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FACTORY & MACHINE Automation Playbook 3 / 252
CONTENTS
11 Playbook Advisors
12 Contributors
15 Introduction
CONTENTS
37 Six steps to success with the IIoT visible factory
CONTENTS
90 10 ways your automation project can fail and how to prevent it
A. Controllers
102 Eight factors to consider in deciding among PLCs, PCs, or PACs
OEM machine designers (in addition to automation end users) will specifically find useful tips in highlighted articles.
FACTORY & MACHINE Automation Playbook 6 / 252
CONTENTS
B. HMIs
113 Five key functionalities for HMIs
C. Motors
126 Six questions to ponder when choosing a motor
131 Six things to know about the new higher efficiency motors
134 Seven key points in applying servo drives, motion controllers and PLCs
OEM machine designers (in addition to automation end users) will specifically find useful tips in highlighted articles.
FACTORY & MACHINE Automation Playbook 7 / 252
CONTENTS
137 16 secrets to specifying sensors in industrial applications
143 12 tips for choosing and sizing pneumatic and hydraulic components
172 Four tips for dealing with wireless latency and bandwidth issues
OEM machine designers (in addition to automation end users) will specifically find useful tips in highlighted articles.
FACTORY & MACHINE Automation Playbook 8 / 252
CONTENTS
174 How network management systems aid firmware, configuration updates
CONTENTS
Section 4: Best practices for asset management and operations
209 Develop a strategy for asset management
219 22 ways to get the most out of OEE and lean manufacturing disciplines
CONTENTS
244 Vendor Selection Resource Guide
FACTORY & MACHINE Automation Playbook 11 / 252
PLAYBOOK ADVISORS
Thomas A. Doney Joe Martin
Senior Research Engineer President
Nestlé Martin CSI
CONTRIBUTORS
Michael Mikolajczak Jad Wehbe Abdulilah Alzayyat William Wang Kurt Wilde Tom Jensen
Bryan Sisler Automate, Lebanon - Jim Hulman DuPont China, China Henniges Automotive, USA Lenze, USA
ABB, USA Germany - Qatar Joaquin Ocampo
Bosch Rexroth, USA Tim Matheny Satish Samineni Stefano Linari
Alex Miller Rafael Arevalo Duque ECS Solutions Inc., USA Halcrow, Qatar Linari Engineering srl, Italy
ABB Robotics, USA Automatizacion Ingenieros Larry W. Ostrander
Especialistas sas, Colombia CADD Tech Support, USA Ed Nachel Tianshun Qiu Dan Perkins
Mike Berryman Elobau Sensor Technology IBM (China) Co. Ltd., China LINAK U.S. Inc., USA
Advantech, USA Peter van den Berg John F. Wozniak Inc., USA
Avans University of Applied CC-Link Partner Alexander Pinkham Jagjeet Paul
Wendy Jacintha Science, the Netherlands Association, USA Julian Martinez ICONICS, USA Little Systems, India
AFLAC, Canada Emerson Network Power,
Stanley Moses Johnny Sorensen Colombia Joel Albert Ken Lauer
Leslie Crothers Bahwan CyberTek Inc., USA Chr. Hansen, Denmark Industrial Networking Middough, USA
Almac, United Kingdom Roy Adams Solutions, USA
John Malinowski John Lewis ERA LLC, USA George Hockett II
Rob Cotner Baldor Electric Company, Cognex Corp., USA Josu Bilbao Miniature Plastic Molding
Anixter, USA USA Vikram Kumar IK4-IKerlan, Spain LLC, USA
Mohbat Tharani EZAutomation, USA
Carl Stelling Shawn Day COMSTATS Institute of John Wilson Deana Fu
Antaira Technologies, USA Henry Menke Technology, Pakistan John Holmes Integrated Automation, Bryan Knight
Balluff Inc., USA Festo Corp., USA Australia Mitsubishi Electric
Lonnie Purvis Hernan Gardiazabal Automation, USA
Apex Manufacturing Jeremy Jones ContrALL, Mexico Robert L. Fischer Sudhendu Banerjee
Solutions, USA Baumer Ltd., USA Fischer Technical Services, Instrumentation Ltd., India Stephen Chilton
Mike Cerda USA Monozee Ltd., United
John Coetzee Jingxu He Control M Automation, Majid Takabi Kingdom
Aristotle Consulting, South Bayer, USA Mexico Eric Esson JGC Co., Iran
Africa Frommelt Safety Products, Todd Desso
Mike Fahrion Sanjay Mishra USA Tom England Eddie Lee
Sujata Tilak B&B Electronics, USA COTMAC Electronics Pvt. Kollmorgen, USA Mike Werning
Ascent Informatics Pvt. Ltd., India Chris Alexander Moxa Americas, Inc.
Ltd., India Eric Byres Givaudan Flavors, USA Pierre Lampron
Mike Miklot Roy Greengrass KSH Solutions Inc., Canada Nelson South
Dave Robinson Belden, Inc., USA Del Monte Foods, USA Dr. Colin Harrison Nelson South Electrical,
Aurora Industrial Glasgow Caledonian Chris Weigmann Australia
Automation, USA A. Klemptner University, United Kingdom Lakeside Manufacturing,
DTE Energy, USA USA » CONTINUED ON PAGE 13
FACTORY & MACHINE Automation Playbook 13 / 252
CONTRIBUTORS
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 WAGO Corp., USA
USA Schneider Electric, France Aaron Schulke Solutions, USA
Joe Sebastian SICK, USA Nathan Schiavo
Diane Trentini Dennis Sanchez Johan Hult Ed Novak Wesco, USA
Optimation Technology RECOPE, Costa Rica Schneider Electric, Sweden Tom Hoffman Trio Motion Technology,
Inc., USA Jeff Miller USA Wilfredo Jimenez
Cheng Xinping Robb Dussault Gregory Richards WJ Automation &
Ben Orchard Rockwell Automation, John Boville Siemens, USA Pramod Parikh Integration Corp., Puerto
Opto 22, USA China Schneider Electric, USA United Phosphorus Ltd., Rico
Tomaz Vidonja India
Scott Klages Chris Brogli Jerry Schultheis Simplysens, Slovenia Karen Leung
Parsec Automation Corp., Paul Brooks Schultheis Automation Fernando Jimenez Worleyparsons, USA
USA Douglas Henderson Control Systems Inc., USA Mark A. Erickson Universidad de los Andes,
Jimmy Koh Skills Improvement Inc., Colombia Erik Nieves
Mark Huebner Amy Peters Eder Mathias USA Yaskawa Motoman
PBC Linear, USA Fatime Ly Seymour SEW-Eurodrive, Brazil Alejandro Pena Robotics, USA
Thomas Sugimoto Pat Gallagher Universidad Distrital,
Jose Gonzalez Valero Rockwell Automation, USA Nesko Kontic Solar Automation Inc., USA Colombia Will Zurkan
PEMEX, Mexico SGS - Wind Energy Zurkan Solutions, USA
Mahendra Dissasekera Technology Centre, China Lewis Gordon Gary Phillips
Helge Hornis Ronan Engineering Co., Tangent Services, USA URS E & C, USA » CONTINUED ON PAGE 14
Pepperl+Fuchs, USA USA Shamsol Shamus
Shamus Technology Ent., Peter Hook Bill Bobbitt
Mark Buckley Sam Shorer Malaysia Tech Innovations LLC, USA Van’s Aircraft Inc., USA
Phoenix Contact, USA SABMiller, South Africa
Dr. Gyan Ranjan Biswal Dave Szurek Sachin Kumar
Rahul Aggarwal Andrea Sammartino Shiv Nadar University, The Mackubin Group, USA Vertex Automation System
Prekar Services & Solutions, Saipem Spa, Italy Noida, India (P) Ltd., India
India Assaf Beckman
Steve Sarovich George Pease Tomatic, Israel Pradeep Soni
Rafey Shahid Sardee Industries Inc., USA Show-Me Machine Works, VSM Venture Control
Qanare Engineering, USA System P. Ltd., Noida, India
Pakistan
FACTORY & MACHINE Automation Playbook 14 / 252
CONTRIBUTORS
Individual Contributors, by Country
Algeria India Israel Pakistan USA John Nix
Nesrine Chaouche Rajesh Keswani Victor Zaltsman Faisal Mirzam Don Baechtel Tim O’Brien
Sarang Kulkarni Jim Brastauskas Tony Olivieri
Bosnia Senthil Kumar Lithuania Saudia Arabia Michael Bowne Tony Paine
Bojan Djurdjevic Arunnun Loganathan Genadij Nesterenko Ghulam Rasul Daniel Bruno Tony Perna
Mukesh Negi Bruce Centofanti Friedrich Purkert
Brazil Avinash Patil Mexico Spain Marc Emmerke Ray Royal
Edson Gonçalves de Oliveira Naveen Kumar Ramasamy Jorge Loza Antonio Anton Greg Fairchild Stephen A. Sajewicz
Babu Reddy T Miquel Vall Boladeras Irene Farquhar William Schmidt
Canada Netherlands Marty Grimes Accounties Smith
Ed Kinakin Iraq R. Hulsebos Sri Lanka Tony Guzman Konstantyn Spasokukotskiy
Amer H. Rasheed Hindrik Koning Suren Stambo Daniel Hood Joe Staples
Guatemala Mark Huebner Jim Tennant
Moises Yac Ireland Nigeria Taiwan Joseph Kolo Suresh Vasan
Joe Burke Oladapo Akinbola Iyedupe Jin-Mu Lin Rajendera K. Kapoor Leonard Walsh
Egypt Michael Kinziger Nick Wisniewski
Mahmoud Abdel Fatah Abo Ahmed Norway David Lamb
Rune Saetre Todd LaRoche Venezuela
Hian Yong Leong Juan Nicolaidis
INTRODUCTION
In a fast-changing, ultra-lean competitive landscape, industrial array of experience-based tips on project planning, component
enterprises need to deliver their products and services efficiently selection, and implementation. There is much more, however,
and effectively as possible. That starts with the automation layer. including a special section on ways to leverage the tools and
Today’s engineers can take advantage of an array of advanced best practices developed for IT in the operations technology (OT)
technologies ranging from smart components to built-in world. You will also find fresh information on how to bring your
connectivity to analytics packages that can make sense of the assets into the industrial Internet of Things (IIoT), an approach
data the hardware harvests. When combined with informed that will become essential over the next few years.
system design and implementation, the result is equipment that
doesn’t just manufacture items and run processes but confers a Our thanks to the more than 275 people from 40-plus
competitive advantage. countries—from end-user companies, system integrators,
machine builders, educators and automation suppliers—who
This edition of Automation World’s Factory Automation Playbook have participated in the development of this playbook. They’ve
puts the focus squarely on ways you can take advantage of the volunteered to share some of the things they’ve learned during
latest technology to improve outcomes. Expect to see the usual their careers as a way to give back to this unique community.
» CONTINUED ON PAGE 15
continued
Introduction
In the following pages, you can benefit from their years of Kristin Lewotsky
industry experience as they share tips for success and pitfalls to Editor, New 2017 Edition,
avoid in your automation journey. The book is designed to be Factory & Automation Playbook
useful, whether you’re a veteran machine designer or working on
your first project. The goal of this playbook is to help everyone
achieve more successful factory and machine automation.
SPOTLIGHT:
THE CONVERGENCEOF IT AND OT
There was a time enterprise IT and operations technologies important but essential to remaining competitive. As part
(OT) were considered two very different domains. The idea of of that, OT departments are increasingly using traditional IT
interfacing critical machine networks with corporate networks technologies on the plant floor. This special section looks at
vulnerable to hacking or the introduction of viruses with an ways to apply tools like data transfer protocols, application
employee mouseclick was unheard of. Meanwhile, IT staff was programming interfaces (APIs) and open-source graphical
completely against the idea of exposing physical assets to the programming environments to simplify development, speed
Internet, no matter the benefits. implementation, and improve performance. The result? Less
time spent linking assets and more time spent benefiting from
Today, all that has changed. Connectivity has become not just connectivity and factory visibility.
FACTORY & MACHINE Automation Playbook 18 / 252
Success in the industrial Internet of Things (IIoT) requires more 2. Secure the network. With a connected world comes
than just sensors and cabling. In order for manufacturers to increased vulnerabilities and risks. One compromised system in a
accrue benefit while maintaining safe and secure operations, the network of devices can act as a catalyst for widespread infection,
information technology (IT) and operational technology (OT) ultimately threatening an entire company’s infrastructure. IT
departments will need to work together effectively. Here are the and OT need to combine forces to effectively maintain network
three main areas that need to be addressed: availability, confidentiality, and integrity. They can also work
together to implement processes that prevent both deliberate
1. Work as one team. Different departments have different attacks and unintentional errors.
priorities. OT professionals typically focus on keeping production
running to avoid the costs of downtime, while IT workers hone Recommended security measures include use of:
in on protecting data integrity. Despite these distinct roles, it’s
important to look at manufacturing holistically and combine • Encryption to ensure data confidentiality and prevent
forces to create an open dialogue between departments. Finding unauthorized data interception when running on public
ways for both departments to work together will help businesses networks.
take advantage of their combined strengths and meet business
goals. • Access control to ensure that only devices allowed to
communicate with one another can do so, and to prevent
unauthorized access to the network during operation.
continued
The process of harvesting value from an IIoT project begins connecting an application to a device, like a supervisory control
with exchanging data between nodes on the network. Multiple and data acquisition (SCADA) system polling a flow computer for
protocols exist to accomplish this step. Two of the most common flow-rate data.
are hypertext transfer protocol (HTTP) and Message Queuing
Telemetry Transport (MQTT). HTTP is a client-server protocol used 2. Choose HTTP for flexibility. HTTP provides a
to enable clients to request data from a server and for the server transport, but doesn’t define the presentation of the data. As
to satisfy those requests. MQTT is a publish/subscribe protocol such, HTTP requests can contain HTML, JavaScript, JavaScript
designed for SCADA and remote networks. Developed in 1998 for Object Notation (JSON), XML, and so forth. In most cases, IoT is
a Phillips 66 pipeline project, MQTT is a bi-directional, lightweight standardizing around JSON over HTTP. JSON is similar to XML—
event- and message-oriented transport that allows devices to without all the overhead and schema validation—making it more
communicate efficiently across constrained networks to backend lightweight and flexible. JSON is also supported by most tools and
systems. programming languages.
Many IoT platforms support HTTP and MQTT as their first two 3. Understand the strengths of MQTT. Like HTTP,
inbound protocols for data. Here, we present key points to MQTT’s payload is application-specific, and most implementations
consider when choosing and implementing a protocol. use a custom JSON or binary format. MQTT isn’t as widely used
as HTTP, but it still has a large market share in IT. There are many
1. Use HTTP to gather data in limited amounts. open source clients/producers, brokers, projects and examples in
HTTP can be effective for poll-response uses that involve every language.
continued
continued
For all of the excitement surrounding factory visualization 1. Get off the bus. Traditional industrial system architecture
and the Industrial Internet of Things (IIOT), there remains the is built around a bus topology. Assets are connected to the bus
central challenge: getting the data from the devices to the and speak the same protocol. The problem with leveraging this
various computing systems and applications that can convert architecture in IIoT applications is that systems that are not a
bits and bytes into actionable information. The problem is that part of the bus and do not understand the bus protocol cannot
while capturing the data from assets can be easy, getting it to leverage the data and resources available on the bus. But for the
the applications in an efficient and secure fashion can be both IIoT to be viable, IIoT hardware and software assets must connect
complicated and challenging. Although number of methods and start talking to each other.
exist to port over data, including gateway PCs and purpose-built
middleware, the cost and complexity have discouraged some 2. Follow the rules. An application programming interface
manufacturing organizations from participating. RESTful APIs (API) is a set of rules for interacting with a software program,
provide an alternative approach. frequently web-based. Google Maps is a good example. The
company doesn’t just have the mapping function, they have a
RESTful APIs are designed to bridge the communication Google Maps API that provides a structure for how an application
disconnect between the physical electrical signals industrial assets should request a map. Instead of building their own mapping
use and the digital systems of the Internet. They can significantly application, developers simply use the API to call the mapping
reduce, if not eliminate the need for gateways and middleware. function. By combining APIs, developers can put applications
together much more quickly than writing from scratch.
continued
4. Start talking. RESTful APIs offer a standard form of sharing 6. IIoT the easy way. Today, thousands of APIs exist,
data and resources between IIoT devices and IIoT software. including a number aimed at simplifying the implementation
Ethernet and TCP/IP were the first step toward the IIoT. RESTful of the IIoT for industrial automation. Look for APIs for predictive
APIs are the next step in moving up the OT/IT technology maintenance, gathering sensor data, and programming and
convergence stack. RESTful APIs are the tools that allow OT and monitoring devices. As an example, a predictive maintenance
IT engineers to connect real-world physical assets like sensors, application (a client) could open a secure HTTPS connection to a
motors, pumps, relays and control systems to the digital world programmable automation controller, or PAC (the server) on the
continued
continued
Forget about the cloud. As companies explore the Industrial Internet of collects the data and performs higher-level processing and analysis.
Things (IIoT), fog computing and edge computing take center stage as This system filters, analyzes, processes, and may even store the data for
strategic ways of dealing with the vast amount of production-related data transmission to the cloud or WAN at a later date.
at the core of IIoT. Although the two terms are frequently used synony- Although it is effective, the fog computing architecture relies on a
mously, they actually refer to two distinct architectures. multi-link chain of communications to move data from physical assets
First, let’s point out the similarities. Both fog computing and edge comput- to the digital world for analysis. Each of these links is a potential point
ing involve pushing intelligence and processing capabilities down closer of failure.
to the devices generating the data: pumps, motors, sensors, relays, etc. The Edge computing
primary difference between the two is where the intelligence and comput-
Edge computing pushes the intelligence, processing power and com-
ing power reside.
munication capabilities of an edge gateway or appliance directly into
Fog computing. devices like programmable automation controllers (PACs).
Fog computing pushes intelligence down to the local area network It shortens the communications chain and reduces potential points of
level of network architecture, processing data in a fog node or IoT failure by wiring physical assets like pumps and motors into an edge
gateway. device like an intelligent PAC. That device collects, analyzes and pro-
In fog computing, the data from the control system program is sent to cesses data while also running the control system program. The PAC
an OPC server or protocol gateway, which converts the data into an In- then uses edge-computing capabilities to determine what data should
ternet-compatible protocol like MQTT or HTTP. Next, the data passes to be stored locally or sent to the cloud for further analysis.
another system, such as a fog node or IoT gateway on the LAN, which
continued
b) An oil and gas company could provide its field engineers with
a mobile interface so they can view historical statistics on oil well
output and trend that data based on current well output.
continued
continued
1. Connectivity. Among the challenges faced by today’s Manageability of these systems becomes increasingly important
industrial companies is how to take advantage of emerging as well. As ever-greater numbers of devices are connected to
technological innovation while still protecting the sizable the network, you must ensure that the devices are manageable
investments already made in existing systems. Legacy in order to guarantee that future policies, system upgrades and
technology cannot simply be abandoned, nor can companies other advances can be deployed and their benefits realized.
undertake the cost of its wholesale replacement. Given that
the typical lifecycle for industrial things exceeds 20 years, the 2. Security. In a world in which security breaches have
connecting of legacy infrastructures with new things must be become all too common, it is increasingly crucial that you ensure
streamlined so all parts can securely and reliably interoperate the protection of your manufacturing plants. The consequences
across the enterprise. of failure could be profound and far-reaching.
continued
Achieving that security starts with ensuring the integrity of through common frameworks based on truly open industry
data, and that means safeguarding the transmission of data as standards. This is not only about the infrastructure, but the
it travels from decentralized locations through new devices and platforms as well.
legacy equipment, across internal networks, and to and from the
Cloud and/or data center. Organizations like the Open Interconnect Consortium (OIC) and
Industrial Internet Consortium (IIC) have been established to
Both hardware and software security and services must be work toward this goal. For example, the OIC seeks to define a
integrated. This is the first step in successfully converting data common communications framework based on industry standard
into greater productivity and efficiency, new business solutions technologies. This would enable companies to wirelessly connect
and services, and faster time to market. and intelligently manage the flow of information between
personal computing and emerging IIoT devices, regardless of form
Accessing secure data is, however, just the beginning. As IIoT factor, operating system or service provider.
accelerates, our challenge shifts to unlocking the value hidden
inside the data. That requires analysis, turning the information 4. Flexibility. If you feel that you’re behind on embracing the
extracted from the data into actionable insight your business IIoT, you may be in a hurry to start implementing new systems. But
can use. To do that, you need the right hardware/software it’s important to stop and consider the flexibility of prospective
infrastructure able to access, analyze, share and store your data. systems so that you can evolve with changing technologies.
3. Interoperability and standards. Secure, reliable The traditional design and augmentation of industrial systems
interconnections and shared information can only be achieved has long been characterized by either (1) designing a proprietary
continued
FASTER.
IIoT represents a massive investment for decades to come.
The only way to meet the needs of today and tomorrow is
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FACTORY & MACHINE Automation Playbook 37 / 252
When it comes to energy visibility and energy management, For example, you could connect a power-monitoring device
how you do it is just as important as what you do. It’s not enough to your plant’s main power feed and start monitoring power
to make the commitment and install the sensors and meters. usage. Once you’ve started collecting power monitoring data,
Logging all the data to a central repository won’t deliver the over time you’ll be able to determine exactly what it costs in real
results you seek. You have to have a concrete goal and a strategy time to turn on a motor, run a process, or have the building air
for achieving it. Follow these tips to set yourself and your conditioning set to 78 degrees.
organization on the road to success.
Or perhaps you want a daily report emailed to you showing
1.Target a problem. The process doesn’t start with the production count, raw material inventory, and average
data, it starts with a pain point. What are the issues you’re trying production time. All of this data can be captured through IIoT
to address, whether that’s excess utility spending, repeated technology and brought right to your mobile device.
downtime, or inconsistent performance among facilities? Don’t
try to cover everything. Don’t capture massive amounts of data 2. Go deep. If the first step is to start small in terms of defining
just because you can. Start with a problem on a manageable the scope of the issue, the second step is to go large, in terms
scale, preferably in one location. Determine exactly what you of gathering granular enough data around that single issue to
need to solve the problem. Most important, have a strategy provide meaningful input. In the case of energy management,
for how you plan to use the data before you ever think about reviewing a utility bill once a month or once a quarter does not
actually acquiring it. provide insight. Monitoring needs to take place on the order of
days, shifts, or even hours.
continued
Look for opportunities to collect data at an asset or “thing” level. analysis to identify best practices and also staffers who may need
For example, is there a sensor you could install to more closely more comprehensive training.
monitor and log your process? The cost of sensors has come
down substantially, allowing increased visibility into all aspects 3. Centralize and analyze. Identify a way to aggregate
of automation. the data into a central repository. This might require some type
of IoT gateway or protocol converter as well as a database to
Walk around your facility, talk to your operators, and identify house the information Once you’ve centralized the data, you
laborious manual processes such as pen-and-paper or Excel can analyze opportunities to optimize processes. For example,
spreadsheet data entry tasks. Identify potentially useful data that develop a report to cross analyze your newly found sensor data
is currently siloed and unavailable to other systems and business with production output. Do certain variables in the process
decision-makers. Good examples might be environmental data, relate to a higher or lower yield?
production data, or data related to your batch process.
4. Make the data easily accessible. Traditional energy
To be useful, data acquisition should go beyond simply tracking audits provide useful information but they are just a snapshot
a quantity over time. Factors can be analyzed geographically: in time. They define how the system is acting now but not how
country to country, state to state, facility to facility, environment it will be in the future. They’re not very useful for monitoring
to environment. It can also take place on an equipment level: equipment to perform predictive maintenance, for example. For
facility to facility, line to line, machine to machine, and even axis machine health monitoring, you need visualization and analysis
to axis. Human factors provide another avenue to insight: facility software that can serve up data on a near-real-time basis. It
to facility, shift to shift, operator to operator. This last enables should be accessible simultaneously to staff throughout your
continued
organization, not just those behind desks on the top floor after the system so that when it reaches the trigger point, the
overnight off-line batch processing. controller recognizes a problem and initiates corrective action
independent of human intervention. The ultimate goal is for the
Look for visualization and analysis software with fast-start equipment itself to reduce energy consumption throughout the
tools that enable users to access preconfigured data plots and facility.
reports, and assemble dashboards. It should also allow them to
apply filters and customize cross correlation so that individuals 6. Turn to the experts. Developing the kind of factory
with different job roles can leverage the results to meet their visibility discussed above delivers huge benefits but it’s not a
objectives. Web-based applications make fresh data available to trivial task. Thanks to purpose-built applications, you no longer
staff on the production floor, managers in offices, and to anyone need a team of developers and software architects to get
off site over portable devices. things running. What you may need, though, is an experienced
integrator who can guide you through the process and get you
5. Look beyond monitoring and analysis. After to the point of realizing value as rapidly as possible. Alternatively,
gathering the data and converting it to actionable information, work with your vendors. Tap their expertise as you work on
your next objective should be to establish procedures to apply your system. You can also take advantage of cloud services that
the information. This can be as simple as sending an alert when deliver visibility without the headaches. Today’s connectivity
the levels exceed preset thresholds. The system can deliver it tools protect even the most sensitive data and systems from
in the form of an alarm on the control panel or HMI, a message outside incursions.
to the maintenance staff, or an email to the facilities manager.
A more sophisticated and effective approach is to automate
continued
continued
control focused on basic engineering disciplines … mechanical mechanical and electrical with optimized motion elements and
and electrical … and each dedicated engineering group did their smart stepper or step-servo closed loop motor technology with
work independently. In the end, somehow the two had to be integrated controls. These can easily be applied to single axis,
brought together and made to operate. This would most often multiple axis, or XYZ Cartesian configurations.
result in a functioning, but far from optimized machine that was
cumbersome to build, wire, connect, and difficult to monitor, Here are the top 10 advantages machine builders and users gain
change, or adjust. when combining these enhanced mechanical components with
advances in smart motor technology and control strategies.
In the old paradigm specifically, mechanical engineering would
work on the physical motion created. Things like the bearings, Top 10 Benefits of Internet Enabled Mechatronics
rails, lead screw, belt, or other drive mechanism, and how to
connect to a motor. Electrical engineering would select the 1. Lower Cost & Enhanced Functionality. The
sensors, attach the I/O, driver, PLC, controller, amplifier, and bottom line is that each of these items has a positive impact on
power supply. The motor would fall somewhere in between, your financial bottom line. Less wiring and connectors, fewer
most often with the electricians because it had to be connected components and sensors, less labor invested, reduced time spent
to power and controlled. in setup and maintenance, and maximized operational uptime
all add up to a cost savings that is substantial in the overall cost
A new model has emerged that simplifies the machine design of ownership and operation.
and build process while easily enabling internet integration
with the use of “smart robot modules”. It is the marriage of
continued
5. Streamlined commissioning. Machine installation and 6. Modular integration. Standardized smart robot
startup is made easier with pre-programmed homing routines, modules make integration into multiple axes, or multiple
and with the ability to make changes at an individual axis without machines a natural and easy process.
continued
Why the added distance and complexity of your plant networking But before you start wondering about how to tackle all that
architecture introduces potential points of failure or data loss, data, it’s important to first understand how the extension of
which can limit the ultimate value of the Internet of Things. Industrial IoT beyond building automation, Wi-Fi and central
data stores is raising bandwidth and connectivity challenges for
The Internet of Things (IoT) is approaching a tipping point. The telemetry systems. Remote device communications typically
IoT market is projected to grow from $33 billion in 2013 to $71 leverage a mixture of wireless, radio, fiber optic, satellite and
billion in 2018, according to Juniper Research. Cisco predicts telephone services. Bandwidth constraints of these different
that some 25 billion devices will be connected by 2015, and 50 technologies have the potential to significantly degrade the data
billion by 2020. IoT will enable smarter automation that allows being communicated through them. Other factors like physical
“things” to share information, learn about their surroundings, obstructions, weather and environmental elements can also
and auto-tune themselves to achieve optimum throughput and result in a loss of connectivity and therefore data.
minimal downtime.
Industry also faces a major challenge associated with prioritizing
With everything from thermostats to pipelines connected and the storage and communications of collected data. After all,
communicating, the question most people fixate on is: How not every device produces enough data or high-priority data to
will we be able to collect and capitalize on the resulting mass of warrant constant live streaming to central storage. Therefore, it is
machine data? essential to preserve data at the point of collection. This protects
against loss of data in the event that connectivity is lost. It also
continued
ensures that potentially lower priority machine data can still be or performing basic data mining in the field related to operations.
compiled and communicated as packages over time.
Though local historians will prove important to IoT success,
Data collected at the device or sensor has an increasing distance, they will still need to feed up to centralized or enterprise data
number of paths, and elements to traverse before it makes its repositories for long-term storage and more in-depth analysis.
way to enterprise storage for deep analysis. With added distance Not surprisingly, we are seeing these repositories migrating to the
to travel and complexity of architecture come more potential cloud for flexibility and the ability to provide additional bandwidth
points of failure or data loss, potentially limiting the ultimate as needed. The power of cloud computing will make the required
value of the IoT. With these considerations in mind, it becomes storage and processing power available to handle the zettabytes
easy to understand why local data storage may be the key to the of data resulting from the continuous build-out of IoT systems.
successful implementation and capitalization of the IoT. A tiered
architecture is ideal to support local data collection, storage and As the IoT continues to proliferate across consumer, enterprise
communication— think of it as multiple mini-data centers. and industrial installations, we will likely see distributed data
architectures become the norm, with local historians playing a
Local historians that collect data at the point of creation provide key role in this increasingly dispersed, foundational architecture.
an economical way to support IoT data collection across a While those who insist upon a centralized architecture will likely
dispersed architecture. Ideally, a local historian can buffer non- fail or at least struggle to support and leverage the deluge of
deliverable data until a later time and support flexible delivery. connected devices, those willing to innovate and address the
challenges of a distributed architecture will be able to capitalize
It could also identify an alternate available delivery channel. Plus, on the connected world.
local historians can be tapped on-site for troubleshooting devices
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FACTORY & MACHINE Automation Playbook 47 / 252
Most of the talk surrounding the Industrial Internet of Things (no pun intended) in its process. The solution involves slightly
focuses on moving data upward and outward. Equally important rearranging the order of the steps in the recipe. If the responsible
is enabling your factory to handle incoming data. machine can be quickly reconfigured to handle this tweak, then
everyone’s happy. However, if the change is arduous, the return
When it comes to your factory’s ability to handle data, there are on investment (ROI) on such a tweak diminishes rapidly.
two use cases: process improvement and process agility.
Machine flexibility includes the network to which it is connected.
Looking first at process improvement, after completing data Network flexibility comes in many forms. This can mean flexibility
collection, analysis and decision-making, the final step involves in the cabling, as in the network should support any topology
taking action. Doing this entails taking data and feeding it back such as line, star, tree, ring and wireless. It should also support
into the manufacturing environment to improve the process. openness and web tools. This means not just creating a machine
automation network, but one to which standard Ethernet
Since improvement means change, the question is: What devices can also be connected. In other words: an open cable.
does change require? The answer: flexibility. Manufacturing This allows for access to acyclic data via the devices’ integrated
machines need to be flexible and modular so that tweaks to the web servers.
production process can be implemented easily.
It should also support simple addressing. Within Profinet, logical
Take, for example, a beverage maker. After analyzing some data, device names can be assigned during engineering, with the
this company recognizes a previously unknown bottleneck PLC programming the station addresses. On the flip side, if the
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PLC is taught the topology of the network, it can automatically Start-Up function enables the identification of stations in less
assign the station names and addresses. This is a powerful than 500 ms, maximizing agility.
feature supporting machine flexibility. And remember, process
improvement can be achieved efficiently only if the machines To further understand the importance of feeding data into
are modular and the network is adaptable. the manufacturing environment, let’s look at the example of a
car manufacturer. Similar to the beverage bottler, let’s say this
The second use case to consider involves process agility. One manufacturer analyzes some Big Data and notices that sections
aspect often glossed over in discussions surrounding the of his line are still consuming energy even when those sections
Industrial Internet of Things (IIoT) is the good old-fashioned are not producing anything. Though only loosely coupled to
Internet itself. As the e-commerce industry crosses the $1.5 the process itself, if he were able to feed that data back into the
trillion threshold, people are becoming ever more accustomed system, he might be able to cut costs (utility bills) during those
to doing business online. It is a perfect example of data feeding periods. With ProfiEnergy, the network enables his robots to go
into a manufacturing environment. While the objectives for this into a sleep state similar to a laptop. When production resumes,
use case are different, the requirement is the same: flexibility. that section of the line starts running again.
The oft-quoted goal of Industry 4.0 is the ability to achieve a These use case scenarios should help make it clear that IIoT is not
lot size of one—in other words, the ability to manufacture one just about getting data out of plants, but also getting data back
widget with the same efficiency as manufacturing 1,000 widgets. into plants. It’s a cycle. Whether the use case is improvement,
To achieve this in modular plants, PLCs need to detect new agility or even energy efficiency, flexibility is a necessity. This
machines or parts as quickly as possible. With Profinet, the Fast means machine modularity coupled with network adaptability.
SECTION ONE:
PLANNING AND IMPLEMENTING
AN AUTOMATION PROJECT
FACTORY & MACHINE Automation Playbook 50 / 252
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boxes, it becomes a Gantt chart. Putting all your objectives (the 10 TIPS FOR A SUCCESSFUL AUTOMATION PROJECT:
completion of functioning subsystems, integration) into one
1. Have complete clarity on the need for and scope of the solution.
simple chart keeps those objectives clear to the whole team.
2. Get all possible information (technical resources, human, financial,
11. Goals at every node. System engineering should technological, etc.).
be geared toward achieving performance goals at every node. 3. Select automation technologies for the project; do a detailed
The goal should be to have dynamic, stochastic, multi-criteria analysis of the advantages and disadvantages of each technology.
optimization of objectives, along with metrics to measure and 4. Perform the possible sequences of automatic sequential.
control whether the objectives are being achieved, at multiple
5. Analyze the most favorable from the point of view of production,
nodes along the process. technical, technological, economic, security, etc.
6. Select virtual design tools.
12. Reducing risk. The greater the uncertainty and lack
of details at the start of the project, the greater the risk. Even 7. Perform a simulation with different virtual tools, verifying the
something small like an undefined piece of hardware or wiring design stage.
can cause problems during a project. The greater the lack of 8. Check to determine if it is the best solution to the need.
details, the more delays and cost over-runs you will experience 9. Perform a virtual prototype and animation project.
as the project moves toward completion. Don’t forget toinclude
10. Validate the project, checking to determine whether it met the four
the cost of training and updates to your system in your project stages of the project: analysis, planning, execution and validation.
budget.
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13. Measure the value to be delivered. It is critical to Instrument drawings should be the key driver for all automation
define the objectives of the project in advance. This is needed to projects. These should have interlock information included
help support the business case and should not be forgotten after to provide common terms of reference for all disciplines on
the project, but tracked and the return and value shown. The what the control philosophy is. A control strategy document
things that get measured are the things that get done. Moreover, with an executive overview that leads into greater levels of
it will be easier for you to show the consequences of automation. control definition provides the context that will ensure that all
parties involved will have a clear understanding of what is to be
14. Keep it simple. Several years ago, a brilliant automation achieved.
engineer talked about a mouse on the table and teaching a
robot not only how to move the mouse, but teaching the robot 16. The essentials. Make sure to write a functional spec,
the characteristics of the mouse, etc. When asked if he used to be define complete design specifications and establish factory
an object-oriented software engineer, he said, "Why yes, how did acceptance criteria.
you know?" This resulted in a multi-million dollar failed project
later because this engineer designed a beautiful, complex, 17. No open bars. It is of paramount importance to define
variable substrate handling system that couldn't be worked in detail the design criteria that the project will have to meet,
on, cost 3X the budget, and still didn't know anything about although many people do not see the importance of this
the mouse. Find the simplest, most reliable system that will preliminary step. Without it, a very large range of solutions to
effectively do the job. a given upgrade are available, with a wide range of associated
costs. At the end of the study, the customer often finds that
15. Define your control strategy. Piping and the resulting cost is prohibitive because his own people were
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CREATE CHECKLISTS
As examples of some overlooked project objectives, consider the and then have others of different sizes also step through it.
following in every project: 5. Remember that checklists help to prompt you when you are in the
1. Make sure the system’s parameters are outlined in a table. Make field. Establish these checklists when you conduct meetings to get
sure they add up to sensible values; get a consensus on the data. everyone’s input. You have to make the decision on the project’s de-
2. Make sure the required power (electrical, pneumatic, hydraulic) is sign and impact, so communicate this clearly and keep an open mind.
available and that all utilities, including ventilation and lighting, are These folks invited to your meeting are your customers and you want
considered. everyone to be accommodated as much as possible. You should be
no stranger to negotiation and getting everyone to understand this
3. Make sure that specifications for these utilities will accommodate
helps you get needed support. The checklist becomes the contractual
the desired gear (clean power supply, battery backup, compressed air
document of accordance.
dew point, etc.).
6. Use the checklist to prioritize needs and rank risks associated with
4. Do a facility siting review with a dimensional layout. Keep service
certain project options. This is the good kind of documentation you
accessibility (dis-assembly) in mind. Do a time/motion study (some-
want to come out of a project meeting.
thing more than a TAKT or spaghetti chart). Step through it yourself
assigned to your first project, there’s complex for non-engineers to deal with.
an organization, Project Management Make sure expectations are established people from these functions on the
Institute, dedicated to establishing early that will keep the needs of the automation team and consult them early
standards, providing training and people who will have to operate and in the design and testing stages for new
certifying individuals in project maintain the systems a priority. Include systems and equipment.
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4. Be ready to adjust. As with any project, unrealistic so that everyone knows exactly what performance measures
projections, poor execution and just plain bad design can cause they need to achieve. Don’t rush the testing phase; make sure
a project to fail. What is important is that when you begin a you leave enough time in the project schedule to accomplish
project, understand that there will be modifications necessary the necessary tests. It’s also important to make sure the right
along with way. The final result is rarely as exactly planned. This people attend the FAT; that includes the lead operator and
is not considered a failure; it’s a realistic need to adjust and maintenance tech, not just the manager.
fine-tune as the project progresses.
6. Follow programming standards. Make sure that
5. Establish testing plans early. It isn’t enough to in-house programmers, system integrators and OEMs use
design a system. You have to test it to prove that it works, not the same PLC programming standards, such as OMAC and
once but twice. It’s easy to get started on designing the tests PackML. There’s nothing worse than custom code that has to
by using a template. Equipment or systems should first be be reworked at the last minute to make it compatible with a
tested at the facilities of the integrator or OEM. This is called plant’s existing systems. Multiple approaches to programming
FAT (Factory Acceptance Testing), and its goal is to prove that can cost a company millions of dollars.
the system design will work. Simulate various scenarios to find
out how the system will react. The final testing stage, SAT (Site 7. Communicate often. Don’t make decisions without
Acceptance Testing), is done when the system is delivered to consulting the team. Unilateral decision-making alienates the
the factory floor. Its objective is to prove that the equipment team, creates confusion and fails to take advantage of the unique
actually does work as designed and is producing product at the expertise of the team members. Foster open communication
level required. Approve the testing plans early in the project and communicate frequently, so that everyone on the team
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understands the issues and is aware of early and have them ready to fill in if Close
any problems that need to be resolved. needed. That same rule applies to the Internal Lifecycle Methods
Kickoff Waterfall
Establish a communications roadmap for system integrator’s team; make sure Agile
Spiral
Site
Requirements Design V Acceptance
vendors; check with them soon into the they’ve identified people with equivalent Development
Other Test
Factory
project to make sure it’s working. skills who can be assigned to the project Specification
Traceability
Acceptance
Test
if required. Design
8. Don’t be a roadblock. As
Subsystem Integration Test
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12. Ask plant staff. Everyone tries to match the product to 15. Four key factors. When selecting components,
the application, but not enough value is placed on obtaining a consider availability of support, whether it’s an import/export
clear understanding of the plant ‘s ability and staff experience part, its security features and ease of installation.
with the product. The plant operations and maintenance
personnel should be used as resources when evaluating if the 16. Use good engineering. Carefully consider the
product is suitable for the site. features of the components. Simpler components are usually
better overall. Verify that the components have the correct
13. Power of open. The fieldbus wars taught us about tolerances for a testing application.
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1. Select and build your internal 2. Select a Project Manager. General Information
project team. This is an important This person will build, execute and • Project name
first step that should never be skipped. monitor the project plan and head up the • Tech Spec revision level
Getting the right people with the right team throughout the entire process to • Tech Spec revision date
attitude will make the project successful. ensure continuity of understanding and • Project description
Work this one through before calling an commitments. This person will be the only • Estimated machine life
equipment supplier; it will save precious contact with the system builder or supplier. • Target cost
time and money.
3. Define your automation Performance Specifications
• Involve departments. Manufacturing, goals. The project manager must set the • Production rate
Quality, Finance, Purchasing, Facilities, agenda for the meetings and be persistent. • Maximum noise levels
Engineering. The goal is to develop a Technical • Capability
• Select people for the team with the Specification (Tech Spec) that lays out the • Operator duties
right combination of skills and attitudes. design parameters and the performance • Number of operators
expectations for the system’s builder. The • Setup and changeover
following list will get you started on a • Repeatability
Technical Specification Form:
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Note: It is very useful to narrow it down to three of the major issues • A sign-off on all technical descriptions of the system
and put dollar amounts and specific justification to those issues. • Production rate of the system
You can review the documentation after the automation project has • Final part drawings from the customer
been up and running and compare that to your original thinking. • Capability to hold tolerances over a period of time
• Progress meetings and milestones
5. Select a supplier. The best supplier is the one that you • Statements regarding noise, safety and environment
can trust. Start by calling a few companies in for interviews. Use • Training for operation and maintenance
the Technical Specification (Item 3) as reference and ask the hard • Recommended spare parts
questions to determine the experience, capacity, capability and • Documentation and manuals
thoroughness of the supplier. Pick the supplier with whom you • Names of selected components
feel most comfortable. • Criteria for acceptance of the system at the supplier
• Criteria for acceptance of the system at your plant
6. The contract. The qualified supplier will be able to • Procedure for handling changes after the order
contribute with ideas and concepts that must be reviewed • Warranty and service policies
with the project team. Solidify those ideas into a contract with • Delivery date
the supplier. The contract should include your commitments • Project price
and those of the supplier. The supplier will use your Technical • Payment terms
Specifications (Item 3) to develop a contract (proposal) that will
address the following:
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7. Monitor the project. It is highly advisable that project 8. Training. Select the person from the project team that
managers from both the buyer and the supplier stay with the will be responsible for the operation and maintenance of the
project throughout the entire process. Good communication on automation system. This key person must take ownership and
all the details between the two is critical throughout the project. develop a plan for involving other people from the plant floor
The supplier should provide a timeline with all the critical and learning as much about the system from the supplier as
milestones: possible. This is crucial as the transfer of ownership takes place
from the supplier to you.
• Process planning
• Design review of electrical, mechanical, and flood power The following list should be covered by the training process:
systems
• Purchase parts ordered • All operational aspects including setup and changeover
• Subassembly procedure
• Final assembly • PLC, operator interface, and other system programming
• Debug time • Interlock and safety systems
• Runoff at supplier • Troubleshooting and repair service training
• Runoff at your plant • Preventive maintenance schedule
• Training • Manual and other documentation
• Installation and startup
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It is now time for the person and company who purchased the
system to demonstrate their readiness by putting the system
into production. This is usually done with the assistance of the
supplier.
Note: This article is as relevant today as it was in 2003 when first Different languages
published. It has been updated several times since then. This language has terms like cash flow, capital and interest.
Campbell, who reveals these definitions later, advises, “You must
For technical managers, it seems like a “no brainer.” Applying identify the positive cash flows you create with a new system,
new technologies will make the process better, faster and more and then, using your company’s method for calculating cash
consistent. Then the inevitable happens—the capital review flow, do the math.”
team, whose members may not know a proximity sensor from a
pressure transmitter, say, “No money available.” Even if we are on a solid footing with the language of finance,
we may not be so good at seeing our projects through an
Keith Campbell, veteran of Hershey’s engineering management investor’s careful eyes. Peter Martin, vice president of Invensys,
team with many years of experience justifying automation a Foxborough, Mass., supplier of process controls and software,
expenditures, says, “Do it in their language; it’s easier to convince says, “When you are justifying automation, it’s important to
them.” remember that it’s an accounting problem. It is possible to
solve the accounting problem through engineering principles,
Shrewd managers make capital decisions based on return on however. For instance, where is the biggest cost accounting
investment. You have to show them how your project will impact database in manufacturing? It is information from all the sensors
the bottom line. If you can’t show the monetary justification in in the production process.” In other words, tap into the data you
the language of finance, you’ll never convince them. have, and translate them into financial numbers.
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This advice directly leads to the conclusion that bringing a A new automation project can be designed to solve any of a
finance person into the automation buying team will reap huge number of problems in the plant. The sidebar accompanying this
continued
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More often than not, risk elimination will strengthen the case lead straightness was specified. But the manufacturing of one
for capital approval. of the components, a relay, was sent to Mexico in order to save
costs. Constant employee turnover in that plant caused quality
Lifecycle costs problems including solder buildup or tape missing over a hole.
Bill Egert, engineering vice president of Addison, Ill.-based The problems just couldn’t be controlled.”
integrator Logic One Consulting, and member of the Board of
Advisors for the Robotics International division of the Society This organization clearly suffered because the decision to
of Manufacturing Engineers, advises calculating all of the costs source in Mexico did not take into account quality tolerances.
associated with the life
cycle of machines. He notes, “Check out Compounding the problem, operations and finance folks
costs associated with changes. For instance, on robotics, evaluate couldn’t team up to demonstrate the cash impact of the scrap
the tooling changes needed to support product changeover plus and productivity loss.
auxiliary equipment such as feeders, conveyors and workstations
associated with material handling.” Justification is technology-independent. The same rules apply
to buildings, automation systems and computer systems, and
Don’t dismiss employee turnover or morale as a factor that to various scopes such as the entire project, just a portion of a
can’t be quantified. Egert reveals, “We had a printed circuit project or even when evaluating competing quotes.
board assembly machine with robots where the component
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Campbell says the fundamentals of justification include these Because projects are expected to pay back funds over several
steps: years, it is important to find a way to normalize the amounts in
order to keep the analysis in proper perspective.
• Identify the base case
• Identify alternatives to the base case Present value
• Determine cash flows associated with the alternatives vs. the The first step is to determine the present value, which is defined as
base case the value of all future cash flows discounted at the cost of capital,
• Use your company’s financial rules to evaluate the alternatives minus the cost of the investment. Discounted means that a future
(payback period, net present value, rate of return, hurdle rate). cash flow is worth less (discounted) than a present cash flow.
The base case is the current state of affairs. Include all the financial So, $100 received three years from now at 8% cost of capital is
data that can be compiled. Then, having identified the correctable the same as receiving $79.38 today.
problems, document various alternatives to the base case.
The Net Present Value (NPV) is the present value of all future
Quantify all the risk, benefit and loss factors that you can. Take cash flows discounted at the cost of capital, minus the cost of
a balanced approach addressing significant pros and cons to investment. Cost of capital is a weighted combination of the
demonstrate your thoughtfulness and enhance your credibility. cost of debt (long-term debt and leases after tax) and the cost
Calculate the numbers and compare to the company’s financial of equity (preferred and common stock). All future cash flows
rules. Those results can then be compared to determine the best means that the PVs are summed over some time horizon, often
alternative to present to management for funding. five or 10 years. Subtract the cost of the initial investment from
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the sum of the PVs to get NPV. The greater the NPV, the better benefits. (Microsoft Excel has functions that easily calculate NPV
the investment. as well as payback and IRR justifications).
What if the company just took the funds and invested them? Emerson’s Loranger discusses the analysis from a slightly
A valuable comparison is the return due to the business different point of view. The balance sheet is where assets and
investment vs. an anticipated return from automation project liabilities are tabulated and the income statement is where
investments. The Internal Rate of Return (IRR) is the interest income and expenses are calculated. The analysis entails
rate that equates the present value of future cash flows to the comparing the Return on Invested Capital (operating earnings
investment outlay. The IRR assumes that cash flows can be from income statement divided by invested capital shown on
reinvested at a rate equal to the IRR. balance sheet) to the weighted average cost of capital, or hurdle
rate. The difference is the economic value added.
The hurdle rate is the minimum rate of return to justify an
investment. This includes cost of capital, risk premium (which will Analysis is good, but often engineers looking at automation
include analysis of the track record of the group asking for money, projects become infatuated with new technologies and fail
type of investment and allowance for overruns), and other factors to match the project up with business strategies. As Loranger
such as working capital requirements. shows in the Business Planning Framework graphic, technology
managers find their comfort zones in evaluating automation
Calculate the cash flows and rates of return for all of the technology alternatives. The profit zone for the business,
alternatives and then the best solutions will pop out. If the however, lies in meeting or exceeding plant, production and
numbers don’t make the hurdle rate, then reevaluate the business objectives. So, when looking for projects with the
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highest probability of approval, make sure that they align with One approach that might change all of the calculations would be
one or more of the objectives in the Profit Zone. to lease new equipment, rather than purchase it. Paul Frechette,
president and chief operating officer of Key Equipment Finance,
Train managers commercial leasing services, a Superior, Colo. unit of Key Corp.,
Logic One’s Egert offers some additional tips on putting together says, “80 percent of American businesses lease equipment. They
a justification package. “Get management trained on technical do it understanding that it is use of equipment, not ownership,
aspects,” he states. “They have lots of knowledge and experience which creates profits. Leasing from the vendor or from a lessor
on finance and marketing, but not much on technical aspects. experienced in the field often yields the best deal, because they
understand the value of the residuals (the value of the equipment
A progressive, smart manager will have those technical after the term of the lease is over). The bigger lessors have been
people. A manager with technical skills will be able to see doing this for a long time and want repeat business, so they treat
some problems coming.” Another problem is management the residuals well. Their goal is to become trusted advisors.”
embracing new technology with no strategy for implementing,
no urgency for training or no technical champion to embrace Assistance in evaluating leasing options is available from
and learn the new stuff. equipment sales people. Another resource close at hand would
be people in the company’s own finance department. They
It’s not just a matter of providing training in some cases, but probably are already leasing equipment and have the process
whether the workforce has the basic background skills to make figured out.
training a practical option.
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also consider high-efficiency electrical power supplies, • Headcount impact—programs that increase headcount
regenerative power supplies for servo drives, and a common don’t fare well during a
hiring freeze. Increasing capacity
DC bus between servo drives. without increasing labor is a good justification. But
automation that can efficiently scale throughput up or down
• How easily can your production system be reconfigured with reduced attention from plant personnel sounds like a
if the intended product line goes away? This is where real winner.
automation can actually help product marketers and
engineers mitigate the risk of their program proposal. • Don’t forget the convergence of advanced technologies
and best practices that have a positive impact on seemingly
• How is your company investing in growth markets? Could unrelated aspects of operations. For example, implementing
your automated line be readily deployed and supported integrated safety doesn’t just make a production line safer;
worldwide with little or no modification, following it means more uptime, which results in measurable Overall
international electrical and safety standards as opposed to Equipment Effectiveness (OEE) improvements. And today,
the local site’s internal standards? That could be a big plus. the safety network can be the same network that links
machinery together on a line, which also improves OEE.
2. Easy replacement. Ensure that components are 5. Three considerations. First, make sure new
user friendly, maintenance friendly, easily available in the components will comply with regulations, standards and best
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7. Stay involved. Has your system integrator done already solved many of the problems you may face if you choose
something similar before? Chances are the pool of talent isn’t one whose experience is outside the necessary area of expertise.
all that big. Can you allocate any resources to working with that
integrator on a day-to-day basis? You will have to take ownership 10. Ask questions. Choosing a system integrator is the
of the system, so you will need to know how to modify it and hardest and easily the most overlooked part of an automation
maintain it or you will be tied into a system that might need project. Ask questions about types of projects they’ve done,
unallocated cash to make changes. Get involved at the zero level vertical preferences and size of projects. Have them include
in the planning, simulation, detailed layout, software handling project details, such as were they on time and on or under
techniques and maintenance requirements as much as you budget, and what percentage of the time.
possibly can in order to get the biggest possible benefits and to
learn in excruciating detail how it all goes together. 11. Experience has its limits. Be aware that most
integrators have experience either in a vertical industry or
8. Take a long-term view. Select an integrator with with a certain type of project, such as PLC/HMI programming.
experience in similar systems, preferably of the same make. Tie Either way, they may lack the capabilities needed to do projects
payments to project milestones. Make sure his services will be outside of that experience. Many HMI/DCS vendors have a
available for upgrades and maintenance by signing a separate list of endorsed or recommended system integrators on their
contract. home page. This is a good place to start.
9. Problem-solvers. Choose an integrator who has 12. Smart isn’t enough. Choose an integrator as you would
experience in the tasks you need performed. They have probably choose an employee. Spend time, talk to references and know
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that while every firm out there enlists very smart engineers, you your requests and ideas. Beware of someone that constantly
don’t want them cutting their teeth on your project. pushes back. If you hear the phrase “nobody does it like that”
or “this is how everyone does it,” you might want to consider
13. Professionalism counts. Make sure an integrator another integrator that is more open minded. You are paying
can confidently provide you with a project plan, with decision that integrator to get what you want and need—not just what
points, contingency plans and staffing that will meet your they are willing to build because it’s easy or they “always do it
timeline and project goals. that way.” Yes, you hired them for their experience and would
like their suggestions, but don’t discount your own ideas just
14. Test the team. Verify the integrator’s capabilities by because this is your first time. Also allow for the ability to
giving a test to the personnel who will perform the work on make some changes—especially if your approach is new and
your project. Make sure those people are listed in the contract, unconventional. Be open for changes and tweaks as you go if it
including fallback or substitute candidates. makes the end result
easier to use and
15. Do they have business skills? Look beyond more flexible. You
technology expertise or project experience to consider an need to stay involved
integrator’s commercial qualifications: Are they CSIA certified? throughout the
Do they have insurance? How many years have they been in whole process. Don’t
business? pass up the learning
opportunity!
16. Are they open? Select an integrator that is open to
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3. If the requirements and proposal terms are properly 5. Establishing a good project requirement list is not only an
defined from the beginning, the result will be a project with essential customer task, but also requires the cooperation of
no or minimum change orders. the system integrator.
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time. The consequence of this common strategy is that you downtime. When two machines need to work together, it is
automatically give up the perfect solution for one that is good critical to use appropriate handshaking signals to avoid any
enough. The tragedy is that, with careful accounting, the cell or machine damage. Bypassing safety is another cause
differential between a white sheet design (starting with a new for problems. Design cells so workers cannot bypass safety
platform that commonly comes with an “App Store”) is much measures.
quicker than the copy/paste/mop strategy. It also retains more
customers because the adoption curve is much quicker for 7. Experts inside. In-house expertise is essential to the
machines with more “canned” features. success of any project. Integrators build good machines and
systems, but when they are deployed in the plant environment,
5. Failure to communicate. One of the most common it’s the in-house expertise that turns a good system into a great
mistakes is not communicating with the end user and technical system.
staff. If a machine does not make their work easier, they will
find a way to make your system do what they want even if it 8. Plan for changes. When designing, or budgeting for
causes other problems. If you do not consider the technical automation projects, usually there is a clear goal or list of
staff, the repairs or adjustments will be met with resentment things that need to happen. But you also need to plan for the
and most likely extended downtime. unforeseen. Something will always come up later on that will
need to be added. To cover this, always add 20 percent to the
6. Handshakes critical. Not paying attention to overall project budget. Also, additional checks or sensors may
handshaking signals and improper use of I/O handling can be needed down the line, so make sure you have extra I/O or at
cause serious damage to equipment, eventually causing more least the flexibility to expand the I/O if needed.
continued
9. Do a punch list. After initial implementation, get 10. Can a machine do the job? If the automation project
agreement from everybody on the punch list of items that is based on replacing labor, you will first need to understand
need to be updated. That includes operators, technicians and the totality of what is being done manually. You may need to
production management. People might disagree on what has go back to the drawing board if a machine cannot do what an
been accomplished and what still needs to be done. operator has been doing.
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FACTORY & MACHINE Automation Playbook 86 / 252
continued
11. Limit program access. Always run an information 13. More mistakes.
session after commissioning to familiarize all personnel who
may be involved with set-point changes, principles of operation, • Not rationalizing alarms or adequately defining the alarm
etc., and use password protection to allow set-point changes management system.
only within a specified range. Never allow full access to program
changes. • Poor selection of field instruments, such as using a mass flow
meter for slurry instead of a magnetic flow meter for conductive
12. Forbid coding from Day 1. Automation engineers liquids.
love to puzzle with the problems they get on their table. Forbid
any use of coding software until the entire scope is clear and • Operator requirements not considered when designing HMI
closed, the delivery has been broken down to manageable pieces screens due to lack of industry experience.
(Work Breakdown Structure) and everybody knows what the
tasks and targets are ahead of them. Also, make sure that the • Audio alarms not considered for all alarm alerts. Using only
tasks and the targets are properly documented before letting visual alarms flashing on screen is inadequate.
the engineers loose on the coding tasks, because to have them
document it afterwards involves twisting their arms to make • Operators not trained for the PLC/DCS screen operation and its
them do it. Diving right into detailed problem solving and coding features.
is the fastest way to failure in an automation project.
• Neglecting to simulate as much of the complete system as
possible before it goes to the customer.
continued
• Failure to include the customer in system demonstrations and 16. Avoid complexity. You’ll make life complicated by
at each stage in development. introducing complexity into the operation, so that what’s
implemented at the site is not what was conceived of in the
• Selecting low-cost components to meet a budget. design. Many times simplicity is ignored when designing
controls. What may be friendly to one smart operator can’t be
• Errors in lead-time calculations. generalized for all operators. Refrain from tailoring the controls
too much. Suggest cost-effective and competitive solutions
14. Will it save money? Being able to automate a process when they already exist.
often leads to the mistaken belief that it will result in a less
expensive process or product being made. This is frequently due 17. Garbage in, garbage out. People tend to assume
to a poorly executed cost/benefit analysis. that the person coming in to do the automation work will just
pick up on what is being done at the plant and how things work.
15. Vendor cautions. Vendors can be great resources Good user and system requirements are a must for any project.
but they are poor manufacturers. They often lack a complete The final automation system will only be as good as what you
understanding of all the factors involved, not only the ask for in the requirements document. Without well-defined
installation of the project but the operation, repair and objectives, you will get scope creep.
maintenance of the project. The vendor is a servant, not an
executive. Research vendors carefully and talk to others who 18. Document everything. A small change requested
have used the vendor. Caution is particularly called for if you by the customer often leads to other changes that are much
are designing or in charge of a project where some of the more costly. If you don’t have paperwork showing the requested
technology, software or application use are unfamiliar or new. change and costs, it will be difficult to bill for the work.
continued
continued
continued
project stakeholders from adding “capabilities” to the process 7. Failure to manage expectations. Make sure all
that can lead to both financial and timeline strains, and stakeholders understand the trade-off between scope, budget
ultimately to a failed project. and time frame. Communicate this deliberately, formally and
frequently.
5. Skills mismatch. Many automation projects are viewed
as successful when the system is in the development and testing 8. Design misalignment. Failure often comes from
stage, but it becomes an entirely different scenario when the a lack of communication on the design of the project, from
project is implemented in the field. Errors begin to crop up. This is component selection to the format of I/O tags, networks
often due to the different skill levels of the people who develop and programming structure. Provide a scope prior to design
the project compared to the people who are sent out to execute that allows all items of the design to be agreed upon. As this
it in the field. document is created, members of the team or the integrator
can then point out potential pitfalls, such as using multiple
6. Poor planning. Most projects fail because of poor networks or not selecting a common controller.
planning. There is a tendency to underestimate the complexity
of the project and overestimate the capabilities of the team. 9. Confusion. An insufficient amount of effort in the front-
Late changes are the worst enemies of any project. The project loading stage, or subsequent budget cuts or direction changes
owner also needs to establish the most important priorities for by management, will result in confusion for the project team.
the team, such as cost, quality, maintenance, training, stocking It’s a standard recipe for failure.
of components, safety, etc. This will assure that decisions are
aligned with the project’s goals.
continued
FIVE POINTS FOR FAILURE. • Insufficient milestones to measure progress and identify
problems.
1. Failure to plan for and handle project resource changes.
• Outdated/incorrect documentation in brownfield projects.
2. Failure to know or admit that requirements are not well defined.
• Insufficient time in the schedule for third-party communications
3. Failure to address requirement definition problems in a timely or for developing a particular section of the system.
fashion.
•M
ismatch in the requirements of the project and the solution
4. Failure to plan and execute design review and approval given by the supplier.
milestones.
5. Failure to engineer the verification of project deliverables
•M
issing of the minute details pertaining to engineering and
scope of supply.
sufficiently, including lack of inspection and test planning.
• Failure to establish a clear schedule to finalize process and
equipment designs.
10. Other reasons for failure.
• L ack of training to enable plant personnel to operate and
• Unrealistic schedules are set. maintain complex systems and new technologies.
• Potential risks are not calculated and planned for.
• Engineers working on a project lack the necessary skill sets or
experience.
continued
continued
programmer or engineer can simulate to verify the results to the Keep it as simple as it needs to be and little more. This is as true
nearest real-world values. in design as it is in cutting metal. Drive for simplicity; save a lot of
headaches.
6. Talk to those who did a project. It’s worth
researching similar projects and simulations. Try to visit the sites 9. Is it real? Models can be very powerful—or
where the work took place. The published version that emerges very misleading. The challenge in creating a useful model
from a project is usually a pale imitation of the blood, sweat and is validating that the output is actually predictive. We are
tears that actually went into a particular software system. If you conditioned to believe what we see. In simulation, what we see
can get a word with those who were actually on the front line of may not be real. While simulation can save time and money,
the system, they tend to be the most truthful about its benefits just make sure you are modeling with the correct variables.
or limitations. Mathematical modeling is the first step in simulation, yet the
most critical step to success. Always validate against real-world
7. Design with modeling. Make sure modeling and conditions.
simulation give you a good image of the problem to solve. Have
a mental model to make sure digital version mimics the real 10. Schematics are key. When doing schematics, utilize
world. location codes and show all termination points. Allow the
schematics to be the set of drawings that live the life of the
8. Keep it simple. CAD/CAM is one of those tools that equipment by including all pertinent information with regards
quietly revolutionized low-volume production. But it is easy to the design as possible. Show wire colors, cables, terminals,
to get caught up in adding features because it is so easy to do. location codes, etc. Do not allow information to be spread across
continued
multiple documents if it can be avoided. The schematics can be simulation constraints (define the limits of the simulation),
used for installation, start-up and ongoing maintenance. visualization and reporting capabilities, procedural objects for
calculation and programming interface.
11. Identify limitations. Know the limitations of your
simulation software before you invest significant project time. 14. Simplify swap-overs. For both PLC and DCS upgrades,
Some simulation programs are more like a drawing program I/O simulators make system swap-overs much more reliable.
than a simulation program. This may be hard to see before you A simulator can also be used in troubleshooting to reproduce
buy it. problems experienced in the field, without interrupting the
actual process.
12. Team reviews. Ensure all members of the design team
have access to CAD software that allows for review of mechanical 15. Post-processor function. The post-processor
designs. A viewer program allows all members, not only the function is the most important tool for implementing CAM
mechanical engineering group, to review and find errors related software.
to their field of expertise.
16. Focus on critical process areas. Robotic and
13. Many factors for simulation. Simulation ergonomic simulation can yield positive results in developing
considerations for a process plant should include: deep manufacturing plans, but over usage can cause elevated costs
understanding of the process to be simulated and its peripherals, for those portions of process development that may not need
simulation hardware (capacities of CPU and memory), data to use simulation. It is important to analyze critical areas first
availability (physical parameters, chemical parameters), and work less critical areas after the fact in order to reduce the
continued
Technology advances, along with a systems approach to design 2. Focus on systems-level design. It is important
where all the components are working together in harmony, to understand the accuracy requirements of the entire
allow engineers to deliver improved performance in motion- electromechanical system when specifying servo drives. The
control applications. Here are some tips and best practices to get control system, position feedback sensing, the drives and
the most out of your motion control solution: final gears/mechanical links have to be carefully chosen to
work together so that the desired resolution of control can
1. Involve all departments from the beginning. be achieved. It is important to work with suppliers who strive
There was a time design started with the mechanical to understand your needs and will provide knowledgeable
engineering department. Once they developed the structure, technical support when complex control strategies need to be
they threw it over the wall to the electrical engineering group, implemented.
who would add motors and drives. That got assed to the controls
engineers, who were supposed to figure out how to make the 3. Plan for surprises. If you’ve ever designed motion
equipment work to spec. By this time, all of the flaws were control systems or served as a project manager, chances are
baked into the design. Today, the focus is on integrated design you’ve run into a few surprises during a project, such as over-
supported by mechatronic modeling. A number of commercially running conditions, inertia, braking and deceleration, current
available applications make it possible to try out many different dissipation, back driving or on-site drive tuning—just to name
designs and conduct detailed performance analysis before a few of the more common issues associated with motion-
anything is ever built. control design. You’re the person responsible for ensuring you
have thought of everything when dealing with motion-control
continued
4. Exceed machine specifications. The problem with 1. Power monitoring for energy management.
motion control is that speed does not necessarily equate to
throughput and motor resolution does not equate to system 2. Balanced and adequate power distribution for immediate needs
(in current and voltage range), as well as an allowance for growth.
accuracy. You need to design the system to exceed the machine
specifications; this means from the drive point back to and
3. Power supply review for variable frequency drives, inverters and
including the motor.
converters to ensure adequate isolation, impedance and grounding.
5. Cubic splines. Use cubic splines for motion planning and 4. Grounding review for supply to drives, drives to motors, motors to
for servo interpolation of position, velocity and acceleration. supply for high-frequency mitigation, as well as safety or PE (potential
earth) and adequate isolated TE (true earth grounding) for control
and communications.
SECTION TWO:
SELECTING PRODUCTS TO BUILD
YOUR AUTOMATED SYSTEM
FACTORY & MACHINE Automation Playbook 102 / 252
continued
6. Do you need flexibility? PC-based controllers not ARE MICRO PLCS AN OPTION?
only lend themselves to customization, they support it over the
lifetime of the equipment. Micro PLCs with flexible, “just enough” control may enable OEMs to
differentiate their equipment, particularly in stand-alone machines.
7. Got the need for speed? In general, a PC-based By developing a range of stand-alone machines using the same
controller will be faster than a PLC. controller platform, OEMs can reduce design time and lower their
costs. Look for micro PLCs that include:
8. What about the future? The increasing integration • Flexible hardware configurations, like USB, up to six serial
of IT and operations technology has begun making PC-based ports and Ethernet for communications.
control more appealing. A PC’s ability to interact with another
PC—and other information technologies in general—makes • U p to three axes of embedded motion.
it more adaptable for the various IT and operations linkages • Plug-ins and 2085 expansion for I/O USB.
we’re seeing more of these days. A PLC can, of course, be used in • S ingle programming software package that eases
installation, configuration, connectivity and maintenance.
continued
• After the main project scope and interoperability foundation have been • The learning curve for programmers and maintenance people can
determined, spend time familiarizing yourself or others working on exceed the cost of the original purchase and installation of the project
the project with the total costs of programming, installation, life cycle if this factor has not been properly considered and given a real and
maintenance and repair before purchasing of hardware, software and definable cost.
training.
• Additionally, the technical support available from hardware suppliers
• The overall cost of hardware can in general be fixed and there are for their software users is widely variable. While it may be difficult to
many options and price points available, but this hardware is useless if determine the real costs, it is critical not to overlook the cost of support
the programming software is difficult to learn, use or get support and since it will be needed on an ongoing basis for the entire lifecycle of the
training for. Simply because the hardware is purchased from a well- project.
established firm does not guarantee the software will be workable with
either the project parameters or the personnel expected to use the • The best, most capable software is useless if the programmer or
software in the field. maintenance people need to have extensive schooling from the
supplier just to use it, or if the technical support provided is difficult
to access or must be purchased.
continued
5. Take it for a test drive. When working with a controller, 7. Think ahead. Don’t go for the cheapest option when
it’s important to know its capabilities and if it meets the needs of installing a PLC. Think five years ahead to accommodate factory
your project. There’s nothing worse than being halfway through integration, peer-to-peer networking and data exchange
the project, only to find out that your controller isn’t capable of between controllers. The modern factory environment is
doing something. If the project includes something you haven’t becoming a network of integrated controllers.
done before, always bench-test the process before committing it
to the project. 8. Can we talk? A primary concern when implementing any
PLC is communications. This has been minimized with the advent
6. Build in some headroom. The controller must meet of ODVA, but can still be a problem when dealing with some
your performance needs today, but consider that the equipment sophisticated sensors or peripherals. Choosing a PLC family that
will probably operate over the next five to 10 years. During this has all the device type communications modules is paramount.
time, changes to the system may require modifications and Most PLCs on the market can communicate on device buses, but
choosing a flexible system upfront can help reduce costs in the not all can accommodate every type of Ethernet.
future. You also need scalability. The best approach is to spec
in a controller that can handle more axes of control than you Do your homework and choose a PLC that can support all your
continued
continued
13. Allow choice. When working with a supplier, do not force 16. Look for a helping hand. Consider what type of
them to use a PLC they have had no experience with. If they have assistance is available to you if you have questions on the
been successful using a particular brand of PLC, even though hardware or software. It can be both frustrating and time-
you may need to expand your spare parts, forcing them to use consuming if your PLC vendor does not provide in-depth support
another product and still meet deadlines will most likely result in in a timely manner. Find out what type of telephone support and
an inferior system. local support you can leverage from the manufacturer. Be sure
you are comfortable with your access to help if needed.
14. Beware hidden costs. Today every company, large
or small, is looking for ways to become more cost-efficient. 17. Ask about the warranty. Everyone wants to know that
Consider the total cost of ownership for the controller. You must his or her system is reliable. Ask your vendor about the warranty.
always consider hardware and software costs, but think about When vendors are confident about their quality, they stand
ancillary costs. Are there annual software licensing fees? Are behind it with lengthy warranties.
there annual technical support fees? What is the cost of training?
All of these costs can greatly increase the total cost of ownership
of a controller.
1. Design first. Designing your software to be modular and 5. Get out of the code. Ask the people at the plant why
to be arranged in layers (hardware through supervisory) before they are running the way they do. Sometimes what you might
starting to write is an absolute must. think is bad programming is really needed to optimally run a
process. On the flip side of the coin, after examining the code, you
2. Prioritize the HMI. When programming your project, often find people think a system is running in a particular way,
it’s best to start with the HMI first. If you write your application but the reality is that it is not.
first, quite often you’ll have to rewrite your code to accommodate
your HMI. 6. Use logic best practices. Utilize standard code to
decrease downtime. Organize code so devices are easy to locate.
3. Embrace ISA 88. The ISA 88 principles are applicable to Create logic to quickly outline reasons a device/function is
both batch and continuous processes, providing an elegant and not working. Don’t attempt to fix bad code from the previous
flexible solution. Say goodbye to spaghetti code. vintage...start over.
4. Compartmentalize. PLC programming is a lovely fossil. 7. Avoid canned code. When planning for PLC-based
If used properly, it can be a stroke of efficiency or a tangled controls, if your in-house techs will be involved in maintaining
continued
and upgrading the new system for future needs, don’t bring 10. Don’t forget to document. Use of programmable
in “canned code.” Ensure that your techs have input as to the controllers offers significant advantages over analog devices.
structure and nomenclature of the program. Bugs and changes However, it brings a new set of issues. First, consider the control
are the norm with any new control system, and you will find your of multiple function block parameters. It is a good practice to
facility rebounding much quicker after such a major change in maintain the software configuration control document that
equipment. summarizes all programmable/tunable parameters in one place.
You will use this document for any disaster recovery event,
8. Clarify interfaces. If multiple people program parts of including cybersecurity issues.
the PLC code, spend some time initially to make sure that the
interfaces are clear and everyone understands them. Dumping a 11. Use a counter. When two or more high-speed bits have
diagram on someone is not good enough. to be checked to ensure they are all on, use a counter instead of
the traditional latch. The latch only tells you it happened at least
9. Check CPU load. It is important to consider the CPU load once, whereas the counter will indicate if it happened with each
if communication handling is vital to the application. Running at part made, or more or less often. This allows you to see if the
the maximum cyclic load will result in poor capacity and response suspected inputs are not being made when required. Count the
times for peer-to-peer and OPC Server communication. Peak number of parts made, check your bits state counter and they
cyclic load should be kept below 65 percent and static cyclic load should compare.
below 60 percent under all conditions. Even lower cyclic loads
(30-40 percent) are desirable if high communication throughput 12. Don’t jump. Try to avoid “jumping” within your code, i.e.
is important. going from line 2 to line 7 and/or line 10 to line 4. Keep in mind
continued
that someone else may have to review your code in the future 14. Include a failsafe. Controllers should be programmed
and it has to be comprehensive. Better yet, use programming to be a stand-alone system to ensure that failure of
templates so that the locations for the code can be accessed communication with the HMI will not affect the process. Any
easily depending on the state of the machine. failure of the controller should put the system and process in
a safe state, known as a fail-safe condition. Scan time, process
13. Prevent empty data. In PC to PLC data collection, time and action time of the controllers are priorities for a robust
signal timing and handshaking are critical. If the PLC sets a control system.
Boolean bit when data is ready to be collected (end of cycle bit,
for example), logic should exist to ensure no empty/null data
exists in the devices to be read prior to setting the bit. String
processing, complex math and other functions can delay PLC
values updating. Failure to confirm can result in missing data.
On the PC application side, if the application is providing a
“completion response” to the PLC, the developer needs to ensure
all data has been read and successfully stored/processed. This
is especially true if the response bit is being used in the PLC to
truncate/reset PLC data.
2. Make it universal. Having multiple control systems 4. Keep it cool. When designing a redundant PLC system,
interacting with one another in a factory can cause major remember to provide sufficient cooling of the power supply, CPU
problems. Because of all the different systems, simple issues and communication processor modules by using a special fan (or
can become very difficult to troubleshoot, and very costly when fans) below the modules.
bringing in external support. In most cases, custom machine
integrators will use the controls platform of your choice. 5. Check daily. Automated tests for embedded software
Standardize on a control platform across an assembly project are extremely useful. Checking all software features on a daily
and in your factory. It will save money in many ways, from basis is a very good way to guarantee that features don’t
minimizing downtime to reducing spares inventory. suddenly break, caused by a little change done by someone in
an apparently unrelated part of the software. Having problems
3. Manage time. When a PLC/PAC needs to deal with many revealed within one day ensures that they get fixed quickly, as
different tasks, the CPU time slice assignment is important, such the person who made the bug still knows what he did yesterday.
as: motion, periodic task, critical (peer-to-peer) communication Better quality software takes the heat away from customer
with other PLCs, and HMI or monitoring tasks. Here the motion support departments.
As manufacturing moves into the connected era with initiatives 2. Prewritten software modules. Integrating an
like industry 4.0 and the much-hyped industrial Internet of HMI with separate ISOs, PLCs, and other controllers can be a
things (IIOT), the role of the human machine interface (HMI) in time-consuming and frustrating process. Look for an offering
automation is assuming a new importance. Today, end-users that includes plug-in software modules designed to simplify
have an array of options from simple versions with small displays development and configuration.
capable of presenting alarms and limited performance data to
high-resolution, multi-touch panels that can support diagnostics, 3. Mobile functionality. Mobile access is gaining
trends analysis, and mobile access. Here, we present a list of momentum as a core automation technology. Today, it confers
characteristics to look for in an HMI: a competitive advantage; in two years, it will be a must have. An
HMI should have embedded Web server software that enables
1. Protocol conversion. Today’s machines are networked, users to access it from client devices via Internet web browsers.
with a dizzying number of protocols backed by various alliances
multi-source agreements. Each vendor aligns with one or more 4. Robust design. The industrial environment is a harsh one.
protocols in all of their components. Your HMI should act as a Equipment needs to survive prolonged exposure to temperature
gateway to exchange data between all connected devices. In extremes, shock and vibration, dust and moisture, and more. If
order to enable yourself to choose best-in-class components your application involves the latter, you may need an HMI with
without concerns about compatibility, select an HMI capable of an ingress protection (IP) rating. Review the IP categories closely
converting between a dozen or more protocols simultaneously. and work with your vendor to ensure you make the right choice.
www.beckhoffautomation.com/AM8000
Web server functionality lets staff ranging from operators to are. This enables them to run diagnostics and gather data to
plant managers access the HMI as though they were standing in understand the problem. It can also put information in the hands
front of the machine. Embedded software on the HMI enables of off-site experts who can work with them to resolve the issue,
client devices to connect via the Internet. Client devices do not no matter where they are located.
require an installed application, just a web browser. As a result,
client devices range from PCs, tablets, and smart phones to thin 2. Monitor multiple pieces of equipment from a
client devices without hard drives or memory. The connection single location. In these days of lean staffing, everybody is
from HMI to cloud takes place over a secure VPN, typically via a doing double duty. Web server functionality makes it possible
password-protected connectivity hub. That hub manages the for a single person to closely track the performance of multiple
connections to ensure that each individual is only allowed to see assets. They spend less time walking from location to location
information and functions appropriate to their job role. and more time solving problems.
Remote access is frequently discussed in the context of off-site 3. Check readings and settings of inaccessible
users, but it can be just as effective in streamlining day-to-day equipment. Frequently, industrial equipment resides in
operations on-site. hazardous areas, controlled areas, remote locations, or simply
spots that are awkward or uncomfortable to reach. Mobile
1. Show data after alarms. When the HMI or PLC HMI functionality makes it possible for staff to view the screen
sends an alarm, maintenance technicians and operators can clearly and up close while remaining at a distance from the
immediately view the mobile HMI screen, no matter where they physical display. As a result, they can check key performance
continued
indicators (KPIs) inside an enclosure without opening the door versions but still requires the operator to move back and
and stopping the machinery, for example, or inside a clean room forth from display to problem area. By accessing the HMI on a
without suiting up. client device, operators can reference instructions as they are
correcting the problem.
4. Commission multiple axes simultaneously.
Mobile HMI software can support access by several users
simultaneously. The sessions are independent so that each
individual can be on a different screen at the same time and click
through two different screens and applications at will.
1. Start with the big picture. HMIs are the user’s eyes and • Documentation: do not leave this out; it is an integral part of the
limbs to a process control solution. Do your homework before project.
starting implementation and understand how the process works:
• Training: prepare to teach plant personnel how to use the
• Study the problems, understand the cost and time constraints, solution.
who will use it and why.
• Follow-up: post project review, usability, effectiveness,
• Determine the best architecture: single/multi screens, local/ troubleshooting, etc.)
remote, usability.
2. Conduct a plant review forum. Hold a design review
• Define the hardware parameters: hardware selection, data with a group of plant personnel to discuss any status notifications,
connectivity, response times. events, alerts and alarms that need to be programmed, both
from the perspective of an audio-visual action and an operations
• Establish software parameters: screen layout, navigation, response. Step through the intended functional system, once as
objects, alarms, event handling. 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
• Implementation issues: ergonomic considerations, accessibility, specifying equipment helps to identify the features that users
markings. will want in the HMI station. It also avoids surprises at point of
commissioning.
continued
3. Standardize. Select one HMI platform for your entire plant, projects in the area. Guard the HMI location so others don’t park
process or machine that is independent of any particular controls or configure something else on top of the station.
architecture. It’s easier for the operators and reduces the back-up
hardware needed on site. Operators and programmers become 6. Mobility challenges. Many people want plant data to
very familiar with the look and feel of the graphics, projects and be available for their mobile devices. While this is an important
operation of a touch screen. Develop your own standards. If you trend, most traditional plant floor information systems tend to
rely on vendors, you will get a mess of different looking systems. be vendor-specific machine control applications and don’t really
play nice with distributed data applications. Today’s web-based
4. Right-size displays. Don’t try to save money by selecting visualization and data management tools allow for a more flexible
an HMI display screen that’s too small. It’s also important not data model at a considerably reduced price point. Consult with
to cram too much information onto a screen. Size the display your IT group prior to any major HMI deployments.
according to the amount of information that is most important
for the operator to see. Always discuss requirements with the 7. Beware HMI-PLC communication. Make sure you
equipment’s operators well ahead of time, not just with their understand how to set up communications between the PLC
managers. Operators usually have different needs and the success and HMI. This can get tricky when you are not using the same
of your system depends on their usage. manufacturer for both products. The client-server philosophy is
useful in new projects. It allows more effective communications
5. Location, location, location. Real estate can be prime with the PLCs.
in a busy production area. Locate the HMI in a practical place,
out of heavy traffic areas but accessible. Be aware of near-future
continued
continued
allows patch testing without effecting production. Testing in the from the PLC program. The problem is that this leads to the
virtual environment is very cost effective. machine program residing in two locations. This complicates
troubleshooting. An HMI is great for scaling the data from user to
6. Don’t be overambitious. Manufacturers are creating PLC format, but if you move too much of the functionality to the
HMI products with more capabilities that allow off-loading HMI, problems arise.
1. Less is more. It’s important to keep the HMI simple and • A void colors that could create problems for people with color
with the operator in mind. It’s best when it’s self-explanatory and blindness.
easily understood. Also, try to make the pages similar and follow
the same page layout throughout. Avoid making the display too • Minimize the use of colors to allow actual device state and
technical. It’s normal for engineers to try to give the customer alarms to stand out.
everything, but when it comes to the HMI, less really is more.
• F or alarming, choose colors that contrast with the normal
2. Use effective design techniques. A good design process view so the operator will notice the change.
requires careful use of layout, color and content. If you get it
wrong, your operator misses an indication, and you lose money, 3. Think about flow. It is essential to have a clear design
or worse, someone is injured. On a poor design, the layout is approach to the HMI. Decide how the display blocks naturally
continued
Alarming is one of the core tasks of an HMI. To execute that task which can affect the perception of red and green, color cannot
effectively, developers need to make careful decisions about be used as the sole indicator of alarms.
what to display, how to display it, and what functionality may be
included. 4. Use pictorial changes Any color change must be
supplemented with a pictorial change and, if the alarm is critical,
1. Have a strategy. Alarming needs to have a well- an audible alert. Pictorial changes could include shape changing,
articulated strategy. Alarms must be used for conditions that a change in the position of an indicator, having additional text
require intervention and must have a clear corrective action or objects appear on an alarm. Flashing of alarms that have
associated with each one. Anything else should not be an alarm. not been accepted is very irritating and stressful and should be
avoided.
2.Show alarms on all pages Alarm status for the overall
plant, preferably organized into groups, should be visible on 5. Avoid auto changes Similarly, automatic changing of
every screen and there should be a simple navigation route to displays should be avoided—to have a page disappear when you
access the screen containing additional details about the alarm. are working on it is irritating and, in extreme cases, a cascade of
alarms can produce so many screen refreshes, an operator can
3. Use color wisely The alarm colors should follow the be locked out of the system.
safety convention: Red = stop, prohibition, danger; Yellow =
caution, risk of danger; Green = safe condition; Blue = mandatory
action. As one in 12 men have some form of color-blindness,
continued
The correct choice of motor (surprise!) depends upon the 2. Do you need full torque at zero or low speed?
needs of the application. With the increasing sophistication One of the drawbacks of a basic vector motor is that it cannot
of drive technologies, designers have more choices than ever develop full torque at zero or very low speed. Add an encoder,
for positioning applications. Below, we outline some factors to however, and it can. The key is the level of resolution required by
consider when choosing among AC vector motors, servo motors, the application. For low-resolution positioning, the vector motor
and stepper motors: with closed-loop feedback will do the job. An encoder will add
cost and complexity to the system but the aggregate cost over
1. How tight are your positioning requirements? time may still be lower than the servo-motor alternative. For
Servo motors used to be the go-to solution for motion, but for applications with higher-resolution needs, consider either a servo
applications with modest positioning requirements, AC motors motor or a stepper motor.
with AC flux-vector drives might be a better fit. The drives require
complex algorithms for control, making them more expensive 3. Do you have a high-performance positioning
than a standard drive for a DC servo motor. That said, DC motors application? Servo motors are the gold standard. They will
have brushes and tend to be more expensive to maintain a more always outdo vector motors and deliver better acceleration and
prone to failure than AC motors. If the performance meets your top-speed characteristics compared to stepper motors.
application requirements, you may discover that the vector motor
is a more economical solution in the long run. 4. Do you need to hold your position? Stepper motors
offer holding torque, unlike servo motors, which need some sort
of brake for vertical applications.
continued
5. Do you want simple? Stepper motors can operate open- 6. Are you dealing with a high magnetic field?
loop (without an encoder). The trade-off is that they can suffer Consider a piezoelectric motor. They offer high speeds and
from lost motion, and without an encoder on the system, there both linear and rotary motion. When built with non-magnetic
will be no way to detect this. Your application has to be flexible housings, they deliver effective performance even in multi-tesla
enough that this does not matter. magnetic fields.
continued
switching by a factor of 10. The intelligent overload will remain in agitator motor or a chiller compressor, take special care to
service indefinitely. place the drive in a hardware panel installed in a dust-free
location, preferably air-conditioned. A better solution for harsh
6. Consider VFDs. Instead of operating an AC induction environments that have maintenance people with minimum
motor at top speed and adjusting the speed of the load skills might be a magnetically coupled drive with variable-speed
mechanically, for example with a control valve, consider a option. Magnetically coupled drives have the advantage of
variable-frequency drive (VFD). It will save energy and prolong decoupling vibration and potential overloading of the motor
the lifetime of the motor. It will also eliminate the need for or driven equipment due to the air gap between the motor
a valve, reducing costs, points of failure, and maintenance. shaft and the other shaft, which can reduce costly damage to
Examples include include pumps, fans, and blowers. mechanical seals.
7. Do your homework. Always check for the proper 9. Focus on economical sparing. Avoid the temptation
rating and proper type of drives or motors for different type of to size a motor separately for each axis. Try to standardize motors
application. Ask the supplier about the fail-safe function of the and drives around a few sizes. This will minimize your spares
system and always check for proper grounding of the system. inventory. Also, instead of stocking multiple spare cards for
Make sure you inform the supplier about the features you want the drive, keep one spare module. This will be an economical
and the process to be controlled. solution.
continued
10. Avoid common drive pitfalls. The reliability of the 12. Aim for good housekeeping. Keep motors and
core components, such as the PLC or a variable frequency drive, drives clean and free of foreign contaminants to keep them
in a control system is important. Drive failure may be caused running for a long period of time. Don’t use the cord as a leash
by many factors: PCB calibrating, IC chip failure, mishandling when you are carrying the motor around.
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.
the motor, the smaller slip. This means for two motors with
the same nominal speed, the Premium Efficiency motor will
be faster than the Energy Efficient motor. Be sure to take
this into account in your designs.
ASK
continued
continued
Seven key points for applying servo drives, motion controllers and PLCs
4. Over-sizing wastes energy, cost and panel 5. Document requirements. When building dedicated
space. Some of the biggest energy wasters on a machine are automation with motion control, whether you source it out or
frequently overlooked. Over-sized servo drive/motor systems, not, it is extremely important to understand the system you are
for example, cause machines to consume more energy than building and the functionality that you intend it to have. There
necessary—something that can easily be avoided through proper are different levels of motion control, especially if using a PLC
design. End users often underestimate the returns from energy- as the primary logic controller. For example, on an indexing
efficiency investments, since it costs more up front and may take a assembly station that used a servo drive to index large assembly
few years to achieve payback. As a result, they often inadvertently pallets from one station to the next, the controls company
build in extra long-term, ongoing costs by overlooking details used an incremental encoding servo drive system rather than
when sizing machine components. When sizing a machine, an absolute encoding system. This error crept in because
the entire motion profile is important, not just speed and load. the original rationale for using an absolute system was not
Having a detailed and accurate profile of needed motion can documented. Consequently, in an emergency stop situation, the
pay dividends. Typically, a less precise profile will lead to an over- indexing system would stop and then want to do a complete
sized servomotor. This means that the energy consumption of the index, starting from its current point. Had absolute encoding
system will be higher than needed. The key to getting the motion been used as originally planned, recovery from an e-stop would
profile right is properly calculating velocity, continuous vs. peak have been very simple. If the expected functionality had been
torques, acceleration, and matching load and motor inertias. properly documented, additional complexity would not have
Further, refine the profile by accounting for cycle times. How long been added to what should have been a simple solution.
does the system have to move from one point to the next, and
how long can it take to complete the entire trajectory?
continued
Seven key points for applying servo drives, motion controllers and PLCs
continued
continued
if the dust level is high. Put proper tags at the site to guide When available, digital output equivalents are usually worth the
servicing. After commissioning, put the instrument on continuous additional purchase price for overall lower cost of ownership.
monitoring/trending to make sure readings are correct and
the calibration is accurate before handing it off to operations 9. Beware of blues. Too often, engineers select the sensor
personnel. (Jeanne, make this one last.) they know best for every job. In many cases, this presents no
problem. At other times, it can be a real headache. For example,
7. Faulty cables. When replacing a “bad” sensor in an existing when using diffuse-type photoelectric sensors, color variations
field application, be sure to also check the condition of the quick- can cause serious sensing issues. This is especially common with
disconnect cable or cord set. In many cases, the pins or sockets blue targets, as they tend to absorb rather than reflect the light
are weakened or corroded, leading to intermittent operation. emitted from the sensors. A good solution for this problem is
Replacing only the sensor may temporarily restore electrical normally to use barrier-type sensors, such as through-beam
contact, but it will certainly fail again because the root cause, or retro-reflective sensors. These can pose other problems,
a faulty mating connector, has not been corrected. Depending however, when there is insufficient space for mounting, since
on the cost of the sensor being replaced, this can be a pretty both technologies require mounting either a sensor or reflector
costly situation when in fact a relatively inexpensive replacement on both sides of the process. Another good solution for such an
connector cable could have solved the problem in the first place. issue is a background suppression sensor. This approach normally
uses either a fixed or an adjustable mechanical angle as a means
8. Digital lowers costs. If linear or proportional output to control what is considered acceptable in terms of distance
sensor devices are needed, avoid analog field devices to minimize from the sensor via the amount of light reflected at one particular
cost and support issues for shielded cables and grounding. receiver of the usually two or more located in the sensor housing.
continued
However, with irregularly shaped items, this technology can also of safety applications and can provide any configuration and
be problematic due to light scattering. For instance, bottles and especially any IP level.
cans with the rounded surfaces can trigger the sensors, especially
when it is not possible to mount the sensor perpendicular to the 12. Check construction materials. Proper material
process due to space limitations. As a result, the sensor can false of construction for the service environment is important. With
trigger. New sensor technology can solve these issues. Sensors so many options, choose the most common and agreed upon
that perform as a retro-reflective sensor, without requiring a materials for longer service life. Once ordered, confirm that the
reflector, can handle the variations in color, and irregularly shaped material of construction is what you requested before installing.
or spaced objects. Rather than the traditionally required reflector,
the sensor uses a wall or a piece of the machine as a reflector. 13. Verify vendor claims. Most manufacturers appeal to
Any object that interrupts the beam between the sensor and the engineers regarding the high reliability of instruments and sensors
target triggers an output. these days. To verify that the claims are true, check the facts with
3rd party reviews and award programs for best practices. Practice
10. Real-time processing. Decoupling measuring circuits summarizing the information as if someone wanted you to qualify
from microcontrollers will enable real-time processing of parametric your decision on the brand and model. If it doesn’t happen on
time series along the entire operational process and provide the job, do it anyway. It’s a true professional practice and you
integrated monitoring of multiple potential failures or malfunctions. get better every time you do it. Engineering reviews (voice of
experience, lessons learned) help to verify the required precision
11. Supplier history. When it comes to sensors, especially has been followed if interlocks, alarms and safety critical devices
safety sensors, the key is finding a supplier that has a long history are to be used with the sensor.
continued
continued
3. Are the sensors mounted outdoors? It is important to enclosure rating. Consider hygienic requirements in sensor
know the maximum and minimum temperatures to which selection, since these are becoming more popular in the
the sensor will be exposed. For extreme environments, food and beverage industry.
an internal or external heating or cooling unit may be
necessary. Sometimes a heating unit is advantageous to 5. Is the sensor exposed to direct sunlight? During sunset or
reduce frost or fog build-up on the exterior of the lens. sunrise, for example, the sun might shine directly into the
receiver of a sensor and give a false output. Reduce the risk
4. Will the sensor be exposed to wash-down conditions? of this happening by using a hooded bracket to minimize
Choose an enclosure with the appropriate NEMA/IP interference.
14. Check the range. Make sure the sensor is appropriately Alleviate them with parallel stations.
sensitive. Target the midpoint of a sensor’s scale for the intended
operating condition, since the sensor’s range is important. The 16. System confidence. Check the functional specs when
application is only as good as the detail you bring to the table. selecting safety-instrumented systems. Failure rates (MTBFs) are
very critical in keeping confidence in a system high. Maintenance-
15.Eliminate bottlenecks. In-motion weigh scale systems intensive calibration and servicing requirements should be
can create a bottleneck in an automated shipping and delivery line. recognized.
Volumes of material exist on proper system design, proper sizing 3. Valve sizing. Correct sizing of components, including
of components, circuit design, valve and control technologies, as piping, valves and actuators, can improve the productive
well as other design considerations. However, here are a few tips capacity of pneumatic systems. Valve sizing is particularly
you may not find in the textbooks: important. If the flow capacity is too small, it can have a negative
impact on production cycles. If you want to improve production
1. Flow vs. pressure. When dealing with pneumatics, it is cycle time and quality, then proper sizing is critical.
critical to understand the difference between pressure and flow.
Too often operators compensate for starved flow with increased 4. Align pipelines. If pipelines are not aligned properly at
pressure. It is often best to install oversized supply lines to a the correct angle, as indicated in the installation drawings, there
process in order to ensure the appropriate volume of air. is a great possibility of equipment damage.
2. Use electric actuators. With ever-increasing energy 5. Choose three-position valves. Wherever operators
costs, designers should consider using energy-efficient electric will be working near an operation, a three-position valve is a
continued
better choice than a two-position valve. This is because a three- 9. Parallel air. Make sure you have an adequate air supply
position valve will stop the equipment instantly in the event of when using pneumatic technology. Costly leaks are often hard
an emergency. This is in contrast to a two-position valve, which to detect in a noisy plant environment. To avoid failure in the
will first complete the operation before stopping. supply of compressed air on a network, it is important to verify
that the distribution is closed so that the compressed air comes
6. Check temperatures. Be sure to check the surface in parallel and not in series. Inspect tubing, ferrule, connection
temperatures of equipment during preventive maintenance and joints for leakages. Make sure the air being produced is dry.
time and make a record. High temperatures could damage the All air filters should be checked periodically for accumulated
viscosity properties of the hydraulic oil. water drainage.
7. Built-in flow control. When you are using a pneumatic 10. Choose quality tubing. To prevent leaks, use nylon
cylinder in a project, especially in high cycle count projects, use a tubing on machines rather than push-on fittings and PE tubing.
fitting that has a flow control valve built in to make the cylinder The leakage often found with soft tubing is hard to detect in a
last longer. plant environment.
8. Use feedback sensors. Don’t rely on software interlocks 11. Inlet side flow control. In a pneumatic logic circuit
to control pneumatic devices unless you account for the controlling a double-acting cylinder, place the flow controls on
delay caused by physical actuation. 100 ms is a long time in the inlet side of your cylinder depending on the direction of
the computer world. Always back up actuators with electrical travel. Air is compressible and positioning will float if controlled
feedback sensors, redundant if possible. on the outlet. This will also create back pressure.
www.beckhoffautomation.com/CX8000
continued
continued
controllers and systems. This embedded approach to control separate, but helps drastically reduce the machine
robotics integration brings the robot module directly into footprint—by up to 50 percent—because there are fewer
the control platform’s chassis. It keeps machine and robot control boxes on a machine.
5. Tooling clearance. It is very important to have a clear, emergency maintenance never happens, and temporary, sub-
defined understanding of the type of end effector for your optimal, rigging ends up hurriedly being used.
application so that tooling does not damage in-order production
parts. Selecting a well thought-out end effector will also help 7. Get early feedback. Try and do as detailed a simulation
minimize the teach time on the final program to ensure the as early as you can and show it to the workforce involved in the
proper clearance to run the robot at the maximum speed. process in order to get feedback on possible operational issues.
You may find that there is more going on in the existing process
6. Plan for maintenance. For large robots, make sure than you knew about and that micro-management is necessary.
means for maintenance are included in the original project
scope. A monorail hoist designed in at the start of the project, 8. Zoning for product size. In a robotic pick-and-place
for example, is much cheaper and easier to install than one built system for thermoformed packaging trays, incorporate zoned
years later. Installing a hoist while running requires scheduling, suction cups that can be isolated or turned on and off, to allow
downtime, lost production, etc. Installing a hoist during for various tray sizes.
continued
continued
continued
5. Match environment. Vision hardware must be chosen resolution, the higher the camera price. PC-based systems might
precisely for the environment. Optics must match the desired appear as lower cost up-front, but programming time is higher.
field of view. Illumination must be robust. Tested software On the other hand, vision sensors might appear to be higher in
libraries help keep the complexities to a minimum. price at the beginning, but the ease of use lowers the time spent
on programming. PC-based systems are faster than vision sensors,
6. Prepare for upgrades. When considering a vision so they might work better with high-resolution cameras. Selecting
system, always bear in mind the effects of Windows upgrades on the wrong camera for the job will cause the project to fail by
the future of the system. A complete backup image system will making the inspection impossible or unreliable, or will elevate the
give the vision system an additional five years of life. project cost, so the project will not be competitive.
7. The right camera. Choosing the right camera is the next 8. Does the system match application needs? The
big issue in vision projects. The camera resolution, and whether it capabilities of a vision system will vary by the application. For
will be a PC-based or stand-alone unit, is fundamental to providing example, if a vision system was designed for semiconductor
a competitively priced vision project. Higher resolution might inspection, it may not be cost-effective or perform well if you try
provide higher field of view and enhanced image details for the to tune it for a label inspection system in a consumer packaged
inspection, but speed is the trade-off. The higher the resolution, goods application.
the lower the inspection rate will be. The level of detail required
in the inspection (smallest unit to be measured or inspected) and 9. Simple interface. The biggest pitfall in machine vision
the inspection rate will define the correct camera; the higher the projects for detecting defects in manufactured parts is often
continued
the proper selection of lighting and proper lens selections, as included in any successful installation, when a new machine vision
well as the timing of the strobe controllers on some high-speed system is installed and the camera begins to find defective or out
projects. The next biggest pitfall is ensuring that the interface is of tolerance parts. The time spent working as a team with the
simple enough for the average operator to use with little effort. quality department will ensure success in the future.
Even when a system usually performs flawlessly, problems will
arise sooner or latter. The operator interface should be designed 11. Avoid scope creep. Without a good understanding
to make it simple enough for even a novice operator to learn. It of the project scope, projects can fall into the programmer’s
pays to include the person who will operate the system during the nightmare known as an “endless loop.” With vision products and
design process. software, many things are possible that might lie just outside the
scope/need of customer. It is important to define the scope in
10. Define expectations. Projects can fail because the writing to give everyone (customer and integrator) a clear goal to
system was designed for perfect parts, but it turns out the real work towards and a clear method of testing the results. Whether
parts are less than perfect and the employees loose interest very it is for 3D imaging, NIR (near infrared) or some new algorithm in
quickly in the system. Even when a system is doing what it was the software, it is common to see requests for new items added to
designed to do, the results can be unexpected. The most effective the application. This can be especially true when introducing new
deployments involve several different departments working types of technology as part of a solution.
together a a team to decide what the acceptable standard will
be, after knowing exactly what the production line is actually 12. Extreme detail. It is not enough to merely to want to
producing. Keep in mind that there will be some “bucket time” detect an object and make sure it has the proper number of holes.
continued
continued
10 questions to ask
Whether you are new to machine vision or an experienced 5. How can you determine the repeatability of a vision
user, consider the following 10 questions when selecting a system’s gauging tools?
stand-alone vision system:
6. How do you evaluate industrial code reading tools and
1. Does the vision system make it easy to set up applications, what are some specific features to look for?
create custom operator interfaces and administer vision
system networks? 7. What networking and communications features are
available?
2. What is the importance of part location tools, and how
can you assess their performance? 8. What should you know about vision system accessories?
3. Does the vision system have a complete set of image pre- 9. Does the vendor offer a wide range of hardware options?
processing tools? Are they rugged enough for your environment?
4. What should you look for in character reading and 10. Does the supplier provide the support and learning
verification capabilities? services you need?
continued
SECTION THREE:
APPLYING TECHNOLOGIES
TO IMPROVE OUTCOMES
FACTORY & MACHINE Automation Playbook 158 / 252
The assets in your plant and on the factory floor offer enormous 2. Move to the ether. Migrate and/or update your
opportunity for insights that can be leveraged to improve technology to Ethernet and move away from older legacy
operational performance, productivity, and safety. The key is to fieldbus systems or proprietary technologies.
harvest that data and put it in the hands of decision-makers in an
easily-consumable form. To do that, you need a reliable, scalable 3. Aim for the best. Take a look at your network design and
infrastructure that can provide end-to-end security to protect ensure you’re following best practices, such as segmenting into
from the increased threats posed by greater interconnectivity. zones and conduits or employing wireless solutions.
The following five steps will help you get the most out of your 4. Choose layers. Protect your network through a layered
industrial Internet of Things (IIoT) initiatives: approach, with security measures built into each level of the
network.
1. Evaluate your starting point. Determine what you
have, where it lives, what it does, who owns and manages it and, 5. Maintain oversight. Establish ongoing monitoring and
ultimately, where you want to be. troubleshooting to keep up as technology and security threats
evolve.
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FACTORY & MACHINE Automation Playbook 160 / 252
One of the biggest concerns regarding the industrial Internet 2. Digital controls over user access. The next layer
of Things (IIoT) is the risk of exposing industrial assets to of securing an IIoT network involves user access to control who
unauthorized access. Security should be implemented in layers, has digital access to data at specific locations. Security at this
starting with physical security and equipment access and level includes password policies, role-based access control and
moving on to data protection and transport. This process of access control lists (ACLs). Simply requiring a passcode for access
layered security is similar to the best practices that have been to touchscreen operator panels, or passwords on terminals,
employed effectively with enterprise networks for years. can significantly reduce compromised data by identifying
and logging when and who is accessing equipment. For some
1. Physical separation. Physical security represents an applications, role-based access control or an ACL can limit user
organization’s ability to physically separate equipment from access to sensitive data based on the credentials provided.
non-authorized users. Fences and enclosures represent easy-to- For example, a technician might require in-depth system
deploy solutions that help keep sensitive equipment safe from access, while an operator might only require a small subset of
theft or tampering. Whether the device or equipment is on a permissions to operate equipment.
factory floor or at a remote pumping station, it is important to
limit access to sensitive data.
continued
3. Secure data transport. Controlling who has access to example of an emerging technology positively impacting
equipment at a site is sometimes the easiest part of securing security for IIoT applications. SDN enables dynamic routing of
sensitive data. A larger challenge is how to effectively collect encrypted information through secure nodes without the need
data across tens or thousands of locations securely and reliably for a dedicated IT team to manage it. Solutions like SDN in an
without requiring a full-time security or IT team. Securing data industrial network, where environmental and backhaul variables
for transport between sites can be accomplished in a number are constantly changing, can help ensure data stays secure and
of ways, but many pose implementation challenges. IPsec, port systems remain operational without IT intervention.
forwarding and open VPN technologies are common ways
to provide remote device access. Though familiar to IT, these Security strategies will continue to evolve as new threats and
methods are more complicated to set up and maintain on the technologies emerge. Though a single security solution doesn’t
operations side of the business. This is why the market needs fit every application, there are common measures that should be
easy-to-use technologies to securely address mass-deployed evaluated to help reduce most threats. Selecting vendors that
sites as part of successful IIoT adoption. offer paths to keep equipment updated with current security
solutions should be a priority.
Emerging technologies are changing the paradigm of how
organizations approach the implementation and maintenance
of security policies. These technologies provide inherently
more secure communications while simplifying the process of
deployment and management, which can significantly reduce
operational costs. Software-defined networking (SDN) is one
Firewalls are essential for ensuring network security and • P ermitting only approved communications between devices to
increasing system robustness and resiliency. What are firewalls? protect against malicious attacks and device or operator errors.
Firewalls protect networks and devices, such as industrial PCs,
control systems and cameras, from unauthorized access by Though a firewall might sound like a single type of device,
preventing network traffic to or from these systems. They are a firewalls come in many different forms, not only in terms
core element of segmenting a network, and they play a crucial of hardware features and industry approvals but also with
role in any industrial Internet of Things (IIoT) related network different filtering capabilities. That leaves users with the task of
security strategy. determining which type of firewall is best suited for each portion
of the application or environment. Below, find four tips for
Firewalls have a few main goals, including: specifying an effective firewall:
• Protecting any connections between enterprise and industrial 1. Tailor it for your network. Like choosing specific IIoT
networks, and preventing external threats. devices, firewalls should be able to accomplish very specific
tasks that support your custom needs and applications. Select
• C reating barriers within a network to prevent internal issues firewalls that match the unique communications patterns and
from spreading. needs of the devices across the network.
continued
2. Inspect at multiple levels. Depending on where it very timeconsuming and error-prone. Teams need to be able
will sit in your system, the firewall will need various filtering to effectively manage and configure the devices when using
mechanisms. Firewalls used close to machines as part of a zones multiple firewalls. It’s important that firewalls can be centrally
and conduits security strategy should understand industrial monitored by network management tools to keep things
protocols and perform deep packet inspection. In contrast, a running smoothly.
firewall used to secure the perimeter between a remote site
and the Internet should be able to process Internet Protocol (IP) Firewalls are just one component of an effective security strategy
traffic. for companies taking advantage of the IIoT. But don’t downplay
their use— they are the cornerstone that holds a holistic security
3. Make sure it’s robust enough. Depending on model together. Having a solid understanding of the types of
your network environment, firewalls could be subjected to firewalls available and the role each plays results in successfully
extended temperature ranges, significant vibration and other securing the network from a range of internal and external
environmental factors. Ensure any firewall you choose can threats lurking out there. By implementing a holistic defense
withstand harsh environments and that they are compliant with strategy that includes firewalls, you can design networks that
all industry standards and approvals. Selecting a firewall without effectively mitigate threats and defend against the errors and
the robustness required for the application will derail a project vulnerabilities introduced by an ever expanding range of IIoT
very quickly. devices and environments.
continued
product going through the entire production phase, see where 6. Plan for future. Give careful consideration to site
it goes and who interacts with it, what information it needs and conditions and possible changes in those conditions. Design
where that information comes from, as well as what information your network to handle not just current conditions, but also
it produces and where that information goes. Getting all the possible changes. This is a particular requirement in hazardous
affected parties involved will not only get you the best solution, environments like cement and power plants. Don’t jump into
it will make everyone understand that they have an investment implementation in the field without prior design, locating
in the project. equipment and identifying signal paths on plans.
4. Functionality varies by vendor. Understand what 7. Keep things simple. Industrial automation networking
functions and performance your network needs to deliver before is great, but remember to keep things simple. If a few discrete
listening to various sales pitches. The functionality various I/O handshakes would serve the purpose, it might be the best
manufacturers implement, even in standard fieldbus or Ethernet design. Even if a fieldbus segment could theoretically be loaded
systems, can vary substantially. Never make assumptions about to the maximum or use a less-traditional architecture, those
any vendor-specific products. designs could reduce system reliability or make it harder to
troubleshoot in the future.
5. Does your team have fieldbus skills? Select a
fieldbus that can be handled by the software team at your 8. Cost savings. Using fieldbus networks versus traditional
disposal. The greatest fieldbus technology in the world will hardwired I/O systems provides significant savings in terms
fail if the software team does not understand the integration, of material and labor costs. Cost reductions approaching 50
implementation or error handling of the selected product. percent in material and labor on initial setup and a 75 percent
continued
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THE INDUSTRIAL MODULAR SOLUTION interstate, do not try to shoehorn the wrong network for a
function.
• 12-gauge steel frame with a 3500-lb. load rating (1.5 safety factor)
has less deflection under load
• Subpanel has more usable space with a higher load rating of 2000 lbs. 10. Communications security is evolving. Don’t
(2.5 safety factor) rest on the processes and implementation practices you’ve
• Durable materials and components provide long-lasting protection for used for the past 20 years. It’s time to review industry best
your system practices. It’s a good training goal for 2013-2014 to consider
• More flexible installation options with the EZ-Load Mounting System how cyber security evolution should be affecting your
and new horizontal loading option system solutions.
• Easily access electrical components by removing doors, tops, sides
and/or bases
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FACTORY & MACHINE Automation Playbook 167 / 252
It all comes down to the details. That’s as true for networking as it to the point of failure. These failure points can be associated with
is for every other aspect of an automation project. Here are some the number of Ethernet port connections, the size and frequency
tips for making sure the details are covered with your industrial of data being managed, as well as data addressing in the PLC.
network: The PLC addresses used in data collection, if not contiguous
or near contiguous, can cause excess read/write cycles to the
1. Keep a list. Networked devices have addresses. It is very PLC. Some PLCs can only provide X number of devices in one
important to keep a list that shows the assigned address, the read. If that number is 1k (1024 devices) and you attempt to
product this address has been assigned to and the line/plant read the values of coils 250, 1400, 5000 and 6500 in one cycle,
location where the product has been installed. It is very difficult it can actually create four separate read requests. This results
to troubleshoot many systems because this basic information in performance issues and missing data. Think of the impact if
was not captured, leading to significant equipment downtime. you want to read 250 values! FMEA (Failure Modes and Effect
Once installed, these devices need to be labeled accordingly Analysis) is a great tool to aid in trying to identify things that can
since it is not uncommon to have several identical devices in go wrong.
close proximity. This information should also be part of any
electrical and mechanical drawing. 3. Be aware of security issues. You have to be constantly
aware of the security aspects of your control network. Seek
2. Test to failure. When developing data collection/data cooperation with the IT professionals; you likely have more
passing applications (PLC to PLC, PC to PLC, etc.) using Ethernet, overlap with office systems than you might know.
fieldbuses and especially proprietary networks, it is critical to test
continued
4. Avoid subnetworks. When selecting fieldbus or network 6. Network everything. Nothing is not in the network
architecture, avoid the use of subnetwork systems or anymore. When you implement a new project or a new system,
expandability features that require configuration of expansion the networking criteria are a critical consideration. Every
modules or field devices separately from the PC or PLC. Subnet device needs a communication port or ports, physical media,
components add an additional burden for end-user support and communication protocol and tools to configure, display,
complexity in software (re-tagging/programming) when the diagnose, analysis, etc.
subnet I/O count or type changes.
7. Route separately for reliability. To have a more
5. Buy a network analyzer. When a system using reliable DCS system in factories, use high-quality network and
a fieldbus/industrial network does not work as expected, fieldbus components and make a separate route for network
somehow the network is always blamed: too slow, too many cables. This will help guarantee system performance.
flipped bits due to EMC (electromagnetic compatibility)
issues, etc. Without proper measuring equipment, a network 8. Match media to conditions. There are a variety of
troubleshooter won’t stand a chance of disproving this. Make different types of network connectivity. Choose the media
sure high-quality network analyzers are available, and the real according to the environment and conditions under which this
root cause of the problems will show up very quickly: very often network will operate. As an example, you would not use Cat6
it is application software. A network engineer without a network wire for an Ethernet communication between buildings. Use
analyzer is like an electrician without a multimeter: clueless. fiber instead due to lightning conditions. You could also use
wireless modems instead of fiber when the distances between
buildings are great.
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4. Learn Ethernet. Take the time to learn (through courses the weakest link. Just because you’re using Cat 6 patch cables
or self-taught) the art of Ethernet networking. It’s never going to doesn’t mean that your permanent cable or connector is rated
go away. If you can seamlessly work through VPNs, port forward, for 6.
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.
5. Get ready for connectivity. It makes sense to The lack of fundamental understanding of Ethernet architectures
implement all PLCs on Ethernet using protocol converters. This is the most common cause of these issues. Prior to deployment
makes your plant ready with data available on Ethernet for future of an Ethernet-based control system, spend time understanding
connectivity with MES/ERP systems. the 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.
2. Control multicast traffic. When implementing wireless 4. Don’t take shortcuts with wireless. Consider the
technology in factory automation projects, be aware of any entire system design and the support lifecycle of the system
multicast traffic coming from PLCs or producer devices. Multicast before choosing technology and vendors. Time spent up front
traffic is handled differently than unicast traffic by wireless on site surveys, path loss calculations and fade margin will pay
access points. Multiple devices can receive multicast traffic, while dividends when it comes time for installation. Design in fade
continued
Four tips for dealing with wireless latency and bandwidth issues
continued
continued
floor, use network equipment designed specifically for industrial accessibility, lockable PLC panels, server rooms), hazard protection
applications. (fire, floods, EMI, etc.), a disaster recovery plan and other features
as appropriate to the needs and concerns of your business.
3. Be on your guard. As with functional safety, the objects
involved in security are not only devices or equipment. There are 5. Defense-in-depth. In the past, industrial network security
human factors as well. Security is more challenging than safety, was accomplished through air gaps. Essentially, this relied on
because it’s always in a state of dynamic change. New malware, having physically separated or isolated systems to protect plant
viruses, worms and tools arise every day. Defenders need to be equipment and networks from the rest of the world. This type of
awake all the time. In an industrial environment, it’s more difficult security resulted in industrial systems with software that wasn’t
than in an office environment. The plant is not allowed to shut kept up-to-date with the latest security patches, as well as pockets
down its process. So policy, procedures and cooperation are very of unsecured networking equipment. Now these systems are
important in implementing an industrial security strategy. slowly becoming connected to public networks for the purposes
of remote administration, programming and monitoring, making
4. Develop a security policy. In addition to malware them vulnerable to many threats. In order to protect these
issues, implementation of a security policy should also include: networks, a defense-in-depth strategy should be deployed. This
an authentication mechanism, data backup procedures, off- type of defense protects in several places, such that bypassing a
site backup of electronic media, physical protection (such as single security device does not provide unfettered access to the
continued
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could be caused by a breakdown in security. Don’t skimp by In addition, there are security threats from within the facility.
using cheap security software. A hack or virus in a system These can be as innocent as an accidental modification to
can cause the entire business to be compromised. a production program or as intentional as a disgruntled
employee. While many security issues can be solved by
External access is only one security consideration. What if better human behavior, there’s no way to guarantee that the
an outside interest gained access to your operation solely behaviors threatening your facility will actually change.
for the purpose of accessing your information without your
knowledge? Gaining access to your product manufacturing Take all of these threats into account when developing
process, your supply chain and other aspects of your a security plan. Considering the risks to your business, it
production could provide invaluable information to an shouldn’t be difficult to justify implementing a security plan
unscrupulous competitor. All of these factors and potential for your facility.
threats should more than justify the cost of implementing a
security plan for your facility.
continued
network. Managed switches also allow the network designer to of a network. Loop prevention protocols include the spanning
disable any unused ports. This prevents unauthorized devices from tree variations such as rapid spanning tree. For industrial
gaining access to the network. The ports can either be disabled or applications, these can be too slow, but optimized solutions
be configured to use a central RADIUS server, which can control such as TurboChain and broadcast storm prevention (BSP) can
access to them using 802.1X. This requires a bit more configuration, provide response time in milliseconds to prevent network loops
but allows for all your network devices to have a single user from occurring. These features can be used to prevent a malicious
database that is centrally administrated, rather than have to manage denial of service outage from occurring as well as prevent an
user names and passwords on individual switches. Make sure you accidental Ethernet cable loopback.
change the default admin password of the switch. It typically comes
set to a default and many fail to change it. It goes without saying 5. Look for redundancy and robustness. Having
that this is a big problem and it should always be changed. equipment that is easy to disrupt makes an attacker’s job easier.
All network components, including cabling, cabinets and active
4. Guard against network loops. Many industrial equipment, need to be industrially hardened, resilient and have
networks are designed with redundant paths in the system and high mean-time-between-failure (MTBF) ratings because of
already employ a redundancy/loop prevention mechanism. This the harsh environments found in an industrial facility. Active
is also a feature of a managed switch. Without loop prevention components in an industrial network, such as switches and
protocols, any port can be connected with an Ethernet cable routers, need to support industrial redundancy technologies
back into another port on a switch and create a broadcast and the level of redundancy required for your production needs.
storm. This can cripple the switch as well as the network. This This will keep operations going in the event of malware or other
kind of problem can also be tricky to track down and flush out network intrusions.
continued
6. Early network warning system. Integrating security 7. Optimize firewalls to protect the right
with industrial control systems is critical for both support and protocols. Firewalls should be optimized to secure SCADA
security event monitoring in a network. Using such a system will protocols such as Modbus and OPC, rather than email or web
facilitate the detection of unusual activity on the network, an area traffic, which have no place on a plant floor system. Products
that is typically poorly done in the industrial automation world. that inspect email and web traffic simply add cost and
Plant personnel need to be immediately alerted if a read-only complexity to the security solution. Design your security system
remote operator station suddenly tries to program a PLC. Waiting to handle very wide power ranges, since the plant floor often
for the IT team to analyze the event the next day is too late. has dirty power.
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3. Mobile workforces: What efficiencies could you realize solutions can satisfy these business needs. But you must realize
by having any data at your fingertips, no matter where you are? that not every company is the same when it comes to wireless
technology deployment.
Improvements to worker productivity are possible with remote
management and control of all systems and process—whether
it’s a worker walking a manufacturing floor with a tablet device
or a network manager checking the status of an unmanned
system at a different location. Essentially, you can take the
control room with you.
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3. Match specifications. It’s important to know all the 6. Delay layouts. The design team working on the project
information about any components you are interfacing to when should not begin the planning and layout drawings for
you develop specifications for a project. If others are supplying distributed I/O in the facility until all equipment OEMs have
parts, find out whether they are NPN or PNP, if analog signals provided general arrangements. Provide the team with an overall
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There was a time safety resided in the components safety relays, 1. Assess hazards and risks. Review machine/design and
pressure mats, light curtains, etc. Any time sensors indicated processes to identify hazardous operations. Quantify the risk of
inappropriate conditions, the relays would cut power to the hazardous conditions occurring during operations.
machine. Today, the focus is on functional safety, in which safety
is defined and executed in the function of the machine. Safety 2. Mitigate risk. Develop a strategy to reduce risk by
is not a question of which components are attached to the designing it out; adding safety measures; or by developing
machine but how the machine is designed to operate as a whole. procedures, information for use (alarms, signals, etc.), and
training to enable personnel to remain safe during risky
tAlthough functional safety is designed to protect workers, operations. Software applications exist for safety planning and
it has an essential side benefit of reducing downtime and monitoring to simplify the process.
increasing productivity. Organizations frequently find that safety
investments can pay for themselves. 3. Implement functional safety. Build the machine,
focusing on best practices including safety-rated components,
Europe has led the functional safety effort with the development redundant design, protection against common-cause and
of a family of functional safety standards. Efforts are underway common-mode failure, etc. Safety PLCs and/or safety drives can
to develop and apply functional safety standards in the be used to place a motor in a safe state any time an enclosure
United States, as well. Here, we list the key steps involved in is breached, for example. These safe states can include options
implementing functional safety on a machine. like Safe Direction and Safe Speed that enable operations to
continue without compromising employee safety.
continued
4. Verify and validate safety. Test and confirm that ESSENTIAL SAFETY STANDARS
safety system operates as designed.
Each of the steps above must be conducted according to the corre-
sponding safety standard. This includes specific standards for tasks like
5. Document and achieve certification. risk assessment and verification. Do your research to ensure that you
choose the standard that applies to the specifics of your system, indus-
try, application, and geographic area. The following functional safety
standards are key:
There was a time safety meant electromechanical relays that 1. Safe Torque Off (STO): Removes power to the motor
cut power to the equipment anytime an operator hit the e- stop but leaves the drive energized. This puts the equipment in a safe
button. Although this was effective, it was hard on equipment state while making it faster and easier to restart.
and often more extreme than circumstances warranted.
Frequent stops cause premature failure in the safety relays. 2. Safe Stop 1 (SS1): This controlled stop enables
Restarting equipment added delays and extended costly equipment to be slowed before STO is invoked. It is an active
downtime. braking 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 equipment to 3. Safe Operating Stop (SOS): Drive holds motor in a
invoke safe states as defined by the function of the system. This static position to within a certain tolerance defined for the drive.
functional safety is implemented by safety-enabled drives and Torque to the motor is not removed; the motor is just held to
PLCs. Functional safety makes it possible to protect workers and zero speed.
equipment while minimizing the impact of those measures on
operating costs and productivity. Here are a few of the key safety 4. Safe Stop 2 (SS2): Controlled braking ramp, once again,
functions that you should know about: suitable for equipment with high kinetic energy. SS2 is typically
followed by SOS, rather than STO.
continued
5. Safe Brake Control (SBC): Controls an external holding 7. Safe Direction (SDI): Restricts drive signal so that
brake in conjunction with safety drive. Typically applied to loads motion takes place in a single direction. This can enable
on vertical axes. operations involving workers to take place at higher speeds, for
example pulling a gripper away from the operator at full speed
6. Safely Limited Speed (SLS): Sets a maximum speed because the direction of motion does not present a risk. It can
at which the drive can run the motor. Useful for protecting also be used for maintenance operations like cleaning rollers.
operators when they are working in close proximity to These can be conducted as clean-and-jog procedures but with
equipment. It enables them to use the power of the motor to SLS and SDI, the rollers can be commanded to rotate away from
assist them in clearing jams without placing them at risk. the operator at a low speed to enable continuous cleaning.
1. Understand human nature. It is not enough to rely 3. Maintain productivity. In surveys, the top response
on industry standards to develop machine safety. You must among workers who override safety systems is that they
work with the manufacturing crews. They have so much insight needed to maintain productivity. Make sure the safety system
into what people are actually going to do to improve their is designed so that it is not a productivity bottleneck. That
throughput and efficiencies, even if it requires them to work will eliminate the temptation for operators to bypass safety
around safety systems. It’s just human nature. By communicating measures and put themselves at risk.
and observing your workforce, you will be able to develop more
robust machine safety systems that will still allow for efficiency 4. Safety education. Machine safety is primarily an
as well as protect your workforce. education issue. Convincing the end customer about the
advantages of safety is difficult, but not impossible. Most end
2. Don’t invite overrides. When designing a safety users view safety systems as a detriment to production, when
system, it’s essential to understand how an operator or the opposite is the case. Good safety principles and finding
maintenance technician needs to interact with a machine. It a vendor who has the products and expertise to assist is 90
you make the safety system too extreme or complex to deal percent of the battle.
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Functional safety takes more than standards Machine safety design should always be done with the
understanding of how and when to compartmentalize (partition)
A misunderstanding between management, operators and machine safety. This helps to avoid the nightmarish outcome
maintenance personnel over just what “safety” constitutes is that maintenance and/or operator personnel have to jump over
one of the most consistent pitfalls to functional safety. OSHA is a or bypass some safety features that do not affect actual human
regulatory body, not an industry resource. OSHA can give advice, safety or the safe operation of the equipment in order to meet
issue fines and warn, but functional safety can only be delivered deadlines or make necessary repairs. This almost invariably leads
with proper understanding, training and commitment, combined to a permanent bypass or short that can eventually cause real
with an atmosphere generated by management that encourages harm.
and demands safety in equipment, operators and maintenance
personnel. When in design, each machine must be reviewed for safety. This
review should be performed with operators, maintenance, the
Machine safety systems are too often overly complicated and OEM and the engineer. Once the machine is reviewed, perform
designed, constructed and documented poorly. When designing the same review as an overall interlock from machine to machine.
safety features, understand that trying to make something Getting everyone’s input and buy-in is critical in having the safety
foolproof is foolhardy. of the line maintained and understood without being avoided or
“jumped” out.
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environment, assets and production. The processes are 5. Look for balance. Safety should be a key part of
categorized as safety critical and mission critical. The SIS (Safety engineering and design. Engineers always need to play the
Instrumented System) should be designed to comply with the devil’s advocate and consider what could go wrong rather than
required SIL (Safety Integrity Level), as derived by HAZOP (Hazard be optimistic. The term “making things idiot proof” may not be
and Operability Studies). When the initial system design demands politically correct, but should be the mantra of the engineering
a SIS with a SIL, then the design should be revisited to reduce the community. There is usually a high cost associated with striving
hazards to the level where the minimum SIL practicable can be to achieve this, so a balance needs to be struck between being
used. SIL is not for the whole system, but should be achieved for fully protected and using accepted safety practices. Sometimes it
each and every loop. is better to use simple mechanical or structural stops and guards
rather than complex safety systems or instrumented interlocks.
From new standards for functional safety to making sure that an 3. Key features for safety systems. Low PFD
e-stop will actually stop everything on a machine, these practical (probability of failure on demand), equivalent to the long-
recommendations address the details of a safety system: accepted TMR (triple modular redundant) benchmark standards,
in either simplex or redundant configurations. Low STR (steps
1. Functional safety. Functional safety, as defined in IEC to reproduce) that meets or exceeds the TMR standard when
61508, is a totally new methodology in automation. It’s based implemented in dual configuration. Exceptional hardware fault
on two main principles: 1. It’s a systems approach. Sensor - tolerance in dual configurations. Safety modules independent
controller - actuator, every component should have the same from the logic solvers. For machines with safety systems offering
SIL/PL. Otherwise, it makes no sense. 2. System/product lifecycle these features, availability has been estimated as high as 99.9999
idea. Today’s safety does not mean tomorrow’s safety. Functional percent.
safety needs a procedure to implement it continuously.
4. Identify risks. Deep dive into Process Hazard Analysis
2. Validate the safety code. Determine each failure mode (PHA) to identify the risks underlying a process. Apply layer-
and validate that it fails to a safe state. Just because the logic of-protection (LOPA) analysis to rate the SIL level and guide
tells you to turn an output on or off when running, does not the SIF design according to IEC 61508/61511. Understand all
necessarily mean it will return to the correct state if there is a aspects of the safety lifecycle before proceeding with design and
fault. It needs to be verified. implementation.
continued
5. Send robots home. When programming a robot that technology. They can be very useful for maintenance and for
has the potential for a crash situation and relies on an operator troubleshooting because they can be installed in a manner that
to manually move the robot out of position, program in flags or will satisfy everyone, from the operator to OSHA.
position steps. Then create a program called “home.” After each
critical move/step of your robot in the program, to avoid other 7. Discharge capacitors. On older AC and DC drives, even
machinery or tooling, use a variable, such as “pos,” and assign when locked out, make sure capacitors are fully discharged
it a numeric or other value like zero as the home value. When before removing the front panels and working within the drive.
you create the home program, you can run it and have a series
of “if” statements. For example, if “pos” = 10, then do this. Now 8. Stop everything. Don’t allow OEMs to place e-stop
you know where the robot was positioned when it crashed and buttons on their consoles if they do not stop all equipment in
you can provide a safe route automatically to exit its current the immediate vicinity.
position and into a safe home position. Make sure to clear your
“pos” values or set them to zero once you make it to the “home”
position. Now the main program can be run from the beginning,
without any worries.
continued
The safety of a machine is not guaranteed by simply using a safety laser Consider also the stop time of the entire system. Realize that the stop
scanner in an application. A safety distance calculation needs to be time may include more than just the stopping of the machine. The time
considered to ensure the correct use and functionality of the scanner it takes for the scanner to react, for the stop signal to travel to the ma-
device. chine, for the machine to actually come to a stop and any other delays
must be considered. These delays may be small, but can have an impact
The safety distance calculation will help determine the size of the safety on the overall size required for the safety field.
field or the distance a scanner plane is mounted from a hazard. How will
the device be mounted? Will it be scanning vertically or horizontally? The stop time of the machine will also be used in calculating the safety
If it is vertical, the scanner plane may have to be mounted farther from distance. By implementing this calculation into your design of a safety
the hazard, similar to a light curtain. laser scanner, you will be on your way to properly complying with stan-
dards and achieving greater employee safety.
More commonly, if it is mounted with a horizontal plane, there may be
a chance for reach-over, which would require a larger-sized safety field.
These two possibilities are called the Depth of Penetration and are a
part of the safety distance calculation.
continued
SECTION FOUR:
APPLYING TECHNOLOGIES
TO IMPROVE OUTCOMES
FACTORY & MACHINE Automation Playbook 209 / 252
When beginning an asset management process, go slowly and to include all the factors, such as operator and maintenance
deliberately with the understanding that it is a process rather training, ease of repair and usage of equipment, which will affect
than an event. Ensure, by free trial runs if possible or in-depth throughput of product, cost of product and cost of using the
research or observation, that the software you purchase for asset.
tracking, generating work orders, inventory control and lifecycle
costs are what you will actually use and not too much or too Develop a program to demonstrate that proper purchasing,
little. operating and maintenance practices are a revenue-generating
process. This will help management realize that ROI is much
After that hurdle has been crossed, you are just beginning a true more than simply purchase price, labor and materials.
asset management program. Reliability is related to predictive,
proactive maintenance and knowing when and how to run to
end of life. This understanding can rarely be obtained quickly
or simply. Set yourself up for success by using the boots on the
ground as a primary source of input for what works and doesn’t
work. Track, report and verify constantly and consistently.
If the people who make the financial decisions are not onboard,
your program will fail. Cost things correctly, comparing the cost
of maintenance vs. the purchase of new equipment. Make sure
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bit toggle where the application sets or resets a bit. In any case, collection can be simplified by using a PLC with the transmitter
the communications link should be monitored and alerts created and relays in one node. The controller can switch the relays and
when they fail. The alert can be as simple as a line-side machine collect the vibration information from the corresponding pumps
alarm or sending an alert email to a group email for IT and or motors.
technicians, or even to a centralized operations center monitor.
Monitoring and notification do not need to be complex to be
effective.
Good calibration practices are an essential part of managing 3. Match transmitter output. When calibrating the
your equipment assets. Here are four tips on proper calibration instrument loop connected to a digital read-out device, it is a
techniques: good idea to fix the read-out measured value and match the
transmitter output, or call it output-vs.-input calibration.
1. Secure connections. When completing calibrations on
thermocouples, pressure transducers and other devices, if you 4. Calibration reminders. An easy way to keep up with
have to unwire the device to put it in a hotwell, make sure you calibration and monitoring systems is via software designed for
get the connections back correct and secure. this purpose (for example, Gage Track). By having a master gauge
for every item, when calibration is due you can send it out to be
2. Calibration expertise. Verify values of actual process recertified per ISO standard.
data before making calibrations. Calibration should be provided
by trained personnel with very accurate equipment. To maintain
calibration, it is essential that the operator be fully trained on
the use of the equipment. Many individuals have learned bad
habits over time in using equipment and their inability to use it
properly causes a lot of equipment damage.
2. Common structure. When implementing a multi-site 5. System requirements. It is crucial that developers
MES it is very important to identify common business processes meet and actually listen to the stakeholders. Depending upon
and standardize them across all sites (as far as possible). This will scope and complexity, a number of meetings may be required.
ensure a common data structure and reporting at a central level. You generally cannot expect people to be able to convey all of
their thoughts and gain a clear understanding in one sitting. As
a requirements document is being developed, keep end-user
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10. MES Interface. When designing your manufacturing 13. Nurture expertise. Creating a department and slots for
to enterprise connectivity strategy, nothing is more important information engineers is critical for manufacturing excellence.
than reliable data access. It is not uncommon to experience Selection, nurturing and management of computer science,
network failures and lose critical data. Make sure to have a “Plan information technologists and electrical engineering teams,
B” in place, such as storing the data locally to be forwarded once (preferably electrical engineers with a minor in computer science
connection to the database is restored. Using an IT connectivity or communications) will be needed to achieve a well-designed
appliance that resides in the rack along with the automation manufacturing control and data acquisition stream
controller will ensure continuous information collection even
when the connection to the IT system is interrupted. 14. Follow ISA88. Read the manual on ISA88 batch
implementation. Ensure that your physical model has been
11. No hard-coded access. Manufacturing databases, in rigorously tested/debated/challenged before you commence
addition to being on separate and isolated subnets, should also coding
avoid hard-coded database access. Adopt standard Windows
passwords, which are subject to frequent change. This reduces 15. Establish rules. Connections between automation and
the number of passwords a technician needs to memorize and IT involve dealing with different groups of people: automation
allows for logging and accountability for changes. engineers and managers, IT managers and engineers,
network engineers and others. To avoid difficulties, define
12. Scheduling. The scheduling function (or dispatching the management rules (who decides about what), technical
function) is the most important thing for implementing a interfaces (what data, what performance) and cybersecurity, as
manufacturing IT system. well as operating modes in case of failure.
continued
16. Understand databases. The engineering and 18. Use the cloud. There are different reasons why
operational communities need to understand what databases companies are not using cloud technology. Often they don’t
are and aren’t and how powerful they are for data analysis. There know much about it and consequently they have many
is a tendency to fear the complexity of databases and regress to questions and lots of fear about data security, authentication
using spreadsheets. Spreadsheets have their place when small and reliability. A transition to the cloud needs lots of work
amounts of data need to be manipulated. When there is a large and the easiest way is to show the references, let people have
amount of data to be analyzed, databases are the only way to complete access to the management of the application and only
practically house and analyze information. With the right tools, use/gather data which are not critical in order to build trust. Start
nearly unlimited amounts of data can be summarized, analyzed with limited data sets. Typically, critical application data is not
and reported very quickly. put in the cloud; it’s mostly used for aggregated data used in
automated reports and analysis.
17. Use intermediate database. Good, basic design of
relational databases is critical for both performance and flexible
extraction of information. Using an intermediate reporting
relational database for summarizing high-speed historian data
prior to reporting, trending and creating dashboards can offer
the best of both.
2. Stakeholder input. Lean manufacturing is critical in 4. Measure the right things. Nothing is worse than the
today’s global economy because it helps you drive your output wrong input. OEE is not always a KPI metric in batch operations.
(product efficiency) higher while maintaining low defects and If you speed up the drying process, for example, the OEE goes
continued
22 ways to get the most out of OEE and lean manufacturing disciplines
down, but you will be making more product in a shorter period 7. Too lean? If you operate with vendors that are stationed in
of time. areas with a high potential for natural disasters, think carefully
about being too lean with your supplies. You’ll need to plan
5. Visual management. Visual management, including for alternative routes and suppliers. Another area that has to
large display screens on the factory floor, are an effective tool be monitored is the amount of time for production to meet
for OEE programs, letting both managers and workers easily customer need. Sometimes manufacturing is too lean and when
monitor the metrics of production lines and track KPIs. Displays there’s a sudden demand, the slow ramp to manufacture can
harness natural human competitiveness. In one experience, cost more money than producing stock.
once data was displayed it started a race between shifts to drive
up OEE. Without any management intervention there was a 20 8. Business support. Make sure the business has
percent increase in productivity. Among the most useful KPIs adopted and fully understands OEE. This can be a huge change
to display: count (good or bad), reject ratio, operating speeds, management nightmare if not well-entrenched prior to the
takt (cycle) time, downtime and OEE (availability multiplied by project (or as part of the project execution). Lean manufacturing
performance and quality) for determining resource utilization. can also be applied to service disciplines, not just product
manufacturing, mostly with only minor adaptations. Look
6. Increase uptime. Lean manufacturing is a very important to these techniques and principles to streamline your own
factor in a production plant. Just by placing materials at the processes and eliminate waste.
point of use within the production floor area, you can increase
production uptime. This is just one small adjustment that will
fine-tune the flow of your product.
continued
22 ways to get the most out of OEE and lean manufacturing disciplines
9. Meaningful reports. Data capture is quite easy. 12. Efficiency tool. OEE has to be automated to be
Reporting the data in a manner that helps implement change successful. The data needs to be driven from machine status,
can be challenging. Don’t assume a single report is sufficient. not humans inputting the status. Any manually derived OEE
Different users need different data. And that data must be system can be fiddled with to produce the expected 85 percent
presented to each user in a manner that is meaningful. efficiency rate. Improving systems and automating OEE
measurements may bring into question the accuracy of historical
10. Improvement tool. OEE can be a very valuable tool OEE data. To avoid internal politics, put an amnesty in place and
to identify problems within a process. Ensure that everyone promote automated data as a new way of measuring OEE. On
understands what the three elements are that make up OEE: the other hand, the only reason to use OEE is to help drive an
availability, speed and quality, and how to calculate each. Once improvement process to increase operational efficiency. If that
processes are stabilized, use OEE to drive improvement. isn’t a widely embraced priority, then save yourself lots of time,
money and effort.
11. Software less important. Software selection plays
only a small part in the OEE process, but that is where customers 13. Improving uptime. OEE can help you identify
spend the most time upfront. Operator involvement, the opportunities to improve your total uptime. First, understand
quality of the integration partner and the ability of the controls the categories that OEE represents. Next, determine what things
hardware to collect data are what truly make an OEE project you want to track and how specific you want to be. There isn’t a
successful. set rule as to what that may be. An example may be that under
your performance efficiency category, you list specific pieces
of equipment in an assembly line to track. By breaking down
continued
22 ways to get the most out of OEE and lean manufacturing disciplines
your categories you will have better opportunities to make 15. Build on current infrastructure. Do not get over
improvements. The last hurdle is how to capture the data used complicated right from the start. Pick a system that leverages
to calculate OEE. Keep it simple and train your people in how to your existing automation infrastructure, and can be expanded
capture the data you need, what it is and why it’s important. and built upon as your needs change in the future. Do one
machine, or one line, or one department, then refine it so that
14. Sharing data. Information is fundamental to making operations, production, and maintenance all have the types of
good business decisions. However, the information must be information they need, then roll out to other areas.
precise and the amount manageable, not overwhelming. When
installing or defining automation products in a production 16. Maintain balance. Lean manufacturing sounds great
line, it is their capacity to share data across the enterprise to accountants and plant managers, but the upshot of the theory
that is important. One of the major causes of failure when can be destructive if not enough product is produced or the
implementing an OEE project is the infrastructure of the lean process creates inefficiency. Remember, there has to be a
automation and inspection controllers (PLC, vision system, etc. balance.
). Vision systems must be able to communicate openly with
other systems, such as OPC Server or databases. Avoid the use of 17. Make Lean work. Lean manufacturing is all about how
products that operate in a closed system and do not provide a an organization can reduce scrap and waste in the production
ready means to share data. process. Evaluate your flow process, such as where product
is placed before the production area or how the product is
transferred to and from the assembly line. If your production line
stops as a result of parts that are not properly staged on the line,
continued
22 ways to get the most out of OEE and lean manufacturing disciplines
you have a product flow problem. This becomes a bullet point in protocols, try to select a protocol that is compatible with most
making Lean work in you plant and should be addressed. of your existing devices. Establish a long-range standard where
all your future automation equipment must be compatible with
18. Select a champion. When implementing these the selected protocol. In this way, your infrastructure will provide
projects, make sure there is an official project champion who is the correct framework where your OEE project can be easily
very senior in the implementing organization and can be the implemented.
bridge 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
achieve a successful project. in the machines, but in the minds of the individuals that the OEE
information is going to help. Without their buy-in the project will
19. Common framework. When implementing projects be no more than a pretty notice board.
for OEE, the communications between systems needs to be
reliable, fast and easy to use and maintain. Ethernet has become 21. Vision drives OEE. Improved process efficiency
the standard in communicating data across automation systems. and profitability through OEE improvements are increasingly
The installed based, along with the expertise already existing in important. Machine vision systems and image-based ID readers
most companies, make Ethernet the most appropriate choice. help with three traditional OEE drivers: material handling,
Avoid devices that use only serial connections (RS-232, RS-485) product quality and package integrity. Vision systems for
or proprietary connections. Try to select one industrial protocol sorting, product orientation and tracking, along with robotic
based on Ethernet. Even though there are some protocol guidance, improve material handling efficiency and flexibility,
converters and gateways that allow the conversion between elevate product quality and yield, and ensure package safety
continued
22 ways to get the most out of OEE and lean manufacturing disciplines
continued
22 ways to get the most out of OEE and lean manufacturing disciplines
CALCULATING OEE
As described in World Class OEE, the OEE calculation is based on three Time is the minimum cycle time that your process can be expected to
factors: availability, performance and quality. Here’s how each of these achieve in optimal circumstances. It is sometimes called Design Cycle
factors is calculated: Time, Theoretical Cycle Time or Nameplate Capacity.
Availability Since Run Rate is the reciprocal of Cycle Time, Performance can also be
Availability takes into account Down Time Loss, and is calculated as: calculated as: Performance = (Total Pieces / Operating Time) / Ideal Run
Availability = Operating Time / Planned Production Time. Rate. Performance is capped at 100 percent, to ensure that if an error is
made in specifying the Ideal Cycle Time or Ideal Run Rate, the effect on
Performance
OEE will be limited.
Performance takes into account Speed Loss, and is calculated as: Perfor-
mance = Ideal Cycle Time / (Operating Time / Total Pieces). Ideal Cycle
continued
manufacturing line. Those who care about manufacturing material costs can be easily tracked to each major piece of
productivity will appreciate it. equipment. This will help you make informed decisions about
whether to replace, upgrade or leave alone each piece. It is also
5. Validation essential. Choose PLM software that is possible with some software providers to use the information to
able to validate the production system in a simulated three- evaluate your techs.
dimensional environment. This allows the risks of failure to be
identified in different parts of the process or equipment. The 8. Digital manufacturing. One element of PLM is digital
software can also be used to determine the best way to lay out manufacturing, an integrated, computer-based system comprised
production lines in order to move material through the factory of simulation, three-dimensional visualization, analytics and
floor. collaboration tools. It’s used to create product and manufacturing
process definitions simultaneously. By enabling product-related
6. Is there a payback? Don’t be afraid to tell others when information to be shared between design and manufacturing
a system is at its end of life. Just because an outdated system is groups, it can reduce the expensive changes often experienced
running today is no guarantee it will be running tomorrow. Strive when faulty product designs reach the manufacturing stage.
to educate operations and management that it’s important to
upgrade as needed. But don’t upgrade just to have the latest 9. Collaborate with suppliers. Collaborate with product
technology if there is no real payback. suppliers to develop a strategy to manage assets in terms of PLM
to maximize an asset’s value and reduce operating costs.
7. Track equipment. If you are looking at new maintenance
software, make sure that downtime, maintenance hours and 10. Update policy. Digital upgrades can become obsolete
continued
continued
2. Select the right tools. A comprehensive energy However, you can’t optimize what you can’t measure. Find an
management program is quite challenging, since every aspect easy and cost-effective way to measure your plant’s power usage
of a manufacturing facility is an energy consumer (processing, by area or major equipment group. Measuring without being
packaging, warehousing, utilities and even the building itself ). able to time stamp data lessens the value of the data.
A common mistake is to expect a traditional process or machine
automation system to be pressed into service for energy 4. Make it granular. The value of energy monitoring is
management applications (EMS). Don’t try to make your existing to gather enough data to truly understand what is happening.
software do the job. Placing meters on one or two motors will not give the results you
need. It is better to fully instrument a small area and concentrate
Choose a purpose-built energy analytics package. It will on the results of that pilot project. You will discover low hanging
deliver results faster, in easily consumable form. Customizable fruit that will help you gain support to broaden the initiative
dashboards, make it easy to create displays that deliver the throughout the plant.
information that different job roles can leverage to improve
results. You want to be able to do more than just view Installing energy-monitoring equipment is the first step in
equipment demand is a function of time. You want to be able to enabling true energy management for your plant or process. This
compare energy use from facility to facility, line to line, machine will give you the data needed to:
to machine, even operator to operator.
• Know where your energy is being consumed, in process and
3. Be focused. Concentrating energy improvement programs non-process applications.
on the high usage systems is usually the best place to start.
continued
• Determine schedules of use. may find compressors or pumps left running when they should
be shut down. You might discover equipment scheduled to
• Determine real energy needs. be left idle running at full speed. You may find machines with
a second or two of title time programmed into each cycle. It’s
•M
anage supply and consumption by schedule and percent by all but impossible to distinguish by sight but adds up over the
shifting time and managing and shedding use. course of a year.
5. Be smart. Apply a current transducer to your load, whether 7. Keep it targeted. Data capture also needs to be strategic.
that is the incoming feed of a building, a line, a machine, or even Monitoring a device just because you can is not just unhelpful,
a motor. You don’t need all new smart components. Adding it’s counterproductive because all of that data clogs up your
sensors to your existing equipment will do just fine. network and fills up available storage. Know how you are going
to use the data before you ever acquire it.
6. Establish a baseline. Once you’ve targeted your first
project, establish a baseline. Gather data from your sensors 8. Break the process into three parts: Once you have
using a data logger. This should encompass not just production the data, you need the aggregation and analysis tools to transfer
lines but facilities and building automation equipment like fans it to a relational database environment where it can be accessed
and blowers, compressors and so on. Data capture needs to be for a range of operations. There are three levels of working with
comprehensive in order to create a full picture of your operation. data: monitoring, analysis, and management. Let’s return to our
energy example:
The exercise is quite likely to include some obvious culprits. You
continued
• Energy monitoring: What energy is being used and how? 10. Track big consumers. Always make sure you have
the means to track the energy performance of large energy
• E nergy analysis: What are the peak consumers? How does consumers. The term “large” can be determined by using a simple
energy usage change over time? Pareto analysis. Make a list of all of your energy users and section
off the top 20 percent. This will identify a large portion of your
• Energy management: Can we put rules and equipment in place energy usage, as well as the focus of your maintenance activities.
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
9. Be patient. Although low hanging fruit is likely, expect system to measure power usage, you should consider one that
to spend several months establishing a baseline and fully can also measure power quality. Poor power quality can lead to
understanding your assets before you can make an informed increased power consumption, as well as equipment failures.
decision on what equipment to investigate for energy Measuring harmonics in a system will provide you with very
improvement programs. Purpose-built energy management beneficial information and the additional cost for this feature is
applications are available with preconfigured dashboards and relatively little.
built in tools for trending and data analysis.
continued
13. Design for efficiency. When designing industrial 16. Reap side benefits. Energy monitoring doesn’t just
equipment with pumps or fans, require efficiency of operation. help the facilities management department. Other areas like
A lot of energy is wasted due to over-design of this equipment. engineering can leverage the data to harvest insights that will
Engineers often use the same pump-motor specification across improve productivity and reduce downtime.
the plant. This can result in motors being as much as 50 percent
under-loaded in fan operations. • Maintenance: Changes in power consumption by a piece of
equipment can reveal the need for maintenance well before
14. Be a giver. Offer energy capacity back to the grid on the component fails.
request in exchange for incentives.
• Engineering: Differences in power consumption between two
15. Go beyond electricity. Don’t forget factors like identical pieces of equipment can show the effect of different
airflow, temperature, and pressure. If you a drop in compressor settings, assembly practices, or maintenance procedures.
airflow, it could be a leak but it could just as easily be caused by
an issue with a bearing or valves. If a process step mostly uses • Operations: By comparing consumption shift to shift, machine
low flow rates, consider replacing that ixed-speed AC induction to machine, or even plant to plant, managers can develop best
motor and control valve with a motor driven by a variable- practices or identify operators who need additional training.
frequency drive (VFD). T
continued
1. Use interns to collect data. It’s fairly simple to identify viable energy 3. Avoid duplication. Many motor control devices now have network
management projects, but it takes real engineering to develop the busi- connections that pass along energy data. There’s no need to duplicate
ness case. If you’re understaffed and strapped cash, reach out to your these data-generating capabilities by installing power monitors over the
local university. You may be able to hire an intern to collect the actual top of intelligent motor control devices.
data points needed to develop a well-founded business case.
In these days of lean operations, controlling costs is never far 1. Raise power factor. Power factor is defined as the
from the thoughts of manufacturing organizations. One way to ratio of the real power flowing to the load (kW) to the apparent
do that is by reducing energy consumption. Supported by broad power in the circuit (kVA). It has a value from 0 to 1; the higher,
connectivity, the new breed of energy management software the better, as far as the power company is concerned. Inductive
and sensors makes it easy to uncover hidden sources of energy loads like high-intensity discharge lighting and electric motors
waste and to lower the bills themselves through informed operating at under full load can drag your power factor down.
scheduling. The latter is a particular issue in applications like conveyors,
compressors, and HVAC fans.
Power companies charge for their services based on several
factors: the amount of energy used and the time of day it You can raise your power factor by adding power-factor
is used (peak or off-peak), scaled by demand charge. The correction capacitors to your electrical distribution system. Using
demand charge typically includes both the peak usage during a VFD with a motor to run a pump or a fan at low speed instead
some specified time interval. To make things just a bit more of the control valve will also improve your power factor.
complicated, your power company may also scale up by power
factor, which is a measure of power utilization. While lowering
consumption will obviously reduce your bill, addressing issues
like peak usage and power factor can deliver big savings.
continued
1. Energy harvesting. Servomotors basically become recording the motion duration and energy consumption for
generators when they decelerate. Normally, that energy gets every NC block, these tools allow users to easily identify where
dissipated as heat using a braking resistor. Add a capacitor there is potential for improvement.
instead to store the energy for the next time the motor
accelerates. If you have multiple axes, link them together on a 4. Open CT shorting block. When installing and
shared DC bus. A decelerating axis pushes its power back on the commissioning power monitors, make sure to open the CT
bus, where it can be used by the next accelerating axis. shorting block. This will activate the CT so the power monitors
will work.
2. Energy saving mode. When running a drive in “Energy
Saving Mode,” there is often not enough current for the motor 5. Compressed savings Compressed air is an energy
to handle sudden load increases and the drive can fault out on source, but the costs are often buried in the overall electric bill
overcurrent. Since the drive already saves energy, you can skip for a facility. Efficient use of compressed air helps save money
the energy saving mode. and reduces the carbon footprint of the facility. As a rule,
potential savings lie within a range of 10 to 35 percent for energy
3. CNC analytical tools. Intelligent automation solutions costs associated with pneumatic systems, which can be realized
such as CNC control can help reduce energy consumption. by means of improved maintenance of the compressed air
Leading technology companies now offer analytical tools to network, improving air quality and optimizing the performance
optimize energy consumption and cycle times. These tools can of pneumatic systems.
be integrated directly into the NC kernel of the CNC control. By
continued
If you want to determine potential savings in compressed air, • Don’t use a VFD if the application doesn’t need to vary speed;
make an airflow consumption and pressure diagnosis of a this will avoid one more element requiring maintenance.
machine in static mode (idle operation) and in dynamic mode
(full operation). Conduct an air leakage audit using ultrasound • Don’t run a VFD at a higher frequency than that of the rated
detection in the tubing, pipes, control devices and actuators frequency of the motor.
in order to evaluate the cost of each air leak. Document each
leak and tag for maintenance. Generally, energy savings can be • Avoid running a motor at less than 30 percent of the rated
identified from leaks that are unknown to the user, as well as frequency using a VFD. You may land into a mismatch of the load
inefficient pressure drops. By optimizing the airflow, you can requirement and the torque requirement on the same motor.
achieve more efficient operation of the entire production line.
continued
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 a breadth of information available from digital sensors. A smart
maintenance culture that includes work processes that facilitate digital sensor not only delivers performance data, it can store
the change. This change is more than just a maintenance matter. information like model number and serial number for tracking
and identification. Some digital sensors allow users to change
3. Choose the right hardware: To be successful, parameters remotely, or automatically upload stored parameters
predictive maintenance strategies require intelligent field at startup.
devices, an open communication protocol, and integrated device
and asset management software. 6. Tune out the noise: Predictive maintenance requires
comprehensive instrumentation but the sheer volume of data
4. Become a history buff: Establish a database of from thousands of devices can be overwhelming. It’s a particular
performance metrics to delineate the boundaries of “normal” problem given that a large percentage of readings report
operation. Through subsequent and ongoing performance steady-state conditions. Use data loggers with triggers to sift out
monitoring and recording, small changes in performance that anomalous readings. Look for purpose-built asset-management
occur over time can be detected and investigated before there is software and analytic software designed to help prioritize
a downtime event. information. Many of these software suites include built-in
application libraries and tools to simplify building dashboards.
continued
7. Pick targeted tools: Determine the requirements for type manager (DTM), which automatically provide proactive
your particular application. The needs of an oil rig, for example, device health alerts. Some DTM’s analyze the data to determine
will be very different from a packaging line for consumer probable cause and corrective action, both for the device in the
packaged goods. Look for niche solutions designed for the network.
specific use case of interest.
The Profibus and Profinet International (PI) organization also
8. Consider wireless: Cutting the cord can simplify supports manufacturing process control and asset management.
installation, cut costs, and reduce maintenance. One North Their approach is to leverage the diagnostic and alarm schemes
American oil refinery installed wireless temperature and pressure built into the instruments themselves. Operating parameters
transmitters on pumps for a 90% savings over conventional for instruments are set during calibration or commissioning.
wired devices. Readings that fall outside these thresholds can generate an
alarm.
9. Open up: Several open standards groups have sprung up
to support predictive maintenance with smart components. 10. Be patient: Shifting to a predictive maintenance regime
The FDT Group AISBL, for example, promotes the open, vendor- is a process, not an event. Although you can begin collecting
independent Field device tool (FDT standard to simplify the data within minutes using some hardware and software tools,
configuration of and access to field devices. Each device uses it typically takes 3 to 6 months before the system has sufficient
a vendor-supplied software application known as a device- history to enable truly effective asset monitoring.
continued
BY THE NUMBERS
COMPANY: Banner Engineering ADDRESS: 9714 Tenth Avenue North, Minneapolis, MN 55441 USA
PHONE: 1-888-3-SENSOR WEB: www.bannerengineering.com
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FACTORY & MACHINE Automation Playbook 245 / 252
including clear,
reflective, and Quality Without
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FACTORY & MACHINE Automation Playbook 246 / 252
philosophy from Beckhoff (one PC-based controller, one software protection to withstand
platform, and one network), leading manufacturers and machine cleaning procedures
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to cooling devices across all global locations of cooling system units. Thus, lowering
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