easy-to-deploy cost effective vision solution. Programming languages.

the OEE goes Return to contents » . Accessing data. What they fail to do is penetrate the details of why it worked. measure their efficiency and identify problems. quality people. These two disciplines are frequently linked because they provide a systematic way to design manufacturing processes. for example. Lean is as much about management engagement in daily operations as it is about the methodology. One of the great challenges when executing a project to gather and report OEE metrics is easy access to manufacturing equipment status. Don’t expect that all equipment information is available via existing automation systems. Here are some tactics to get the most out of your lean and OEE initiatives: rework. what support structure is required and how that translates to their internal business. Nothing is worse than the wrong input. thereby increasing throughput in quality. Be prepared to install simple data acquisition systems to gather the necessary data to track OEE. Lean manufacturing is critical in today’s global economy because it helps you drive your output (product efficiency) higher while maintaining low defects and Share article » Add comment » 4. Measure the right things. hold meetings and keep them in the loop throughout the project. OEE is not always a KPI metric in batch operations. manufacturing engineers and process engineers. Get their input. Before building a lean cell. Lean management. 2. one size does not fit all. The obstacles may include islands of automation or even equipment that’s not automated. talk to your operators. If you speed up the drying process. They are the main stakeholders who will eventually approve of your cell. 3. Lean manufacturing is a powerful concept when employed correctly. along with other methodologies. 1. and then try to implement it internally.FACTORY & MACHINE Automation Playbook 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. Stakeholder input. Managers can get caught up in how it improved this company or industry. The problem is that with lean.

not just product manufacturing.FACTORY & MACHINE Automation Playbook 120 / 167 continued 13 ways to get the most out of OEE and lean manufacturing disciplines down. Visual management. takt (cycle) time. but you will be making more product in a shorter period of time. once data was displayed it started a race between shifts to drive up OEE. This can be a huge change management nightmare if not well-entrenched prior to the project (or as part of the project execution). think carefully about being too lean with your supplies. including large display screens on the factory floor. 6. 5. Sometimes manufacturing is too lean and when there’s a sudden demand. fine-tune the flow of your product. Look to these techniques and principles to streamline your own processes and eliminate waste. Too lean? If you operate with vendors that are stationed in areas with a high potential for natural disasters. Lean manufacturing can also be applied to service disciplines. reject ratio. Make sure the business has adopted and fully understands OEE. Just by placing materials at the point of use within the production floor area. 8. Among the most useful KPIs to display: count (good or bad). the slow ramp to manufacture can cost more money than producing stock. Without any management intervention there was a 20 percent increase in productivity. you can increase production uptime. Lean manufacturing is a very important factor in a production plant. This is just one small adjustment that will Share article » Add comment » Return to contents » . Displays harness natural human competitiveness. letting both managers and workers easily monitor the metrics of production lines and track KPIs. Business support. Increase uptime. In one experience. downtime and OEE (availability multiplied by performance and quality) for determining resource utilization. mostly with only minor adaptations. You’ll 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. operating speeds. 7. Visual management. are an effective tool for OEE programs.

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Calculating OEE
As described in World Class OEE, the OEE calculation is based on three factors: availability, performance and quality. Here’s 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.
» CONTINUED ON PAGE 122

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

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13 ways to get the most out of OEE and lean manufacturing disciplines
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
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E = Product Output F = Actual Good Product
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OXPCIe-952 Isolated RS-232, 2x DB9, isolated RS-422/485
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SJA1000 CANBus, CANOpen, 2x DB9

OXPCIe-954 UART, NonIsolated RS-232, 1x DB37, Non-isolated RS-422/485

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13 ways to get the most out of OEE and lean manufacturing disciplines
9. Meaningful reports. Data
capture is quite easy. Reporting the data in a manner that helps implement change can be challenging. Don’t 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.

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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. Network configuration. determine what things you want to track and how specific you want to be.com/tia-portal Up to 30% reduction in engineering effort for faster time to market. proven engineering environment.FACTORY & MACHINE Automation Playbook 124 / 167 continued 13 ways to get the most out of OEE and lean manufacturing disciplines If that isn’t a widely embraced priority. PC-based control. There isn’t a set rule as to what that may be.  usa. OEE can help you identify opportunities to improve your total uptime. Next. First.siemens.siemens. Request a trial license today! usa. understand the categories that OEE represents. Keep it simple and train your people in how to capture the data you need. Drives. money and effort. Share article » Add comment » Return to contents » . and Safety in a single. 13. then save yourself lots of time. An example may be that under your performance efficiency category.com/tia-portal-trial-license Answers for industry. Improving uptime. HMI. By breaking down your categories you will have better opportunities to make improvements. what it is and why it’s important. you list specific pieces of equipment in an assembly line to track. The last hurdle is how to capture the data used to calculate OEE.

lifecycle costs in the equation. It’s Share article » Add comment » Working with PLM software For more information about using PLM software to facilitate collaborative work. Here are some suggestions for selecting and using PLM systems: not a bad idea to look at tool features to begin with. Project teams implementing PLM can get lost in the weeds.to/023 Source: Siemens Return to contents » . 1. get your process defined first. while capturing best practices and lessons learned along the way. download an ARC white paper at 3. Don’t let the tools dictate your process. It allows them to work in a parallel rather than linear fashion by creating a shared information resource of product and process knowledge. Then look at tools and map them to your requirements. Have clear results and improvement goals in mind.FACTORY & MACHINE Automation Playbook 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. When evaluating equipment options. This can encourage innovation. produce. always include http://awgo. The most important function of a PLM system is to foster collaboration among people with different functional responsibilities. Lifecycle costs. the upfront 2. with any known gaps resolved. In most capital equipment situations. Fostering collaboration. to make sure that you are aware of best practices and capabilities that can be leveraged. support and retire the products they make. Its goal is to improve the quality of products and processes. improve quality and shorten time to market for new products. Don’t let tools dictate process. but don’t let a tool dictate a process.

Validation essential. while the rest is the cost to run and maintain the equipment.FACTORY & MACHINE Automation Playbook 126 / 167 continued Eight ideas for improving product lifecycle management cost of the equipment is 2-5 percent of the lifecycle costs. 4. Those who care about manufacturing productivity will appreciate it. Strive to educate operations and management that it’s important to upgrade as needed. 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. But don’t upgrade just to have the latest technology if there is no real payback. Is there a payback? Don’t be afraid to tell others when a system is at its end of life. can be understood by plant maintenance personnel. Choose Share article » Add comment » Return to contents » . The most elegant and complex system design does not help a customer unless it is faster. PLM software that is able to validate the production system in a simulated threedimensional environment. Just because an outdated system is running today is no guarantee it will be running tomorrow. Sometimes it is better to sacrifice elegant and complex for basic and simple if the result is a faster. easier-to-maintain manufacturing line. easier to maintain. Keep it basic. Remember that hardware and software designs have a direct impact on industrial productivity. above all. uses less energy and. 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. This allows the risks of failure to be identified in different parts of the process or equipment. visit http://awgo.to/024 Source: National Center for Manufacturing Sciences 5. 6.

analytics and collaboration tools. three-dimensional visualization. Digital manufacturing. make sure that downtime. maintenance hours and material costs can be easily tracked to each major piece of equipment.FACTORY & MACHINE Automation Playbook 127 / 167 continued Eight ideas for improving product lifecycle management 7. By enabling product-related information to be shared between design and manufacturing groups. upgrade or leave alone each piece. it can reduce the expensive changes often experienced when faulty product designs reach the manufacturing stage. computer-based system comprised of simulation. It’s used to create product and manufacturing process definitions simultaneously. an integrated. It is also possible with some software providers to use the information to evaluate your techs. Track equipment. If you are looking at new maintenance software.  Share article » Add comment » Return to contents » . One element of PLM is digital manufacturing. 8. This will help you make informed decisions about whether to replace.

You must work with the manufacturing crews. even if it requires them to work around safety systems. It you make the safety system too extreme or complex to deal with. Return to contents » . They have so much insight into what people are actually going to do to improve their throughput and efficiencies. 2. Understand human nature. Safety education. it’s essential to understand how an operator or maintenance technician needs to interact with a machine. Engineers who design safety systems need to keep that fact top of mind. 1. you’re actually inviting them to override the safety system in order to get their jobs done. When designing a safety system.to/017 Source: Siemens 3. It’s just human nature. End users should make sure they see a new machine operate with all the safety features functioning before they accept the machine.FACTORY & MACHINE Automation Playbook 128 / 167 Seven human factors to consider when developing safety systems People will do whatever they have to do to get the job done. Machine safety is primarily an education issue. download a white paper at http://awgo. It is not enough to rely on industry standards to develop machine safety. a glossary of safety terms and a discussion of machine safety standards. even if that means evading systems designed to keep them safe. you will be able to develop Share article » Add comment » Machine safety standards There are many organizations dedicated to improving machine safety. For links to them. Don’t invite overrides. 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. By communicating and observing your workforce.

especially when it’s a poorly supported or poorly organized project. etc. 5. There have been many incidents of hand injury because the operator forgot to put Share article » Add comment » $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. Operator safety. the buy-in for the 4. while interlocking equipment. where everyone contributes and that result in good documentation.to/015 Source: Occupational Safety and Health Administration Return to contents » .FACTORY & MACHINE Automation Playbook 129 / 167 continued Seven human factors to consider when developing safety systems Convincing the end customer about the advantages of safety is difficult. the project’s purpose will not be properly communicated. maintenance. service. when the opposite is the case. It gives scenarios based on lost time (litigation is not included) from the insurance industry. This means real meetings that have a purpose. This is key to having a safe approach when integrating controls. emergency conditions. interfaces and other automation gear that enhance the workplace.). but not impossible. you need to ensure that it is a foolproof and mistakeproof system. It is easy to create a negative condition when upgrading. Also. Without representatives assembled to discuss every interacting department’s needs (such as training. Wherever operator safety is required. Get real feedback. the adjacent equipment in manual mode before adjusting his machine’s setting. which can demonstrate the effect of severe injuries on sales and profits. There’s no room for a safety failure because of operator mistake or negligence or bypassing of a few sensors. Most end users view safety systems as a detriment to production. Good safety principles and finding a vendor who has the products and expertise to assist is 90 percent of the battle. http://awgo. always consider the adjacent equipment if it is sequence-related to the equipment. Arrange cross-functional meetings.

production due to an injury or downtime from faulty equipment. On the other side. 7. which is vendor neutral with regards to fieldbus and supports safe operations with interoperable technologies. Saving someone from injury by paying for training courses is better than losing http://awgo. project management is demonstrated and confidence is instilled in the management of change. or pay later.FACTORY & MACHINE Automation Playbook 130 / 167 continued Seven human factors to consider when developing safety systems change will be seriously impaired and. A lot of money can go towards guarding. Pay now. unsafe conditions may arise. 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. By conducting proper meetings and maintaining clear communication with all impacted personnel. Bringing their viewpoints into the design review process will help eliminate costly surprises during the testing or rollout phases.to/019 Source: Ethernet Powerlink Standardization Group Source: Ethernet Powerlink Standardization Group Share article » Add comment » Return to contents » . visit 6. the end user should not cut costs by eliminating machine safety features just because they don’t understand the need for implementing safety systems. For more information.  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. even worse. only to find that the machine will be in a secure area that cannot be accessed during operation.

 LOPA chart courtesy of ABS Consulting. awgo. 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.FACTORY & MACHINE Automation Playbook 131 / 167 continued Seven human factors to consider when developing safety systems Safety standards online Be proactive and try to stay ahead of regulation before changes are mandated. Apply LOPA (layer-of-protection) analysis to rate the SIL level and guide the SIF design according to IEC 61508/61511. Operatior Supervision and Manual Intervention Basic Controls.to/018 Share article » Add comment » Return to contents » . The Internet is a great source of information about current regulations and standards—and what might be coming next. Understand all aspects of the safety lifecycle before proceeding with design and implementation. Community Emergency Response Plant Emergency Response Physical Protection (Dikes) Physical Protection (Relief Devices) Automatic Action SIS or ESD Critical Alarms.

It’s a systems approach.controller actuator.FACTORY & MACHINE Automation Playbook 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. Functional safety needs a procedure to implement it continuously. in either simplex or redundant configurations. these practical recommendations address the details of a safety system: 2. as defined in IEC 61508. Sensor . Validate the safety code. Exceptional hardware fault tolerance in dual configurations. 3.9999 percent. System/product lifecycle idea. Otherwise. equivalent to the longaccepted TMR (triple modular redundant) benchmark standards. Low STR (steps to reproduce) that meets or exceeds the TMR standard when implemented in dual configuration. Determine each failure mode and validate that it fails to a safe state. every component should have the same SIL/PL. Functional safety. does not necessarily mean it will return to the correct state if there is a fault. Low PFD (probability of failure on demand). visit http://awgo. Functional safety.to/016 Source: International Electrotechnical Commission Safety modules independent from the logic solvers. Key features for safety systems. 2. Share article » Add comment » Return to contents » . It needs to be verified. By choosing safety systems with these features. Just because the logic tells you to turn an output on or off when running. IEC 61508 explained For a comprehensive look at functional safety and the IEC 61508 standard. it makes no sense. Today’s safety does not mean tomorrow’s safety. 1. is a totally new methodology in automation. availability has been estimated as high as 99. It’s based on two main principles: 1.

such as “pos. then do this. When you create the home program. if “pos” = 10. 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. They can be very useful for maintenance and for troubleshooting because they can be installed in a manner that will satisfy everyone. Then create a program called “home. Magnetic lock systems have come a long way and they really simplify the way you can design and safeguard a machine. “pos” values or set them to zero once you make it to the “home” position. Send robots home. Don’t allow OEMs to place e-stop buttons on their consoles if they do not stop all equipment in the immediate vicinity. Now the main program can be run from the beginning. program in flags or position steps.  Share article » Add comment » Return to contents » . Deep dive into Process Hazard Analysis (PHA) to identify the risks underlying a process. 6. Discharge capacitors. make sure capacitors are fully discharged before removing the front panels and working within the drive. without any worries. to avoid other machinery or tooling. use a variable. Stop everything.” After each critical move/step of your robot in the program. you can run it and have a series of “if” statements. Apply LOPA (layer-of-protection) analysis to rate the SIL level and guide the SIF design according to IEC 61508/61511. 5. even when locked out.FACTORY & MACHINE Automation Playbook 133 / 167 continued Eight tips for the technical side of safety systems 4. For example. 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. Interlocks are built in and they are a little harder to bypass than previous generations of the technology. 8. Make sure to clear your 7. from the operator to OSHA. Identify risks.” and assign it a numeric or other value like zero as the home value. Consider magnetic locks. On older AC and DC drives. Understand all aspects of the safety lifecycle before proceeding with design and implementation.

FACTORY & MACHINE Automation Playbook 134 / 167 continued Eight tips for the technical side of safety systems Don’t overlook safety distance calculations The safety of a machine is not guaranteed by simply using a safety laser scanner in an application. These two possibilities are called the Depth of Penetration and are a part of the safety distance calculation. How will the device be mounted? Will it be scanning vertically or horizontally? If it is vertical. 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. which would require a larger-sized safety field. if it is mounted with a horizontal plane. » CONTINUED ON PAGE 135 Share article » Add comment » Return to contents » . More commonly. there may be a chance for reach-over. the scanner plane may have to be mounted farther from the hazard. similar to a light curtain.

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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. 

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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 manufacturer’s 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 machine’s 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

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Wiring, safety PLC programming critical to machine safety performance
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Some examples: standstill. Restoring a safe state. When executing a safety function. New and improved safety strategies offer manufacturers a way to improve productivity and competitiveness in the market. Safety inputs are monitored with special modules that detect input discrepancies and they are processed in a safety controller. 2. In a hydraulic press machine. A safety-related system thus implements the required safety functions by detecting hazardous conditions and bringing operation to a safe state. takes place. when necessary. human safety was achieved by using a light curtain at the job press’s work area to hold the press for any human interrupt. Functional safety in machinery usually means systems that safely monitor and. ensuring that a desired action. 3. which are standard in all European nations and now accepted worldwide. such as monitoring a crawl speed that deviates from the expected value (such as too fast).  Share article » Add comment » Return to contents » . The press can only resume operation when the operator comes out of the working area and acknowledges the action. which generates safety code. stopping and 4. direction of movement. 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. such as safe as stopping. as another example. Human response required. Safety system monitoring can include machine speed.FACTORY & MACHINE Automation Playbook 138 / 167 Europe sets standards for safety design The European Union has defined required safety methods for machines. 1. Detecting deviations. override the machine applications to ensure safe operation. Safety modules.

security architectures. In the IT world. reliability requirements. They’re both about identifying the bad things that can happen. By discussing these differences and gaining an understanding of each group’s expectations and priorities. 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. VLANs. Pay attention to the basics. Most IT security experts say the implementation of basic security features available on network devices solves over 90 percent of concerns. it’s all about the safety of people and the process. 2. Collaboration should be the rule. including the addition of a firewall between. security goals and different assumptions about security. There’s an incredible overlap between safety and security. routed interfaces and simple firewall features can stop the majority of malware and intrusions. Network security can be a complex topic. risk management goals. As a simple practice. The two systems have different performance requirements. IT and control engineers within an organization can develop a solid foundation for communication and cooperation. Keep a logical separation between enterprise and control networks. On the plant floor. Basic tools such as port security. IT and control engineers should define a role list to avoid misunderstandings. it’s about information confidentiality. Collaboration rules. On the plant 1. The policies for the enterprise network cannot be the same for control networks. operating systems and applications. use a Share article » Add comment » Return to contents » .FACTORY & MACHINE Automation Playbook 139 / 167 Six strategies for creating a secure industrial network Security and safety are the same word in many languages. not the exception. You can’t have a secure system unless you know who’s running the equipment and what they’re doing. and finding ways to minimize the chances that they will.

So policy. In the past. offsite backup of electronic media. lockable PLC panels. a defense-in-depth strategy should be deployed. programming and monitoring. the objects involved in security are not only devices or equipment. worms and tools arise every day. Now these systems are slowly becoming connected to public networks for the purposes of remote administration. as well as pockets of unsecured networking equipment. In an industrial environment. because it’s always in a state of dynamic change. server rooms). etc. This type of security resulted in industrial systems with software that wasn’t kept up-to-date with the latest security patches. New malware. As with functional safety. Develop a security policy. a disaster recovery plan and other features as appropriate to the needs and concerns of your business. 5. EMI. use network equipment designed specifically for industrial applications. procedures and cooperation are very important in implementing an industrial security strategy.). making them vulnerable to many threats. industrial network security was accomplished through air gaps. it’s more difficult than in an office environment. 3. implementation of a security policy should also include: an authentication mechanism. In order to protect these networks. The plant is not allowed to shut down its process. Defense-in-depth.FACTORY & MACHINE Automation Playbook 140 / 167 continued Six strategies for creating a secure industrial network floor. This type of defense protects in several places. floods. Security is more challenging than safety. accessibility. such that bypassing a single security device does not provide unfettered access to the 4. physical protection (such as Share article » Add comment » Return to contents » . There are human factors as well. Defenders need to be awake all the time. viruses. In addition to malware issues. Essentially. data backup procedures. this relied on having physically separated or isolated systems to protect plant equipment and networks from the rest of the world. Be on your guard. hazard protection (fire.

Every control system has one or more assets that would seriously impact production. A defense-in-depth strategy should provide secure remote access through the use of VPN gateways to provide encrypted access at the external boundaries. Prioritize your efforts. 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. 6. 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. download the white paper at http://awgo. internal zone and cell levels. the chance of a truly serious cyber incident is massively reduced. The internal zone boundaries should employ firewall and network address translation.  Protecting control systems For more information about protecting industrial control and SCADA systems from security threats.FACTORY & MACHINE Automation Playbook 141 / 167 continued Six strategies for creating a secure industrial network rest of the network. It can also provide critical device protection by isolating malfunctioning devices from broadcasting packets to the entire network and creating a denial of service.to/020 Source: Tofino Security Share article » Add comment » Return to contents » . such as accessing a malicious external website. the PLC controlling chlorine levels in a water filtration plant or the RTU in an electrical substation. If these assets are aggressively protected. These might be the SIS (safety integrated system) in a refinery. safety or the environment if successfully attacked. Plant personnel know what really matters in an operation.

which are planned and intentional. or if only one operation in the facility was disrupted. With all of the eavesdropping and international espionage in the news. The cost could be devastating. external security is becoming an issue that in the past was typically not even a consideration. With manufacturing facilities becoming more wired and automated. from both outside and from within the facility must now be incorporated as part of any automation project. Security. Consider how much cost is involved when the production facility is shut down for standard maintenance operations. Cost is becoming less an issue when compared to the potential damage that » CONTINUED ON PAGE 143 Share article » Add comment » Return to contents » .FACTORY & MACHINE Automation Playbook 142 / 167 continued Six strategies for creating a secure industrial network Security threats confront every manufacturing plant Network security is becoming a more important issue. as well as accessible from outside the facility. Now consider the cost impact if the facility was maliciously shut down. it is becoming more important to secure the automated facility and protect operations from outside interests (including foreign governments).

In addition. While many security issues can be solved by better human behavior. External access is only one security consideration. there’s no way to guarantee that the behaviors threatening your facility will actually change. 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. Don’t skimp by using cheap security software. A hack or virus in a system can cause the entire business to be compromised. there are security threats from within the facility.FACTORY & MACHINE Automation Playbook 143 / 167 continued Six strategies for creating a secure industrial network could be caused by a breakdown in security. All of these factors and potential threats should more than justify the cost of implementing a security plan for your facility. Considering the risks to your business. These can be as innocent as an accidental modification to a production program or as intentional as a disgruntled employee.  Share article » Add comment » Return to contents » . Take all of these threats into account when developing a security plan. your supply chain and other aspects of your production could provide invaluable information to an unscrupulous competitor. it shouldn’t be difficult to justify implementing a security plan for your facility.

as Share article » Add comment » Return to contents » . which allow data flow control and reduce loads on the network. Recovery and uptime are the critical priorities on the factory floor. Here are a few security details to keep in mind when constructing your network: the production network into three sections—PLCs. Utilize an accessible IP list to limit administrative access to your network devices. reception door locks. etc. 1. a separate management VLAN can be created for this purpose as well. These devices contain a management interface that will give you great control over their operation. 2. Failure to restrict access can be disastrous. It’s often useful to divide 3. Design your network with managed switches. This list will only allow connections to the management interface of a switch from a list of pre-selected IP addresses. For example. Divide VLANs. Access to the management interface of your network switches can also be controlled. Separate your production floor assets from the management functions (office computers. many industrial networks operate in a single VLAN with a flat IP scheme. HMI users and servers—to reduce traffic where it is not required.) using different VLANs. but the accessible IP list can often provide just the right amount of protection along with the desired simplicity.FACTORY & MACHINE Automation Playbook 144 / 167 Seven details to remember when implementing network security Network security is absolutely necessary for today’s industrial networks. Creating separate VLANs can introduce a bit more complexity into the average system. don’t create a security system that shuts down the equipment if a panicked operator enters the wrong password in an emergency situation. However. Use managed switches. 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. Access to unsecured ports can lead to network loops being accidentally created. Access to your network by untrained persons can lead to misconfigured network devices. Keep production running. To further prevent access to the management interface.

protocols. rather than have to manage user names and passwords on individual switches. Loop prevention protocols include the spanning tree variations such as rapid spanning tree. It goes without saying that this is a big problem and it should always be changed. these can be too slow. Guard against network loops. All network components. For industrial applications. 5. resilient and have high mean-time-between-failure (MTBF) ratings because of the harsh environments found in an industrial facility. Managed switches also allow the network designer to disable any unused ports. This requires a bit more configuration. cabinets and active equipment. Make sure you change the default admin password of the switch. but allows for all your network devices to have a single user database that is centrally administrated. These features can be used to prevent a malicious denial of service outage from occurring as well as prevent an accidental Ethernet cable loopback. need to be industrially hardened. including cabling. but optimized solutions such as TurboChain and broadcast storm prevention (BSP) can provide response time in milliseconds to prevent network loops from occurring.1X. any port can be connected with an Ethernet cable back into another port on a switch and create a broadcast storm. This kind of problem can also be tricky to track down and flush out of a network. Without loop prevention Share article » Add comment » Return to contents » . Active 4. which can control access to them using 802. The ports can either be disabled or be configured to use a central RADIUS server. This can cripple the switch as well as the network. Many industrial networks are designed with redundant paths in the system and already employ a redundancy/loop prevention mechanism. It typically comes set to a default and many fail to change it. This prevents unauthorized devices from gaining access to the network. Having equipment that is easy to disrupt makes an attacker’s job easier.FACTORY & MACHINE Automation Playbook 145 / 167 continued Seven details to remember when implementing network security well as limit access to the network. This is also a feature of a managed switch. Unmanaged switches do not provide any type of control and allow any device to be plugged into the network. Look for redundancy and robustness.

Early network warning system. This will keep operations going in the event of malware or other network intrusions. Firewalls should be optimized to secure SCADA protocols such as Modbus and OPC. such as switches and routers.FACTORY & MACHINE Automation Playbook 146 / 167 continued Seven details to remember when implementing network security components in an industrial network. need to support industrial redundancy technologies and the level of redundancy required for your production needs. which have no place on a plant floor system.  Share article » Add comment » Return to contents » . Waiting for the IT team to analyze the event the next day is too late. Products that inspect email and web traffic simply add cost and complexity to the security solution. 6. 7. an area that is typically poorly done in the industrial automation world. rather than email or web traffic. Plant personnel need to be immediately alerted if a read-only remote operator station suddenly tries to program a PLC. Integrating security with industrial control systems is critical for both support and security event monitoring in a network. Design your security system to handle very wide power ranges. since the plant floor often has dirty power. Using such a system will facilitate the detection of unusual activity on the network. Optimize firewalls to protect the right protocols.

Share article » Add comment » Return to contents » . Find a user group. Integration simulation. Experience suggests that there’s never been a startup where 4.FACTORY & MACHINE Automation Playbook 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. electro-pneumatic. Start with a database. 1. electro-hydraulic. see how a design works or compare different design options and technologies. it is useful to find out if there’s a software user group or online community that shares problems and solutions or good and bad examples. Study software concepts well and avoid going too far before creating a full. Simulate industrial control systems on the bench to the greatest extent possible and practical. PLC ladder programming or function block diagram by simulating the entire integration of these technologies into a new project. consistent components database. This is especially important if the software supplier provides only paid help or support. Simulation software has become an essential tool for successful automation projects. Test and test again. electric control. Here are some tips for getting the biggest bang from your software investment: anyone said. “We performed too much simulated testing. hydraulic. You can increase productivity for automated systems using pneumatic. 2.” 3. White papers and a few application examples in the manual cannot compare with real experiences shared by users. For any software. Using soft technologies as support for projects allows you to analyze the behavior of the entire system.

This is as true in design as it is in cutting metal. But it is easy to get caught up in adding features because it is so easy to do. Design with modeling. Drive for simplicity. Keep it simple. just make sure you are modeling with the correct variables. Before applying any hardware ideas. yet the most critical step to success. a programmer or engineer can simulate to verify the results to the nearest real-world values. Always validate against real-world conditions. what we see may not be real. Talk to those who did a project.FACTORY & MACHINE Automation Playbook 148 / 167 continued Nine ways to get the most from simulation and CAD/CAM software 5. Try to visit the sites where the work took place. CAD/CAM simulation helps the programmer and engineer to know about the working of a machine before it’s built and for troubleshooting as well. While simulation can save time and money. If you can get a word with those who were actually on the front line of the system. Verify performance. 6. 8. Is it real? Models can be very powerful—or very misleading. Have a mental model to make sure digital version mimics the real world. It’s worth researching similar projects and simulations. simulation give you a good image of the problem to solve. Mathematical modeling is the first step in simulation. Keep it as simple as it needs to be and little more. CAD/CAM is one of those tools that quietly revolutionized low-volume production. The challenge in creating a useful model is validating that the output is actually predictive. Make sure modeling and Share article » Add comment » Return to contents » . 9. they tend to be the most truthful about its benefits or limitations. sweat and tears that actually went into a particular software system. We are conditioned to believe what we see. In simulation. It’s also useful for research.  7. The published version that emerges from a project is usually a pale imitation of the blood. save a lot of headaches.

with buy-in from all. limited variability programming. Here are some suggestions for implementing workflow software: PHASE IT IN It’s a good idea to implement workflow automation software in two planned projects. 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. be specific when discussing and documenting software requirements. fixed programming. 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. But to facilitate standard responses to activities or events. If you don’t do this up front and Return to contents » . the bigger projects that span groups can be tackled with knowledge and confidence in the workflow tool. responsibility and authority reside in one group. etc. 2. Define your objectives. workflow may be too structured for you to benefit. Define subsets. If you have processes that change all the time. And make sure you get the operators to agree and quantify the “standard work” (if it’s available). full variability programming. For workflow software. where the systems. workflow software is a good solution.FACTORY & MACHINE Automation Playbook 149 / 167 Five recommendations for implementing workflow systems Workflow software is a useful tool in many applications. embedded software. Ensure that the real production workflow is accurately documented and understood for all products and all variations before you start the project. methods and objectives. 1. you need to first discuss what you want to use the workflow software to do. utility software. Document standard work. Recognize and define the expanding subsets of workplace software (for example. Do you want it to enforce compliance. for example. firmware. from enforcing standards and compliance to feeding into an MES. Once there is proven success with this project.) and Share article » Add comment » 3. Plan and execute the first workflow project within a limited domain.

Pushing them beyond their work capacity with unrealistic schedules can result in mistakes and project delays. Share article » Add comment » Return to contents » . then you will end up running in circles. Improving code.  Do not be overly analytical and make it unnecessarily complicated. allow sufficient time for your programmer or integrator to make the changes.  Ensure proper channels of workflow.  Use IEC 61131-3 for programming machine behavior. A proper design is essential to avoid delays in a workflow project. When you ask for additional product flexibility that will require workflow software code changes. agreed on and the “future state” well understood.  5. 4.  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.FACTORY & MACHINE Automation Playbook 150 / 167 continued Five recommendations for implementing workflow systems get everything documented.  Use templates to save a lot of time. More workflow tips.

FACTORY & MACHINE Automation Playbook VENDOR SELECTION RESOURCE GUIDE 151 / 167 Advantech Advantech. Embedded Automation Computers Advantech offers complete line of embedded automation computers with rugged and cableless designs. and other user-friendly VIDEO programming tools and utilities. an integrated I/O and control feature with HMI/SCADA software enables efficient integration. Major product lines include: Automation Controllers Advantech’s Programmable Automation Controllers (PAC) combine a PLC’s ruggedness with PC-based technology.to/202 PHONE: (800) 800-6889 Share article » Add comment » Return to contents » . OPC WEB RESOURCES Server. Advantech’s Industrial Automation Group is proving to be a global leading Automation Product and Services provider. Cincinnati. awgo. By combining connectivity. COMPANY: Advantech Corporation awgo.to/200 WHITE PAPER How has the recent strides in automation changed the factory floor? awgo. SoftLogic programming tools. ruggedness and being at the leading-edge of Internet of Things technology. rich I/O modules and power software. With compact and multiple IOs. high performance CPU. industrial automation panel PCs. the Industrial Automation Group of Advantech is a pioneer in intelligent Automation technology. Advantech – Now and Beyond Intelligent HMI Platforms With a complete range of intelligent operator panels.advantech.to/201 PRODUCT  ADDRESS: 11380 Reed Hartman Hwy. including fanless box PCs and industrial control devices. Advantech offers a wide range of human machine interface (HMI) products for industrial automation panel needs. OH 45241  WEB: www. multiple expansion solutions and multiple mounting methods.com Multi-touch wide screen monitor with waterproof M12 connectors. and industrial monitors. an open architecture. flexibility. a pioneer in Intelligent Automation Technology With more than 30 years of experience in providing a full range of products to different vertical markets. Automation Software Advantech’s automation software lineup includes SCADA software. In addition. touch panel computers.

from ISA to USB.000 talented people. industrial monitoring. Serial Device Servers. Data Acquisition and Control Advantech offers wide range of industrial data acquisition and control devices with various interfaces and functions. Cellular IP Gateways.The Advantech Industrial Automation Groups “Intelligent Automation. Based on PC technology. affordable. and signal conditioning to graphical software tools. Cincinnati. Advantech’s industrial I/I products are reliable. Products include Industrial Ethernet Switches. we cooperate closely with our partners to help provide complete solutions for a wide array of applications across a diverse range of industries. smart transportation. Industrial Communication Solutions Advantech’s Industrial Communication products provide reliable wired and wireless communication for mission critical applications. building energy efficiency. sales and marketing network in over 20 countries worldwide. Industrial Wireless AP/CPE. Whether in public safety.FACTORY & MACHINE Automation Playbook VENDOR SELECTION RESOURCE GUIDE each embedded automation platform is suitable for a wide variety of automation applications in a wide range of environments.com Return to contents » PHONE: (800) 800-6889 Share article » Add comment » . COMPANY: Advantech Corporation  ADDRESS: 11380 Reed Hartman Hwy. and suitable for many industrial automation applications. and Serial Communication Cards. can make to this new era of intelligent automation. Seamless Integration” mission statement looks forward to the contribution that Advantech. smart grids. In addition. Modbus Gateways. 152 / 167 Advantech With more than 6. Advantech operates an extensive support. environmental monitoring. smart homes and other areas with our expertise and experience we can provide the best solution to create better tomorrow. Media Converters. RS-based I/O Modules (ADAM-4000 series). and Ethernet-based I/O Modules (ADAM-6000 series) to monitor and manage field sites easily.  Distributed I/O Modules While the Internet-of-Things is rapidly becoming a reality. together with its partners. accurate. OH 45241  WEB: www. customers can take advantage of Advantech’s machine-to-machine I/O modules (ADAM-2000 series).advantech.

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

  Didactic’s charter is to provide automation technology training for manufacturing employees at our industrial customers worldwide. validation. analysis. Festo can provide the resources you need to meet your unique requirements in every stage of industrial production and manufacturing. fully equipped learning centers – we can create a customized offer to suit your personal requirements for efficient learning and guaranteed results. control and handling of complex networked CIM systems and complete.festo.com/us Return to contents » Share article » Add comment » . COMPANY: FESTO 154 / 167 Festo engineering. • 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. including: conceptualization. Paper & Converting • Water/Wastewater Complete System Solutions Our experienced engineers provide complete support at every stage of your development process. and production. teaching programs and on-site services. • Automotive • Biotech/Pharmaceutical • Electronics/Light Assembly • Flat Panel/Solar • Food & Beverage • Lab Automation • Printing. design. 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.   PHONE: 1 800 99 FESTO  WEB: www. Festo Didactic is the knowledge and learning division of Festo Corporation.FACTORY & MACHINE Automation Playbook VENDOR SELECTION RESOURCE GUIDE • Pneumatic Drives • Servo Pneumatic Technology • Handling & Vacuum Technology • Air Preparation. assembly. documentation. From basic training packages to the planning.

safety and security solutions. Graybar has high quality electrical. COMPANY: Graybar Power Supplies Industrial-grade power supplies for demanding applications and harsh environments. Industrial Networking Ruggedized industrial Ethernet products designed specifically to network in tough environments. and accommodate the environmental rigors of the location. reduce costs and increase safety. Let Graybar’s team of Industrial customer-focused sales professionals and automation and control technical specialists help you boost output.com/industrial Return to contents » Share article » Add comment » . low maintenance and increased system availability. Graybar is uniquely positioned to provide the solutions needed from the factory floor to the corporate boardroom. support the industrial protocols transmitted across these networks. electrical. networking.FACTORY & MACHINE Automation Playbook VENDOR SELECTION RESOURCE GUIDE 155 / 167 Graybar GRAYBAR: Your nationwide resource for automation. Enclosures Industrial enclosures and enclosure solutions that isolate critical controls from harsh environments and help ensure reliable performance in a range of extreme conditions. PLCs and I/O User-friendly PLCs providing secure industrial connections. Graybar’s 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. including: Software A wide range of easy-to-use software programs that will help you easily migrate to newer platforms. automation and control products common to the factory floor or automation processes.  PHONE: 1-800-GRAYBAR (472-9227)  WEB: graybar. Operator Interfaces The latest technologies in the human-machine dialogue field to help machine builders and industrial users meet new control system standards. Wireless Wireless data communication solutions for indoor and outdoor applications that offer reliable transmission.

Sensors Technical specialists to help you select the right sensor for your application.  Terminal Blocks and Interface Products A comprehensive line of DIN-rail mounted products to choose from. arc flash analysis. study trends. KEY COMPANY CONTACT Brett Felton. and control loads and generators.com/industrial Return to contents » Share article » Add comment » . 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. lighting. including proximity sensors. Safety Plant-wide safety audit provisions.felton@graybar. isolate problems. 156 / 167 Graybar Power Monitoring Power management systems designed to help manage real-time conditions. electronic pressure sensors. National Marketing Manager PHONE: (314) 573-9200 • LOCATION: St. lockout/tagout provisions. Services A wide variety of services to support our customers’ facility needs in power. Louis. space and money. networking. energy management. Our technical specialists help customers in all these areas today and continually expand their knowledge and skills to master new technologies.FACTORY & MACHINE Automation Playbook VENDOR SELECTION RESOURCE GUIDE 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. Graybar’s automation specialists are certified by Schneider Electric for VFD stat-up and commissioning. and personal protective equipment (PPE) to help avoid electrical hazards that can result in serious injury or death. security and more. featuring an array of termination methods that save time.com COMPANY: Graybar  PHONE: 1-800-GRAYBAR (472-9227)  WEB: graybar. MO EMAIL: brett. photoelectric sensors and limit switches.

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

IL • EMAIL: salesnet@omron. electronic components. automotive electronics and healthcare make up the balance • 35.5 billion sales (USD. IL 60173 Return to contents » Toll-free: (800) 556-6766  WEB: www. founded in 1933 • $6. Schaumburg.FACTORY & MACHINE Automation Playbook VENDOR SELECTION RESOURCE GUIDE 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. social systems. April 2012) • 40% of our sales come from industrial automation.com Share article » Add comment » .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.omron247.com  ADDRESS: One Commerce Drive.

industrial SNAP PAC System with guaranteed-for-life I/O. No plugins. then tag them VIDEO from your own tag database. buttons. too.opto22. What system do you 14 ways to build an operator interface have: Allen-Bradley. Simplicity. Mobility. and more. updates are simple.FACTORY & MACHINE Automation Playbook VENDOR SELECTION RESOURCE GUIDE 159 / 167 Opto 22 Three Reasons To Call Opto 22 for Your Automation Application Simple-to-build groov mobile operator interfaces.to/166 users refresh their screens. Siemens. ABB? Now it doesn’t matter. Interface Simplify your job with a groov mobile interface.com PHONE: (800) 321-6786 Share article » Add comment » . With groov. no reinstallations. Just have http://awgo. Modbus. Temecula. CA  92590  WEB: www.to/168 Return to contents » mobile simple. web-enabled device regardless of manufacturer or screen size: smartphones. Your COMPANY: Opto 22 groov interface works on virtually any authorized. even live video all scale to match the device you’re using. and a 40-year history of engineers responding to your monitoring and control needs: three reasons your automation project— and you—deserve to work with Opto 22. No user or device keys. tablets. Yokogawa. groov is all you need to build mobile operator interfaces for your system and securely view them from virtually any smartphone or tablet. all you need to build interfaces is a web browser. Get your free trial.  Gauges.  ADDRESS: 43044 Business Park Drive. you can build mobile PRODUCT interfaces to all of these and many groov makes http://awgo. And there’s no coding or programming. groov: Your system on your mobile™.to/167 With groov. Just drag and drop WEB RESOURCES touchscreen-ready indicators and controls onto the screen. WHITE PAPER Connectivity. 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. labels. that works. but never become too small to use. http://awgo. no extra software.

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

net  E-MAIL: info@redlion. 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. 17406 • USA  FAX: (717) 764-0839  WEB: www.redlion.FACTORY & MACHINE Automation Playbook VENDOR SELECTION RESOURCE GUIDE 161 / 167 Red Lion Controls Red Lion Controls As the global experts in communication. Our awardwinning technology enables companies worldwide to gain realtime data visibility that drives productivity. PA. 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. Red Lion Controls has been delivering innovative solutions for over forty years. data logging and web server capabilities with visualization functionality for PLCs. anytime: • Controllers: PID controllers. monitoring and control for industrial automation and networking.net Share article » Add comment » Return to contents » . The following industrial automation products collect. present and process data anywhere.

call +1 (717) 767-6511 or visit www.net/together.11a.redlion. PA.redlion.3 Layer 2 industrial switches with automatic speed. 17406 • USA  FAX: (717) 764-0839  WEB: www. secure communication for remote sites To learn more.FACTORY & MACHINE Automation Playbook VENDOR SELECTION RESOURCE GUIDE 162 / 167 Red Lion Controls In addition.net  E-MAIL: info@redlion.n hardened radios support data bandwidths up to 300 Mb/s • Cellular M2M Routers: provide uninterrupted. Red Lion now offers an industrial networking portfolio that includes: • Unmanaged Switches: compact IEEE 802.b. 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.net Share article » Add comment » Return to contents » .g. COMPANY: Red Lion Controls PHONE: (717) 767-6511  ADDRESS: 20 Willow Springs Circle • York.

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

Alpharetta. and drives.us@siemens. 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. Totally Integrated Automation (TIA) saves time in engineering as a result of the efficient interoperability of PLCs.FACTORY & MACHINE Automation Playbook VENDOR SELECTION RESOURCE GUIDE Efficient automation starts with efficient engineering Totally Integrated Automation: Efficiency driving productivity Efficient engineering is the first step towards better production: faster. Inc  ADDRESS: 3333 Old Milton Parkway. HMIs.com/tia-portal-trial-license • Lower cost in design. 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.siemens. safety. and more intelligent.siemens.usa. reducing engineering costs up to 30% usa. GA 30005  EMAIL: info.com Return to contents » WEB: www. commissioning & maintenance • Reduced downtime • Faster time-to-market • Greater flexibility COMPANY: Siemens Industry.com/industry Share article » Add comment » . more flexible.

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

together with a rich suite of capabilities and options that can be applied to the most challenging applications. MA 01821  WEB: www. 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. 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.com Return to contents » PHONE: 978-670-2000 Share article » Add comment » . These include single 640 x 480 standard camera configurations to high-performance multi-camera models with 1600 x 1200 color resolution. 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. Billerica. Sherlock provides advanced functionality in terms of scripting.teledynedalsa.FACTORY & MACHINE Automation Playbook VENDOR SELECTION RESOURCE GUIDE Teledyne DALSA’s vision systems are available in a range of costeffective models to satisfy a broad variety of user requirements. customization and support for 3rd-party tools. Sherlock software offers experienced vision integrators additional flexibility. iNspect Express’ logical setup is built from the experience and algorithms that have been put to the test over the course of many years. They support line scan technology to address challenging large format or cylindrical unwrapping applications.

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