2106 AWPlaybook

THE AUTOMATION
PLAYBOOK 2021
The bottom line for key automation
issues for discrete, batch process
and continuous process industries.
• 5 Factors to Consider Before

Launching an IIoT Initiative
• 4 Ideas for Active
Ingredients Management
• 8 Ideas for Successful DCS
Implementation
SPONSORS
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TABLE OF CONTENTS
SECTION 1
Factory & Machine Automation

12 5 Factors to Consider Before Launching an IIoT Initiative
14 RFP Guidelines Help Deliver Capital Project Excellence
15 How to Properly Select and Vet a System Integrator
20 23 Common Mistakes People Make in Automation Projects
27 Key Factors to Consider in Deciding Among PLCs, PCs or PACs
30 12 Guidelines for Selecting Motors and Drives
33 Top Considerations for Selecting and Deploying Industrial Robots
37 Best Practices for Implementing Industrial Ethernet
39 Guidelines for Using HTTP and MQTT Protocols
42 7 Safety Functions That Can Save You Money
44 22 Ways to Get the Most Out of OEE and Lean Manufacturing Disciplines
51 Strategies for Achieving Your Energy Management Objectives
57 10 Tips for Switching to Predictive Maintenance
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TABLE OF CONTENTS
SECTION 2
Batch Processing
65 9 Tips for Achieving Balance in Recipe Management
68 How Reusable Code Streamlines Recipe Management
72 10 Commandments for CIP Design
74 Top Recommendations for Designing and Using Skid-Based Equipment
77 Agreeing on OEE
82 Safety: The Lifecycle Approach
88 Conducting a Risk Assessment
90 How to Avoid Mistakes With Control System Remote Access
94 Options Analysis Tool for Remote Equipment Access
95 4 IT Standards You Should Understand
97 Tips for Dealing With Wireless Latency and Bandwidth Issues
99 Achieving Sustainability Excellence
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TABLE OF CONTENTS
SECTION 3
Continuous Processing
106 8 Ideas for Successful DCS Implementation
109 PLC vs. DCS: Which Is Right for Your Operation?
112 Procedural Automation for Greater Safety and Productivity
115 13 Suggestions for Control System Migrations
118 Managing for Reliability Key to Asset Performance
120 Measure First to Improve Control System Performance
124 10 Steps to Creating the Perfect HMI
127 Practical Tips for Implementing Intrinsic Safety
131 Wireless Sensor Applications
133 Managing Emissions With Automation
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INTRODUCTION
By Aaron Hand, Executive Editor
For years, Automation World has provided hands-on information, automation

implementation tips and best practices for specific industry cross-sections in the
form of the Factory & Machine Automation Playbook, Continuous Process Playbook
and Batch Process Playbook. But in an industrial world that grows ever more complex,
manufacturers and producers need to look outside their own industries to learn how
other processes—whether discrete, batch or continuous—can help their own operations.
The Automation Playbook is a useful source of information for all industries as you
look for guidance in how to approach the Industrial Internet of Things (IIoT), new
communication protocols, control implementation, safety, asset management,
predictive maintenance, a mobile workforce, and so much more.
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SECTION 1 Factory & Machine Automation
Placeholder
SECTION 1
FACTORY & MACHINE

AUTOMATION
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The following experts
SECTION 1 Factory & Machine Automation CONTRIBUTORS
contributed to this playbook:
Thomas A. Doney Joe Martin

Senior Research Engineer President
Nestlé Martin CSI
Paul Brinks Jeff Miller, PMP

COO Director of Project Management
Koops Inc. Interstates Control Systems Inc.
Stephen M. Goldberg Howard Skolnik

Director - Information Technologies President/CEO
Matrix Technologies Inc. Skolnik Industries
Michael Hake Arthur C. Smith

Senior Facilities Systems Support Technician Senior Automation Controls Engineer
Data Device Corp. MT&E - Machine & Automation Systems
Corning Inc.
Robert Lowe
Executive Director
Control System Integrators Association (CSIA)
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Michael Mikolajczak Jad Wehbe Jim Hulman William Wang Kurt Wilde Tom Jensen
Bryan Sisler Automate, Lebanon - Joaquin Ocampo DuPont China, China Henniges Automotive, USA Lenze, USA
ABB, USA Germany - Qatar Bosch Rexroth, USA
Tim Matheny Satish Samineni Stefano Linari
Alex Miller Rafael Arevalo Duque Larry W. Ostrander ECS Solutions Inc., USA Halcrow, Qatar Linari Engineering srl, Italy
ABB Robotics, USA Automatizacion Ingenieros CADD Tech Support, USA
Especialistas sas, Colombia Ed Nachel Tianshun Qiu Dan Perkins
Mike Berryman John F. Wozniak Elobau Sensor Technology IBM (China) Co. Ltd., China LINAK U.S. Inc., USA
Advantech, USA Peter van den Berg CC-Link Partner Association, Inc., USA
Avans University of Applied USA Alexander Pinkham Jagjeet Paul
Wendy Jacintha Science, the Netherlands Julian Martinez ICONICS, USA Little Systems, India
AFLAC, Canada Johnny Sorensen Emerson Network Power,
Stanley Moses Chr. Hansen, Denmark Colombia Joel Albert Ken Lauer
Leslie Crothers Bahwan CyberTek Inc., USA Industrial Networking Middough, USA
Almac, United Kingdom John Lewis Roy Adams Solutions, USA
John Malinowski Cognex Corp., USA ERA LLC, USA George Hockett II
Rob Cotner Baldor Electric Company, Josu Bilbao Miniature Plastic Molding
Anixter, USA USA Mohbat Tharani Vikram Kumar IK4-IKerlan, Spain LLC, USA
COMSTATS Institute of EZAutomation, USA
Carl Stelling Shawn Day Technology, Pakistan John Wilson Deana Fu
Antaira Technologies, USA Henry Menke John Holmes Integrated Automation, Bryan Knight
Balluff Inc., USA Hernan Gardiazabal Festo Corp., USA Australia Mitsubishi Electric
Lonnie Purvis ContrALL, Mexico Automation, USA
Apex Manufacturing Jeremy Jones Robert L. Fischer Sudhendu Banerjee
Solutions, USA Baumer Ltd., USA Mike Cerda Fischer Technical Services, Instrumentation Ltd., India Stephen Chilton
Control M Automation, USA Monozee Ltd., United
John Coetzee Jingxu He Mexico Majid Takabi Kingdom
Aristotle Consulting, South Bayer, USA Eric Esson JGC Co., Iran
Africa Sanjay Mishra Frommelt Safety Products, Todd Desso
Mike Fahrion COTMAC Electronics Pvt. USA Tom England Eddie Lee
Sujata Tilak B&B Electronics, USA Ltd., India Kollmorgen, USA Mike Werning
Ascent Informatics Pvt. Ltd., Chris Alexander Moxa Americas, Inc.
India Eric Byres Roy Greengrass Givaudan Flavors, USA Pierre Lampron
Mike Miklot Del Monte Foods, USA KSH Solutions Inc., Canada Nelson South
Dave Robinson Belden, Inc., USA Dr. Colin Harrison Nelson South Electrical,
Aurora Industrial A. Klemptner Glasgow Caledonian Chris Weigmann Australia
Automation, USA Abdulilah Alzayyat DTE Energy, USA University, United Kingdom Lakeside Manufacturing, USA
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Kenn Anderson Mark Battisti Gilbert Brault Jim Anderson Matthew T. Seiman Charlie Norz
Nova Systems Inc., USA QPoint Robotic Solutions, Antonio Chauvet Jill Oertel Trelleborg Sealing Solutions, WAGO Corp., USA
USA Schneider Electric, France Aaron Schulke USA
Joe Sebastian SICK, USA Nathan Schiavo
Diane Trentini Dennis Sanchez Johan Hult Ed Novak Wesco, USA
Optimation Technology Inc., RECOPE, Costa Rica Schneider Electric, Sweden Tom Hoffman Trio Motion Technology, USA
USA Jeff Miller Wilfredo Jimenez
Cheng Xinping Robb Dussault Gregory Richards Pramod Parikh WJ Automation & Integration
Ben Orchard Rockwell Automation, China John Boville Siemens, USA United Phosphorus Ltd., India Corp., Puerto Rico
Opto 22, USA Schneider Electric, USA
Chris Brogli Tomaz Vidonja Fernando Jimenez Karen Leung
Scott Klages Paul Brooks Jerry Schultheis Simplysens, Slovenia Universidad de los Andes, Worleyparsons, USA
Parsec Automation Corp., Douglas Henderson Schultheis Automation Colombia
USA Jimmy Koh Control Systems Inc., USA Mark A. Erickson Erik Nieves
Amy Peters Skills Improvement Inc., USA Alejandro Pena Yaskawa Motoman Robotics,
Mark Huebner Fatime Ly Seymour Eder Mathias Universidad Distrital, USA
PBC Linear, USA Thomas Sugimoto SEW-Eurodrive, Brazil Pat Gallagher Colombia
Rockwell Automation, USA Solar Automation Inc., USA Will Zurkan
Jose Gonzalez Valero Nesko Kontic Gary Phillips Zurkan Solutions, USA
PEMEX, Mexico Mahendra Dissasekera SGS - Wind Energy Lewis Gordon URS E & C, USA
Ronan Engineering Co., USA Technology Centre, China Tangent Services, USA
Helge Hornis Bill Bobbitt
Pepperl+Fuchs, USA Sam Shorer Shamsol Shamus Peter Hook Van’s Aircraft Inc., USA
SABMiller, South Africa Shamus Technology Ent., Tech Innovations LLC, USA
Mark Buckley Malaysia Sachin Kumar
Phoenix Contact, USA Andrea Sammartino Dave Szurek Vertex Automation System
Saipem Spa, Italy Dr. Gyan Ranjan Biswal The Mackubin Group, USA (P) Ltd., India
Rahul Aggarwal Shiv Nadar University, Noida,
Prekar Services & Solutions, Steve Sarovich India Assaf Beckman Pradeep Soni
India Sardee Industries Inc., USA Tomatic, Israel VSM Venture Control System
George Pease P. Ltd., Noida, India
Rafey Shahid Show-Me Machine Works,
Qanare Engineering, Pakistan USA
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Algeria India Lithuania Saudia Arabia Greg Fairchild Stephen A. Sajewicz
Nesrine Chaouche Rajesh Keswani Genadij Nesterenko Ghulam Rasul Irene Farquhar William Schmidt
Sarang Kulkarni Spain Marty Grimes Accounties Smith
Bosnia Senthil Kumar Mexico Antonio Anton Tony Guzman Konstantyn
Bojan Djurdjevic Arunnun Loganathan Jorge Loza Miquel Vall Boladeras Daniel Hood Spasokukotskiy
Mukesh Negi Mark Huebner Joe Staples
Brazil Avinash Patil Netherlands Sri Lanka Joseph Kolo Jim Tennant
Edson Gonçalves de Oliveira Naveen Kumar Ramasamy R. Hulsebos Suren Stambo Rajendera K. Kapoor Suresh Vasan
Babu Reddy T Hindrik Koning Michael Kinziger Leonard Walsh
Canada Taiwan David Lamb Nick Wisniewski
Ed Kinakin Iraq Nigeria Jin-Mu Lin Todd LaRoche
Amer H. Rasheed Oladapo Akinbola Iyedupe Hian Yong Leong Venezuela
Guatemala USA John Nix Juan Nicolaidis
Moises Yac Ireland Norway Don Baechtel Tim O’Brien
Joe Burke Rune Saetre Jim Brastauskas Tony Olivieri
Egypt Michael Bowne Tony Paine
Mahmoud Abdel Fatah Israel Pakistan Daniel Bruno Tony Perna
Abo Ahmed Victor Zaltsman Faisal Mirzam Bruce Centofanti Friedrich Purkert
Marc Emmerke Ray Royal
Thanks as well to the many contributors who wanted to remain anonymous.
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5 Factors to Consider Before

The Industrial Internet of Things (IIoT) promises big benefits like 2. Protocols/communications: Along with the equipment, what
increased productivity, better quality products, and reduced protocols are being used by the devices in your network? How
cost of operations. Organizations should not blindly launch many are in use? Do they need to be converted in order to get
an IIoT initiative, however. Success requires more than just the devices to communicate with others in your environment?
planning for how to use data. It requires a careful assessment of What type of media (cabling) are you using in your locations?
current assets, resources, and processes in place. Fiber-optic cable? Serial (RS-232/422/485)? Copper?
Here are five issues industrial organizations should consider 3. Location/environment: Where is your facility located? If
before making any moves: your equipment is in a remote location, can your devices be
monitored via cellular networks? Are 3G or 4G/LTE networks
1. Legacy equipment: Take inventory of automation devices such available to reach your site? If not, are broadband or fiber-
as PLCs, RTUs, robots and drives. How old are they? Do they based networks available? Also, within the building itself, what
need to be replaced or upgraded? Is your legacy equipment going is the overall environment? Is it hot and dusty or kept at a
to be able to communicate with newer equipment? How much controlled temperature? Is there lots of vibration? Are you
time and money will this take? What cost-effective solutions can using industrial-grade equipment that is designed with wide
address your current infrastructure? environmental ratings and industry certifications?
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SECTION 1 Factory & Machine Automation IP67
RATED
CONTINUED 5 Factors to Consider Before
4. Security: According to a recent Business Insider Intelligence

survey, 39 percent of executive respondents indicated that
privacy and security are the most significant barriers to IoT
investment. Security was the most commonly cited concern
among respondents. Though this survey applies to all items
in IoT, security should be an important concern for IIoT as
well. How can sensitive data be protected when it is collected
and transferred? What security measures are in place for the
systems that collect, monitor, process and store IIoT data? Are
there any regulations regarding the protection of data and I/O SYSTEM FIELD
information that you need to be aware of?
A MODERN APPROACH TO
IP67 RATED DISTRIBUTED I/O
5. Staff: As more technology-based devices are added to
• Fieldbus Communications – PROFINET, EtherNet/IP, EtherCAT,
your network, do you have IT staff on hand, as well as other Modbus, IO-Link
• IIoT Protocols – MQTT, OPC UA, HTTP(S), Bluetooth
employees who are tech savvy and can help with installation • Integrated Load Management – Monitor power consumption,
set alarms, and adjust output current
and monitoring on the factory floor? Is software or remote • Ready for the Future – Made for TSN
monitoring needed to keep tabs on devices in other locations? www.wago.us/systemfield
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RFP Guidelines Help Deliver

Capital Project Excellence
Doney, expert engineer, Nestlé R&D Transversal Technology Unit.
By Sean Riley
Senior Director, Media and Industry Communications, PMMI
For CPG companies, achieving vertical startups of packaging
and processing equipment lines consistently and effectively are
Convened by PMMI, The Association for Packaging and imperative. After using the RFP guidelines and template, CPGs
Processing Technologies, the OpX Leadership Network’s new can provide the bidder with a high-level abstract of the project,
Request for Proposal (RFP) Guidelines for CPG Industry and requirements, purpose and a detailed timeline. Information such
companion template ensure complete and collaborative RFPs. as insurance requirements, technical and validation specifications,
special contract needs, site drawings and safety standards are also
The free document provides seven key steps for collaboration included in the template to assist in the RFP process.
among stakeholders in developing a robust RFP. The
accompanying RFP template is designed to help clarify The OpX Leadership Network was founded in 2011 by PMMI
project requirements and minimize costly misunderstandings. to ensure CPG companies and OEMs are well-connected and
well-prepared to solve common operational challenges, make
“The OpX Leadership Network RFP solutions enable both OEMs smarter decisions and achieve operational excellence.
and CPGs greater understanding of project requirements,
resulting in better outcomes for all stakeholders involved in the The RFP guidelines, as well as other operational solutions, are
process of specifying and executing capital projects,” says Tom available for free download at www.opxleadershipnetwork.org.
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How to Properly Select and

Vet a System Integrator
The process of finding a qualified system motion control may not have the expertise
integrator for your automation project to handle a complex SCADA project.
requires effort and attention to the
details. Experience, expertise, staff 2. Be suspicious of over-promises. If during
capabilities and financial wherewithal are negotiations and setting requirements, a
all crucial factors to consider in finding system integrator continues saying, “No
the right integrator partner. problem. That’s easy. We can do all you
want”... you can be sure that It will be a INTEGRATOR SOURCE
An excellent source for information
1. Selection criteria. Search for a system problem, it will not be so easy and It will
useful in selecting a systems
integrator who has a long list of successful be something that is more complicated integrator is the Control System
projects in the areas you are looking for. than assumed. The integrator should prove Integrators Association (CSIA). You
can search their membership by
Check out any references they provide and that he understood your requirements, expertise, state, certification, etc.,
find out how long they have been in the didn’t underestimate the project and that to find exactly the right fit for your
automation project.
field. They should also have a broad range of he has experience with similar projects. Be
products they have worked with and have especially careful if you get a much lower
enough staff to handle all the various areas price than expected or than others have HTTP://AWGO.TO/027
Organization: Control System Integrators Association
of a project. People who have done a lot of quoted.
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CONTINUED How to Properly Select and Vet a System Integrator
3. Familiarity with standards. Find with expertise and domain knowledge

out what partners the integrator in your business area. DO YOUR HOMEWORK
works with since no one can do it Extensive planning is
alone. It’s also important to see how 5. Expertise. Focus on their complete, timelines
an integrator manages a project knowledge, techniques and skills. and schedules are
determined, budgets and
and what their code library looks Make sure they have full knowledge ROI calculated and all the
like. Do they follow S88 and S95 of system engineering, as well as textbook preparations and
methodologies? They don’t need to sufficient experience to handle your considerations have been
met. What could go wrong?
follow these to the letter, but if they project. A proven track record and
Plenty! Always vet your
don’t have a methodology and aren’t references from the projects they system integrator. Get
even aware of the standards, don’t have done are essential. references, see a system
even consider them. designed and implemented by
them in use, visit their factory
6. Current experience. Prior and, most important, run
4. Comfort factor. In addition experience in your discipline is key credit checks and investigate
to reliability and professional to the selection of your Integrator. their financial health. Nothing
is more destructive than
capabilities, choose an integrator Experience keeps the integrator
having an integrator run out
you feel comfortable with, who current on new technologies and of money before the project
understands your process needs and new hardware and software. As has been completed.
who has experience in the field. The a result of the recent recession,
integrator also needs to have a staff integrators are not as abundant as
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before, with many unable to survive the economic turmoil. 8. Take a long-term view. Select an integrator with experience
Many integrators have reduced staff, minimized technology in similar systems, preferably of the same make. Tie payments
education opportunities and made other cutbacks. Take the to project milestones. Make sure his services will be available
time to assess the strengths and weaknesses of any integrator for upgrades and maintenance by signing a separate contract.
you consider to ensure that they are capable of delivering the
system that you require. 9. Problem-solvers. Choose an integrator who has experience
in the tasks you need performed. They have probably already
7. Stay involved. Has your system integrator done something solved many of the problems you may face if you choose one
similar before? Chances are the pool of talent isn’t all that whose experience is outside the necessary area of expertise.
big. Can you allocate any resources to working with that
integrator on a day-to-day basis? You will have to take 10. Ask questions. Choosing a system integrator is the hardest
ownership of the system, so you will need to know how to and easily the most overlooked part of an automation project.
modify it and maintain it or you will be tied into a system Ask questions about types of projects they’ve done, vertical
that might need unallocated cash to make changes. Get preferences and size of projects. Have them include project
involved at the zero level in the planning, simulation, detailed details, such as were they on time and on or under budget,
layout, software handling techniques and maintenance and what percentage of the time.
requirements as much as you possibly can in order to get the
biggest possible benefits and to learn in excruciating detail 11. Experience has its limits. Be aware that most integrators
how it all goes together. have experience either in a vertical industry or with a certain
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type of project, such as PLC/HMI programming. Either way, 15. Do they have business skills? Look beyond technology
they may lack the capabilities needed to do projects outside expertise or project experience to consider an integrator’s
of that experience. Many HMI/DCS vendors have a list of commercial qualifications: Are they CSIA certified? Do they
endorsed or recommended system integrators on their home have insurance? How many years have they been in business?
page. This is a good place to start.
16. Are they open? Select an integrator that is open to your
12. Smart isn’t enough. Choose an integrator as you would requests and ideas. Beware of someone that constantly
choose an employee. Spend time, talk to references and know
that while every firm out there enlists very smart engineers,
you don’t want them cutting their teeth on your project.
13. Professionalism counts. Make sure an integrator can

confidently provide you with a project plan, with decision
points, contingency plans and staffing that will meet your
timeline and project goals.
14. Test the team. Verify the integrator’s capabilities by giving

a test to the personnel who will perform the work on your
project. Make sure those people are listed in the contract,
including fallback or substitute candidates.
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pushes back. If you hear the phrase “nobody does it like that” because this is your first time. Also allow for the ability to
or “this is how everyone does it,” you might want to consider make some changes—especially if your approach is new and
another integrator that is more open minded. You are paying unconventional. Be open for changes and tweaks as you go
that integrator to get what you want and need—not just what if it makes the end result easier to use and more flexible. You
they are willing to build because it’s easy or they “always do it need to stay involved throughout the whole process. Don’t
that way.” Yes, you hired them for their experience and would pass up the learning opportunity!
like their suggestions, but don’t discount your own ideas just
DETAIL THE REQUIREMENTS

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

Make in Automation Projects
In their rush to complete an automation project, people make the kinds of strange equipment behavior later, when it’s hard to
same mistakes over and over again. This ready-fire-aim approach locate the source of the problem.
to planning and executing an automation project inevitably causes
major headaches, cost overruns and delayed schedules. 3. Start with the integrator. Don’t select and buy equipment
based on a specific vendor’s recommendations, then hire an
1. Don’t limit input. The most common mistake is limiting the integrator to get it to work. Instead, hire the integrator to
initial input to too few people. Many managers are surprised do the design and program and start up the system. In the
when they hear an insight from a person in their plant. It’s end, it will not cost more. Time spent in the field getting a
much easier, and less expensive, to build that insight into the mix of components to work together is extremely inefficient
project planning from the start. vs. implementing a system with devices that are designed to
work together. An experienced system integrator inherently
2. Never assume. Mistakes are most often made during the designs a system to perform to a customer’s requirements
definition phase, when you think that everything will be while minimizing the time it takes the integrator to deliver it.
easy to do—motors just need to move from point A to B
with synchronized speed, for example, and then during the 4. Copy and paste. People don’t make mistakes when
installation phase, when signal cables are routed together with planning automation projects; the mistakes are planned in.
power cables and shielding is simply forgotten. This causes all This is because most machines are sold before they are fully
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CONTINUED 23 Common Mistakes People Make in Automation Projects
developed and rely on the experience of previous projects using a copy

and paste approach to get them completed on time. The consequence of Seven Automation Don’ts
this common strategy is that you automatically give up the perfect solution
1. Don’t over-complicate the solution.
for one that is good enough. The tragedy is that, with careful accounting,
Keep the solution simple.
the differential between a white sheet design (starting with a new platform
2. Don’t program the machine first. Always
that commonly comes with an “App Store”) is much quicker than the copy/
program or storyboard the HMI first.
paste/mop strategy. It also retains more customers because the adoption
3. Don’t neglect the communication
curve is much quicker for machines with more “canned” features.
protocols and interface terminals when
evaluating control products.
5. Failure to communicate. One of the most common mistakes is not
4. Don’t waste too much time planning
communicating with the end user and technical staff. If a machine does without customer input. That could cause
not make their work easier, they will find a way to make your system do critical planning errors that will need to be
what they want even if it causes other problems. If you do not consider corrected at heavy expense and effort.
the technical staff, the repairs or adjustments will be met with resentment 5. Don’t forget the grounding.
and most likely extended downtime. 6. Don’t propose a project without a good
understanding of the requirements. That
6. Handshakes critical. Not paying attention to handshaking signals and guarantees scope creep.
improper use of I/O handling can cause serious damage to equipment, 7. Don’t always believe what salesmen tell
eventually causing more downtime. When two machines need to work you. Do your homework and make your
own decisions for your application.
together, it is critical to use appropriate handshaking signals to avoid any
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cell or machine damage. Bypassing safety is another cause for updated. That includes operators, technicians and production
problems. Design cells so workers cannot bypass safety measures. management. People might disagree on what has been
accomplished and what still needs to be done.
7. Experts inside. In-house expertise is essential to the
success of any project. Integrators build good machines 10. Can a machine do the job? If the automation project is
and systems, but when they are deployed in the plant based on replacing labor, you will first need to understand
environment, it’s the in-house expertise that turns a good the totality of what is being done manually. You may need to
system into a great system. go back to the drawing board if a machine cannot do what an
operator has been doing.
8. Plan for changes. When designing, or budgeting for
automation projects, usually there is a clear goal or list of 11. Limit program access. Always run an information session after
things that need to happen. But you also need to plan for the commissioning to familiarize all personnel who may be involved
unforeseen. Something will always come up later on that will with set-point changes, principles of operation, etc., and use
need to be added. To cover this, always add 20 percent to the password protection to allow set-point changes only within a
overall project budget. Also, additional checks or sensors may specified range. Never allow full access to program changes.
be needed down the line, so make sure you have extra I/O or
at least the flexibility to expand the I/O if needed. 12. Forbid coding from Day 1. Automation engineers love to
puzzle with the problems they get on their table. Forbid any
9. Do a punch list. After initial implementation, get agreement use of coding software until the entire scope is clear and
from everybody on the punch list of items that need to be closed, the delivery has been broken down to manageable
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pieces (Work Breakdown Structure) and • Operator requirements not considered

everybody knows what the tasks and when designing HMI screens due to lack TIME MATTERS
targets are ahead of them. Also, make of industry experience. Time management: The project
sure that the tasks and the targets are should follow a scheduled
timeline. Sometimes people
properly documented before letting • Audio alarms not considered for all alarm
procrastinate and time runs fast.
the engineers loose on the coding tasks, alerts. Using only visual alarms flashing on
Cycle time: Sometimes people
because to have them document it screen is inadequate.
don’t consider the required
afterwards involves twisting their arms to cycle time for machine
make them do it. Diving right into detailed • Operators not trained for the PLC/DCS functions when they make
problem solving and coding is the fastest screen operation and its features. changes to the system. At the
end of the project the machine
way to failure in an automation project.
cycle times becomes very slow,
• Neglecting to simulate as much of the which causes low production
13. More mistakes. complete system as possible before it rates and loss of a lot of money.
• Not rationalizing alarms or adequately goes to the customer. Troubleshooting time:
defining the alarm management system. Some people working on a
project don’t care about the
• Failure to include the customer in
complexity of machines. The
• Poor selection of field instruments, system demonstrations and at each stage engineer should design the
such as using a mass flow meter for slurry in development. whole system in a way that
instead of a magnetic flow meter for others can easily understand.
conductive liquids.
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• Selecting low-cost components to meet a budget. 16. Avoid complexity. You’ll make life complicated by
introducing complexity into the operation, so that what’s
• Errors in lead-time calculations. implemented at the site is not what was conceived of in the
design. Many times simplicity is ignored when designing
14. Will it save money? Being able to automate a process controls. What may be friendly to one smart operator can’t
often leads to the mistaken belief that it will result in a less be generalized for all operators. Refrain from tailoring the
expensive process or product being made. This is frequently controls too much. Suggest cost-effective and competitive
due to a poorly executed cost/benefit analysis. solutions when they already exist.
15. Vendor cautions. Vendors can be great resources but 17. Garbage in, garbage out. People tend to assume that the
they are poor manufacturers. They often lack a complete person coming in to do the automation work will just pick up
understanding of all the factors involved, not only the on what is being done at the plant and how things work. Good
installation of the project but the operation, repair and user and system requirements are a must for any project.
maintenance of the project. The vendor is a servant, not an The final automation system will only be as good as what you
executive. Research vendors carefully and talk to others who ask for in the requirements document. Without well-defined
have used the vendor. Caution is particularly called for if you objectives, you will get scope creep.
are designing or in charge of a project where some of the
technology, software or application use are unfamiliar or new. 18. Document everything. A small change requested by the
customer often leads to other changes that are much more
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costly. If you don’t have paperwork showing the requested of functionalities, in a limited and controlled part of the
change and costs, it will be difficult to bill for the work. production process. As soon as possible, do a trial using real
data. Don’t design a system that, if it fails, would completely
19. Consider more than cost. Too many companies allow stop or seriously impact the production process.
dollars to determine what types of equipment to install. They
also fail to find out whether local support for the equipment 22. Plan for maintenance. We should not install anything if we
will be available. You must be able to source both hardware have not planned properly for maintenance. Proper system
and software within a time frame that suits the client. maintenance is a must.
20. K.I.S.S. Some programmers go far above and beyond the 23. Listen to the experts. Among the most common
necessary when it comes to programming. Try to keep in mind the problems, from a manufacturer’s perspective, are:
individual at the factory level who has to support this system after
the integrator is gone. They do not see high-level programming • Failure to ask for help early.
on a regular basis and will struggle mightily at trying to decipher
logic that is much more complicated than it ever needs to be. • Not following manufacturers’ suggestions.
While there are times when complex programming and high
level functionality are called for, most projects need to apply the • Not investing at least a minimum amount of time in training.
K.I.S.S. rule when the system is being developed.
• Making assumptions that turn out to be wrong, and thus
21. Start small. The best way to ensure long-term success ultimately wasting a lot of time.
is to think (plan) big, but start small with a limited number
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CONTINUED 23 Common Mistakes People

S THE
Make in Automation Projects THING
PREROSUP2PLY
POW
T DO:
CANNO
NO SHORTCUTS
There are no shortcuts in automation projects. To estimate
time and costs for a project requires seriously taking into
account the skill levels and experiences of employees.
The hardware design is usually the easy part. Software
specification, programming, testing and, commissioning
are much more difficult tasks to estimate. If the available
employees for the projects are not familiar with the
process, the time to develop and implement a reliable
DOESN’T SING
control and automation system can easily double or
triple from the estimate. Committing to a fixed cost
KARAOKE –
commissioning of a complex automation project usually BUT SPEAKS
ends up in a serious monetary loss. As most automation
projects require well-functioning mechanical equipment, MODBUS, IO-LINK
issues with the mechanical equipment and with production
demands will eventually extend the duration of fieldwork.
OR EtherNet/IP!
Discover how an intelligent and communicative power supply can
maximize factory up-time.
www.wago.com/us/communication-pro2
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Key Factors to Consider in Deciding

Among PLCs, PCs or PACs
The controller acts as the brains of your system. It’s no ladder logic, which is familiar to many maintenance techs.
exaggeration to say that it is the most important element PACs are also designed to deliver a combination of high
of the system. If you don’t get the controls right, you might levels of functionality with ease of integration. In contrast,
as well stop right there. It begins with selecting the right PC-based controllers involve a significant amount of
platform. The points below walk you through the process. customization. Before going down this route, consider
whether you have the in-house expertise to support it.
1. How important is cost? If cost is a factor, consider a PC- Remember, if existing staff leaves, you will need to be able
based controller. They are often cheaper than their PLC to find replacements.
counterparts. Some of the reasons for this cost difference
can attributed to supplier pricing, but it’s also due to the costs 3. How unusual is your application? All things being equal,
associated with the ruggedized factors common to PLCs. it is generally easier to customize a PC-based controller
to handle an atypical application than it is to customize
2. What is the skill set of your staff? In general, the PLC a PLC. Developers can choose their functionalities, their
is a mature solution, which makes it relatively easy to find languages, and they can even work with a non-Windows
a knowledgeable controls engineer with experience on operating system.
any given device. Many PLCs, particularly in the US, use
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CONTINUED Key Factors to Consider in Deciding Among PLCs, PCs or PACs
4. How complex is your application? PLCs excel at operations like

managing I/O, counting, and timing. They can handle limited motion ARE MICRO
control but their updates are too slow for more sophisticated motion. For PLCS AN OPTION?
machines with highly synchronized motion and higher axes counts, such Micro PLCs with flexible, “just enough”
as packaging machines, consider adding a dedicated motion controller control may enable OEMs to differentiate
their equipment, particularly in stand-alone
to the PLC. For larger, more complex systems like packaging lines, a
machines. By developing a range of stand-
programmable automation controller might be the best solution. alone machines using the same controller
platform, OEMs can reduce design time and
5. How harsh is your environment? Decades have gone into lower their costs. Look for micro PLCs that
include:
ruggedizing PLCs for the industrial environment. They can be
expected to last for 10 or 20 years. The new generation of purpose- • Flexible hardware configurations, like
USB, up to six serial ports and Ethernet for
built industrial PCs has made PC-based controllers tougher than ever, communications.
but the harshest environments still call for PLCs.
• Up to three axes of embedded motion.
6. Do you need flexibility? PC-based controllers not only lend themselves • Plug-ins and 2085 expansion for I/O USB.
to customization, they support it over the lifetime of the equipment. • Single programming software package
that eases installation, configuration,
connectivity and maintenance.
7. Got the need for speed? In general, a PC-based controller will be
faster than a PLC.
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CONTINUED Key Factors to Consider in Deciding Among PLCs, PCs or PACs
8. What about the future? The increasing

integration of IT and operations technology
has begun making PC-based control
more appealing. A PC’s ability to interact
with another PC—and other information
technologies in general—makes it more
adaptable for the various IT and operations
linkages we’re seeing more of these days.
A PLC can, of course, be used in much the
same manner as a PC-based controller, but
gateways, switches and/or servers are often
needed as an intermediary connection step. It’s
worth considering also that the engineers and
technicians now leaving school are more likely
to have skill sets compatible with PCs and PLCs.
As your workforce transitions, you may find
PC-based control and more appropriate choice.
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12 Guidelines for Selecting

Motors and Drives
Motors and drives are two of the foundation components of any characteristics is fully enclosed by the diagram of the motor
automated system. Here are a few tips and best practices for characteristics, the motor is adequate.
choosing a motor and drive that will get the job done:
3. Think system. When doing an equipment upgrade, think of the
1. Accurately size motors… All too often, the rule of thumb drive train as an integrated system and choose components with
is to start with the previous motors and add a cushion. Over similar efficiency ratings. It makes no sense to couple a high-
several generations of a platform, this leads to well oversized efficiency pump to an inefficient worm gear. The motor used to
motors. Most motion control manufacturers now feature drive the load could be half the horsepower with a more efficient
motor sizing calculators on their websites. Just gather some gear reducer because of the reduced energy losses.
information about your application and use the software to
determine the motor you need. 4. Match firmware. When changing a drive, make sure the
firmware of the drive or motion controller matches the one
2. …or at least use the speed-torque diagram. Selecting a you are replacing.
motor needs a bit more than just calculating the maximum
rotational speed and torque. The useful way to assess a motor 5. Go for intelligence. When you want to improve uptime,
is by drawing a speed-torque diagram of the load and the think about replacing standard IEC electromechanical motor
maximal allowed speed-torque diagram of the motor (as starters with an intelligent overload with a hybrid contactor.
defined for continuous operation). If the diagram of the load Now you have the best of both worlds—a programmable,
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CONTINUED 12 Guidelines for Selecting Motors and Drives
intelligent overload that has motor load feedback (alarm back 8. Beat dust with magnetic coupling. For variable-speed control
to operator as well as shutdown parameters) with a hybrid of rotating equipment, such as drives for an agitator motor or
contactor. The hybrid contactor extends the time between a chiller compressor, take special care to place the drive in a
end-of-life motor switching by a factor of 10. The intelligent hardware panel installed in a dust-free location, preferably air-
overload will remain in service indefinitely. conditioned. A better solution for harsh environments that have
maintenance people with minimum skills might be a magnetically
6. Consider VFDs. Instead of operating an AC induction motor coupled drive with variable-speed option. Magnetically coupled
at top speed and adjusting the speed of the load mechanically, drives have the advantage of decoupling vibration and potential
for example with a control valve, consider a variable- overloading of the motor or driven equipment due to the air gap
frequency drive (VFD). It will save energy and prolong the between the motor shaft and the other shaft, which can reduce
lifetime of the motor. It will also eliminate the need for a costly damage to mechanical seals.
valve, reducing costs, points of failure, and maintenance.
Examples include include pumps, fans, and blowers. 9. Focus on economical sparing. Avoid the temptation to size a
motor separately for each axis. Try to standardize motors and
7. Do your homework. Always check for the proper rating drives around a few sizes. This will minimize your spares inventory.
and proper type of drives or motors for different type of Also, instead of stocking multiple spare cards for the drive, keep
application. Ask the supplier about the fail-safe function of one spare module. This will be an economical solution.
the system and always check for proper grounding of the
system. Make sure you inform the supplier about the features 10. Avoid common drive pitfalls. The reliability of the core
you want and the process to be controlled. components, such as the PLC or a variable frequency drive, in a
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CONTINUED 12 Guidelines for Selecting Motors and Drives
control system is important. Drive failure may be caused by

many factors: PCB calibrating, IC chip failure, mishandling
during installation, operating environment, etc. Even
though the manuals of some drives claim that using certain
technologies, such as MOV, common-mode choke, common-
mode capacity and others, can make the drive more EMI
compatible, it can also make them easier to damage.
11. Try manual mode. The manual mode, which allows maintenance
to check if one specific motor has a problem or not, is usually
forgotten. If the motor will not run correctly, put the drive into
manual and run the motor for a short time. This eliminates the
drive from the problem and points to the controller or, if local
control does not work, the drive could be suspect.
12. Aim for good housekeeping. Keep motors and drives clean
and free of foreign contaminants to keep them running for a
long period of time. Don’t use the cord as a leash when you are
carrying the motor around.
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Top Considerations for Selecting

and Deploying Industrial Robots
As manufacturers embrace the business case for reach into the cell while the robot is in full motion. Make
implementing robots, engineers are challenged to design sure all cell doors have safety interlocks and light curtains as
systems using today’s highly complex and increasingly needed, and make sure you make the robot aware of these
sophisticated robot technology. safety devices so it can do the job better. When it comes to
designing your robot cell (electrical and mechanical layout) and
1. Redefining robots. Too much focus on humanoid robotics is a programming, always consider safety as your top most priority.
misplaced definition of objectives. A robot is really a modular, This aspect is even more important given all the codes and
autonomous platform combining measuring circuits, active regulations for robotic safety. For more information on new
RFID, RF, acoustic, laser and power technologies for in-situ data safety requirements, visit http://awgo.to/026.
processing and real-time communication. Distributed architectures
with this type of robot are revolutionizing industrial automation. 4. Complexity can be barrier. When implementing robotics,
engineers need to ensure the system is scalable, will mitigate
2. Don’t fight the laws of physics. Adjust your expectations to safety and security risks, and has built-in energy management.
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
3. Safety first. Pay attention to the cell layout from the discrete and process automation systems deliver operating
operator’s perspective. Fence the area so the operator cannot data. Unfortunately, the complexity of the design process can
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CONTINUED Top Considerations for Selecting and Deploying Industrial Robots
often be a barrier to achieving the cost savings and efficiency your application so that tooling does not damage in-order
gains expected with robots. production parts. Selecting a well thought-out end effector
will also help minimize the teach time on the final program
5. Tooling clearance. It is very important to have a clear, to ensure the proper clearance to run the robot at the
defined understanding of the type of end effector for maximum speed.
TIPS FOR ROBOTICS INTEGRATION

Whether you’re looking to integrate robotics into existing 2. Use a single network technology and a common control and
equipment or scale your control and information platform visualization environment. A networked approach integrates the
to accommodate robots, here are some general tips on the robot control system with the machine control system. This is the
three primary options: most cost-effective solution for quickly integrating robotics into an
existing application. Doing so gives the machine’s controller access
1. Use a single control platform that can be scaled to fit a wide
to the robot’s control system, including diagnostics, necessary
range of robotics applications, regardless of size or complexity.
automation interlocks, troubleshooting, alarming and reporting.
This method allows the highest level of integration because it
combines kinematic robot control within a machine’s controller. 3. Use a common control engine and development environment
All configuration, programming, kinematics, troubleshooting and to help eliminate the need for separate controllers and systems.
operations are performed within a single control platform, which This embedded approach to robotics integration brings the
helps reduce engineering costs, training, maintenance and the robot module directly into the control platform’s chassis. It
overall machine footprint. keeps machine and robot control separate, but helps drastically
reduce the machine footprint—by up to 50 percent—because
there are fewer control boxes on a machine.
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CONTINUED Top Considerations for Selecting and Deploying Industrial Robots
6. Plan for maintenance. For large issues. You may find that there is
robots, make sure means for more going on in the existing process MECHATRONICS FOR OEMS
maintenance are included in the than you knew about and that micro- The perception of robots in the
original project scope. A monorail management is necessary. industrial workplace follows a form
hoist designed in at the start of factor that leads users towards a limited
amount of mechanical models. This
the project, for example, is much 8. Zoning for product size. In a
feels modular, but it’s not mechatronic.
cheaper and easier to install than robotic pick-and-place system for Changing the definition of robotics
one built years later. Installing a hoist thermoformed packaging trays, to coordinated axes synchronized
while running requires scheduling, incorporate zoned suction cups that by a single software and processor
opens up conventional machine design
downtime, lost production, etc. can be isolated or turned on and off, to modular code and mechanisms—
Installing a hoist during emergency to allow for various tray sizes. or mechatronics. OEMs that have
maintenance never happens, and adopted this new outlook make robotic
machines that are faster, smoother
temporary, sub-optimal, rigging ends 9. Electronic changeovers.
and more flexible, not by changing
up hurriedly being used. Customization is only a fraction their mechanics but by changing their
of the normal line production, but approach. The choice for OEMs is even
7. Get early feedback. Try and do as the ability to create electronic easier because they need only migrate
their control philosophy to those
detailed a simulation as early as you changeovers between formats in capable of true mechatronics.
can and show it to the workforce a small footprint streamlines the
involved in the process in order to customization process.
get feedback on possible operational
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Mastering challenges.
Opening communication channels.
Redefining flexibility.
R10x and R20x Series
CONTINUED Top Considerations for
Selecting and Deploying
All photoelectric sensing modes in standard
housing styles for maximum flexibility and more
integration possibilities
Industrial Robots Simple installation and setup with one user
interface for all housing styles and sensing modes
IO-Link and Smart Sensor Profile in every sensor:
standardized communication down to the sensor
10. Error codes. When you are programming a robot, many level as the basis for Sensorik4.0®
lines of code are involved. If you build in your own error
www.pepperl-fuchs.com/pr-rx
codes in the program, it is easier to identify where in the
program the error has occurred and to diagnose the issue.
If it is a new issue, add it to the list of your error programs.
11. Faster remastering. For a robotic cell, design in a

location datum point into the cell. Having an independent
datum point outside of the usual work area (still within the
robot work envelop) will allow quick remastering of an axis
or robot following maintenance. This is critical for users of
just a few robots, who don’t typically have a lot of robot
axis mastering experience. Witness marks on joints can
fall off, and having an independent means to establish the
coordinate system is a major time saver.
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Best Practices for Implementing

Industrial Ethernet
Ethernet is everywhere on the factory floor, but standards for widely distributed network compared to many other fieldbus
dealing with it may be lacking. Here are some suggestions for networks. Classless IP address scheming is important here.
updating your practices: VLAN technology makes it easy to manage traffic. For a
large plant floor, different areas can be zoned for control and
1. Need industrial IT strategy. With the rapid growth of industrial monitored independently. Industrial Ethernet can make media
Ethernet devices, the lack of an industrial IT strategy at many redundancy very flexible, and the convergence time is very
companies is becoming a real problem. It’s not uncommon short, often milliseconds with Resilient Ethernet Protocol
to have thousands of Ethernet devices on the plant floor, but (REP) and Device Level Ring (DLR).
strategies for data management, security, redundancy, reliability,
etc., are often seriously lacking. Start with a basic industrial 3. Maintain standard Ethernet frames. Ethernet is the
networking standards document, just as you have an electrical, future of real-time and long-distance industrial networking.
controls or HMI strategy. Simple rules for implementing Ethernet It is being adopted for many aspects of automation,
networks (wired or wireless) save many problems down the road including controls and I/Os, servos, safety, configuration
and support easy expansion in the future. and diagnostics, synchronization and motion. To realize the
benefits of these technologies, however, requires a good
2. Ethernet is fast, flexible. One of the many benefits of integration of standard Ethernet frames when selecting an
industrial Ethernet is that it can be used to build a very large, industrial Ethernet technology. Users mainly select industrial
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CONTINUED Best Practices for Implementing Industrial Ethernet
Ethernet because they want to fully benefit from Ethernet 7. Speed issues. It is important to understand that the
and its higher-level functionality, such as web server, operating frequency of the core switches will determine the
diagnostic, firmware upgrade, etc. speed (throughput) of your network. Educate yourself on
switch and network compatibility issues. Your network is only
4. Learn Ethernet. Take the time to learn (through courses or as fast as the weakest link. Just because you’re using Cat.
self-taught) the art of Ethernet networking. It’s never going 6 patch cables doesn’t mean that your permanent cable or
to go away. If you can seamlessly work through VPNs, port connector is rated for 6.
forward, subnet masks and IP addresses, your job is only going
to become more interesting. 8. Network slowdowns. Most network audits revolve around a
slow or degrading network as new devices are added. The lack
5. Get ready for connectivity. It makes sense to implement of fundamental understanding of Ethernet architectures is the
all PLCs on Ethernet using protocol converters. This makes most common cause of these issues. Prior to deployment of an
your plant ready with data available on Ethernet for future Ethernet-based control system, spend time understanding the
connectivity with MES/ERP systems. data impact of additional devices. It’s also essential to spend
time training staff on Ethernet and associated protocols.
6. Choose fiber. For Ethernet networks, be proactive
about choosing fiber over copper for primary connections.
Distance capabilities, noise immunity and immensely scalable
bandwidth will pay off quickly.
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Guidelines for Using

HTTP and MQTT Protocols
The process of harvesting value from an IIoT project begins 1. Use HTTP to gather data in limited amounts. HTTP can be
with exchanging data between nodes on the network. effective for poll-response uses that involve connecting an
Multiple protocols exist to accomplish this step. Two of the application to a device, like a supervisory control and data
most common are hypertext transfer protocol (HTTP) and acquisition (SCADA) system polling a flow computer for flow-
Message Queuing Telemetry Transport (MQTT). HTTP is a rate data.
client-server protocol used to enable clients to request data
from a server and for the server to satisfy those requests. 2. Choose HTTP for flexibility. HTTP provides a transport, but
MQTT is a publish/subscribe protocol designed for SCADA doesn’t define the presentation of the data. As such, HTTP
and remote networks. Developed in 1998 for a Phillips requests can contain HTML, JavaScript, JavaScript Object
66 pipeline project, MQTT is a bi-directional, lightweight Notation (JSON), XML, and so forth. In most cases, IoT is
event- and message-oriented transport that allows devices standardizing around JSON over HTTP. JSON is similar to
to communicate efficiently across constrained networks to XML—without all the overhead and schema validation—making
backend systems. it more lightweight and flexible. JSON is also supported by
most tools and programming languages.
Many IoT platforms support HTTP and MQTT as their first two
inbound protocols for data. Here, we present key points to 3. Understand the strengths of MQTT. Like HTTP, MQTT’s
consider when choosing and implementing a protocol. payload is application-specific, and most implementations use
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CONTINUED Guidelines for Using HTTP and MQTT Protocols
a custom JSON or binary format. MQTT isn’t as widely used plate calibration coefficients might be useful from a SCADA
as HTTP, but it still has a large market share in IT. There are or manufacturing execution systems (MES) standpoint.
many open source clients/producers, brokers, projects and Because operations is already polling that device for the
examples in every language. flow rate data, however, adding more polls will not only be
complex, it will also upset the plant-floor polling cycle.
4. Know the sweet spots. Use HTTP for sending chunks of
data, like one-minute temperature readings every hour. Don’t MQTT helps prevent polling problems by having the
use HTTP for streaming high-velocity data. HTTP can do plant floor device transmit all its data to an MQTT server
sub-second data, but 100-ms updates over HTTP are difficult. on a constant, real-time basis. Then you connect your
It has a lot of overhead per message, so streaming small applications—as many as you want—to the MQTT server. You
messages is inefficient. can access whatever data you need from the device without
connecting directly to the device itself, thereby avoiding any
Use MQTT when bandwidth is at a premium and you don’t know effect on its operation.
your infrastructure. It focuses on minimal overhead (2- byte
header) and reliable communications. It’s also very simple. 6. Get in a state. Unlike HTTP, which is stateless, MQTT has state.
That makes it well-suited for use in a control system environment.
5. Avoid polling problems with MQTT. That flow computer
doesn’t just generate flow rate data. Other information from 7. Keep it protected. Always secure HTTP communications
that device such as end-of-batch tickets, audit trails, orifice- using HTTPS.
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CONTINUED Guidelines for Using HTTP

and MQTT Protocols
8. Build your infrastructure. If you are using MQTT, make sure you
or your vendor have an MQTT broker you can publish data to—and
always secure communication via Transport Layer Security (TLS). Filling the labor gap.
9. Be aware of interoperability issues. Just because two products One cobot
support HTTP/REST/JSON doesn’t mean they’ll work together at a time.
out of the box. Often the JSON formats are different and require
minimal integration to get things working. Similarly, just because two
As the manufacturing industry restarts, are you struggling to maintain social
applications support MQTT doesn’t mean they are interoperable. distancing? Perhaps you’re spreading employees across multiple shifts, leaving
gaps in your operation? Time to consider collaborative automation to fill those
labor gaps while improving productivity.
10. Leverage open-source tools. Does the end application not Quick and easy to program, cobots are less than half the cost of traditional industrial
support MQTT? If so, there are a lot of open source tools for robots, and handle a wide range of tasks, including machine tending, assembly,
packaging and palletizing.
getting MQTT data into databases and other formats like HTTP.
Request a cobot demo today!
As with most things in engineering, there is no one best solution.
Call 844-462-6268 or
Consider the features of the two protocols and weigh them us.marketing@universal-robots.com
against the needs of your application. Don’t forget to take into www.universal-robots.com
account the skill sets of your staff and your levels of vendor
support. You will need to build a system that will serve your
needs over the long term.
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7 Safety Functions
That Can Save You Money
There was a time safety meant electromechanical relays 1. Safe Torque Off (STO): Removes power to the motor but
that cut power to the equipment anytime an operator hit leaves the drive energized. This puts the equipment in a safe
the e- stop button. Although this was effective, it was hard state while making it faster and easier to restart.
on equipment and often more extreme than circumstances
warranted. Frequent stops cause premature failure in the 2. Safe Stop 1 (SS1): This controlled stop enables equipment
safety relays. Restarting equipment added delays and to be slowed before STO is invoked. It is an active braking
extended costly downtime. operation that can safely and more effectively stop equipment
with high kinetic energy.
Today, the modern crop of safety standards such as EN/
IEC 62061, EN/ISO 13849-1 and IEC61800-5-2 enable 3. Safe Operating Stop (SOS): Drive holds motor in a static
equipment to invoke safe states as defined by the function position to within a certain tolerance defined for the drive.
of the system. This functional safety is implemented by Torque to the motor is not removed; the motor is just held to
safety-enabled drives and PLCs. Functional safety makes it zero speed.
possible to protect workers and equipment while minimizing
the impact of those measures on operating costs and 4. Safe Stop 2 (SS2): Controlled braking ramp, once again,
productivity. Here are a few of the key safety functions that suitable for equipment with high kinetic energy. SS2 is
you should know about: typically followed by SOS, rather than STO.
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CONTINUED Seven Safety Functions That Can Save You Money
5. Safe Brake Control (SBC): Controls an external holding

brake in conjunction with safety drive. Typically applied to
loads on vertical axes.
6. Safely Limited Speed (SLS): Sets a maximum speed at

which the drive can run the motor. Useful for protecting
operators when they are working in close proximity to
equipment. It enables them to use the power of the motor to
assist them in clearing jams without placing them at risk.
7. Safe Direction (SDI): Restricts drive signal so that motion

takes place in a single direction. This can enable operations
involving workers to take place at higher speeds, for example
pulling a gripper away from the operator at full speed because
the direction of motion does not present a risk. It can also be
used for maintenance operations like cleaning rollers. These
can be conducted as clean-and-jog procedures but with SLS
and SDI, the rollers can be commanded to rotate away from
the operator at a low speed to enable continuous cleaning.
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22 Ways to Get the Most Out of OEE

and Lean Manufacturing Disciplines
Overall equipment effectiveness (OEE) and lean 2. Stakeholder input. Lean manufacturing is critical in today’s
manufacturing have won many converts. These two disciplines global economy because it helps you drive your output
are frequently linked because they provide a systematic way (product efficiency) higher while maintaining low defects
to design manufacturing processes, measure their efficiency and rework, thereby increasing throughput in quality. Before
and identify problems. Here are some tactics to get the most building a lean cell, talk to your operators, quality people,
out of your lean and OEE initiatives: manufacturing engineers and process engineers. Get their
input, hold meetings and keep them in the loop throughout
1. Accessing data. One of the great challenges when executing the project. They are the main stakeholders who will
a project to gather and report OEE metrics is easy access eventually approve of your cell.
to manufacturing equipment status. The obstacles may
include islands of automation or even equipment that’s not 3. Lean management. Lean manufacturing is a powerful
automated. Don’t expect that all equipment information is concept when employed correctly. The problem is that with
available via existing automation systems. Be prepared to lean, along with other methodologies, one size does not
install simple data acquisition systems to gather the necessary fit all. Managers can get caught up in how it improved this
data to track OEE. company or industry, and then try to implement it internally.
What they fail to do is penetrate the details of why it
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CONTINUED 22 Ways to Get the Most Out of OEE and Lean Manufacturing Disciplines
worked, what support structure is required and how that OEE (availability multiplied by performance and quality) for
translates to their internal business. Lean is as much about determining resource utilization.
management engagement in daily operations as it is about
the methodology. 6. Increase uptime. Lean manufacturing is a very important
factor in a production plant. Just by placing materials at the
4. Measure the right things. Nothing is worse than the wrong point of use within the production floor area, you can increase
input. OEE is not always a KPI metric in batch operations. If you production uptime. This is just one small adjustment that will
speed up the drying process, for example, the OEE goes down, fine-tune the flow of your product.
but you will be making more product in a shorter period of time.
7. Too lean? If you operate with vendors that are stationed in
5. Visual management. Visual management, including large areas with a high potential for natural disasters, think carefully
display screens on the factory floor, are an effective tool about being too lean with your supplies. You’ll need to plan
for OEE programs, letting both managers and workers for alternative routes and suppliers. Another area that has to
easily monitor the metrics of production lines and track be monitored is the amount of time for production to meet
KPIs. Displays harness natural human competitiveness. In customer need. Sometimes manufacturing is too lean and
one experience, once data was displayed it started a race when there’s a sudden demand, the slow ramp to manufacture
between shifts to drive up OEE. Without any management can cost more money than producing stock.
intervention there was a 20 percent increase in productivity.
Among the most useful KPIs to display: count (good or bad), 8. Business support. Make sure the business has adopted
reject ratio, operating speeds, takt (cycle) time, downtime and and fully understands OEE. This can be a huge change
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management nightmare if not well-entrenched prior to 11. Software less important. Software selection plays only a small
the project (or as part of the project execution). Lean part in the OEE process, but that is where customers spend the
manufacturing can also be applied to service disciplines, most time upfront. Operator involvement, the quality of the
not just product manufacturing, mostly with only minor integration partner and the ability of the controls hardware to
adaptations. Look to these techniques and principles to collect data are what truly make an OEE project successful.
streamline your own processes and eliminate waste.
12. Efficiency tool. OEE has to be automated to be successful.
9. Meaningful reports. Data capture is quite easy. Reporting The data needs to be driven from machine status, not humans
the data in a manner that helps implement change can inputting the status. Any manually derived OEE system can be
be challenging. Don’t assume a single report is sufficient. fiddled with to produce the expected 85 percent efficiency rate.
Different users need different data. And that data must be Improving systems and automating OEE measurements may
presented to each user in a manner that is meaningful. bring into question the accuracy of historical OEE data. To avoid
internal politics, put an amnesty in place and promote automated
10. Improvement tool. OEE can be a very valuable tool to identify data as a new way of measuring OEE. On the other hand, the
problems within a process. Ensure that everyone understands only reason to use OEE is to help drive an improvement process
what the three elements are that make up OEE: availability, to increase operational efficiency. If that isn’t a widely embraced
speed and quality, and how to calculate each. Once processes are priority, then save yourself lots of time, money and effort.
stabilized, use OEE to drive improvement.
13. Improving uptime. OEE can help you identify opportunities
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to improve your total uptime. First, understand the categories with other systems, such as OPC Server or databases. Avoid
that OEE represents. Next, determine what things you want the use of products that operate in a closed system and do
to track and how specific you want to be. There isn’t a set not provide a ready means to share data.
rule as to what that may be. An example may be that under
your performance efficiency category, you list specific pieces 15. Build on current infrastructure. Do not get over
of equipment in an assembly line to track. By breaking down complicated right from the start. Pick a system that leverages
your categories you will have better opportunities to make your existing automation infrastructure, and can be expanded
improvements. The last hurdle is how to capture the data used and built upon as your needs change in the future. Do one
to calculate OEE. Keep it simple and train your people in how machine, or one line, or one department, then refine it so that
to capture the data you need, what it is and why it’s important. operations, production, and maintenance all have the types of
information they need, then roll out to other areas.
14. Sharing data. Information is fundamental to making good
business decisions. However, the information must be precise 16. Maintain balance. Lean manufacturing sounds great
and the amount manageable, not overwhelming. When to accountants and plant managers, but the upshot of
installing or defining automation products in a production the theory can be destructive if not enough product
line, it is their capacity to share data across the enterprise is produced or the lean process creates inefficiency.
that is important. One of the major causes of failure when Remember, there has to be a balance.
implementing an OEE project is the infrastructure of the
automation and inspection controllers (PLC, vision system, 17. Make Lean work. Lean manufacturing is all about
etc. ). Vision systems must be able to communicate openly how an organization can reduce scrap and waste in the
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production process. Evaluate your flow process, such as most companies, make Ethernet the most appropriate choice.
where product is placed before the production area or how Avoid devices that use only serial connections (RS-232, RS-
the product is transferred to and from the assembly line. 485) or proprietary connections. Try to select one industrial
If your production line stops as a result of parts that are protocol based on Ethernet. Even though there are some
not properly staged on the line, you have a product flow protocol converters and gateways that allow the conversion
problem. This becomes a bullet point in making Lean work between protocols, try to select a protocol that is compatible
in you plant and should be addressed. with most of your existing devices. Establish a long-range
standard where all your future automation equipment must
18. Select a champion. When implementing these projects, be compatible with the selected protocol. In this way, your
make sure there is an official project champion who is very infrastructure will provide the correct framework where your
senior in the implementing organization and can be the bridge OEE project can be easily implemented.
between staff and management. The champion will need to
drive the changes that will be needed to business processes to 20. Win over minds. The first place to start with OEE is not in
achieve a successful project. the machines, but in the minds of the individuals that the OEE
information is going to help. Without their buy-in the project
19. Common framework. When implementing projects for OEE, will be no more than a pretty notice board.
the communications between systems needs to be reliable,
fast and easy to use and maintain. Ethernet has become the 21. Vision drives OEE. Improved process efficiency and
standard in communicating data across automation systems. profitability through OEE improvements are increasingly
The installed based, along with the expertise already existing in important. Machine vision systems and image-based ID
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CONTINUED 22 Ways to Get the Most

Out of OEE and Lean
Manufacturing Disciplines
readers help with three traditional OEE drivers:

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material handling, product quality and package productivity.
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As the manufacturing industry restarts, are you struggling to remain competitive?
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and it works perfectly in theory. Many companies www.universal-robots.com
use statistical and not real-time data from their

production facilities to calculate their OEE. Though
OEE is easy to understand in theory, in practice there
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are many questions, especially how to properly calculate it if make a monthly C-level business report based on real-time
your manufacturing process often changes, is dynamic or if production data, which makes much more sense then a
some machines are used to produce different parts/products detailed, heavy-to-read collection of graphed information.
in the same shift. One solution is to use a simple wireless This way you can adapt the OEE/lean process to a company’s
sensor network to monitor basic functions in real time and specific needs and understanding.
OEE BENEFITS CALCULATOR
OpX Leadership Network’s OEE Benefits Calculator helps production quantity. This will result in reduced direct labor
you find opportunities for increased efficiency on the plant expense related to fewer paid hours and reduced overtime
floor. More specifically, the OEE Benefits Calculator will help premiums.
you calculate the product cost impact of future performance
improvements and enable development and comparison of Raw Material Ingredient and Packaging Yield
various improvement scenarios. Unplanned stops on the production line result in scrap and waste from:
• Quality variation and rejects caused by instability in the
Savings obtained via OEE calculations are attained in two key areas: production process.
• Spilled, damaged or incomplete product that must be scrapped.
Direct Labor Wages & Overtime Reductions in unplanned stops will result in improved yield.
Improvement in OEE will enable a line to meet production
targets in fewer direct labor-crewed scheduled run hours. >> Download the OEE Benefit Calculator User Guide
So improved OEE could enable a reduction in the number
of weekend days that must be scheduled to meet the target >> Download the OEE Benefit Calculator Example
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Strategies for Achieving Your

Energy Management Objectives
Whether your primary goal is to reduce operating costs or Such assessments can help to establish the scope of an
achieve your company’s sustainability goals, finding ways to effort to reduce energy consumption, define key metrics
reduce energy consumption requires good tools and good and put resources in place that can take a holistic view of
information. energy for the organization. Recommendations may include
low-investment modifications, such as shifting maintenance
Key steps for getting started: operations to non-peak times, or may be more involved,
such as programming changes to equipment. Evaluation and
1. Kick off with an audit Energy assessments and audits can prioritization of capital improvement
help companies identify a wide range of changes they can
make to help reduce their consumption. Audits can be simple, An assessment, regardless of scale or scope, should help
such as a walkthrough of a building or facility to identify quick- answer the following key questions:
hit opportunities, or much more detailed efforts. These are
not one-time projects, but rather ongoing efforts to identify • Where am I likely to find quick returns?
variables, such as how seasons might affect production costs
and whether previously implemented improvements are • What key metrics should I put in place?
continuing to perform as planned.
• How can I encourage ongoing improvements?
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CONTINUED Strategies for Achieving Your Energy Management Objectives
2. Select the right tools. A comprehensive energy 3. Be focused. Concentrating energy improvement programs
management program is quite challenging, since every aspect on the high usage systems is usually the best place to start.
of a manufacturing facility is an energy consumer (processing, However, you can’t optimize what you can’t measure. Find an
packaging, warehousing, utilities and even the building itself). easy and cost-effective way to measure your plant’s power
A common mistake is to expect a traditional process or usage by area or major equipment group. Measuring without
machine automation system to be pressed into service for being able to time stamp data lessens the value of the data.
energy management applications (EMS). Don’t try to make
your existing software do the job. 4. Make it granular. The value of energy monitoring is to
gather enough data to truly understand what is happening.
Choose a purpose-built energy analytics package. It Placing meters on one or two motors will not give the results
will deliver results faster, in easily consumable form. you need. It is better to fully instrument a small area and
Customizable dashboards, make it easy to create displays concentrate on the results of that pilot project. You will
that deliver the information that different job roles can discover low hanging fruit that will help you gain support to
leverage to improve results. You want to be able to do more broaden the initiative throughout the plant.
than just view equipment demand is a function of time.
You want to be able to compare energy use from facility to Installing energy-monitoring equipment is the first step in
facility, line to line, machine to machine, even operator to enabling true energy management for your plant or process.
operator. This will give you the data needed to:
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• Know where your energy is being consumed, in process and just production lines but facilities and building automation
non-process applications. equipment like fans and blowers, compressors and so on.
Data capture needs to be comprehensive in order to create a
• Determine schedules of use. full picture of your operation.
• Determine real energy needs. The exercise is quite likely to include some obvious culprits.
You may find compressors or pumps left running when
• Manage supply and consumption by schedule and percent by they should be shut down. You might discover equipment
shifting time and managing and shedding use. scheduled to be left idle running at full speed. You may find
machines with a second or two of title time programmed into
5. Be smart. Apply a current transducer to your load, whether each cycle. It’s all but impossible to distinguish by sight but
that is the incoming feed of a building, a line, a machine, or adds up over the course of a year.
even a motor. You don’t need all new smart components.
Adding sensors to your existing equipment will do just fine. 7. Keep it targeted. Data capture also needs to be strategic.
Monitoring a device just because you can is not just unhelpful,
6. Establish a baseline. Once you’ve targeted your first it’s counterproductive because all of that data clogs up your
project, establish a baseline. Gather data from your network and fills up available storage. Know how you are
sensors using a data logger. This should encompass not going to use the data before you ever acquire it.
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8. Break the process into three parts: Once you have the data, understanding your assets before you can make an informed
you need the aggregation and analysis tools to transfer it to a decision on what equipment to investigate for energy
relational database environment where it can be accessed for improvement programs. Purpose-built energy management
a range of operations. There are three levels of working with applications are available with preconfigured dashboards and
data: monitoring, analysis, and management. Let’s return to built in tools for trending and data analysis.
our energy example:
10. Track big consumers. Always make sure you have the
• Energy monitoring: What energy is being used and how? means to track the energy performance of large energy
consumers. The term “large” can be determined by using a
• Energy analysis: What are the peak consumers? How does simple Pareto analysis. Make a list of all of your energy users
energy usage change over time? and section off the top 20 percent. This will identify a large
portion of your energy usage, as well as the focus of your
• Energy management: Can we put rules and equipment maintenance activities.
in place so that when equipment exceeds thresholds, it
automatically compensates? 11. Manage idle states. Minimize energy draw during energy
savings idle process conditions.
To accrue savings, you need to follow through on all three.
12. Evaluate power quality. If you are investing in a system
9. Be patient. Although low hanging fruit is likely, expect to measure power usage, you should consider one that can
to spend several months establishing a baseline and fully also measure power quality. Poor power quality can lead to
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increased power consumption, as well as equipment failures. induction motor and control valve with a motor driven by a
Measuring harmonics in a system will provide you with very variable-frequency drive (VFD).
beneficial information and the additional cost for this feature
is relatively little. 16. Reap side benefits. Energy monitoring doesn’t just help
the facilities management department. Other areas like
13. Design for efficiency. When designing industrial equipment engineering can leverage the data to harvest insights that will
with pumps or fans, require efficiency of operation. A lot improve productivity and reduce downtime.
of energy is wasted due to over-design of this equipment.
Engineers often use the same pump-motor specification • Maintenance: Changes in power consumption by a piece of
across the plant. This can result in motors being as much as 50 equipment can reveal the need for maintenance well before
percent under-loaded in fan operations. the component fails.
14. Be a giver. Offer energy capacity back to the grid on • Engineering: Differences in power consumption between two
request in exchange for incentives. identical pieces of equipment can show the effect of different
settings, assembly practices, or maintenance procedures.
15. Go beyond electricity. Don’t forget factors like airflow,
temperature, and pressure. If you a drop in compressor • Operations: By comparing consumption shift to shift,
airflow, it could be a leak but it could just as easily be caused machine to machine, or even plant to plant, managers can
by an issue with a bearing or valves. If a process step mostly develop best practices or identify operators who need
uses low flow rates, consider replacing that fixed-speed AC additional training.
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ECONOMICAL WAYS TO
ACHIEVE SAVINGS
1. Use interns to collect data. It’s fairly simple to
identify viable energy management projects, but it
takes real engineering to develop the business case. If
you’re understaffed and strapped cash, reach out to
your local university. You may be able to hire an intern
to collect the actual data points needed to develop a
well-founded business case.
2. Take advantage of incentives. It can often be difficult

to find the funds to invest in projects that will reduce
energy consumption by your plant. Federal, state
and local governments offer a range of incentive and
rebate programs for energy saving projects and using
alternative energy sources.
3. Avoid duplication. Many motor control devices

now have network connections that pass along
energy data. There’s no need to duplicate these data-
generating capabilities by installing power monitors
over the top of intelligent motor control devices.
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10 Tips for Switching to

Predictive Maintenance
The primary goal in manufacturing is to keep the line running before an unexpected filter-cleaning shutdown is required or
and building salable product. Maintenance has evolved to before air cavitation damage occurs.
fulfill that mandate. It started with reactive maintenance –
equipment failed and was replaced. Next, the industry shifted Frequent routine device checks in the field are no longer
to preventative maintenance, which involves performing necessary. Most of the things a technician can do with a hand-
service and replacing equipment on a schedule designed to held device while standing at the device can now be handled
preempt failures. Today, courtesy of intelligent, networked from the control room or maintenance shop. Checking a
components, forward-looking organizations are transitioning device that appears to be malfunctioning can also be done
to predictive maintenance. without a visit to the field.
In predictive maintenance, condition monitoring makes it With a few work process changes and a focus on information
possible to identify equipment issues before they escalate from intelligent measurement devices, companies can
to full-blown problems. Tracking energy consumption of an transition from preventive maintenance to conducting a daily
ordinary motor can turn it into a complex sensor. Abrupt predictive routine, dramatically improving plant operations
changes or slow increases can indicate a failing winding and reducing maintenance costs. Here are some tips for
or worn bearing before it becomes critical. In a pumping success in making the transition:
application, it could indicate clogged filters or dry running,
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CONTINUED 10 Tips for Switching to Predictive Maintenance
1. Make the case: Begin keeping a log of unplanned 4. Become a history buff: Establish a database of performance
downtime, including details on duration and estimated metrics to delineate the boundaries of “normal” operation.
cost. This will help you make a convincing ROI argument. Through subsequent and ongoing performance monitoring
Review your existing equipment. You may already have and recording, small changes in performance that occur
functionalities such as networked components, data loggers, over time can be detected and investigated before there is a
and analytics software. downtime event.
2. Find a champion: Moving from reactive or preventive 5. Go digital: The 4-20 mA current loop might be the most
maintenance regimes to predictive maintenance requires a common sensor output signal, but it does not provide the
culture shift. Management support is essential to enacting breadth of information available from digital sensors. A smart
a maintenance culture that includes work processes that digital sensor not only delivers performance data, it can
facilitate the change. This change is more than just a store information like model number and serial number for
maintenance matter. tracking and identification. Some digital sensors allow users to
change parameters remotely, or automatically upload stored
3. Choose the right hardware: To be successful, predictive parameters at startup.
maintenance strategies require intelligent field devices, an
open communication protocol, and integrated device and 6. Tune out the noise: Predictive maintenance requires
asset management software. comprehensive instrumentation but the sheer volume of
data from thousands of devices can be overwhelming. It’s a
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particular problem given that a large percentage of readings 9. Open up: Several open standards groups have sprung up
report steady-state conditions. Use data loggers with to support predictive maintenance with smart components.
triggers to sift out anomalous readings. Look for purpose- The FDT Group AISBL, for example, promotes the open,
built asset-management software and analytic software vendor-independent Field device tool (FDT standard to
designed to help prioritize information. Many of these simplify the configuration of and access to field devices. Each
software suites include built-in application libraries and tools device uses a vendor-supplied software application known as
to simplify building dashboards. a device-type manager (DTM), which automatically provide
proactive device health alerts. Some DTM’s analyze the data
7. Pick targeted tools: Determine the requirements for your to determine probable cause and corrective action, both for
particular application. The needs of an oil rig, for example, the device in the network.
will be very different from a packaging line for consumer
packaged goods. Look for niche solutions designed for the The Profibus and Profinet International (PI) organization
specific use case of interest. also supports manufacturing process control and asset
management. Their approach is to leverage the diagnostic
8. Consider wireless: Cutting the cord can simplify and alarm schemes built into the instruments themselves.
installation, cut costs, and reduce maintenance. One North Operating parameters for instruments are set during
American oil refinery installed wireless temperature and calibration or commissioning. Readings that fall outside these
pressure transmitters on pumps for a 90% savings over thresholds can generate an alarm.
conventional wired devices.
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10. Be patient: Shifting to a predictive maintenance

regime is a process, not an event. Although you can BY THE NUMBERS
begin collecting data within minutes using some Predictive maintenance can deliver big benefits.
hardware and software tools, it typically takes three Consider the results of a life-sciences company that
to six months before the system has sufficient made the switch:
history to enable truly effective asset monitoring. • 40 percent reduction in time spent on maintenance.
• Savings of more than $52,000 per year.
• Component replacement only when indicated by conditions.
• Savings of $16,500 per year.
• Annual maintenance shutdown reduced by half.
The 2010 NPRA Reliability and Maintenance Conference

reported that reactive maintenance costs could be up to
50 percent greater than planned maintenance.”
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SECTION 2
BATCH
PROCESSING
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SECTION 2 Batch Processing CONTRIBUTORS
Chris Bacon John Rezabek
Production Manager Process Control Specialist
Graham Packaging Ashland Specialty Ingredients
Brooke Robertson Joe Staples

Project Manager Regional Control Specialist, EPCD Head of Manufacturing Systems North America
Momentive Specialty Chemicals Inc. Bayer CropScience
Michael Thibodeaux Chris Wells

Industrial Automated Systems Security Engineer Senior Staff Instrumentation Engineer
BASF ExxonMobil Chemical Company
Dennis Brandl Steven Toteda

President Chairman of WINA
BR&L Consulting (Wireless Industrial Networking Alliance)
Dave Chappell Dr. David W. K. Acheson

CTO, Complete Manufacturing Managing Director for Food and Import
Automation Associates Safety at Leavitt Partners and former
(formerly with P&G) Associate Commissioner for Foods at
U.S. Food and Drug Administration (FDA)
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Bob Rochelle Juan Cuevas Tim Matheny
Food and Packaging ECS Solutions
Industry Specialist,
Staubli Corporation
Darrell Davey Henry Menke
Intelligent Measurement Balluff Inc.
Solutions LLC
Dave Woll
Vice President Devkant Gandhi Hector Re
ARC Advisory Group Inc. IQA
David Hoenig Amitkumar A. Sawant

DH Technical Consulting LLC Schneider Electric India Pvt. Ltd.
Frede Vinther
Senior Automation Specialist
German Martinez Dave Szurek
NNE Pharmaplan
The Mackubin Group
Don Mastenbrook Danny Wouters
Herman Storey
Co-Vice Chair
ISA-108 Standards
Thanks as well to the many contributors
Committee
who wanted to remain anonymous.
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Control System Integrators Chetan Chothani Bryan Curtis, P.E.
Association (CSIA) President Senior Consultant, Power/
Automation World worked with Adaptive Resources Facilities Dept., Matrix
CSIA to gain access to the expertise Technologies
of its system integrator members
to bring you much of the content in
this playbook. Alan E. Lyon, P.E. Antonio Manalo
Lead Engineer Automation Systems Integrator
To become a member of CSIA, a
control system integration firm Avid Solutions Avid Solutions
must demonstrate experience and
commitment to the field. Members
who earn CSIA Certification have
passed an independent audit of Alex Palmer Dario Rossi
80 criteria covering all aspects of Team Lead Chief Engineer
business performance, including Aseco Integrated Systems Aseco Integrated Systems
general management, financial
management, project management,
quality management, supporting
systems, human resources and more. Scott Saneholtz, P.E. Robert Snow
To maintain their certification, CSIA Manager Senior Process Control
Certified members must be re- Process Solutions Dept. Engineer Optimation
audited every three years.
Matrix Technologies
For more information about CSIA
and its system integrator members,
Ronald Studtmann, P.E. Russel Treat
visit http://www.controlsys.org.
Associate Dept. Manager, Power/ President-CEO
Facilities Dept., Matrix Technologies EnerSys Corp
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SECTION 2 Batch Processing
9 Tips for Achieving

Balance in Recipe Management
Food companies and others are trying to standardize software or adjusting parameters, you can easily save-as into a new/
and systems across plants, and even countries, while at the modified master recipe.
same time permitting flexibility in recipe management. Here
are some recommendations to make it easier to achieve the 2. Split screens. Recipe screens should follow in the same
right balance: order as the operation and troubleshooting manuals. Use split
screens so the operator can see the specific screen on one
1. Phased development. Implement a batch structure that window and the sequential state of the specific step in the
makes use of small phases: the smaller the phase, the overall process in another window. The larger the screens and
greater the flexibility. Another capability that supports the the more uniform the fonts/colors, the easier the information
development environment is implementing a batch execution will be to access and operators will make fewer mistakes.
system that enables you to first create the recipe while you
are running it and then save-as to bring the control recipe 3. Maintain recipe control. Centralized control of recipes is
into a new master recipe. Start a control recipe with only a essential. These should not be kept at the plant level, but must
few building blocks and add phases and/or operations from be “checked out” from a centralized (controlled) database.
a library while you are creating the product. If you have Limiting the number of people who can change the recipe,
done this recipe creation from almost scratch or if you have or at least throttling down the parameters available, can help
improved an existing recipe by changing structure and/ limit mistakes from incorrect recipe changes. Also critical is
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CONTINUED 9 Tips for Achieving Balance in Recipe Management
protecting the intellectual property of these tangible assets. who often don’t understand the problems of programmers.
Have a safe practice to transfer the recipe from the nutrition Formalize recipe descriptions to avoid ambiguity in their
department to the plant. It could be wireless. Make sure it has interpretation by the programmers. It is very useful to
a buffer to keep the new recipe until the old one is done. simulate recipe-based processes to demonstrate the work
of the program that implements the specified recipe. After
4. Simplify changeovers. Follow ISA S88 standards for the first such demonstration for recipe authors, it is highly
quick and automated changeovers. Procedures are clearly probable that the recipe records will need to be changed.
defined and can be monitored. If a specific process
cell is troublesome, it can be isolated, analyzed and 6. Keep ingredients separate. Avoid contamination in any
corrected. The correction could range from rewording the changes that are made by keeping the ingredients separate.
procedure to improving the instrumentation or automating Form/fill/seal machines have to be cleaned thoroughly when
the process—all without requiring a facility rebuild. changing from one mix to another. Once changed, be sure
Miscategorizing CM, EM, phase and other values can make to run a batch for checking the components of the mix. Any
for long, cumbersome recipes or inflexible ones. The clues software changes have to take into account all the items
are in ISA-88 and ISA-106TR. contained in the original software.
5. Simulate programs. Control process recipes are usually 7. Database concerns. Recipe management software
developed by technologists who understand the processes but should be based on the dynamic of current standards
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CONTINUED 9 Tips for Achieving Balance in Recipe Management
for each country. Common that will provide the service

classifications for these countries and support associated with a 2 PRINCIPLES FOR
should be located in the same traditional propriety product. RECIPE DEVELOPMENT
database. How the database, Make sure the system is Take into account two basic
names, classification, etc., are upgradeable or expandable. Always principles when developing a recipe:
developed is critical. In terms perform an electrical power survey 1. Recipe cost. Estimate the final
of classification, there should first when considering upgrades. cost of the new recipe, including
extra costs arising from industrial
be a different database for food
trial, designs and OEE.
components functions and their 9. Servo solutions. Servo control
2. Scalability. Don´t forget to check
relative importance for the recipe. makes it easier to change line
the recipe’s viability from the point
It is also important to provide speed than with cam control, of view of industrial scale, including
a database for manufacturers, which often causes problems. all matters like cleaning due to
allergens, flowability, pieces per
distributors and issues related Servo control also allows for quick
minute, etc.
to final potential users, such as and repeatable product changes.
diabetic or allergenic concerns. Connecting the servo drives to a
field bus also minimizes wiring.
8. Open and expandable. Stick
to open platforms as much as
possible, while seeking vendors
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How Reusable Code Streamlines

Recipe Management
By Jeanne Schweder
Contributing Writer, Automation World
Looking for a way to implement a flexible production

strategy without breaking your budget or spending weeks
or months writing new software code? The answer can
be found in ANSI/ISA-88.00.03-2003, a control industry
standard that establishes best practices for automating batch
manufacturing plants and batch control.
Although originally designed for batch manufacturing

processes, the ISA-88 standard is also helping users save time
and money in automating continuous production processes.
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CONTINUED How Reusable Code Streamlines Recipe Management
Common process control language The standard sets forth a set of building blocks for process control
ISA-88 accomplishes this by defining a common language at all levels: enterprise, site, area, process cell, unit, equipment
for process control to improve communication between the module and control module. The three highest levels explain how
various players involved in controlling plants and production the standard’s language can interface with the business systems
processes. It also creates a structure with consistent concepts of the area, plant site and business enterprise as a whole.
and models for batch processes that provides a map for how
developers should organize their software code. The next two levels, process cell and unit, are the building
blocks of the production process. One or more units are
contained in each process cell. Each unit is a collection of
controlled equipment.
Within the unit are the equipment and control modules. An

equipment module defines a small group of equipment with a
process function and can contain control modules and subsidiary
equipment modules. The control module contains the equipment
and systems that perform the actual process control.
Universal structure
The standard can be applied to either simple or complex
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processes, so that one programming system can be used for • Recognize the need for modular and reusable control
all production processes in a plant. Using this methodology, functionality.
users and programmers can:
Reusable software code blocks are central to the ISA-88
• Identify the structure and format for recipes and standard and are programmed using IEC 61131-3-compliant
procedures. software, which is available from all major automation
vendors. Code can be programmed in ladder diagram as well
• Define levels of recipes and procedures. as structured text, function block diagram, instruction list or
sequential function chart languages.
• Recognize product-specific recipes and procedures that are
separate from process-oriented equipment and its direct Each vendor includes libraries of reusable control modules and
control. algorithms that define common machine functions and recipe
steps in their software. Once the initial process or recipe has
• Identify a hierarchy of manufacturing equipment and its been programmed, modular code blocks can be reused for the
dedicated control. same functions with minimal modifications. This eliminates the
need to reinvent the wheel for different recipes, and allows
• Recognize equipment capabilities used during recipe and future changes to be made almost dynamically.
procedure driven production.
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According to industry experts, users typically achieve a • Reduce a user’s time to reach full production levels for new
30 percent savings in programming time and costs for products.
the first project, and as much as 70 percent savings on
subsequent projects. • Enable vendors to supply appropriate tools for implementing
batch control.
Broad applicability
Industry experts say an estimated 50 percent of all U.S. • Enable users to better identify their needs.
manufacturing is now accomplished using techniques and
technologies consistent with the ISA-88 standard, which has • Make recipe development straightforward enough to be
been proven in thousands of applications and can be applied in accomplished without the services of a control systems
either DCS or PLC control environments. engineer.
The ISA-88 standard can be so widely applied because its • Reduce the cost of automating batch processes.
central objectives are to:
• Reduce lifecycle engineering efforts.
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10 Commandments
for CIP Design
1. Always remember that water runs downhill…
By Maya Norris
Managing Editor, ProFood World
2. …and that it is easier to pump water into a tank
than to pump it out.
Clean-in-place (CIP) systems play an integral role in
sanitary plant design. They not only help food and beverage
manufacturers clean parts of equipment that are difficult
to reach, but CIP minimizes cleaning time and the labor
needed for it, ensures consistency and repeatability of the
cleaning process, improves efficient use of water and cleaning
chemicals, and ultimately increases the productivity of the
plant. Here are some tips from The OpX Leadership Network’s
CIP for CPGs: Clean-in-Place Guidelines for Consumer
Products Manufacturers that will help food and beverage
manufacturers design effective CIP systems.
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CONTINUED 10 Commandments for CIP Design
3. Pitch tank “CIP Return” manifold/connections continuously 9. Pitch all lines to easily opened drain points.
to pump inlet.
10. Design and install supports to eliminate “friendly” piping
4. Keep tank head nozzles few in number, short in length and that waves when starting pumps and opening and closing
large in diameter. valves because friendly systems are short-lived.
5. Avoid three-port divert valves like the plague. To download CIP for CPGs: Clean-in-Place Guidelines
for Consumer Products Manufacturers and CIP
6. Design to close all valves against flow. for CPGs: Clean-in-Place Checklist, visit www.
opxleadershipnetwork.org/hygienic-equipment-design/
7. Locate CIP systems in (near) and (when possible) beneath content/clean-place-guidelines-infographic.
the center of CIP loads.
8. Eliminate all “dead ends” (branches of more than 1½ pipe

diameters) because they will trouble you forever.
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Top Recommendations for Designing

and Using Skid-Based Equipment
Modular, skid-mounted process equipment—such as integration layer acts as the only interface between ISA 95
CIP systems, bio processors, blowers and dryers, and level 2 and level 3.
compressors and pumps—is increasingly common. The
following design recommendations will help ensure that 2. Skid design tips. All pipe outlets and inlet should be
your skid-based systems are flexible and easy to integrate, self-sealing and quick connect on one side of the skid,
and simplify maintenance: with horizontal bend of 90 degree (or 45 degree if more
convenient). Inlet and outlet should be marked with
1. Create interface layer. To apply S88 in an environment with an arrow that is etched or otherwise made permanent.
many different OEM equipment units, which all have their own Valves should be accessible for removal from one side of
way of handling recipes, create an integration layer for central the skid. The skid should be fully protected and guarded
control, monitoring, and recipe and batch management. with a controlled interlock if doors are provided, allowing
Don’t force the OEM vendor to customize his product to your for natural ventilation or directed ventilation if needed.
wishes. This creates issues with vendor support, qualification Guards need to be strong enough for incidental forces.
and additional costs, etc. Use the vendor standard, but Provide tempered safety glass windows where gauges or
implement an integration layer to do the specific translation mechanical action needs to be observed for either casual
of the unit procedure into the OEM equipment language process verification or debugging.
using the specific required interface (OPC, XML, etc.). The
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CONTINUED Top Recommendations for Designing and Using Skid-Based Equipment
3. Skid construction. Ensure that the materials used 5. Modular design. The best way to design a skid is to lay out
in construction are acceptable for the intended plant the design in the beginning and determine the area required.
environment. Some facilities will not allow wooden skids, In the design phase, a layout can be made to determine the
for example, and the substitute for this must be approved best location fit. Although skid designs vary according to
well in advance. the engineer involved with the design of the equipment, the
best approach is to provide a modular layout so that in the
4. Similar to rafting. Skid mounting is similar to “rafting” of future changes can be made with the least amount of effort.
roll forming equipment. There are many elements of the roll Modular is the best layout because it makes it possible to
forming line, but the pre-process equipment incorporates the change the requirements.
coil handler and straightener and the post-process equipment,
including welder, cutter, deburrer and stacker, which are all 6. Base skid design on components. Create standard skids
easy to change over. The roll form can take hours; that piece based on the most important and standard components, such
is duplicated and indexed left or right. When left is forming, as number of membranes for RO units or other membrane
right is in changeover. Duplicating and indexing an element systems, or based on typical capacity of blowers and tanks.
of a line that requires extra attention could be interesting. Make sure to simulate the system to determine whether it
Indexing allows equipment to be swapped in a controlled will permit selection of a range of operation. Work in modules
manner, without the need for a forklift. located in parallel or series to increase capacity.
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SCHMERSAL INNOVATIONS
SAFETY LIGHT CURTAINS WITH BLUETOOTH INTERFACE
CONTINUED Top Recommendations

for Designing and Using
Skid-Based Equipment
7. Size for container frames. If you want mobile equipment,
design and choose the machines that can fit inside a
container frame. Some plumbing systems can be pre-
engineered in the frame; install and test these in a
dedicated workshop to make sure the quality standards
■ Integrated bluetooth interface, standard on all
are met. Mount starters and controls on the wall. Install
SLC440 and SLC440COM safety light curtains
vacuum pump/blower setup plugs in with supplied power
■ Access data via SLC ASSIST app, available for
only, allowing for plug-and-play replacement of spare units. Android and iOS smartphones and tablets
■ Secure data transmission up to 5 meters

8. Test before buying. Thoroughly inspect a demo unit prior
■ Real time status, troubleshoot faults quickly
to specifying and ordering. Specify parts that you already
have access to in network. Drive standardization. ■ Installation alignment aid setting
■ Verify enabled functions and settings.
■ Generate and save documentation
888-496-5143
salesusa@schmersal.com
www.schmersalusa.com
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Agreeing on OEE
“I don’t think we can say from our experience there is an
By Sean Riley industry standard. Too many variables at play within each
line,” says Celie Reid, sales and marketing manager at Triple/S
Dynamics in Dallas. “The problem [with standard calculators]
As overall equipment effectiveness (OEE) insinuates itself into for us, as a conveyor manufacturer, is all of the bits and pieces
every sales opportunity, OEMs know that customers have a that make up the equation are totally out of our control.”
certain number in mind that represents their required OEE.
Defining OEE
The problem for OEMs is determining how their customers At a granular level, OEE can be calculated as the product of three
define that number. One company might perceive another percentages: availability, rate performance and quality. All losses
company’s accepted efficiency differently, since there are identified through the data collection process can and should be
many ways to calculate—downtime related to changeovers, attributed to one of these three categories to systematically drive
product in vs. product out, etc. There is also a variety of change at the appropriate level and magnitude.
calculators out there for determining OEE.
• Availability describes the losses that result from downtime,
From an OEM point of view, there is not yet an accepted both planned and unplanned. Some of the most common
industry standard for calculating OEE. types of availability losses result from maintenance and
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CONTINUED Agreeing on OEE
cleaning activities, line changeovers, equipment failures,

starvation due to missing input materials upstream, and
blockages due to outages in downstream conversion work
centers or handling processes.
• Rate performance describes the losses that result from

running the equipment at speeds below the target rate. Rate
losses inherently occur during ramp-down and ramp-up around
machine stops, or from machine settings that differ from the
target rate. The target rate is generally defined as the best
demonstrated instantaneous rate that a SKU can run through
the chokepoint of the production system. A machine might run
different SKUs at different rates, but there should be only one
target rate for each SKU for that machine.
• Quality describes the losses that result from quality defects.

These losses must take into account all scrap and rework incurred
over the identified interval for the given process. Sanitation
defects, out-of-spec production, in-process damage, and incorrect
material usage are some of the common examples of quality.
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The OpX Leadership Network’s OEE Operational Reliability Robertson believes that most of the customers Pearson works
Solutions Group indicates 100 percent OEE is practically with understand what levels are achievable and what levels
impossible. Even if all three factors were 95 percent, OEE are pipe dreams. In the rare cases where customers require a
would calculate to just fewer than 86 percent. The worldwide higher-than-achievable level of performance, Pearson will do
average OEE rate in manufacturing plants is about 60 percent, everything it can to negotiate a workable compromise. If that
with 85 percent serving as the baseline from good to great. doesn’t happen, Pearson will decline the project rather than
risk disappointing a customer.
Leo Robertson, COO at Pearson Packaging in Spokane, Wash.,
agrees that 85 percent is considered a world-class figure. Being aware of your limits as an OEM is important when it comes
“The formula for that result would probably look like this: 90 to OEE, according to Bob Williams, vice president and general
percent availability x 95 percent performance x 99.9 percent manager at Raleigh, N.C.-based Axon, a division of ProMach.
quality= 85 percent world-class OEE,” he says. Of course,
actual expected performance and quality figures vary by “An OEM must know their equipment and accurately assess
model and application. “Based on the range of equipment the probability of success given the unique characteristics
[Pearson] manufactures, we can predict OEE figures to range of each application,” Williams says. “A customer who is not
from as low as 75 percent to as high as 89 percent. Availability realistic is dangerous. No one can afford a bad install, and
is primarily under the control of the end user and is usually the there are times when, given the conditions, it is better for
most variable metric.” an OEM to walk away than to take an order and then spend
thousands of man-hours and dollars trying to meet an
unrealistic performance guarantee.”
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That being said, he feels there is usually some level of It is at this point in the process that OEMs must push back
negotiation with OEE expectations, but timing is everything. against CPGs or avoid the project all together. Obviously, it
helps if you know your solution is the best or only one that will
“When pursuing the order, there seems to be no wiggle work for that particular application.
room and CPGs are looking for a number,” he says. “But after
the [purchase order] is placed, the expectations become “It really helps if the OEM has experience with the product,”
somewhat relaxed when other factors come into play like Reid says. “The main thing we do every time we receive
plant conditions, operators, environment, materials, etc.” an OEE requirement is to have several people read it very
carefully. Then we try to negotiate out things that we can’t
Reid has experience dealing with customers seeking the control, and keep our fingers crossed [that the CPG will be
impossible and responds with the caveat that what happens on realistic].”
the line before or after their machine is not included. She deems
this as the critical part of the equation for fellow OEMs. Several OEMs recommend reminding customers that
a machine builder cannot guarantee what an end user’s
“Most performance guarantees that we have been handed call employees will do once they receive the machine. The buyer’s
out ‘no less than 99.99 percent mechanical reliability, running undertrained employees can be a big problem, so those
for 15-20 eight-hour shifts,” Reid says. “This statement expectations need to be negotiated as part of the terms
is qualified by including the phrase ‘that an upstream or and conditions prior to purchase. Otherwise, it creates the
downstream event will not be included.’ Depending on where opportunity for disagreements further down the road. Some
your equipment is in the line, you can negotiate with a CPG.” OEMs ask that their customers’ employees have completed
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a training program as a condition of warranty. The high rate able to confidently commit to high performance and quality
of employee turnover creates opportunities for customers to figures. We also regularly break out availability factors such
change their expectations and not communicate it. as changeover time and machine breakdown issues to be
considered separately.”
While Pearson will walk away from
unrealistic expectations, Robertson
thinks those situations should be the
exception rather than the rule.
“Our intent is to find methods to

support our customers in ways that
meet their needs and support effective
factory and plant acceptance testing,
and to provide long-term satisfaction
with their packaging systems,” he says.
“The vast majority of the time, we can
accomplish this by focusing on the
factors that comprise OEE, where we
can have the greatest effect. We are
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Safety:
The Lifecycle Approach
For the process industries, IEC 61511 is probably the
By James R. Koelsch most widely used safety standard because it applies to
Contributing Writer, Automation World those industries that base their safety systems upon
instrumentation. The goal of safety-system design in IEC 61511
Dave Woll
is for the process, whatever it may be, to go to a safe state
Vice President, ARC Advisory Group
whenever a process parameter exceeds preset limits.
David Greenfield
Director of Content/Editor in Chief, Automation World A new way of approaching safety
Understanding IEC 61511 means that you must know a
thing or two about IEC 61508—a functional safety standard
Production safety is generally thought of as a series of that provides the framework for building industry-specific
steps necessary to ensure safe interaction with industrial functional standards. IEC 61511 was created from the
equipment. The process of identifying, agreeing upon guidelines established by IEC 61508.
and delineating those steps is where things tend to get
complicated. That’s why international standards groups play The key point to understand about IEC 61508 is that it is
such a significant role, as they set the guidelines for all of designed to establish an engineering discipline that will
industry to follow. generate safer designs and build safer processes. The uniform
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CONTINUED Safety: The Lifecycle Approach
procedures built on these disciplines are contingent upon

appropriate experts within a company contributing to projects. In
addition, the standard also makes it easy for outside auditors and
governmental agencies to follow the process.
IEC 61508 can seem confusing at first because its underlying

philosophy is new for safety standards. Older, more
conventional safety standards stipulated specific rules and
specifications for making processes safe. IEC 61508 and its
derivative standards, such as IEC 61511, departed from this
approach by being more functional, or performance-based.
A principal aspect of this new approach to safety standards is

that it leverages two fundamental principles: safety lifecycles
and probabilistic failure analysis. Unlike previous standards
that claimed to cover the entire lifecycle of a project, IEC
61508 and its offshoots actually do—from project conception
to maintenance to decommissioning.
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In essence, the standards specify safety lifecycle activities Specific activities include:
that need to be followed over the entire life of a production
system. Safety lifecycle management provides a method • Perform hazard and risk analysis: Determine hazards and
or procedure that enables companies to specify, design, hazardous events, the sequence of events leading to hazardous
implement and maintain safety systems to achieve overall conditions, the associated process risks, the requirements of
safety in a documented and verified manner. risk reduction and the safety functions required.
Four phases of the safety lifecycle

The IEC 61511 standard promulgated by the International
Electrotechnical Commission specifies 12 steps in the safety
lifecycle. These are segmented into four phases: analysis,
realization, maintenance and ongoing functions.
Safety Lifecycle I: Analysis phase

The analysis phase includes the initial planning, identification
and specification of safety functions required for the safe
operation of a manufacturing process.
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• Allocate safety functions to protection layers: Check the • Design and develop other means of risk reduction: Means
available layers of protection. Allocate safety functions to of protection other than programmable safety systems
protection layers and safety systems. include mechanical systems, process control systems and
manual systems.
• Specify requirements for safety systems: If tolerable risk
is still out of limit, then specify the requirements for each • Install, commission and validate the safety protections:
safety system and its safety integrity levels. Install and validate that the safety system meets all the
safety requirements to the required safety integrity levels.
Safety Lifecycle II: Realization phase
The realization phase not only includes design, installation and Safety Lifecycle III: Maintenance phase
testing of safety systems, but also the design, development The maintenance phase begins at the startup of a process
and installation of other effective risk reduction methods. and continues until the safety system is decommissioned or
Specific activities include: redeployed. Specific activities include:
• Design and engineer a safety system: Design the system to • Operate and maintain: Ensure that the safety system
meet the safety requirements. functions are maintained during operation and maintenance.
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• Modify and update: Make corrections, enhancements and adaptations to

the safety system to ensure that the safety requirements are maintained.
• Decommissioning: Conduct review and obtain required authorization

before decommissioning a safety system. Ensure that the required safety
functions remain operational during decommissioning.
Safety Lifecycle IV: Ongoing functions

Certain functions are ongoing. Examples include managing functional safety,
planning and structuring the safety lifecycle, and performing periodic safety
system verification and safety audits over the whole lifecycle. Specific
activities include:
• Manage
functional safety, safety assessment and safety audit: Identify
the management activities that are required to ensure that the functional
safety objectives are met.
• Plan and structure safety lifecycle: Define safety lifecycle in terms of

inputs, outputs and verification activities.
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engineering services powered by SCHMERSAL
• Verify safety system: Demonstrate by review, analysis and/

or testing that the required outputs satisfy the defined
requirements for each phase of the safety lifecycle.
Activities for Phases I to III are typically carried out

consecutively, while Phase IV runs concurrently with the
other phases. However, like all models, the safety lifecycle
PUTTING THE PIECES TOGETHER
is an approximation.
Machine safety can be challenging and complex, for both machine builder
and user. Many times, it is difficult to stay up to date on all applicable safety
Bottom line: A requirements definition standards and guidelines. It is also not easy to interpret standards and apply
them to equipment. We can help you put the pieces together with engineering
Readers should note that the standards define requirements services from tec.nicum:
for safety management, rather than system development. Not ACADEMY ENGINEERING
all safety lifecycle phases will be relevant to every application; training courses planning and design
in-house training tests and measurements
management must define which requirements are applicable
in each case. The standards do not prescribe exactly what TECHNICAL SERVICES INTEGRATION
should be done in any particular case, but guide management troubleshooting installation services
risk analysis device programming
toward decisions and offer advice.
888-496-5143
salesusa@schmersal.com
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Conducting
a Risk Assessment
stop the machine for changeovers, to clear jams, or to clean or
By Jim Chrzan perform routine maintenance.
VP, Content and Brand Strategy, PMMI Media Group
Manuals for training, warning labels, guards, alarms and e-stops

Risk assessment is a process that machinery manufacturers are all critical to preventing incidents, but accidents still occur.
use to evaluate their equipment for potential health and safety In the event a litigation case results, the OEM and end user
hazards before a hazard can cause an accident or incident. can be called on in court to prove they were aware of the risks
Many end users now require risk assessments as part of the and instituted reasonable measures to protect against any
procurement process, wanting to make sure they have taken all harm. Having a documented risk assessment can be extremely
steps necessary to reduce potential harmful accidents. Blades, valuable in such cases.
gears, grinders, conveyors, robots, etc., all can potentially pose
risk to operators and maintenance personnel. Noise levels and Risk assessment is required for compliance to the ANSI/
electrical hazards can be problematic as well. PMMI B155.1-2016 standard and for compliance with the
EU machinery directive 2006/42/EC. PMMI has expanded
Beyond regular operation of the machinery, safety hazards the scope of the PMMI risk assessment training program to
also occur when operators and maintenance personnel have to include the important issues that generate the most questions
from PMMI members.
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Perfect Match. The one-in-a-million HMI system
that perfectly fits your application.
CONTINUED Conducting a Risk Assessment

VisuNet FLX—The New Modular
HMI Platform for Use up to Zone For more information, visit
PMMI Risk Assessment Workshops address: 2/22, Div. 2 pepperl-fuchs.com/flx
• Global standards—why harmonization is important and what

standards to use.
• Risk assessment basics—what it is, why to do it, the iterative
process, how to do risk assessment and when are you done.
• Hands-on risk assessment using PackSafe/designsafe software.
• Legal implications of risk assessment—new equipment,
legacy equipment.
• How to deploy risk assessment.
For more information about PMMI’s Risk Assessment

programs, visit https://pmmi.org/risk-assessment-workshops.
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How to Avoid Mistakes With

Control System Remote Access
typical of problems that occur when automation products are
By David Greenfield implemented hastily, without doing proper research, planning,
Director of Content/Editor in Chief, Automation World
or analyzing current and future goals, or without realizing that
implementing remote access monitoring for a facility is just
As more operations aspects are tied to Ethernet networks step one of many.
and, therefore, are open to Internet-based access, the
potential for greater collaborative operation and a freer work 2. Anticipate network interactions. When people have
environment increases. But so does the potential for security installed devices on a proprietary network then try to
problems. Following are some basic tips and considerations use something different (e.g., Wi-Fi or another protocol),
for achieving secure and reliable remote access: individual systems may conflict. Or they may just cancel each
other out, so that there is no communication whatsoever.
1. Map out your project from the start. When companies More often you find yourself managing so many different
fail to map out their projects thoroughly from the start, applications, protocols, and systems that you have more work
they often find themselves saddled with applications and and headaches than you imagined possible. This issue can
automation products that don’t work cohesively as a single be avoided if you select a network that is open and allows
system. Once you start implementing various silos—be they everything to work together.
applications or products—things get more complex. This is
3. Understand users and roles. Understanding users and their
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CONTINUED How to Avoid Mistakes With Control System Remote Access
roles can have a significant impact on how the remote access

strategy evolves. In most control systems operations, the
roles that may require remote access to control assets could
include, but are not limited to:
• System operators and engineers for local systems
• System operators and engineers for remote systems
• Vendors
• System integrators
• System support specialists and maintenance engineers
• Field technicians
• Business/supply chain partners
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• Reporting or regulatory entities • The attacker can use captured or guessed credentials to
impersonate the user.
• Managed service providers
The roles of users that would require remote access to

mission-critical operations can be extensive, and the
assignment of specific access depending on those roles can
be complicated. Map out and document all acceptable access
policies and procedures related to allowable network access
and coordinate this with industrial control system security
experts. Any user access that goes beyond simple viewing
of data and permits changes to system parameters should be
extremely limited.
4. Know your vulnerabilities. Beginning at the remote user

and following the connection to the data or service, remote
access can be compromised at any of the following points:
• The user or system can be impersonated to fool the target system.
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• The attacker can intimidate or coerce the user to provide (does not rely on impersonation) or intercepted during
valid credentials, or to perform activities at the attacker’s initiation (impersonating both user and target, also known as
demand. a man-in-the-middle attack).
• The user’s access device (laptop, PDA, etc.) can be • Parts of a communication can be replayed to a target, even
attacked, compromised, and used to access the control if the attacker cannot decipher the content (also known as a
system network. replay attack).
• The target system can be impersonated by an attacker to • The target communication software listening for requests
fool the user and thus gain credentials or other information can be attacked and potentially compromised.
from the user system.
• An attacker can impersonate a valid communications node
• Communication can be listened to by third parties anywhere and gain access to the underlying communications medium.
along the communication chain.
• A denial-of-service attack can happen to the authentication
• The communication can be interrupted or jammed. server (e.g., radius server or RAS).
• Communications can have data injected into them by an attacker. • A denial-of-service attack can happen to the outward
communication device (e.g., an outside router for remote
• Communication can be hijacked after it has been initiated access).
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Options Analysis Tool for

Remote Equipment Access
from understanding the evaluations of skills required, costs,
By Sean Riley reliability and security to enable safe and secure remote
Senior Director, Media and Industry Communications, PMMI equipment diagnostics and assistance.
Convened by PMMI, The Association for Packaging and Processing “While the technologies enabling remote equipment access
Technologies, the OpX Leadership Network’s new Remote have been present for some time, adoption has been slow,”
Equipment Access: Options Analysis tool provides a common says Christopher Hough, general manager of ZPI, a ProMach
understanding of the industry methodologies for remotely Product Brand. “The OpX Leadership Network’s new solution
accessing equipment installed in manufacturing facilities. can help bridge the gap and provide guidance on remote
equipment access options.”
Based on the collective experience of the OpX Leadership
Network’s Remote Equipment Access Solutions Group, this The OpX Leadership Network was founded in 2011 by PMMI
discussion tool was created for production teams to consider to ensure CPGs and OEMs are well-connected and well-
approaches for enabling access to equipment for diagnosis, prepared to solve common operational challenges, make
potential repair and performance improvements from remote smarter decisions and achieve operational excellence.
suppliers that are not part of the customer’s company.
Remote Equipment Access: Options Analysis, as well as other
Consumer packaged goods (CPG) companies as well as operational solutions, are available for free download at
their suppliers, OEMs and service providers can benefit www.opxleadershipnetwork.org.
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4 IT Standards You
Should Understand
• The ANSI/ISA 88 standard on batch control.
By Dennis Brandl
Chief Consultant, BR&L Consulting Inc. • The ANSI/ISA 95 standard for MES and ERP-to-MES
communication.
Imagine a world without electrical standards, such as 110 V • The ANSI/ISA 99 technical reports in industrial cyber
at 60 Hz, or 220 V at 50 Hz, or a world where every phone security.
had a different type of connection and required a different
type of switchboard. Just as these standards are critical to • The new ANSI/ISA 106 technical report on procedure
the basic functioning of electrical equipment, there are also automation.
IT standards used daily to ensure optimal functioning of
production systems in the process industries. These standards and technical reports define the best
practices for implementing automated and manual control
There are four production-related IT standards of special on the systems that reside above the programmable logic
interest to the processing industries: controller (PLC) and distributed control system (DCS) level,
and which perform the basic control that keeps production
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CONTINUED 4 IT Standards You Should Understand
running. These four standards all share a common view of a The ANSI/ISA 99 reports define structures and policies for
production facility, providing a consistent terminology that designing effective and secure networked production facilities.
makes it easier to compare plants within a company and
across companies. The new ISA 106 reports define the procedural control
strategy for continuous production during upsets,
The ANSI/ISA 88 standard defines the most common and switchovers, and other types of process changes.
effective method for defining control systems for batch
operations or for continuous and discrete startups and Because these standards establish a commonly accepted
shutdowns. terminology, functions and process models by which
technical professionals are trained, and upon which solution
The ANSI/ISA 95 standard defines the most commonly used providers develop applications used in batch and process
method for exchanging information between enterprise production operations (as well as discrete manufacturing),
resrouce planning (ERP) systems, such as SAP or Oracle, they should be of particular interest to those who are new to
and the multitude of shop floor systems. It has also become the field and those seeking a refresher on the fundamentals
the de facto standard for defining manufacturing execution of industrial processes.
system (MES) and manufacturing operations management
(MOM) specifications.
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Tips for Dealing With Wireless

Latency and Bandwidth Issues
More and more, system engineers are taking advantage of multicast traffic coming from programmable logic controllers
industrial wireless technologies to reduce the amount of (PLCs) or producer devices. Multicast traffic is handled
cabling in their designs. There are some issues to be aware differently than unicast traffic by wireless access points.
of, however, when replacing dedicated connections with Multiple devices can receive multicast traffic, while unicast is
wireless links: destined for only one device. Wireless access points transmit
multicast traffic at a minimal rate to ensure that all listening
1. Need latency tolerance. Today’s wired Ethernet clients will be able to receive the traffic. This results in low
connections are full duplex. This means that each end device aggregate bandwidth over the wireless access point as it has
can both transmit and receive at the same time. On the to lower its transmit rate down from the maximum.
other hand, wireless technologies such as 802.11a/b/g/n
are half duplex. This means that when any one device is 3. Low bandwidth requirements. Make sure that your
transmitting, all other devices must wait. Make sure that application’s bandwidth requirements are low enough to
your application is designed to be tolerant of the latency be satisfied by the lower rates. Many designers overlook
introduced due to the half-duplex nature of wireless. these points and experience problems when moving to
wireless solutions. Being aware of the limitations of wireless
2. Control multicast traffic. When implementing wireless technology can ensure that your upfront design will work in
technology in factory automation projects, be aware of any a wireless deployment.
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CONTINUED Tips for Dealing With Wireless Latency and Bandwidth Issues
4. Don’t take shortcuts with wireless. Consider the entire

system design and the support lifecycle of the system
before choosing technology and vendors. Time spent up
front on site surveys, path loss calculations and fade margin
will pay dividends when it comes time for installation. Design
in fade margin. Wireless is very reliable when well designed,
but if you don’t design in appropriate fade margin you’ll have
problems in the future.
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Achieving Sustainability Excellence

journey-sustainability-excellence), you can also access PMMI’s
By Sean Riley Triple Bottom Line tool to help you make the business case
for sustainability-related resource allocations. This paper also
serves as a valuable platform for participation in the OpX
PMMI offers a paper titled “Journey to Sustainability Sustainability Solutions Group (www.opxleadershipnetwork.
Excellence for the Food & Beverage and Consumer Packaged org/sustainability/group), where participants focus on
Goods Industry and Their Suppliers.” By focusing on the developing a Sustainability Risk Assessment platform and
opportunities, resources, management and profitability of an industry recognition program for food, beverage and
social, environmental and economic sustainability initiatives, consumer products manufacturers. The goal of the group is
this paper provides an understanding of the market forces to identify appropriate tools, methods and systems to support
that affect factors from the corner office to the production sustainability in operations as “good for business” for suppliers
line. You’ll also learn the 18 attributes of the journey to and CPG manufacturers.
sustainability and get hands-on examples from Procter &
Gamble, Smithfield Foods, Del Monte Foods and Sunny You can also access the Sustainability Solutions Group
Delight Beverages Co. Resource Guide—a 43-page PDF guidebook that provides
step-by-step tools on how to cost-effectively implement
By viewing this paper (www.opxleadershipnetwork.org/ sustainability programs in the face of increasing competitive
sustainable-manufacturing/download/executive-summary- and economic pressures.
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SECTION 3
CONTINUOUS
PROCESSING
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SECTION 3 Continuous Processing CONTRIBUTORS
Brooke Robertson John Rezabek
Project Manager Regional Control Specialist, EPCD Process Control Specialist
Momentive Specialty Chemicals Inc. Ashland Specialty Ingredients
Michael Thibodeaux Joe Staples

Industrial Automated Systems Security Engineer Head of Manufacturing Systems North America
BASF Bayer CropScience
Dennis Brandl Chris Wells

President Senior Staff Instrumentation Engineer
BR&L Consulting ExxonMobil Chemical Company
Steven Toteda Steve Elwart, P.E.

Chairman of WINA Director of Systems Engineering
(Wireless Industrial Networking Alliance) Ergon Refining Inc.
Dave Woll Bob Rochelle

Vice President Food and Packaging Industry Specialist
ARC Advisory Group Inc. Staubli Corporation
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Cyle Nelson Steven Baird Dave Emerson
Senior Software Architect Moxa ISA-106 Editor
Adept Technology Yokogawa
S.N. Banerjee House Fang

Instrumentation Limited Rockwell Automation
Chris Bacon
Production Manager
Graham Packaging George Buckbee, P.E. Juan Facundo Ferrer
(formerly with Pepsi ExperTune
Bottling Ventures)
Sergio Canales Robert L. Fischer

Herman Storey Fischer Technical Services
Co-Vice Chair
ISA-108 Standards Committee
Richard Caro David R. Gulick
CMC Associates Hexagon Lincoln
Dani Alkalay Rama Chandran Kevin Davenport

MTL Instruments Jacobs Engineering Group Inc. Cisco Manufacturing
Ken Austin Ted Dimm Augie DiGiovanni

Phoenix Contact Honeywell Process Solutions Emerson Process Management
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Randy Durick Vignesh Kumar Dale Reed
Turck ISA-106 Editor Rockwell Automation
Yokogawa
Avihu Hiram Pierre Lampron Steve Robben

Hiram Process Control KSH Solutions Inc. City of Greeley
Engineering
Allen Hough Greg Livelli Sam Roosth

Itw Drawform ABB
Dave Huffman Francisco Mejia

Ulf Kristian Sandvik
ABB Manufacturing IT Consultant
Bryan Jones Erik Mathiason Paul Schneling

Emerson Member, ISA-108 Standards Emerson Process Management
Committee
Emerson Process Management
R.V. Kaushik Robert Schosker
Matt Newton Pepperl+Fuchs
Opto 22
Krishnakumar
Haya Water, Muscat
Anup Pandit Bryan Sellner
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Robin Slater Maurice Wilkins

Valin Corporation Managing Director
ISA-106 Standards Committee
Yokogawa
Jeff Smith James Wilkinson

American Axle & Manufacturing MTL Instruments
Kevin Starr Bill Wray, PE

ABB Process Automation Service Co-Chair, ISA-106 Standards Committee
Bayer Material Science
Jose Gonzalez Valero Roberto Zucchi

Pemex ABB
Sarah Wang
Fluor
Thanks as well to the many contributors who wanted to remain anonymous.
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Control System Integrators Chetan Chothani Bryan Curtis, P.E.
Association (CSIA) President Senior Consultant, Power/
Automation World worked with Adaptive Resources Facilities Dept., Matrix
CSIA to gain access to the expertise Technologies
of its system integrator members
to bring you much of the content in
this playbook. Alan E. Lyon, P.E. Antonio Manalo
Lead Engineer Automation Systems Integrator
To become a member of CSIA, a
control system integration firm Avid Solutions Avid Solutions
must demonstrate experience and
commitment to the field. Members
who earn CSIA Certification have
passed an independent audit of Alex Palmer Dario Rossi
80 criteria covering all aspects of Team Lead Chief Engineer
business performance, including Aseco Integrated Systems Aseco Integrated Systems
general management, financial
management, project management,
quality management, supporting
systems, human resources and more. Scott Saneholtz, P.E. Robert Snow
To maintain their certification, CSIA Manager Senior Process Control
Certified members must be re- Process Solutions Dept. Engineer Optimation
audited every three years.
Matrix Technologies
For more information about CSIA
and its system integrator members,
Ronald Studtmann, P.E. Russel Treat
visit http://www.controlsys.org.
Associate Dept. Manager, Power/ President-CEO
Facilities Dept., Matrix Technologies EnerSys Corp
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SECTION 3 Continuous Processing
8 Ideas for Successful

DCS Implementation
Implementing a new distributed control system (DCS) is one sure you understand the supplier’s grounding requirements
of the biggest and most complicated projects in a process for your DCS system. Grounding principles need to be
control engineer’s career. Doing one successfully requires clearly understood by all automation engineers, not just the
everything from a well-defined project document to good electrical staff. International standards can be misinterpreted.
grounding practices. Here are recommendations for best Instruments and the control system need to be grounded
practices and some pitfalls to avoid. separately. Double check the grounding before powering up
any DCS system to avoid any short circuits, particularly during
1. Standardize. Use of standard wiring throughout the factory acceptance or site acceptance testing (FAT/SAT).
system will make it for easier for others to understand and
troubleshoot. Use standard, off-the-shelf components for 3. Is communication complete? While most automation
ease of stocking and reordering. If possible, have two sources suppliers have different software versions for communicating
for the products being used or purchase interchangeable with the system, make sure they will transmit all the
brands. required information. Many systems only transmit the basic
parameters, which means all diagnostic features will not be
2. Remember the basics. It’s the little things that can trip you available. The introduction of the “Control in Field” concept,
up. Make sure you use proper grounding, proper grouping although not often used, has added some complications and
of signals and proper termination of electrical signals. Make needs to be thoroughly examined when implementing a DCS.
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CONTINUED 8 Ideas for Successful DCS Implementation
4. Structuring I/O. Since today’s electronics are available

with high-temperature specs and may be G3 compliant KNOW YOUR PROCESS
(conforming coating), the I/O structures should be moved When using a DCS, you need to
to the field, reducing the rack room footprint and cabling understand the process clearly. Many
cost. Communication links should be used over fiber optic, in times the programmability of the DCS
renders a “take it easy” attitude in the
a ring configuration to provide some level of redundancy, to engineers, leading to costly downtime in
interconnect the field I/O structures. Extended I/O terminal commissioning the plants. Be sure you
blocks (three to four terminals per channel) should also be know the implications of controlling one
way or another. Try to understand the
used to allow field wiring to be connected directly, avoiding
interrelations among the variables and
marshaling terminal strips with the related space, additional the best way to control these.
cost, installation cost and the possibility of poor connections.
5. Dual purpose. The purpose of DCS is twofold. Centralized

human control and interface to the plant as well as a
centralized location for MIS info to the management network.
DCS control should not include auto tuning of control loops
other than simple on/off or start/stop functions. These should
be the function of a local dedicated controller. Use the DCS
to update the tuning parameters.
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CONTINUED 8 Ideas for Successful DCS Implementation
6. Good links. Distributed control systems are only as good as

their communications links. Choose a very solid and reliable DEFINE IN DETAIL
link between processing units. Successfully implementing a DCS project
requires that all stakeholders (operations,
7. FAT is where it’s at. Make sure you do a comprehensive maintenance, project team, vendor,
management, etc.) have a clear definition
and detailed factory acceptance test (FAT) before cutover.
of what they want from the system. In both
FAT involves experienced operations people interacting with upgrading and installing new DCS systems, the
engineering to validate graphics and verify that instruments in best tip is to keep the end in mind. Good up-
the configuration exist and will remain in service. front engineering pays dividends. Automation
technology can only assist us if we know what
the needs are. Maintenance must know what
8. Use single server. Base the selection of a DCS system on reports and information they really require to do
its redundant capability. A single server system is preferred. their work. Operations must be completely sure
how they operate and what is the best way to
Pay attention to the hardware license for client and server to
do it. Don’t assume anything. Write everything
avoid delays during a system or hard-disk crash. Care must down that’s actually required and all the things
also be taken in selecting appropriate layered switches for the technology can do. Be very specific. In the
communication. Make sure you properly configure trends and end, the best DCS is the one that best satisfies
all the important requirements in the plant.
history data for future analysis. Writing and signing this definition document
should be the first step in any project.
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PLC vs. DCS: Which Is

Right for Your Operation?
The DCS, on the other hand, was developed to replace PID
By Jeanne Schweder controllers and is found most often in batch and continuous
production processes, especially those that require advanced
control measures. The vendor handles system integration, and
Over the past decade, the functionality of different control HMIs are integral.
systems has been merging. Programmable logic controllers (PLCs)
now have capabilities once found only in distributed control As users demanded more production information, PLCs
systems (DCSs), while a DCS can handle many functions previously gained processing power and networking became common.
thought more appropriate for PLCs. So what’s the difference PLC-based control systems began to function like a mini-DCS.
between the two control approaches, where’s the dividing line and At the same time, the DCS hybridized to incorporate PLCs
are there still reasons to choose one over the other? and PCs to control certain functions and to provide reporting
services. The DCS supervises the entire process, much like the
PLCs grew up as replacements for multiple relays and are used conductor in an orchestra. Protocols, like OPC, have eased
primarily for controlling discrete manufacturing processes and interactions between the two control systems.
standalone equipment. If integration with other equipment is
required, the user or his system integrator typically has to do Since PLCs are less expensive and can now perform much like
it, connecting human-machine interfaces (HMIs) and other a DCS, wouldn’t it make sense to convert everything to PLCs?
control devices as needed. The answer, like most things in the world of automation, is
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CONTINUED PLC vs. DCS: Which Is Right for Your Operation?
that it depends on the needs of your application. Here are six geographic area with thousands of I/O points, a DCS makes
key factors to consider: more sense.
1. Response time 3. Redundancy

PLCs are fast, no doubt about it. Response times of one- Another problem with PLCs is redundancy. If you need power
tenth of a second make the PLC an ideal controller for near or fault tolerant I/O, don’t try to force those requirements
real-time actions such as a safety shutdown or firing control. into a PLC-based control system. You’ll just end up raising the
A DCS takes much longer to process data, so it’s not the costs to equal or exceed those of a DCS.
right solution when response times are critical. In fact, safety
systems require a separate controller. 4. Complexity
The complex nature of many continuous production processes,
2. Scalability such as oil and gas, water treatment and chemical processing,
A PLC can only handle a few thousand I/O points or less. continue to require the advanced process control capabilities
It’s just not as scalable as a DCS, which can handle many of the DCS. Others, such as pulp and paper, are trending
thousands of I/O points and more easily accommodate new toward PLC-based control.
equipment, process enhancements and data integration.
If you require advanced process control, and have a 5. Frequent process changes
large facility or a process that’s spread out over a wide PLCs are best applied to a dedicated process that doesn’t
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CONTINUED PLC vs. DCS: Which Is Right for Your Operation?
change often. If your process is complex and requires and a generation of experienced process control personnel
frequent adjustments or must aggregate and analyze a large has begun to retire. As a result, the quality of support has
amount of data, a DCS is typically the better solution. Of become a critical factor in vendor selection.
course, the very flexibility of a DCS system also makes it
much more vulnerable to “meddling” by operators that can
cause spurious shutdowns.
6. Vendor support
DCS vendors typically require users to employ them to
provide integration services and implement process changes.
System integrators perform similar functions for PLC-

based systems. It has also become common for PLC
vendors to offer support services through their network of
system integrator partners.
Process control has become increasing complex. It’s

difficult for any individual to know everything about these
sophisticated systems, increasing the need for vendor
support. Manufacturers also continue to reduce factory staff
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Procedural Automation for

Greater Safety and Productivity
with sudden emergencies, as well as the more routine changes
By Jeanne Schweder in state that can occur.
Processing’s most vulnerable areas

Continuous process environments tend to be stable—until The fact is, every continuous process has non-continuous
they’re not. When that happens, the consequences can be elements, such as startup, ramp-up, emptying and filling of
catastrophic. Think Deepwater Horizon. tanks, shutdown, emergency shutdown and clean-in-place
activities. A continuous process is really just a batch process
The very stability of a continuous production process often with a very long steady state in the middle.
induces a false sense of security in operators. Lack of
experience with system failure or unexpected alarms can The ISA-88 standard has established a common terminology
lead operators to freeze when systems suddenly cascade and a framework for writing software to control batch
out of control. production processes and procedures. ISA-95 did the
same for enterprise to manufacturing data integration.
Procedural automation standards originally developed for ISA-95’s “common denominator” data structure facilitates
batch processes and discrete manufacturing hold promise for communication between business and process systems, so
helping continuous process operators deal more effectively that operators and managers can make better decisions.
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CONTINUED Procedural Automation for Greater Safety and Productivity
The thinking behind both of these standards has important ISA-106 defines continuous process procedures
implications in areas where continuous process control is most A new ISA committee is working to develop standard
vulnerable—process variations and disruptions. These can methods and terminology for automating continuous process
result in unanticipated shutdowns that plant operators can be procedures. “ISA-106, Procedural Automation for Continuous
ill equipped to counter because they’re not confronted with Process Operations”, will define repeatable procedural steps
them frequently enough to hone their skills. that can lower the chances of accidents due to human error.
The intent of the new standard is to reduce process variability,
Automating procedural steps can counteract variations in reduce risk to facilities and increase operational productivity
operator skills and will become increasingly important as the in continuous process industries.
current generation of experienced process control engineers
retires. Defining common process procedures can also The ISA-106 committee plans to issue a series of documents
provide additional support for employees who are executing to help users standardize designs to handle operator errors in
operations that can be more manual, as is typical in equipment normal, critical, and abnormal situations.
and plant startups, shutdowns and transitions.
As a first step, the ISA-106 committee, which includes
representatives from the largest companies in the
petrochemical industry, is working on its first technical
report targeted at oil refineries, upstream offshore oil
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CONTINUED Procedural Automation

for Greater Safety and
Productivity
rigs and chemical plants. The report will give
users common definitions to describe the
requirements in improvements, upgrades, and
changes in procedural automation to system
integrators and automation suppliers.
The technical report will also include standards

for modularizing procedural steps, exception
handling for abnormal situations, state mode
procedural logic, process unit orientation and
current practices.
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13 Suggestions for Control

System Migrations
As anyone who has been involved in a control maintenance, proactive incident response,
system migration will tell you, it’s never production execution, etc.) and the different
an easy process. Whether it’s an upgrade, degrees of automation (automating just a few
expansion, stepwise migration or rip-and- actions, partial workflows or end-to-end) will
replace, the bigger and more complex the determine your strategy in terms of resources,
project, the more fraught with tension and time scale, production stops, etc.
risk. To help you get through the project with
your sanity intact, Automation World readers 2. Virtualize first. Automation upgrades or
share their recommendations and suggest migrations need to be scheduled properly in
pitfalls to avoid: terms of system commission date to extend
the warranty or for a vendor’s obsolete
1. Determine strategy. Your migration strategy notice date. The best practice is to conduct a
will depend on which type of automation virtualization of the new automation system.
you’re dealing with: scripts, workflow tools, The future of automation will need virtualized
policy-based orchestration, configuration infrastructure and platforms to deal with
or control systems. The different activities the IT spectrum, cyber security and better
that can be automated (provisioning, management capabilities. Virtualization
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CONTINUED 13 Suggestions for Control System Migrations
has many benefits in terms of technology, investment, 5. Consider three critical migration issues. When doing a
maintenance and lifecycle cost. migration there are three points to think about: how to update
software and whether you have the right conversion tools; what
3. Take it one step at a time. Avoid changing the entire system you need to do to avoid system failure or risk for the migration
or manufacturer if you are upgrading. Upgrading to the newer step; what is the expected lifecycle of the new system.
modules or systems of the same vendor provides a bit more
reliability, since the basic architecture remains the same. 6. Make no assumptions. Try to foresee every small step in
a migration implementation. Don’t assume anything. Every
4. Don’t experiment. While innovation is important, there implementation is done to achieve some objective of the
is a counter-argument for doing what you know will work. operation. The needs could range from some reporting or alarm
If rip-and-replace is possible (and that means you have to functions to an action initiated due to alarm. Always visit the site
stop the plant for several days, weeks, or months depending to understand the requirements and the nuances completely.
on the circumstances) and you know that it works, that is
the best choice. But if you can’t afford a shutdown, then go 7. Changing suppliers adds some complexity. The difficulty
for a step-by-step migration. Make sure you work with an of a process migration usually increases when you change
experienced vendor and proven technology. DCS suppliers, since different brands often don’t have similar
functions. Factor that into your timeline and risk assessment
when weighing whether to switch vendors.
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CONTINUED 13 Suggestions for Control System Migrations
8. Start with data needs. First you need to understand what 11. Technology education. It is important to educate everyone
data the user will require and how quickly the data is needed. on the new technology. Remember, it is easy to use “old”
That should be the starting point in developing your migration thinking instead of changing practices to take advantage of
strategy. The second priority is to determine the impact on the benefits of the new technology.
the safety and productivity of the plant.
12. Decentralize. The architecture has to be critically reviewed
9. Focus on controllers. The best strategy is to first upgrade and transformed, keeping in view the improved performance
the controllers, then replace the I/O chassis piece-by-piece of the local controllers. Your mantra should be to decentralize
going forward. Some I/O changes could be driven by other the controls as far as possible.
projects, such as a motor control center(MCC) replacement.
13. Aging equipment. Depending on the technology you
10. Do your homework. Do some upfront analysis to avoid have installed, when your equipment is more than 10 years
creating problems for yourself by not choosing the right old you will need to implement a rip-and-replace. If you are
migration path. For example, migrating from one generation just making some modifications you can upgrade or make
of processor to another one may not be a wise choice. an expansion only. Most of the problems that arise during a
Reviewing the instruction sets and information available about migration are with the field equipment you have installed and
conversions and manufacturer recommendations will give you control room facilities.
insight into the difficulty of the conversion. If you do your
homework, you might choose a different processor to make
the conversion easier.
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Managing for Reliability

Key to Asset Performance
and quality issues, while the other was performing to goals.
By Jeanne Schweder The question was, why?
Proactive vs. reactive maintenance

The powerful combination of smart devices and An analysis by an automation supplier found the answer. The
communication networks has great potential for helping findings revealed the root cause of the disparity: the plant
industrial plants achieve significant gains in productivity and experiencing difficulties operated under a run-to-failure
efficiency. But making that happen requires companies to use philosophy for maintenance, spending nearly 35 percent of
the information from their production equipment to change maintenance time on unscheduled corrective procedures.
their asset management and maintenance practices.
In contrast, the plant meeting its goals spent only eight
Take the example of two plants, owned by the same company percent of maintenance time on unscheduled activities.
but located on opposite sides of the globe. The two sites More revealing, 34 percent of their maintenance time was
made the same products, using identical production spent on preventive maintenance, and another 12 percent
equipment, quality specifications and automation systems. on optimizing assets. Employees at the proactive plant also
They both spent a similar amount of time on maintenance. received more than three times the amount of training as
Yet one plant was experiencing constant failures, shutdowns those working at the reactive plant.
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CONTINUED Managing for Reliability Key

to Asset Performance
Unfortunately, this lack of training is not uncommon at plants

with a reactive approach to asset management. Reactive
managers assume it’s less costly to fix something only when
it’s broken and they know what to fix. They see training as
wasted dollars. But industry experts will tell you this is a
mistake and results in frustrated engineers who take longer
to solve a problem and are unsure of the best practices to
use to make sure the problem does not come back.
Proactive-minded users, on the other hand, have seen the

benefits of this service philosophy. They see training and
certification as an investment to ensure not only that results
don’t erode, but that production and quality performance
continue to improve.
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Measure First to Improve

Control System Performance
Most continuous process plants have lost millions of dollars or more. A typical oil refinery may have 3,000 control loops,
from poor control system performance, yet many plant with 600 to 900 in manual at any given point, representing
managers and engineers are unaware of these losses. a lost investment of over $6 million. And that doesn’t even
To capture savings, you must measure and manage the count the annual process losses, which are at least as high.
performance of your
control system.
Basic steps, such as

measuring the percentage
of the plant running in
manual mode, are a good
place to start. A typical
process plant runs with
between 20 and 30 percent
of controls in manual mode.
Consider that a typical
control loop costs $10,000
FIGURE 1 – Square wave /sawtooth pattern indicates valve stiction.
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CONTINUED Measure First to Improve Control System Performance
Additional simple measures, such as the percentage of control The next step is to measure and monitor control performance
valves at a limit, and overall variability, can give you a better regularly. Software tools can monitor various measures,
idea of the opportunity for savings at your plant. Start by provide reporting and notification of problems. This step is
taking a random sample of 100 control loops. In one hour critical to recognizing where problems exist in your plant on
sitting with the operator, you can confirm whether your plant any given day.
has a significant opportunity to improve.
FIGURE 2 – Ladder pattern on FIGURE 3 – Power spectral density

PV vs. CO plot confirms stiction. chart identifies oscillations.
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Automated monitoring also allows for more sophisticated various parts of the process, need more sophisticated analysis.
measures and diagnostics. Modern software tools can find Tools such as Fourier Transforms and the resulting power
failed instruments, broken control valves, poorly tuned spectrum chart, shown in Figure 3, can find the cause of
controllers and process problems. These analytics are needed oscillation problems.
for the next step: resolving the root cause of the problem.
Process Interaction analysis, as shown in Figure 4, can also be
If 30 percent of controllers are operating in manual mode, the used to pinpoint the cause of a problem that may be far
solution is not as simple as putting everything into automatic upstream in the plant.
mode. Chances are, the operator put these controllers in
manual for a reason. Any good control performance project With the problems identified and prioritized, your focus can
can use data from your process historian to help pinpoint and now turn to managing the required repairs, tuning changes
resolve the true root cause of the issue. and process adjustments. This work should be managed and
organized like any project: with specific plans, assignment of
Some problems, such as valve stiction, have a unique signature responsibilities and expected completion dates. Some repairs
pattern, as shown in Figure 1. The square wave pattern on the may need to wait until planned shutdowns, but others can be
process measurement and sawtooth movement of the control completed on the fly.
output are a sure sign of valve stiction. The ladder pattern in the
PV/CO plot shown in Figure 2 further confirms valve stiction. Finally, it is important to track the effect of these
improvements. A simple before/after trend can be very
Other problems, such as oscillations and interactions between useful to show the results. Whenever possible, you should
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also identify the economic impact of your work, and share it

with your management team.
If you have enough staff at your plant, each of these steps can
be accomplished in-house. Experienced software and service
suppliers can also provide all or part of these activities as a
service, starting with site evaluation and progressing all the
way through capture of benefits and sustaining the results.
What kind of results can you expect? That depends, of

course, on your starting situation. But it is common to
see reductions in variability that lead to energy savings,
production increases and quality improvement. Because
automation system improvements have a direct effect
on process results, the return on investment is typically FIGURE 4 – Process interaction map pinpoints
measured in months, not years. the root cause of process problems.
This article was adapted from content provided by George

Buckbee, P.E., ExperTune
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10 Steps to Creating
the Perfect HMI
When developing HMI screens, realize that you are the display according to the amount of information that
attempting to capture the essence of the machine or process, is most important for the operator to see. Always discuss
not just posting key automation variables and control requirements with the equipment’s operators well ahead of
mechanisms. Operational feedback is vital for efficient HMI time, not just with their managers. Operators usually have
screen layouts. Think of yourself as an artist, commissioned by different needs and the success of your system depends on
manufacturing operations to create the HMI screens. their usage.
1. Less is more. It’s important to keep the HMI simple and with 3. Design tips. A good design requires careful use of layout,
the operator in mind. It’s best when it’s self-explanatory and color and content. If you get it wrong, your operator misses
easily understood. Also, try to make the pages similar and an indication, you lose money, or worse, someone is injured.
follow the same page layout throughout. Avoid making the The “bad” screen is less than satisfactory: The layout is poor,
display too technical. It’s normal for engineers to try to give the plant representation isn’t logical and the screen layout
the customer everything, but with HMI, less really is more. makes it difficult to locate the data. Poor selection of colors,
excessive use of capitals in a serif font and repetitive use of
2. Right-size displays. Don’t try to save money by selecting units with all data values makes this a really difficult screen to
an HMI display screen that’s too small. It’s also important read—especially at a glance or from a distance. Avoid colors
not to cram too much information onto a screen. Size that could create problems for people with color blindness.
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CONTINUED 10 Steps to Creating the Perfect HMI
Minimize the use of colors to allow actual device

state and alarms to stand out. For alarming, choose
colors that contrast with the normal process view
so the operator will notice the change.
4. Plant review forum. Hold a design review with

a group of plant personnel to discuss any status
notifications, events, alerts and alarms that need
to be programmed, both from the perspective of
an audio-visual action and an operations response.
Step through the intended functional system, once
as the designer, once as the user and then invite
at least two levels of users who will be interfacing
with the HMI. Doing this prior to specifying
equipment helps to identify the features that users
will want in the HMI station. It also avoids surprises
at point of commissioning.
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CONTINUED 10 Steps to Creating the Perfect HMI
5. Location, location, location. Real estate can be prime in information from the process database for the historian. This
a busy production area. Locate the HMI in a practical place, will reduce the load on the system and keep it from stalling or
out of heavy traffic areas but accessible. Be aware of near- failing. Don’t forget the need for maintenance and make sure
future projects in the area. Guard the HMI location so others you schedule periodic backups.
don’t park or configure something else on top of the station.
9. Think about flow. It is essential to have a clear design
6. Back up work periodically. Backups are especially important approach to the HMI. Decide how the display blocks naturally
before implementing upgrades or changes. Software such flow and how sections need to be grouped together for
as Norton’s Ghost Image can be invaluable to support and the operator. Do not blindly follow P&I diagrams. The S88
maintain HMI systems. functional hierarchy is a good place to start. Make paper-
based designs to get a feel for screens, navigation and other
7. Visualize the process. HMI graphics should illustrate the requirements, and review with clients prior to designing and
production process in the plant to provide better visualization making electronic screens.
to the operators, giving them a sense of the action that’s
required. Use hardware that meets minimum requirements 10. Alarm strategy. Alarming needs to have a well-
and keeps the number of failure points low and assures high articulated strategy. Alarms must be used for conditions
availability of the system. that require intervention and must have a clear corrective
action associated with each one. Anything else should not
8. Only essential data. Make control and monitoring of be an alarm.
the process simpler by selecting only the most essential
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Practical Tips for

Implementing Intrinsic Safety
North American companies are beginning to move toward and non-incendive instruments can be used. There is little to
intrinsically-safe systems, already well established in Europe, no difference in the cost of explosion-proof non-incendive
that use currents and voltages too low to spark an explosion and intrinsically safe instruments, but non-incendive devices
in a hazardous environment—and away from costly explosion- do not require intrinsic safety barriers. Someday, perhaps,
resistant wiring or construction. Their experiences suggest a wireless will solve this dilemma.
number of tips and pitfalls to avoid when considering whether
to implement intrinsic safety in an installation. 2. Weigh safety alternatives. Both intrinsically-safe and
explosion-proof products are going to cost a premium.
1. Evaluate by zone. Removal of one of the three sides of the However, explosion-proof tends to be so heavy-duty and
fire triangle is always a good idea, but not necessarily cost- huge that it causes space issues and is more likely to injure
effective. Most process plants are not Zone 0 rated, which the personnel who have to install it. There is also a real
requires intrinsically safe-rated or inherently safe instruments possibility that the mount for an explosion-proof device
such as pneumatic or wireless. Even wireless instruments, if will be homemade and not engineered, which could lead to
they are not rated intrinsically safe, may not be suitable for other injuries. As long as the equipment is durable enough to
maintenance in a Zone 0 plant area. For most chemical and withstand the application, intrinsically safe is recommended
oil and gas plants, operational areas are now classified Zone 1 over explosion proof.
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CONTINUED Practical Tips for Implementing Intrinsic Safety
3. Do it right. Using the right barriers and the proper certified 5. Limit risk. Don’t operate equipment in hazardous areas
devices at both the field and the systems end should solve needing intrinsic safety systems. As for operator safety, keep
the problem. The standards clarify the requirements and it is control signal voltages below 24 VDC. No human-operated
absolutely essential that the standards be followed with zero selector or push button should have voltages over 24 VDC. It
exceptions. It also makes sense to seal conduits to eliminate simplifies servicing and monitoring.
the migration of hazardous gases. With all systems, proper
grounding is very important. No compromise should be 6. Protect controllers. If you are installing intrinsically
tolerated when it comes to safety. safe systems, it’s very important to protect all automation
controllers and module cards. Intrinsic barriers for fieldbus,
4. Test everything. The most important thing when Modbus and conventional I/O card loops is a best practice.
implementing an intrinsic safety system is to test it. Make
sure that what has been done is correct so you can sleep 7. Troubleshooting issues. Intrinsic safety brings along some
well at night. Test the design and the system, make it pass all troubleshooting issues. Any time you decrease your current
the assessments and put it as a requirement for the project. you allow the possibility that smaller voltage drops will give
It will be first page news if something goes wrong, so make you bigger issues. Inputs and outputs are easily affected by
sure to supervise the installation very closely, and be sure loose connections on intrinsic safety circuits. Make sure all
that the design is not changed at the execution. connections are tight and practice good wiring practices to
minimize this issue.
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8. Less maintenance. An intrinsically safe solution is 10. Hardware intensive. Security people may think all the
recommended over explosion-proof technology if only areas need to be explosion proof. It really depends on the
a limited number of instrument loops are involved. After experience with your equipment or plant. Look at incident
implementation, this technology does not require any special statistics and the problems you see to determine where
maintenance attention compared to the traditional North you need intrinsic safety and where not. Implementation
American approach. There are even DCS I/O modules that of intrinsic safety is often very hardware intensive, so many
are IS-certified and do not require a separate IS barrier. By plants try to avoid it. Many PLCs and hardware out there are
refurbishing with low power equipment, you can reduce the Class 1 Div. 2 compliant. A separate IS implementation may
surveillance rounds and maintenance checks. not be essential.
9. Voltage drops. Do not neglect the voltage drop due to 11. Alternative approaches. Early in a safety project, develop a
resistance of field wiring when designing 4-20 mA loops. comprehensive P&ID followed with a hazop review to assess
During commissioning, it is common to find loops that risk and identify safety issues. This will allow you to investigate
functioned properly at low currents but stopped operating alternative ways to minimize risk, such as process modifications
entirely as the current approached 20 mA. This is because or changes in the type of process equipment. The intent is to
enough voltage dropped across the field wiring to reduce minimize the need to implement an SIS system or to minimize
voltage across transmitters to less than the compliant SIS loops. Focus safety efforts on protecting the areas of the
voltages they needed to operate. process most critical to the continuity of production.
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12. Preliminary testing. Prior to designing a safety system,
it’s essential to prepare the safety system using a preliminary
testing procedure that places the process equipment out of
service. Whether a safety system is operating properly needs
to be verified before starting up process equipment. It should
also be tested independently, without using engineering
station simulation tools. This is especially important for
a boiler burner management system. Signals from safety
instrumentation may be used for process control tasks, but
signals from process control loops can never be used for
safety tasks. Root valves for control and safety transmitter
impulse lines need to be separate.
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Wireless Sensor Applications

then sends a signal to the pump controller to start pumping
By David Greenfield out the tank to lower the level. When the fluid level drops to
Director of Content/Editor in Chief, Automation World a safe level, the switch then sends a signal to the controller
to turn off the pump.
If you’re working in a facility without a great deal—or any—
wireless sensors in place, you may be suspicious about the • The safety and security of oil pipelines is largely handled by
viability of wireless sensor networks. To help illustrate how wireless sensor networks, according to Steve Toteda, vice
ubiquitous wireless sensors have become across industry, president and general manager of the wireless business
following are a few examples of wireless sensor deployments unit at Cooper Industries and chairman of the Wireless
that have become so common that they could be considered Industrial Networking Alliance (WINA). “We’re doing
textbook application examples. a lot of work in Mexico now to monitor and maintain
oil pipelines,” he says. “In these applications, there is
• Wireless limit switch networks are commonly used to a hierarchy of networking tools with sensor networks
prevent the overflow of liquid storage tanks. Their operation being used with instrumentation on the pipeline itself to
is simple: As the tank fills up, the fluid level forces a change capture data and transmit it back to the control system via
in the position of the limit switch. The wireless limit switch high-speed backhaul. This combination of technologies—
wired, wireless and cellular—has really brought wireless
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CONTINUED Wireless Sensor Applications
to the forefront because you’re mixing multiple

technologies to monitor pipelines in 20-30 km
segments. As you do this with several segments,
you’re effectively able to monitor hundreds of
kilometers of pipelines.
• A
major pharmaceutical manufacturer recently
decided to instrument all of its R&D equipment,
such as incubators and cryofreezers, and connect
them to the company’s control systems for 24/7/365
monitoring. Because much of this equipment has
casters, it was difficult to wire them, as they need to
be moved around. This project is still ongoing, but
there are currently nearly 2,000 pieces of equipment
equipped with wireless sensors on the company’s
R&D campus, which covers an area of about 1.5 km.
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Managing Emissions
With Automation
industrial facilities, including trash burners and industrial
By Jeanne Schweder boilers, even if they only generate process steam. More
stringent controls on particulates will also require new
investments in emissions technologies.
Industries where emissions control is critical include electric
utilities, oil and gas, chemical processing, iron and steel, NOx and SOx reduction
paper, food, mining, metals and cement. But emission control The U.S. Clean Air Act, the Clean Water Act, the pending
concerns are not limited to these industries. Systems to Casper regulations and proposed Environmental Protection
control and reduce emissions are required for any industrial Agency (EPA) limits on greenhouse gases are driving the
process that produces sulphur and nitrogen dioxides development of improved emissions control technologies.
(popularly referred to as SOx and NOx), the major causes of Casper regulations will further reduce NOx and SOx emissions
acid rain, as well as airborne particulates and volatile organic limits in the Northeast and in certain states such as Texas
compounds (VOCs). and Illinois. In addition to these government measures, green
initiatives by corporations also emphasize emission reductions.
On the horizon are new regulations designed to limit
mercury emissions in flue gas. These rules will also apply to The list that follows touches upon the primary emission
reduction methods used in industry:
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CONTINUED Managing Emissions With Automation

• Optimized process control is central to reducing NOx emissions and control heat levels within the boiler to
emissions from coal-fired power plants. Oxygen is injected prevent the build-up of slag. By tightening process controls,
into the boiler to improve combustion and prevent pockets operators can decrease the amount of raw materials and
of NOx from being created. A secondary technology, energy used while reducing waste.
selective non-catalytic reduction, or SNCR, injects urea or
ammonia into the boilers, further reducing NOx emissions • Scrubbers, using either dry or wet processes, use automated
by up to 20 percent. New low-NOx burners have also been systems that regulate water flows, monitor pH levels and
introduced that allow a cooler, more complete burn. spray lime or apply a slurry of limestone to remove 95
percent or more of sulphur dioxide. A by-product of the
• The most successful NOx reduction technology—at 90 scrubber process is calcium sulphate, which is then used to
percent—has been selective catalytic reduction (SCR). This make wallboard.
capital-intensive technology, which is viable only for large
coal-fired plants, involves very large reactors and again • At the stack, the air from the process is passed over a rack
injects ammonia into the flow. Automated systems measure of sensors that measure oxygen, carbon dioxide and carbon
NOx levels before and after the reduction process, enabling monoxide levels, as well as sulphur dioxide, sulphur trioxide
operators to fine-tune the process. and nitrogen oxide content.
• Distributed control systems (DCSs) manage the complex • Most air pollution control devices (APCDs) come as pre-built
processes involved in balancing boilers, injecting air and OEM packages that include PLC-based automation systems
adjusting dampers to optimize combustion, measure that tend to operate independently of the central DCS.
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As new regulations drive greater investment

in these APCDs, these systems will need to
work together in a more holistic fashion.
Achieving this goal will likely require additional
automation integration.
Alternative fuel strategies

Although coal has traditionally made up 50
percent of the fuel source for American electric
utility plants, many operators have begun
building natural gas-fired plants that do not
produce nitrogen or sulphur dioxide. Others are
using flexible fuel processes, replacing up to 25
percent of their coal fuel with natural gas. Still
others are blending coal from different regions,
mixing high-sulphur but lower cost Appalachian
coal with low-sulphur but higher cost Western
coal to reduce the amount of sulphur dioxide
their processes have to remove.
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Each of these alternative fuel strategies,

however, can complicate process control
and require additional steps and systems to
optimize combustion and reduce emissions.
Blending high- and low-sulphur coal, for
example, can create a slag layer in boilers
that requires installing a soot-blowing
system to break up and remove it.
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VENDOR SELECTION RESOURCE GUIDE PEPPERL+FUCHS
Pepperl+Fuchs: An Innovator in the Field of

Industrial Sensors and Explosion Protection
Pepperl+Fuchs is one of the world’s leading providers of industrial
sensors and explosion protection. For more than 70 years, we have
continued to develop new components and solutions to support
our customers’ applications. Pepperl+Fuchs is a leading supplier
of automation equipment for a wide range of industries and has
been associated with sensors, sensor solutions, and safety in
hazardous areas for decades. Our vast expertise enables us to offer a
complete range of automation solutions for the factory and process
automation industries.
Pepperl+Fuchs’ product portfolio for explosion protection includes

intrinsic safety isolators, Zener barriers, signal conditioners, fieldbus
technology, Remote I/O, HART interfaces, level measurement, purge Our product portfolio of industrial sensors for factory
and pressurization systems, Human Machine Interfaces (HMI) for automation is characterized by a high degree of innovation. It
hazardous environments, custom cabinets, and junction boxes. A new consists of inductive, photoelectric, capacitive, magnetic, and
addition to our explosion protection portfolio is the ecom line of ultrasonic sensors. Additionally, we offer powerful components
intrinsically safe mobile devices, including phones, tablets, cameras such as rotary encoders, positioning and identification systems
and watches designed for use in hazardous and explosive areas. (RFID, Data Matrix, and Barcode),
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AS-Interface, as well as suitable accessories. Industrial vision systems

and vision sensors round off the comprehensive product range. With
the acquisition of the business of Comtrol Corporation, a US-based
pioneer in industrial Ethernet communication and IO-Link Masters,
Pepperl+Fuchs has enhanced its portfolio of forward-thinking
Industry 4.0 solutions. By expanding our range of Ethernet-based
communication products and field-interface devices with industrial
Ethernet switches, serial to Ethernet gateways, and IO-Link masters
with OPC UA standard, Pepperl+Fuchs now offers a comprehensive
portfolio that seamlessly integrates into your plant while enabling
data flow from field devices directly into the cloud.
Factory automation markets include mechanical engineering,
Different industries present different automotive industry, material handling, packaging, print and paper
engineering and manufacturing challenges. industry, doors, gates and elevator construction, process equipment,
mobile equipment, and renewable energy.
Market-based, customer-focused products mean that customers
get industry solutions optimized for their industrial automation Pepperl+Fuchs pioneered the development of the proximity sensor
operations. We provide process industry companies all over the more than 50 years ago, and today we continue to set the standard
world with proven components and tailor-made solutions for a for innovation and quality. We take great pride in our ability to solve
diverse range of applications in markets including the oil and gas problems with products that nobody else can match. Around the
industry, petrochemical, chemical industry, pharmaceutical industry, world and in our own backyard, Pepperl+Fuchs sets the standard for
as well as wastewater treatment plants, and power technology. excellence in automation.
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WEB RESOURCES COMPANY CONTACT
Pepperl+Fuchs, Inc.
1600 Enterprise Parkway
Twinsburg, Ohio 44087
R10/R20X VIDEO 330-425-3555
R10x and R20x Series for Maximum Performance www.pepperl-fuchs.com
COMPANY CONTACT
ECOM WHITEPAPER Robert Smith,

Mobile Device Safety in Hazardous Areas
Chief Operating Officer
Twinsburg, Ohio
(330) 486-0031
rsmith@us.pepperl-fuchs.com
HMI VIDEO
Engineered VisuNetHMI Solutions by Pepperl+Fuchs
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VENDOR SELECTION RESOURCE GUIDE Schmersal
Machine Safety Solutions And

Engineering Services For Your Industry
Machine safety is a complex topic. Companies are increasingly integrated a Bluetooth
calling on qualified safety specialists for their specific know-how interface into our
to guide them in making the appropriate decisions for their safety safety light curtains, so
needs. For Schmersal machine safety is part of our DNA: 75 operators can access
years of technical knowledge and industry experience allows us important operational
to combine the building blocks of safety-rated components with data via smartphones or
control systems and software for customized and comprehensive tablet computers. We
safety systems. Our mission is to provide safe, reliable, and take pride in our ability
innovative solutions oriented towards ensuring the safety of to develop new ideas
man and machine. We are developing sustainable and long-term to meet the changes in
alliances which benefit our customers by continuously improving industry applications for
our processes through technology and market experience. machine safeguarding.
Machine safety has changed over the years and Schmersal products As machine safety becomes more connected to machine
have evolved to meet the demand of local and international automation, Schmersal is at the forefront of connectivity, industrial
requirements. We have embraced new technology, such as enhanced networking, and communications. SFB safety field boxes allow
RFID devices for the most stringent safety needs. We also designed for series connection and free interlinking of up to eight safety
IP69K rated products for extreme wash down applications to meet switchgear devices, via plug and play connectors, to PROFINET
requirements such as the food modernization act. We recently or PROFIsafe fieldbus. Electronic devices with Serial Diagnostic
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capabilities can be integrated in to popular field bus systems via SD Gateways.

Our PROTECT PSC1 is a programmable, modular safety controller which includes
the development of custom applications and their integration into higher-order
control systems. And we’ve partnered with AS-I to provide safety components
with integrated AS-Interface for easy installation into their system. These four
installation systems are available for optimal personal safety and process safety
in complex machine plants
Through decades of experience our safety focus has given us the experience
to become knowledge leaders in machine safety automation which has led to
the Tec.nicum Engineering Services Group. With tec.nicum we offer customers
a product- and manufacturer-neutral consultation on all the latest statutory
guidelines and assist them in designing their machines and workplaces to be safer
places. The Functional Safety Engineers at SCHMERSAL tec.nicum are certified
by TÜV Rheinland and have hands-on practical expertise in the field of safety
technology thanks to many years of experience from working with machine
builders, facility engineers, and with various associations and institutions. They
can perform Risk Analysis, stop time measurements, and provide documentation
and validation of safety systems. Client specific education sessions designed to
give customers tailored training for their specific needs. Sessions include general
machine safety, safety circuits & wiring, risk assessment, and others.
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CATALOG Schmersal USA

Find safety products in our 15 Skyline Drive
Online Product Catalog Hawthorne, NY 10532
products.schmersal.com/en_US
914-347-4775
VIDEO
Our YouTube channel has
product demos and webinars
www.youtube.com/user/SchmersalUSA COMPANY CONTACT
Gary Ferguson
WHITEPAPERS Managing Director
Explore more safety 914-347-4775 x601
topics in technical articles Hawthorne, NY
www.schmersalusa.com/service/
gferguson@schmersal.com
technical-articles/
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VENDOR SELECTION RESOURCE GUIDE Universal Robots
Universal Robots Continues to

Pioneer Collaborative Robotics
Ninety percent of physical tasks performed in production less than an hour. That’s the time it takes an untrained operator
environments today can’t be practically or economically automated to unpack the robot, mount it, and program the first simple tasks.
with conventional robots unable to adapt to real world variability Programming is intuitive; users simply grab the robot arm to
in the workspace or operate effectively in semi-structured teach the desired movement, or use the touch screen. Product
environments. By offering a user-friendly, affordable robot that portfolio includes the UR3, UR5, UR16 and UR10 robot arms
works right alongside people on ever-changing tasks, Universal named after their payloads in kilos, they feature down to 30 Micron
Robots (UR) has lowered the automation barrier, pioneering the repeatability and span in reach from 19.7” in to 51.2”.
collaborative robot industry, now the fastest growing segment of
industrial automation. UR’s collaborative robots – or cobots – deliver
all advantages of advanced robotic automation with none of the
traditional added costs associated with robot programming, set-
up, and shielded work cells. The Danish-designed cobots automate
production in all industries – even in SMEs that regard automation as
costly, cumbersome, and difficult to integrate.
As the UR cobots take over the “3D jobs” – the Dull, Dangerous
and Dirty – employees with no prior programming experience
are now promoted from operators to robot programmers. The
“out-of-box experience” with a collaborative UR robot is typically
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The lightweight UR robots can be easily be moved and Included in the UR+
redeployed, automating high mix/low volume production runs. program is UR’s own
Force-sensing technology in the e-Series makes the robot stop ActiNav, a flexible
operating when encountering an employee, eliminating the need machine loading kit.
for safety guarding in most scenarios. This unique feature greatly ActiNav empowers
reduces the complexity and uncertainty involved in performing manufacturers
pre-deployment risk assessments. with little to no bin
picking deployment
With more than 50,000 units sold globally, the four Universal expertise to quickly
Robots cobot models hold a 50%+ global market share; more than all achieve high machine
competitors combined. uptime and accurate
part placement
Universal Robots also pioneered an entire ecosystem of accessories with few operator
for their cobots, called UR+ (pronounced “UR plus”). The UR+ interventions. It combines real-time independent motion control,
showroom is a rapidly expanding portfolio of plug & play products collaborative robotics, vision and sensor systems in one easy-to-use,
certified for seamless integration with the UR cobots. The program, fast-to-deploy and cost-effective kit.
which includes individual components and application kits, features
a wide range of grippers, machine vision, software and protective Universal Robots’ US headquarters is in Ann Arbor, MI, and has local
equipment, currently featuring 130+ different solutions with close to offices in New York, Los Angeles, Boston and Dallas, plus a network
400 companies participating in the developer program. of more than 100 distributors and integrators across North America.
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CASE STUDIES Universal Robots USA

See real-world case study videos 5430 Data Ct, Suite 300
featuring UR cobots. Ann Arbor, MI 48108
View Case Studies
1-844-GO-COBOTS
E-BOOKS (1-844-462-6268)
Get educated about UR cobots
with these helpful ebooks.
Download Ebooks
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VENDOR SELECTION RESOURCE GUIDE Wago
WAGO Corporation provides North America with

innovative Interconnect, Electronic Interface, and
Automation solutions. Headquartered in Germantown,
WI, WAGO features state-of-the art manufacturing
and 75,000 square feet of storage capacity for 37,000
product locations. Extensive engineering resources,
a 25,000+ product portfolio, custom manufacturing,
and a global network of dedicated professionals
ensure WAGO has the resources and expertise to help
you get the job done. To see our capabilities in action,
watch the video at www.wago.us/capabilities.
RECENT INNOVATIONS:
A Modern Approach to
IP67 Rated Distributed I/O
The IP67 rated I/O SYSTEM FIELD provides dependable,
cabinet-free automation designed to meet the
requirements of modern decentralized production applications. Both modules support popular IIoT protocols as well
facilities. There are two types of housings available; cast zinc as industrial fieldbuses. With configurable DIO ports and innovative
housings with encapsulated electronics for harsh environments, load management, one SYSTEM FIELD module can do it all.
and lightweight non-encapsulated plastic housing for mobile Learn more: www.wago.com/us/discover-io-systems/field
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Meet the Heart of Your Control Cabinet:

Highly Efficient Power Supplies
Pro 2 Power Supplies include 6 units with up to 96.3% efficiency
that incorporate an interface allowing them to be tailored to any
application requirement. These units also offer monitoring functions
that provide continuous power supply data information and signal
errors for application monitoring. The Pro 2 also has an easy
fieldbus connection with snap-on communication modules with
WAGO’s exclusive high-performance TopBoost and PowerBoost
capabilities, maximizing system uptime and lowering hardware
costs. See where it will fit in your application: www.wago.us/pro2
Lean Managed Switches Optimized for Industrial Networking

Lean managed switches are engineered for use in industrial environments
that are installed and maintained by control minded automation
engineers. Unique tools such as a graphical active topology map and
diagnostic dashboards provide users information to easily monitor and
troubleshoot any industrial network. These switches are equipped with
network tools that control engineers need without the overhead of IT
related features that are not commonly used on the plant floor.
Watch the video: www.wago.com/us/lean-managed-switches
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WAGO Corporation
Design your DIN Rail with
N120W19129 Freistadt Rd. Germantown, WI 53022
the Online Configuration Tool:
configurator.wago.com/profile/login 1-800-DIN-RAIL (346-7245)
www.wago.us
Video Series:
Our customers’ moments of success:
wago.com/us/moments-of-success
Interested in purchasing our products?

Find out where to buy:
wago.com/us/store-finder/wholesaler/us
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VENDOR SELECTION RESOURCE GUIDE Winsted
Winsted is a worldwide leader in control room console solutions. combine the disciplines of industrial design,
We create attractive, ergonomic consoles that work with your ergonomics and interior design to create
operators to improve comfort and optimize efficiency. We offer solutions that are both efficient and eye-catching. We give special
stock, customized and custom consoles suitable for any control consideration to the ergonomic requirements of your operators to
room application. Whether you are building a state-of-the-art build consoles that reduce fatigue, improve productivity and inspire.
control room from the ground up, or simply need to upgrade your Our commitment to customer service is second-to-none and your
operations, Winsted can provide the ideal solution. Our experts satisfaction is guaranteed.
Since its inception in 1963, Winsted has consistently been a pioneer

in product design and development. Product concepts and designs
are driven by industry needs and demands, with many product
ideas suggested by customers and developed with their input.
Our modular system approach, developed for the early broadcast
industry, has become the industry standard for all markets, and our
experience developing specialized custom products enables us to
offer console and furniture solutions for any application.
A dominant factor in U.S. markets for many years, Winsted

expanded into overseas markets in 1975, primarily in England.
In 1976 the company began concentrated efforts to establish
distribution in the Far East. Winsted’s international distribution
was firmly established in 1984 with the formation of Winsted, Ltd.
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in England. Since then, Winsted, Ltd. has become a successful In 2002, Winsted acquired Technical Interiors,
marketing and manufacturing operation serving the European, a Georgia-based company with 25 years of
Middle Eastern and African markets. In 1986, distributor experience designing and manufacturing custom consoles of the
agreements were established in Australia, Japan, Hong Kong, highest standards for the nuclear power industry. Technical Interiors
Taiwan and Korea. was renamed Winsted Custom Division in 2010 and solidifies our
mission of providing the highest quality console and furniture
solutions to mission critical facilities around the world.
In 2011, Winsted further expanded its custom capabilities with

the launch of a new division. Winsted Custom Wood will focus on
manufacturing custom cabinetry and millwork for control room
installations. The Custom Wood Division enables Winsted to further
expand our custom control room capabilities and fully realize our
value proposition of offering stock, customized and custom console
solutions to our customers. With the expansion, Winsted has added
many skilled craftsmen who bring years of custom woodworking
experience, as well as a state-of-the-art production facility.
Our family of companies, broad range of capabilities and an ongoing

commitment to Customers, Products and Service is why Winsted is
“Preferred by Professionals Worldwide.”
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WEB RESOURCES
WHITE PAPER:
Human Factors: Planning & Designing a Control Room
http://winsted.com/img/resources_literature/human_factors.pdf
ONLINE CATALOG:
http://catalog2012.winsted.com/t1.asp
YOUTUBE CHANNEL:
http://www.youtube.com/user/winstedcorp
PRODUCTS:
http://winsted.com/products.htm
COMPANY CONTACT
ADDRESS: 10901 Hampshire Ave. South, Minneapolis, MN 55438 USA

Phone: 800-447-2257
WEB: winsted.com
email: brentl@winsted.com
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THE AUTOMATION

• 5 Factors to Consider Before

Factory & Machine Automation

For years, Automation World has provided hands-on information, automation

FACTORY & MACHINE

Thomas A. Doney Joe Martin

Paul Brinks Jeff Miller, PMP

Stephen M. Goldberg Howard Skolnik

Michael Hake Arthur C. Smith

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

5 Factors to Consider Before

4. Security: According to a recent Business Insider Intelligence

monitoring needed to keep tabs on devices in other locations? www.wago.us/systemfield

RFP Guidelines Help Deliver

How to Properly Select and

CONTINUED How to Properly Select and Vet a System Integrator

3. Familiarity with standards. Find with expertise and domain knowledge

CONTINUED How to Properly Select and Vet a System Integrator

CONTINUED How to Properly Select and Vet a System Integrator

13. Professionalism counts. Make sure an integrator can

14. Test the team. Verify the integrator’s capabilities by giving

CONTINUED How to Properly Select and Vet a System Integrator

DETAIL THE REQUIREMENTS

23 Common Mistakes People

CONTINUED 23 Common Mistakes People Make in Automation Projects

developed and rely on the experience of previous projects using a copy

CONTINUED 23 Common Mistakes People Make in Automation Projects

CONTINUED 23 Common Mistakes People Make in Automation Projects

pieces (Work Breakdown Structure) and • Operator requirements not considered

CONTINUED 23 Common Mistakes People Make in Automation Projects

CONTINUED 23 Common Mistakes People Make in Automation Projects

CONTINUED 23 Common Mistakes People

Key Factors to Consider in Deciding

CONTINUED Key Factors to Consider in Deciding Among PLCs, PCs or PACs

4. How complex is your application? PLCs excel at operations like

CONTINUED Key Factors to Consider in Deciding Among PLCs, PCs or PACs

8. What about the future? The increasing

12 Guidelines for Selecting

CONTINUED 12 Guidelines for Selecting Motors and Drives

CONTINUED 12 Guidelines for Selecting Motors and Drives

control system is important. Drive failure may be caused by

Top Considerations for Selecting

CONTINUED Top Considerations for Selecting and Deploying Industrial Robots

TIPS FOR ROBOTICS INTEGRATION

CONTINUED Top Considerations for Selecting and Deploying Industrial Robots

11. Faster remastering. For a robotic cell, design in a

Best Practices for Implementing

CONTINUED Best Practices for Implementing Industrial Ethernet

Guidelines for Using

CONTINUED Guidelines for Using HTTP and MQTT Protocols

CONTINUED Guidelines for Using HTTP

CONTINUED Seven Safety Functions That Can Save You Money

5. Safe Brake Control (SBC): Controls an external holding

6. Safely Limited Speed (SLS): Sets a maximum speed at

7. Safe Direction (SDI): Restricts drive signal so that motion

22 Ways to Get the Most Out of OEE

CONTINUED 22 Ways to Get the Most

readers help with three traditional OEE drivers:

use statistical and not real-time data from their

OEE BENEFITS CALCULATOR

Strategies for Achieving Your

CONTINUED Strategies for Achieving Your Energy Management Objectives

CONTINUED Strategies for Achieving Your Energy Management Objectives

• 5 Factors to Consider Before

• Component replacement only when indicated by conditions.

• Modify and update: Make corrections, enhancements and adaptations to

• Decommissioning: Conduct review and obtain required authorization

• Plan and structure safety lifecycle: Define safety lifecycle in terms of

• Verify safety system: Demonstrate by review, analysis and/

• Global standards—why harmonization is important and what