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Contents
A4 Balancing the bagging triangle
Applying the bagging triangle can ensure that packagers
maintain efficiency, productivity, and profitability.
A8 PID tuning improves
process efficiency
Tuning a PID controller correctly can bring the setpoint
closer to the constraint with reduced variability.
A12 Standardizing control room HMIs
Next generation HMIs create an environment where operators
and technicians can move at speed of manufacturing and make
decisions that increase the bottom line.
C OMME NT
From packaging to tuning to visualization
T
he cover story in this issue of
AppliedAutomation talks about packag-
ing—specifically, the bagging process.
Industrial bag packaging machines are
designed to fill plastic and paper bags with dry
bulk products, such as powders, granules, or
flakes. The author points out that efficient, effec-
tive, and accurate bagging is a direct result of
Jack Smith optimizing the relationship between the bagging
Edit or machine, the bag, and the product. Finding the
right combination of these three factors should
be obvious. However, if one of them changes,
one—or sometimes both—of the others may
need to change as well.
This issue also includes an article about
PID tuning—a topic frequently covered by
AppliedAutomation, Control Engineering, and
Plant Engineering. My first exposure to PID tun-
ing was a vintage ISA training film (not a video;
the film predated even VCRs) about tuning
A4
On the cover
The bag filler shown in the photo features electronic
bag weighing and a filling channel valve that can be
adjusted for fine and coarse flow. Courtesy: Haver
Filling Systems Inc.
A12
pneumatic controls. The concepts are the same.
However, the ways they are applied continue to
advance. The author provides PID tuning advice,
explains different tuning processes, and explains
the theory behind modeling processes. Automatic
tuning software can greatly simplify the PID
tuning process in many cases. Although auto-
matic software has been around for more than
30 years in one form or another, it continues to
advance as well.
The third article revisits HMIs—another topic
that continues to be popular among automa-
tion and control professionals. In this article, the
author advocates HMI system standardization,
which involves using standard graphics, naming
conventions, and application design concepts to
provide a consistent look and feel among multiple
HMIs throughout the plant. The author contends
that HMI standardization can increase productivity,
simplify operation, and reduce operating costs.
Applied Automation December 2013 • A3
 COVER STORY

Balancing the bagging triangle

Applying the bagging triangle can ensure that packagers maintain efficiency,
productivity, and profitability.

By Markus Lackmann
H av er Filling Syst ems In c .

D
ry bulk packag-
ing is a simple
yet sensitive
balancing act.
Maximum effi-
ciency and pro-
ductivity are at the center of
a triangle with product, bag,
and machine at the vertices.
This delicate balance is
called the “bagging triangle.”
It describes the relationships
Figure 2: Saving a few cents
among the three corners
and how the right combina- for each bag filled can add up
tion can positively impact an quickly.
operation’s bottom line. It’s
a simple concept: a shift or tion of machine and bags
change in one corner—the for maximum efficiency and
product, bag, or machine— production. Everything has
necessitates a change in been tested and projections
one, or sometimes both, of look excellent.
the others. The new machine is
While it’s common installed, it’s in harmony
for packagers to blame with the product and bags,
machines when bagging and the company is meet-
efficiency goes down, experi- ing quotas. All is well until
ence shows that equipment an operator notices some-
often is not the culprit. It’s Figure 1: The bag filler shown features electronic bag weighing thing’s off: the machine is
just as likely that product and a filling channel valve that can be adjusted for fine and coarse not filling at the expected
specs or the bag have flow. All images courtesy: Haver Filling Systems Inc. rates or it’s consistently
changed and disrupted hitting the target rate in
efficiency. Packagers who the morning, but it always
are able to work with their bag suppliers and machine manu- drops after midday. At a more basic level, maybe the
facturers in applying the bagging triangle can pinpoint the operation is losing a half pound of product for every bag.
source of the problem more quickly, get their operations back Simple math shows how significant these scenarios
into three-corner balance, and consistently hit the sweet spot can be (see Figure 2). It’s easy to understand why com-
of efficiency, productivity, and profitability (see Figure 1). panies want to address them quickly, and they often look
to their machine manufacturer for answers.
Harmony equals profit
For example, consider a product manufacturer that Key points
decides to upgrade its packaging machines. The company’s Regardless of which type of bag an operation uses—
project engineers, the bag supplier, and the machine manu- valve, form-fill-seal, or open mouth—the ultimate goal for
facturer get on the same page regarding the right combina- dry bulk packagers is to fill and seal as many bags as pos-

A4 • December 2013 Applied Automation

Figure 3: The goal for dry bulk packagers is to fill and seal as many bags as possible with exceptional accuracy in a specified time period.

sible with exceptional accuracy in a specified time period ered, including whether the bag is made with traditional
(see Figure 3). The number that a company can actually paper, high-performance paper, plastic, or a combina-
fill depends on the delicate balance of the bagging tri- tion. The weight of the material and the number of lay-
angle’s three corners. ers also require consideration. The ability to de-aerate
Product: The installation of any new packaging equip- also is impacted by the inside mechanics of the bag,
ment should begin with a thorough analysis of the product such as whether there is a layer of polyethylene (PE),
and its properties. Material composition, consistency, to what extent the PE is perforated or sliced, and where
size of particles, what form they are in, and how they in the layer sequence the PE is inserted. The impact
are distributed all come into play. of de-aeration properties creates
Drilling down further reveals other The installation of any new a trickle-down effect that subse-
crucial traits, such as flow property, quently impacts filling speed and
bulk density, moisture content, de-
packaging equipment should overall machine performance. For
aeration characteristics, compaction begin with a thorough analysis of example, if the air in the bag takes
properties, and trickling capability. a long time to escape, the entire
Occasionally a product manufac- the product and its properties. packaging process is slowed.
turer will change the formulation of The second factor, bag consisten-
its product after the equipment has been operating for a cy, can impact the process in three ways. First, if the valve
period of time. Whenever this happens, it’s important to size and placement are not the same from bag to bag and
test and analyze the new material mix to determine the order to order, the machine might have issues consistently
ideal machine settings and bag characteristics for bagging placing the bag on the spout for filling. Second, inconsis-
triangle balance. tencies in the bags will affect the way they stack in the
Bag: It seems like it should be pretty straightforward— magazine, which can lead to misfeeding in the system.
pick a bag and fill it—but it’s not that easy. Many times, Finally, if there are issues with the quality of the bag or
when companies experience a drop in efficiency or pro- inconsistency in characteristics such as perforation, effi-
ductivity, the issue can be traced back to a change in the ciency can be compromised due to poor de-aeration.
bag. Some of the most important characteristics of a bag Sometimes a bag change may have nothing to do with
are de-aeration properties and consistency in manufac- a supplier, but is instead the result of a well-intentioned
turing. Both of these factors can have a significant impact machine operator who sees an opportunity to save a
on efficiency. penny or two per bag by making a change. Or perhaps the
Perhaps the more critical of the two is the bag’s ability company’s purchasing department decides to switch to a
to de-aerate, and that depends largely on the materials bag with fewer layers. Regardless of the reason, the com-
used to fabricate the bag. Many factors must be consid- pany must consider how the change will impact efficiency

Applied Automation December 2013 • A5

 COVER STORY
Figure 4: Operators can use mobile technology to schedule remind-
ers for routine maintenance and ensure equipment is running at
peak efficiency.
and make adjustments to the other two points of the bag-
ging triangle to compensate.
Machine: The key to machine selection is to work with
a manufacturer that understands the bagging triangle
and fully tests product, bag, and machine—both indepen-
dently and together—before making equipment recom-
mendations.
The process starts with obtaining product from the end
user to analyze. Testing the product is a critical step that
helps define the product characteristics, and the bag’s
filling behaviors, durability, and quality. From there, the
company can identify and define the proper filling tech-
nology to achieve the ideal productivity level. In addition,
this testing helps determine optimal filling rates, how
many spouts are needed to hit those rates, and what
settings will need to be maintained on the machine to
achieve them.
The initial setup is only the beginning. As a machine
operator or company makes changes to the other sides of
the triangle, it is imperative that they evaluate the effect
of those changes and adjust parameters on the machine
to maintain balance. Before making the machine adjust-
A6 • December 2013 Applied Automation
ments, it’s always wise to consult the manufacturer.
Remember, a change in one corner of the bagging triangle
impacts the other two, and tinkering can quickly result in
sacrifices in capacity, weight accuracy, and cleanliness.
Maintaining balance
Product plus bag plus machine equals efficiency, pro-
ductivity, and profitability. A little here and a little there can
really add up, and packagers always want to reach maxi-
mum efficiency and productivity.
Finding the right combination of product, bag, and
machine, and keeping all three corners of the bagging
triangle in synch requires constant monitoring. A key to
maintaining the right balance is to work with partners that
understand and can apply the concept. By understanding
the bagging triangle, packagers can reach quality outputs
and high weight accuracy, and be proactive toward pre-
ventive maintenance (see Figure 4).
Markus Lackmann is sales manager for the U.S. and
Canada at Haver Filling Systems Inc., a bag/packag-
ing manufacturer that specializes in the handling and
packaging of solid dry bulk materials, liquids, and pasty
products. He has more 15 years of experience work-
ing in the industrial machinery industry with a special
emphasis on material handling, weighing, packaging,
and filling technologies.
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 PID TUNING

PID tuning improves

process efficiency
Tuning a PID controller correctly can bring the setpoint closer
to the constraint with reduced variability.

By Merle Likins, PhD, PE Control loop basics

Yo k o g awa Cor p. of Am e ri c a In a typical control loop, a parameter, such as tempera-

P
rocess industry plants must optimize regu-
latory and advanced control to maximize
profitability while maintaining safe opera-
tion. Regulatory control stabilization is key to
achieving these goals. Stabilization can often
be improved through closer evaluation of a
plant’s regulatory control loops.
Most of these loops are operated by a proportional-
integral-derivative (PID) controller. By better under-
standing how to tune these loops, plant personnel can
improve quality and efficiency while ensuring plant
safety. Moreover, achieving regulatory control stabiliza-
tion forms the foundation for advanced process control
implementation, which can further optimize operations.
In addition to maintaining safe operation, a stable
regulatory control system can increase profitability
by reducing emissions and energy consumption, and
increasing the life span of equipment. By automating
troublesome control loops, the need for manual opera-
tions is reduced, saving labor hours and increasing
product consistency.
This article offers an introduction on how to achieve
a stable, well-tuned regulatory control system, with
emphasis on improved PID control.
ture or pressure, must be controlled. This parameter is
called the process variable (PV). A sensor usually mea-
sures the PV, and this measured variable is provided as
feedback to the controller in a closed-loop system.
The desired value for the PV, such as 40 F in the case
of a temperature control system, is called the setpoint
variable (SV). If the PV is only 30 F, for example, the
controller will react to adjust its output to increase the
temperature.
A constraint is the limit at which the process can be
performed safely and efficiency. For example, the heat at
42 F will destroy the compounds in a liquid during a cer-
tain process. Therefore, the process must remain below
this constraint. However, a process operating at 36 F is
so far below the constraint that quality is lost and/or the
process becomes inefficient. Thus, the goal is to control
the PV and keep it as close to the SV as possible with
minimal variability. When variability is minimized, the SV
can be moved closer to the constraint, improving opera-
tions.
PID controllers
The PID controller is the most commonly used control-
ler type in process plants, with more than 95% of the
control loops in a typical plant under PID control. The
familiar PID controller can be a great tool for improving

Figure 1: In a closed-loop
Disturbance system, processes can
be optimized by tuning
the controller to reduce
Error=SV-PV MV Final Control
SV + Controller Process the error between the
- Element
PV and the SV. Courtesy:
Yokogawa Corp. of
America

PV
Measurement

A8 • December 2013 Applied Automation


70
PV(%)
68 NB = 1%
66
40
CO(%)
CO bump
35
300 325 350
Time (min)
quality, energy efficiency, and production.
PID controllers offer good performance in a variety of
operating conditions and they can be operated in a sim-
ple, direct manner. They can be stand-alone or embed-
ded, and they can be used for one or for many control
loops. They can also be combined with sequential logic
and advanced control functions to form complex automa-
tion systems.
The PID algorithm consists of three basic elements:
proportional, integral, and derivative. The setting for each
of these three elements is varied to achieve an optimal
response: to maintain the PV as close to the SV as pos-
sible with minimal variability. Each element is linked to a
certain task that has a specific effect on the control loop.
A PID controller receives the measured PV data from
a sensor, and then determines the difference (error)
between the measured PV and the desired SV. It then
computes the desired controller output or manipulated
variable (MV) based on the error. The MV in turn acts on
the final control element (for example, a steam valve),
which in turn affects the process to change the PV (see
Figure 1).
There are many techniques for calculating the tuning
constants for PID controllers. Most are based on develop-
ing a mathematical model for the combined final control
element, process, and measurement.
The model for describing the controller is simply the
PID Algorithm. If a model can be determined for the pro-
cess (final control element, process, and measurement),
then a mathematical model for the entire loop is in place.
At that point, tuning the controller becomes a matter of
matching the controller tuning constants (P, I, and D) to
the parameters of the process model, and optimizing the
Figure 2: Data from the
bump test should show a
dynamic cause and effect
from the change in the
controller output. In this
DPV = 4% example, a CO bump causes
the PV to move significantly.
Courtesy: Yokogawa Corp. of
America
375 400
three PID constants to produce a desired response.
In the real world, the controller output is usually not the
only signal that affects the system. There may be ele-
ments within the environment that cause deviations, such
as ambient noise. These elements are called disturbanc-
es. While disturbances must be factored in when control-
ling the process, they are also intentionally introduced on
a temporary basis as an initial step to tune the controller.
Tuning a PID controller
The process of tuning a PID controller involves five
steps:
1. Introducing a disturbance into the control loop
2. Fitting the resulting response to a mathematical
model
3. Using tuning correlations to calculate controller
parameters
4. Implementing the new P, I, and D parameters
5. Documenting the results.
The first step in tuning the PID controller involves
inserting a disturbance that creates a new controller
output (CO) into the loop. This is called a bump test.
The disturbance introduced into the loop must be large
enough to force a clear PV response, and the response
must be large enough to distinguish it from any noise in
the system. Unmeasured disturbances can corrupt the
PV data, so larger CO bumps are better (see Figure 2).
Self-regulating process vs. integrating process
Any number of model types is possible for describing
a process. But before choosing a model, one must first
determine if the process is self-regulating or integrating
Applied Automation December 2013 • A9
 PID TUNING
Figure 3: Advanced software can simplify PID controller tuning
and reduce the possibility of error. This trend screen shows a flow-
rate response resulting from changing the SV. Courtesy: Yokogawa
Corp. of America
(non-self-regulating). This determination is essential
in tuning a controller because the different processes
require different mathematical models.
After a change in the CO is introduced, a self-regu-
lating process will eventually find a steady state as long
as the CO and disturbance variable remain steady, as
the process has an internal method of regulating the PV
that balances the change in the CO. For example, in a
flow loop, if a valve is opened an additional 10%, the
flow will increase to a new value and will stay at that
value until the valve is moved again. Most processes
are self-regulating.
However, in an integrating process, the PV will keep
changing unless the CO is returned to its original posi-
tion. With an integrating process, the PV will continue to
rise or fall in a linear fashion in relationship to the CO
change. This means an integrating process can be dif-
ficult to control. An example of an integrating process is
changing the liquid level in a tank. If more flow is intro-
duced into the tank, the level will keep rising; if more
flow is let out, the level will continue decreasing.
Tuning control loops for self-regulating processes
tends to be easier than tuning integrating processes.
Negative consequences can happen very easily and
quickly if an integrating loop is tuned incorrectly. The
inability to achieve equilibrium after a change in the CO
is introduced in an integrating process could lead to
problems, for example, a liquid overflowing or running
dry, which could cause equipment (pump) damage, envi-
ronmental damage, or significant safety issues.
Self-regulating processes require both proportional
and integral (and occasionally derivative) control modes
for good performance. Despite their nomenclature, inte-
grating processes rely much less on the integral control
A10 • December 2013 Applied Automation
mode. Different tuning rules must be applied because
the process models are different.
Using modeling
After the bump test is performed and the type of
process involved is determined, the next step involves
fitting a model to the data. Modeling is one of the best
ways to understand process data. A first order plus dead
time (FOPDT) dynamic process model is usually suffi-
cient to describe the process response and allow calcu-
lation of good tuning constants.
In this model, the PV is the measured process vari-
able and the CO signal is the manipulated variable. The
FOPDT model is simple (low order and linear), thus it
only approximates the behavior of the real process. It’s
represented by the following equation:
p dPV + PV = K p * CO (t -  p)
dt
Lumped parameter process model
The lumped parameter model is an FOPDT model.
This model describes the process response with simple
linear equations comprised of three parameters: gain
(K p ), time constant (tp ), and dead time (0p ).
For the lumped parameter model, two forms of models
are required depending on the nature of the process
control loop: the self-regulating process (flow, tempera-
ture, etc.) and the integrating process (level).
Because an integrating process is more difficult to
control, a different model must be used to describe this
type of process, which is described by this equation:
dPV
= K’ p * CO (t -  p)
dt
Tuning correlation
There are many different tuning correlation methods
used to calculate the PID tuning constants.
Ziegler-Nichols and Cohen-Coon are the two most popu-
lar techniques for calculating tuning constants. These two
techniques emphasize speed of response. Internal model
control (IMC), also referred to as the “Lambda rules,”
offers a robust alternative that balances speed of response
with controller stability or robustness. IMC tuning can be
used for linear and nonlinear processes, and it produces a
smoother FOPDT response than other techniques.
IMC tuning is based on the concept that ideal control is
possible with an exact model of the process. However, a
mismatch between the model and the actual process can
occur because of external disturbances that affect the
process, which can lead to faulty results. As a result, IMC
was designed to have methods for compensating for dis-
turbances and modeling error, including filters and com-
pensators in the higher frequency domain where many
errors occur in other models.
 Like other tuning procedures, a step test must be per-
formed with IMC to determine the process characteristics.
After determining the lumped parameter process model, a
desired closed loop time constant (tCLtaucl ) for the con-
trol loop must be selected.
If the closed-loop time constant is too large, a slow con-
trol loop will result. Therefore, a smaller (tCL) value will cre-
ate a faster control loop. But if the closed-loop time constant
(t CL) is set to be shorter than the FOPDT process time con-
stant (tp ), the advantages of IMC tuning will disappear.
Generally, the value for (tCL) should be set between
one and three times the value of (tp ). In many cases,
(tCL = 3 x tp ) is optimal to achieve a very stable control
loop. Therefore, after determining the FOPDT process
model, the IMC technique has one single tunable param-
eter: the closed-loop time constant. The controller speed
is made more aggressive or more conservative by chang-
ing the closed-loop time constant.
IMC has one drawback in that the controller’s integral time
is set to equal the process time constant. A process with a
very long time constant means the controller will also have a
very long integral time—and long integral times lead to very
slow recoveries from disturbances.
Properly tuning a PID controller isn’t a simple process, but
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it’s one of the best methods for improving productivity, qual-
ity, and safety in a process. By achieving a stable regulatory
control system through improved PID tuning, the SV can be
safely moved closer to the constraint while reducing the vari-
ability of the PV, thus reducing inefficiencies in the process.
However, collecting data and performing all of the mod-
eling mathematics can be difficult and time consuming.
Fortunately, advanced software can simplify PID controller
tuning and reduce the possibility of error (see Figure 3).
Whether PID loop tuning is performed manually or
with assistance from loop tuning software, the resulting
improvements in the performance of each control loop will
lead to significant overall performance gains throughout
the process plant.
Dr. Merle Likins, PE, retired, has undergraduate and
graduate degrees in chemical engineering from the
University of Louisville. He is a licensed professional
engineer in five states and has more than 35 years of
experience in process automation. Dr. Likins has an
extensive background in petroleum and chemical pro-
cesses. He also has many years of experience in mul-
tivariable control, online process models, and online
optimization. Prior to retirement, Dr. Likins worked with
Yokogawa Corp. of America from 1992-2013.
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 V isualization

Standardizing control room HMIs

Next generation HMIs create an environment where operators and technicians can move
at speed of manufacturing and make decisions that increase the bottom line.

By Chris Parkinson, P ol yt ron In c . accessed devices, then the user will have a basis on how

T
to interact with them.
At the site level, users who move between manufac-
he operator interfaces to control manufactur- turing systems understand how controls work regard-
ing systems have grown from push buttons less of assignment. Consistent controls between manu-
and lighted switches to today’s computerized facturing systems benefit operations by allowing them
and engineered HMI touchscreens that control to efficiently work on multiple systems more seamless-
virtually every part of the manufacturing facility. ly. In addition, maintenance benefits from consistent
Sophisticated graphical interfaces with 3D rep- troubleshooting capabilities across the systems. For
resentations of equipment, HMIs provide a window into example, a motor fault on Line A is reported and reset
the controls and/or manufacturing intelligence system. exactly the same way as on Line B. Finally, consistent
Unlike controller code that is seen by few, anyone can HMI systems reduce training effort for both students
see the HMI. and trainers.
As the manufacturing industry moves rapidly into the vir- The maximum benefit of HMI standardization is real-
tual, paperless era, the standardized working environment ized at the enterprise level. Users who move between
for managing manufacturing operations requires tools sites know how to operate and troubleshoot more effi-
such as HMI 3D visuals and flat screen monitors in con- ciently. Training and documentation become even more
trol rooms and at strategic points throughout the facility. efficient. And, from a development perspective, opera-
Imagine a plant with large flat screens tions with the proven best practices
at key locations and standardized HMI can leverage solutions across the
screens at every control point for pro-
The maximum benefit enterprise. For example, Plant A may
cess and production. The entire plant of HMI standardization have more experience on the process
becomes a virtual control room. It is while Plant B has more experience
becoming the norm, not the exception. is realized at the on packaging. Plant A can leverage
Today’s manufacturing environment process solutions for both sites while
demands a leaner workforce, higher enterprise level. Plant B leverages packaging solu-
machine and system efficiencies, great- tions. Standardization allows both
er flexibility, and increased productivity and quality targets, plants to share solutions and maximize the capability
which sets the stage for the highest efficiency in standard- across multiple sites.
ized HMI performance for operational excellence. The result is a seamless workflow for the workforce to
operate at the highest level of performance. The stan-
HMI system standardization dardized HMI also facilitates fast and easy training on
Standardization involves graphic standards, naming con- changes or updates, and new employee training is con-
ventions, and application design concepts—a consistent sistent across the entire workforce.
look and feel to promote greater efficiency on the plant The three most important benefits of standardized
floor. It is the best practice of applying easily recognized HMI are:
visuals to increase the productivity at the point of use. As 1. Increased productivity: The ease of use and func-
standards become applied on an enterprise scale, overall tionality of HMI systems will increase overall equipment
benefits multiply. effectiveness and workforce productivity. The updated con-
At the system and machine level, standardization pro- trol system makes it easier to start, stop, troubleshoot, and
vides consistency to promote user confidence with regard make changes in production.
to expectations on how things operate. For example, a 2. Easy-to-understand technology: In addition to
button that takes the user back to the main menu should increased productivity for operators, other tasks improve
be placed in the same location every time it is used. If the as well. Training, troubleshooting, and line changes are
location varies from screen to screen, confusion and ineffi- simplified. A trained line operator can walk up to the HMI
ciency prevail. In addition, if controls for seldom-accessed at any time and easily understand what is going on in a
devices work the same way as those for frequently particular stage of production. Applied programming stan-

A12 • December 2013 Applied Automation

Modern HMI technology allows multilevel plant floor access with
information screens for immediate help and training. Courtesy:
Polytron Inc.
dards make it easy for users to dig deeper into the con-
trols through the HMI to receive more information about a
situation.
3. Cost efficiency: The return on investment for
HMI standardization is quickly recaptured through the
efficiency it brings to operations through reduced down-
time for equipment issue resolution and changes, and
increased productivity by operators, maintenance, and
engineering.
It’s important to focus on an efficient HMI design that
functions well and looks good. Flashy animations and
software might look impressive in an HMI demonstra-
tion, but they don’t contribute to the HMI’s effective-
ness. In fact, they slow down the operator’s navigation
to devices and information. It is an HMI best practice to
turn data into actionable information.
Programming standards
The ability to achieve the same look and feel across
platforms isn’t a luxury, it’s an operating necessity. Good
HMI platforms are often driven by end users to integrate
with their currently installed systems.
Standardization translates into sustainable efficiency
with regard to development. The platform provider tends
to have well-defined and more rigid HMI standards to mini-
mize costs, while some system integrators also have well-
defined HMI standards with more flexibility to accommo-
date the customer’s requirements. It is possible to blend
flexibility and standardization with an 80/20 approach: a
standard that accommodates 80% of provider standards
with 20% for project-specific requirements. Applying
standards at the proper level of granularity is vital to this
approach. In addition, proven standards can be deployed
Applied Automation December 2013 • A13
 V isualization
across different software platforms for maximum flexibility.
Because the HMI and controller devices work closely
together, HMI standards advance additional efficiencies
through controller programming standards. Consistency on
the graphic and logic sides further reduces effort and pro-
vides more time for the 20% project-specific requirements.
This leads to enhanced code reusability, which significantly
reduces application development effort. In the same way that
standards help the customer to leverage consistent experi-
ence in the enterprise, standards also help developers to not
reinvent the wheel and apply industry expertise effectively.
Beyond application development, standards facilitate
documentation and training. Standard documentation and
training materials can be developed for the 80%, forming a
module—complete with graphics, controller code, documen-
tation, and training materials. These modules can form the
basis for a comprehensive application development library.
3D HMI
A top-down view of a production line is typical in an HMI.
However, when the line contains a spiral or multilevel con-
veyor, a top-down view will significantly diminish the power
of the HMI for appropriate line management. Ideally, an
HMI should be capable of viewing the line from the side,
and at different angles and levels—with the ability to zoom
in at any point. This provides operators and technicians
with the ability to clearly see what is happening on the
entire line from the perspectives they need to make bet-
ter decisions and changes. In addition to multiple views,
the 3D approach provides an opportunity to use additional
graphical techniques to add clarity to complex equipment
arrangements:
n Equipment can be hidden for a particular view so
the HMI screen can focus on the components that
are important.
n Equipment can be rendered transparent to provide
common reference points without being distracting.
n Cutaways, elevations, and key views can be gener-
ated to add additional clarity as needed.
n Use of a model allows changes to be made one time.
Multiple affected views can be regenerated quickly,
saving time.
Next generation HMI
The new software and hardware technology available
today presents the opportunity for the next generation HMI
to provide information, not just data. It has flooded users
with data, but the challenge is extracting actionable infor-
mation at the point of use.
The flexibility of the HMI can bring the information to
the operator anywhere on the plant floor, and the large flat
panel displays or scoreboards on the plant floor bring infor-
mation to users where needed. With a glance, users can
understand how the line is performing, display faults, warn-
ings, quality issues, and performance to established key
performance indicators (KPIs) and production goals. This
A14 • December 2013 Applied Automation
real-time information allows the operator to make the appro-
priate decisions and changes to meet or exceed targets.
Other interactive interface devices, such as smart-
phones and tablets, connect with the same customized
and standardized view of actionable information delivered
to those who need it, where they need it, anywhere in the
enterprise. Smartphones provide a window into KPIs, criti-
cal faults, and quality issues, allowing the ability to make
higher level decisions for overall operational excellence.
Tablets provide mobile wireless HMI for diagnostics and
troubleshooting. Using a tablet as a troubleshooting tool
puts the HMI where the technician needs it, typically on
the plant floor and always on the move.
Workflow software provides a logical extension to the
HMI. The HMI provides a here-is-what-is-happening, here-
is-what-is-wrong view. Shared workflow provides the now-
what to the equation for information on the location of the
root cause of the alarm or quality issue, and the action to
take to correct it. The addition of standardized workflow in
next generation HMIs raises the level of operational effi-
ciency to the next level.
Workflow can be applied in several different ways:
n Standard operating procedures: Streamline and send
a consistent message on how things should be done
n Changeovers and machine setup: Track critical
planned downtime events and provide feedback to
increase efficiency when not in production
n Online reference and documentation: Provide relevant
reference information at the appropriate time and
place; supplement training with quick references,
single point lessons, and interactive tutorials
n Fault correction: Provide troubleshooting procedures
for machine stops, quality issues, and performance
deviations.
Data gathered from the workflow provides an electronic
record of what happened when to ensure procedures are
being followed. This helps close the loop on continuous
improvement initiatives.
Supported by a smart HMI, and armed with and actively
broadcasting information, operators and technicians can
move seamlessly through the facility with confidence to
keep production at the highest level. Workflow augments
training by providing real-time and pertinent access to
standard procedures, troubleshooting guides, and valu-
able reference material. Automated escalation of critical
faults and quality issues ensures that the right people are
informed at the right time to take right action.
The next generation HMI creates an environment where
operators and technicians are moving with the speed of
manufacturing and looking ahead to make decisions to
impact the bottom line of the business.
Chris Parkinson is a control systems engineer at
Polytron Inc., where he has worked for nearly 20 years.
He is a graduate of Georgia Institute of Technology and
specializes in HMI and data tracking solutions.
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