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Hands-on practical advice on selecting and implementing controllers, motion control, drives, HMI, I/O, networking, pneumatics, robotics, sensors, vision, and much more.
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SPONSORS
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CONTENTS
7
Playbook Advisors
8 Contributors 11 Introduction
Section 1: Planning and implementing an automation project
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12 points to consider before even beginning your automation project Nine tips for automation project managers
20 Automation project management from a machine builders perspective 25 How to justify capital projects: Speaking finance gets results 35 Eight tips for selecting the right automation system components 37 How to properly select and vet a system integrator 43 12 common mistakes people make in automation projects 47 10 ways your automation project can fail and how to prevent it
OEM machine designers (in addition to automation end users) will specifically find useful tips in highlighted articles.
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CONTENTS
Section 2: Selecting products to build your automated system
52 16 best practices for specifying PLCs, PACs or PC controllers 58 10 steps to creating the perfect HMI 63 Eight steps to I/O engineering success 65 11 recommendations for selecting motors and drives 70 Four tips for improving motion control systems 72 Seven considerations for applying servo drives, motion controllers and PLCs 75 Seven issues to think about before you develop an industrial network 77 Six things to think about when you get down to the network details 79 Five considerations for implementing Ethernet for an industrial network 82 Four tips for dealing with wireless latency and bandwidth issues 84 How network management systems aid firmware, configuration updates
OEM machine designers (in addition to automation end users) will specifically find useful tips in highlighted articles.
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CONTENTS
86 12 tips for selecting and sizing pneumatic and hydraulic components 89 11 considerations for selecting and deploying industrial robots 93 A role for robots in lean 95 10 secrets to selecting and implementing sensors in industrial applications
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106 Develop a strategy for asset management 107 Five best practices for more reliable asset management 109 Four considerations for monitoring equipment assets 111 Four tips for calibrating equipment 112 Nine strategies for achieving your energy management objectives 116 Nine recommendations for building effective manufacturing IT systems
OEM machine designers (in addition to automation end users) will specifically find useful tips in highlighted articles.
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CONTENTS
119 13 ways to get the most out of OEE and lean manufacturing disciplines 125 Eight ideas for improving product lifecycle management 128 Seven human factors to consider when developing machine safety systems 132 Eight tips for the technical side of safety systems 136 Wiring, safety PLC programming critical to machine safety performance 138 Europe sets standards for safety design 139 Six strategies for creating a secure industrial network 144 Seven details to remember when implementing network security 147 Nine ways to get the most from simulation and CAD/CAM software 149 Five recommendations for implementing workflow systems 151 Vendor Selection Resource Guide
OEM machine designers (in addition to automation end users) will specifically find useful tips in highlighted articles.
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PLAYBOOK ADVISORS
Thomas A. Doney
Senior Research Engineer Nestl
Joe Martin
President Martin CSI
Paul Brinks
COO Koops Inc.
Stephen M. Goldberg
Director - Information Technologies Matrix Technologies Inc.
Howard Skolnik
President/CEO Skolnik Industries
Michael Hake
Senior Facilities Systems Support Technician Data Device Corp.
Arthur C. Smith
Senior Automation Controls Engineer MT&E - Machine & Automation Systems Corning Inc.
Robert Lowe
Executive Director Control System Integrators Association (CSIA)
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CONTRIBUTORS
Michael Mikolajczak Bryan Sisler ABB, USA Alex Miller ABB Robotics, USA Mike Berryman Advantech, USA Wendy Jacintha AFLAC, Canada Leslie Crothers Almac, United Kingdom Rob Cotner Anixter, USA Carl Stelling Antaira Technologies, USA Lonnie Purvis Apex Manufacturing Solutions, USA John Coetzee Aristotle Consulting, South Africa Sujata Tilak Ascent Informatics Pvt. Ltd., India Dave Robinson Aurora Industrial Automation, USA Jad Wehbe Automate, Lebanon Germany - Qatar Rafael Arevalo Duque Automatizacion Ingenieros Especialistas sas, Colombia Peter van den Berg Avans University of Applied Science, the Netherlands Stanley Moses Bahwan CyberTek Inc., USA John Malinowski Baldor Electric Company, USA Shawn Day Henry Menke Balluff Inc., USA Jeremy Jones Baumer Ltd., USA Jingxu He Bayer, USA Mike Fahrion B&B Electronics, USA Eric Byres Mike Miklot Belden, Inc., USA Abdulilah Alzayyat Jim Hulman Joaquin Ocampo Bosch Rexroth, USA Larry W. Ostrander CADD Tech Support, USA John F. Wozniak CC-Link Partner Association, USA Johnny Sorensen Chr. Hansen, Denmark John Lewis Cognex Corp., USA Mohbat Tharani COMSTATS Institute of Technology, Pakistan Hernan Gardiazabal ContrALL, Mexico Mike Cerda Control M Automation, Mexico Sanjay Mishra COTMAC Electronics Pvt. Ltd., India Roy Greengrass Del Monte Foods, USA A. Klemptner DTE Energy, USA William Wang DuPont China, China Tim Matheny ECS Solutions Inc., USA Ed Nachel Elobau Sensor Technology Inc., USA Julian Martinez Emerson Network Power, Colombia Roy Adams ERA LLC, USA Vikram Kumar EZAutomation, USA John Holmes Festo Corp., USA Robert L. Fischer Fischer Technical Services, USA Eric Esson Frommelt Safety Products, USA Chris Alexander Givaudan Flavors, USA Dr. Colin Harrison Glasgow Caledonian University, United Kingdom Kurt Wilde Henniges Automotive, USA Satish Samineni Halcrow, Qatar Tianshun Qiu IBM (China) Co. Ltd., China Alexander Pinkham ICONICS, USA Joel Albert Industrial Networking Solutions, USA Josu Bilbao IK4-IKerlan, Spain John Wilson Integrated Automation, Australia Sudhendu Banerjee Instrumentation Ltd., India Majid Takabi JGC Co., Iran Tom England Kollmorgen, USA Pierre Lampron KSH Solutions Inc., Canada Chris Weigmann Lakeside Manufacturing, USA Tom Jensen Lenze, USA Stefano Linari Linari Engineering srl, Italy Dan Perkins LINAK U.S. Inc., USA Jagjeet Paul Little Systems, India Ken Lauer Middough, USA George Hockett II Miniature Plastic Molding LLC, USA Deana Fu Bryan Knight Mitsubishi Electric Automation, USA Stephen Chilton Monozee Ltd., United Kingdom Todd Desso Eddie Lee Mike Werning Moxa Americas, Inc. Nelson South Nelson South Electrical, Australia CONTINUED ON PAGE 9
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CONTRIBUTORS
Kenn Anderson Nova Systems Inc., USA Joe Sebastian Diane Trentini Optimation Technology Inc., USA Ben Orchard Opto 22, USA Scott Klages Parsec Automation Corp., USA Jose Gonzalez Valero PEMEX, Mexico Helge Hornis Pepperl+Fuchs, USA Mark Buckley Phoenix Contact, USA Rahul Aggarwal Prekar Services & Solutions, India Rafey Shahid Qanare Engineering, Pakistan Mark Battisti QPoint Robotic Solutions, USA Dennis Sanchez RECOPE, Costa Rica Cheng Xinping Rockwell Automation, China Chris Brogli Paul Brooks Douglas Henderson Jimmy Koh Amy Peters Fatime Ly Seymour Thomas Sugimoto Rockwell Automation, USA Mahendra Dissasekera Ronan Engineering Co., USA Sam Shorer SABMiller, South Africa Andrea Sammartino Saipem Spa, Italy Steve Sarovich Sardee Industries Inc., USA Gilbert Brault Antonio Chauvet Schneider Electric, France Johan Hult Schneider Electric, Sweden Robb Dussault John Boville Schneider Electric, USA Jerry Schultheis Schultheis Automation Control Systems Inc., USA Eder Mathias SEW-Eurodrive, Brazil Nesko Kontic SGS - Wind Energy Technology Centre, China Shamsol Shamus Shamus Technology Ent., Malaysia Dr. Gyan Ranjan Biswal Shiv Nadar University, Noida, India George Pease Show-Me Machine Works, USA Jim Anderson Jill Oertel Aaron Schulke SICK, USA Tom Hoffman Jeff Miller Gregory Richards Siemens, USA Tomaz Vidonja Simplysens, Slovenia Mark A. Erickson Skills Improvement Inc., USA Pat Gallagher Solar Automation Inc., USA Lewis Gordon Tangent Services, USA Peter Hook Tech Innovations LLC, USA Dave Szurek The Mackubin Group, USA Assaf Beckman Tomatic, Israel Matthew T. Seiman Trelleborg Sealing Solutions, USA Ed Novak Trio Motion Technology, USA Pramod Parikh United Phosphorus Ltd., India Fernando Jimenez Universidad de los Andes, Colombia Alejandro Pena Universidad Distrital, Colombia Gary Phillips URS E & C, USA Bill Bobbitt Vans Aircraft Inc., USA Sachin Kumar Vertex Automation System (P) Ltd., India Pradeep Soni VSM Venture Control System P. Ltd., Noida, India Charlie Norz WAGO Corp., USA Nathan Schiavo Wesco, USA Wilfredo Jimenez WJ Automation & Integration Corp., Puerto Rico Karen Leung Worleyparsons, USA Erik Nieves Yaskawa Motoman Robotics, USA Will Zurkan Zurkan Solutions, USA CONTINUED ON PAGE 10
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CONTRIBUTORS
Individual Contributors, by Country
Algeria Nesrine Chaouche Bosnia Bojan Djurdjevic Brazil Edson Gonalves de Oliveira Canada Ed Kinakin Guatemala Moises Yac Egypt Mahmoud Abdel Fatah Abo Ahmed India Rajesh Keswani Sarang Kulkarni Senthil Kumar Arunnun Loganathan Mukesh Negi Avinash Patil Naveen Kumar Ramasamy Babu Reddy T Iraq Amer H. Rasheed Ireland Joe Burke Israel Victor Zaltsman Lithuania Genadij Nesterenko Mexico Jorge Loza Netherlands R. Hulsebos Hindrik Koning Nigeria Oladapo Akinbola Iyedupe Norway Rune Saetre Pakistan Faisal Mirzam Saudia Arabia Ghulam Rasul Spain Antonio Anton Miquel Vall Boladeras Sri Lanka Suren Stambo Taiwan Jin-Mu Lin USA Don Baechtel Jim Brastauskas Daniel Bruno Bruce Centofanti Marc Emmerke Greg Fairchild Irene Farquhar Marty Grimes Tony Guzman Daniel Hood Joseph Kolo Rajendera K. Kapoor Michael Kinziger David Lamb Todd LaRoche Hian Yong Leong John Nix Tim OBrien Tony Olivieri Tony Perna Friedrich Purkert Ray Royal Stephen A. Sajewicz William Schmidt Accounties Smith Konstantyn Spasokukotskiy Joe Staples Jim Tennant Suresh Vasan Leonard Walsh Nick Wisniewski Venezuela Juan Nicolaidis
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INTRODUCTION
Manufacturers, machine builders and system integrators have been automating production systems for more than 30 years. But as aging systems become obsolete, technology advances, competition becomes fiercer and priorities change, a new wave of automation is changing the landscape of manufacturing. The drive for cheaper, better, faster has added another elementthe need to become smarter, not just about whats happening on the production floor but about how companies use resources, the skills they require of their workers and how they interact with their customers and supply chains. This edition of Automation Worlds Factory Automation Playbook will explore these themes, sharing guidance from your peers and suppliers about how to plan and manage automation projects, how to justify an automation investment, how to select products, systems and service providers and how to achieve your business and technology objectives. Our thanks to the more than 275 people from 40-plus countriesfrom end-user companies, system integrators, machine builders, educators and automation supplierswho have participated in the development of this playbook. Theyve volunteered to share some of the things theyve learned during their careers as a way to give back to this unique community. In the following pages, well share their ideas about the best practices to follow and common pitfalls to avoid. We hope this information will be useful, whether youve been doing automation projects for more than a decade or are part of the
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Introduction
new generation of engineers just entering the field. The goal of this playbook is to help everyone achieve more successful factory and machine automation projects. Just as important, it is to remind all of us why automation adds value to our world. As one of our contributors pointed out, Automation is not about technologyit is about people. Automation is a tool to help people. Keep those people, the stakeholders, in the forefront of your mind as you go about your work.
Jeanne Schweder
Contributing Editor
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SECTION ONE:
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do it for free. If you bring them in at this stage, so that they understand the history of the project, they can contribute to decisions that will improve the chances for a successful project.
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http://awgo.to/028
Organization: Project Management Institute
people from these functions on the automation team and consult them early in the design and testing stages for new systems and equipment.
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9. Make sure you have bench strength. Theres nothing that delays
a project more than a team member who gets assigned to another project and no longer has the time to devote to your project. Identify alternative resources early and have them ready to fill in if needed. That same rule applies to the system integrators team; make sure theyve identified people with equivalent skills who can be assigned to the project if required.
Requirements
Development Specification
Traceability
Design
Subsystem Unit/Module
8. Dont be a roadblock. As
project manager, its your responsibility to respond to information requests and approve various aspects of the project in a timely fashion. Stay involved and be responsive to prevent delays in the projects timeline.
Development
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General Information
Project name Tech Spec revision level Tech Spec revision date Project description Estimated machine life Target cost
Performance Specifications
3. Define your automation goals. The project manager must set the
agenda for the meetings and be persistent. The goal is to develop a Technical Specification (Tech Spec) that lays out the design parameters and the performance expectations for the systems builder. The following list will get you started on a Technical Specification Form:
Quality, Finance, Purchasing, Facilities, Engineering. S elect people for the team with the right combination of skills and attitudes.
Production rate Maximum noise levels Capability Operator duties Number of operators Setup and changeover Repeatability
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Operation sequence Guarding Ergonomics Cycle activation Frame configuration Size footprint Power requirements Quality/Poka-Yoke*
Acceptance Criteria
DEFINITION
Poka-Yoke is a Japanese term that means mistake-proofing. A poka-yoke is any mechanism in a lean manufacturing process that helps an equipment operator avoid mistakes. Its purpose is to eliminate product defects by preventing, correcting or drawing attention to human errors as they occur. More broadly, the term can refer to any behavior-shaping constraint designed into a process to prevent incorrect operation by the user.
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A sign-off on all technical descriptions of the system Production rate of the system Final part drawings from the customer Capability to hold tolerances over a period of time Progress meetings and milestones Statements regarding noise, safety and environment Training for operation and maintenance Recommended spare parts Documentation and manuals Names of selected components Criteria for acceptance of the system at the supplier Criteria for acceptance of the system at your plant Procedure for handling changes after the order Warranty and service policies Delivery date Project price Payment terms
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10. Installation, final acceptance, and production startup. The acceptance criteria as stated
in the contract will be the standard. This can be a critical time since all the planning done previously must come together at this point. It is now time for the person and company who purchased the system to demonstrate their readiness by putting the system into production. This is usually done with the assistance of the supplier. Notwithstanding warranty and service agreement coverage, most suppliers are eager to have the system running smoothly before leaving the plant.
Koops Inc., Grand Rapids, Michigan, builds assembly and process automation systems and workstations for a broad range of industries. www.koops.com
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Different languages
This language has terms like cash flow, capital and interest. Campbell, who reveals these definitions later, advises, You must identify the positive cash flows you create with a new system, and then, using your companys method for calculating cash flow, do the math. Even if we are on a solid footing with the language of finance, we may not be so good at seeing our projects through an investors careful eyes. Peter Martin, vice president of Invensys, a Foxborough, Mass., supplier of process controls and software, says, When you are justifying automation, its important to remember that its an accounting problem. It is possible to solve the accounting problem through engineering principles, however. For instance, where is the biggest cost accounting database in manufacturing? It is information from all the sensors in the production process. In other words, tap into the data you have, and translate them into financial numbers.
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Technical managers may be sitting on a gold mine of cost detail that can be used to determine where the manufacturing problems lie, as well as the crucial data that can be used to figure out the best solutionand how to get through the financial maze to approval. This advice directly leads to the conclusion that bringing a finance person into the automation buying team will reap huge
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Lifecycle costs
Bill Egert, engineering vice president of Addison, Ill.-based integrator Logic One Consulting, and member of the Board of Advisors for the Robotics International division of the Society of Manufacturing Engineers, advises calculating all of the costs associated with the lifecycle of machines. He notes, Check out costs associated with changes. For instance, on robotics, evaluate the tooling changes needed to support product changeover plus auxiliary equipment such as feeders, conveyors and workstations associated with material handling. Dont dismiss employee turnover or morale as a factor that cant be quantified. Egert reveals, We had a printed circuit board assembly machine with robots where the component
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Identify the base case Identify alternatives to the base case Determine cash flows associated with the alternatives vs. the base case Use your companys financial rules to evaluate the alternatives (payback period, net present value, rate of return, hurdle rate).
Present value
The first step is to determine the present value, which is defined as the value of all future cash flows discounted at the cost of capital, minus the cost of the investment. Discounted means that a future cash flow is worth less (discounted) than a present cash flow. So, $100 received three years from now at 8% cost of capital is the same as receiving $79.38 today. The Net Present Value (NPV) is the present value of all future cash flows discounted at the cost of capital, minus the cost of investment. Cost of capital is a weighted combination of the cost of debt (long-term debt and leases after tax) and the cost of equity (preferred and common stock). All future cash flows means that the PVs are summed over some time horizon, often five or 10 years. Subtract the cost of the initial investment from
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The base case is the current state of affairs. Include all the financial data that can be compiled. Then, having identified the correctable problems, document various alternatives to the base case. Quantify all the risk, benefit and loss factors that you can. Take a balanced approach addressing significant pros and cons to demonstrate your thoughtfulness and enhance your credibility. Calculate the numbers and compare to the companys financial rules. Those results can then be compared to determine the best alternative to present to management for funding.
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Graphite
Introducing the industrys rst rugged HMI solution. With cast-aluminum construction, Red Lions new Graphite series combines exible plug-in modules with protocol conversion, data logging and webbased monitoring to meet all of your industrial automation needs. From factories to extreme remote locations, Graphite enables customers worldwide to connect, monitor and control processes across a broad range of industries.
Graphite 7 touchscreen
Plug-In Modules
Graphite 10 touchscreen
Graphite 15 touchscreen
Calculate the cash flows and rates of return for all of the alternatives and then the best solutions will pop out. If
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business objectives. So, when looking for projects with the highest probability of approval, make sure that they align with one or more of the objectives in the Profit Zone.
Train managers
Logic Ones Egert offers some additional tips on putting together a justification package. Get management trained on technical aspects, he states. They have lots of knowledge and experience on finance and marketing, but not much on technical aspects. A progressive, smart manager will have those technical people. A manager with technical skills will be able to see some problems coming. Another problem is management embracing new technology with no strategy for implementing, no urgency for training or no technical champion to embrace and learn the new stuff. Its not just a matter of providing training in some cases, but whether the workforce has the basic background skills to make training a practical option.
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Security
Industrial Networking
OEE Dashboards, DCS and SCADA, Micro Data Center Solutions
Electrical Infrastructure
Electrical Distribution
Industrial Enclosures
Control Panels and Control Panel Cooling Solutions
Graybar offers dependable automation solutions for all applications. Our network of eld automation specialists are there for you to answer even the simplest of questions on process control, facility automation and industrial networking.
EVERYTHING. Automation, networking, electrical, safety and security EVERYWHERE. 240 locations nationwide EVERY DAY. Since 1925
Thats Graybar. Call us. Well be there.
1-800-GRAYBAR (472-9227) graybar.com/pb-1
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usage, electricity, and/or floor space that must be lighted, heated and cooled? Most plants today face corporate mandates to hit reductions in all these resources, and every bit helps.
most to reduce your total system carbon footprint Will it be that green roof proposal or your production line improvements that produce less scrap and use less energy? Lean production lines wont make the same photo opp that goats munching turf on your plant roof willbut your chief
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also consider high-efficiency electrical power supplies, regenerative power supplies for servo drives, and a common DC bus between servo drives.
dont fare well during ahiring freeze. Increasing capacity without increasing labor is a good justification. But automation that can efficiently scale throughput up or down with reduced attention from plant personnel sounds like a real winner.
and best practices that have a positive impact on seemingly unrelated aspects of operations. For example, implementing integrated safety doesnt just make a production line safer; it means more uptime, which results in measurable Overall Equipment Effectiveness (OEE) improvements. And today, the safety network can be the same network that links machinery together on a line, which also improves OEE.
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3. Dont forget power. Make sure you have all the needed
power requirements in the locations intended for your new devices for the instrumentation you are using. Dont forget to update all prints to reflect your changes.
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7. Look for support. Make sure to do the research and consider the ease with which a system can be modified if needed. Always evaluate whether support will be available after the project is completed. It does no good if the system will be obsoleted within two years and will no longer be supported. If buying from a machine builder, look at the OEMs track record and see how often it advances to newer generations of equipment.
equipment so you dont need a spare parts room the size of a small plant. Go green wherever possible. Retrofit pneumatics, for example, using electric cylinders instead; restrict the number of stroke lengths to no more than three. Use similar criteria to simplify selection for other product categories, whether its motors, servos or other components.
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Integrator source
An excellent source for information useful in selecting a systems integrator is the CSIA (Control System Integrators Association). You can search their membership by expertise, state, certification, etc., to find exactly the right fit for your automation project.
http://awgo.to/027
Organization: Control System Integrators Association
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opportunities and made other cutbacks. Take the time to assess the strengths and weaknesses of any integrator you consider to ensure that they are capable of delivering the system that you require.
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425.745.3229
Every Machine Needs the Human Touch
www.maplesystems.com
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1. Not getting maintenance and operators involved from the start. Some assembly jobs have been
done by hand for years. The worker who has been on the line for a long time will have seen what has and has not been done in the past. Just because components on paper are all uniform does not mean that they are in tolerance in the real world. Maintenance workers have dealt with more fixes and operator complaints than the design engineer. The key to a new piece of equipment working well is maintenance and operators taking ownership of the system. If they arent on board, the machine may just end up being a big paperweight.
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frequently.
9. Confusion. An insufficient amount of effort in the frontas cost, quality, maintenance, training, stocking of components, safety, etc. This will assure that decisions are aligned with the projects goals. loading stage, or subsequent budget cuts or direction changes by management, will result in confusion for the project team. Its a standard recipe for failure.
Unrealistic schedules are set. Potential risks are not calculated and planned for.
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SECTION TWO:
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Most PLCs on the market can communicate on device buses, but not all can accommodate every type of Ethernet. Do your homework and choose a PLC that can support all your buses without a lot of pain.
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10. Get out of the code. Ask the people at the plant why
they are running the way they do. Sometimes what you might think is bad programming is really needed to optimally run a
process. On the flip side of the coin, after examining the code, you often find people think a system is running in a particular way, but the reality is that it is not.
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http://awgo.to/025
Source: Rockwell Automation
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Use hardware that meets minimum requirements and keeps the number of failure points low and assures high availability of the system.
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Tightly Integrated Vision System Easy to use Embedded Software Sensor Resolution: VGA to 1600x1200 Factory Communications
Industrial Enclosures 360 Direct Mounting Factory Style Connectors Ideal for Single Point Inspections
continued
10. Alarm strategy. Alarming needs to have a wellarticulated strategy. Alarms must be used for conditions that require intervention and must have a clear corrective action associated with each one. Anything else should not be an alarm.
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Alarming guidelines
The key aspect of an HMI display is the dynamic plant data. There are two basic types of dynamic data: Alarms and normal Plant Status data. 1. Alarm status for the overall plant, preferably organized into groups, should be visible on every screen and there should be a simple navigation route to access the screen containing additional details about the alarm. 2. The alarm colors should follow the safety convention: Red = stop, prohibition, danger; Yellow = caution, risk of danger; Green = safe condition; Blue = mandatory action. As one in 12 men have some form of color-blindness, which can affect the perception of red and green, color cannot be used as the sole indicator of alarms. 3. Any color change must be supplemented with a pictorial change and, if the alarm is critical, an audible alert. Pictorial changes could include shape changing, a change in the position of an indicator, having additional text or objects appear on an alarm. Flashing of alarms that have not been accepted is very irritating and stressful and should be avoided.
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4. Similarly, automatic changing of displays should be avoidedto have a page disappear when you are working on it is irritating and, in extreme cases, a cascade of alarms can produce so many screen refreshes, an operator can be locked out of the system. 5. Audible alerts can be very useful, especially if the system is able to create multiple tones and pitches. These tones can be used to transmit the importance of an alarm. Research has shown that a high-pitched, fast-pulsing sound automatically conveys urgency; a lower-pitched, slow-pulsing sound is less urgent. 6. Whatever convention is used, alarms should be placed where they can be easily seen, such as along the top of the screen.
Our expertise in automation, both electric and pneumatic, can solve all your motion challenges
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To find a compact drive that can do more and maximize value, engineers should examine features in the following four key areas:
communication options, dual port connectivity supporting ring topologies with device level ring (DLR) functionality, and support for other open industrial networks.
automation controller (PAC)-integrated programming to reduce development time. Features such as descriptive scrolling text on LCD human interface modules (HIMs) and intuitive software with standard connectivity help speed up drive configuration.
help protect personnel and equipment, meeting ISO 138491 standards with ratings up to and including SIL 2/PLd Cat 3.
allow simultaneous configuration and installation while offering flexible mounting options with small footprints, high ambient operating temperatures and low clearance requirements, saving valuable panel space.
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Seven considerations for applying servo drives, motion controllers and PLCs
Technology advances in servo drives have made them the workhorses of motion control. Here are some recommendations for implementing servo drives: that can quickly pay for itself, especially for users who run multiple format sizes on the same production line.
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Seven considerations for applying servo drives, motion controllers and PLCs
4. Over-sizing wastes energy, cost and panel space. Some of the biggest energy wasters on a machine are
frequently overlooked. Over-sized servo drive/motor systems, for example, cause machines to consume more energy than necessarysomething that can easily be avoided through proper design. End users often underestimate the returns from energy-efficiency investments, since it costs more up front and may take a few years to achieve payback. As a result, they often inadvertently build in extra long-term, ongoing costs by overlooking details when sizing machine components. When sizing a machine, the entire motion profile is important, not just speed and load. Having a detailed and accurate profile of needed motion can pay dividends. Typically, a less precise profile will lead to an over-sized servomotor. This means that the energy consumption of the system will be higher than needed. The key to getting the motion profile right is properly calculating velocity, continuous vs. peak torques, acceleration, and matching load and motor inertias. Further, refine the profile by accounting for cycle times. How long does the system have to move from one point to the next, and how long can it take to complete the
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entire trajectory?
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Seven considerations for applying servo drives, motion controllers and PLCs
6. Minimize vibrations. The latest vibration suppression
algorithms in some servo drives can actually minimize vibrations from occurring on overhung loads and in the machine base without additional sensors. These vibration suppression algorithms, combined with auto-tuning and filtering, can allow for high-performance motion without complicated mechanical damping or heavy bracing. LOAD TO MOTOR INERTIA RATIOSIMPROVE RESPONSE TIME
Calculating an inertia ratio is often overlooked by newcomers to servo sizing, but is arguably the most important factor in determining the performance of a servo system. Inertia ratio is calculated by dividing the load inertia by the motor inertia. Lower load-to-motor ratios improve response times, reduce mechanical resonance and minimize power dissipation. An inertia mismatch of greater than 10:1 can produce oscillations and extended settling times. To prevent overshooting and oscillations with very large mismatches, the control gain may have to be reduced. A motion system with a load-to-motor inertia less than 10:1 can reach a set speed or move into position in less time than one with a ratio greater than 10:1. Large inertia mismatches require higher current to drive the motor, thus they dissipate more power. For example, a mismatch of only 5:1 will dissipate six times more power, and it gets worse as the load inertia increases.
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Data delivery reliability Future proofing to include scalability Data/network security requirements Current on-site expertise Ease of architecture Total cost of ownership
3. Design for the process. When implementing an
industrial network (be it Ethernet or traditional fieldbus), be sure to get all affected parties involved during the initial design. This could include production workers on the plant floor, IT, engineering and more. One method is to simulate your product going through the entire production phase, see where it goes and who interacts with it, what information it needs and where that information comes from, as well as what information it produces and where that information goes. Getting all the affected parties involved will not only get you the best solution, it will make everyone understand that they have an investment in the project.
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Six things to consider when you get down to the network details
It all comes down to the details. Thats as true for networking as it is for every other aspect of an automation project. Here are some tips for making sure the details are covered with your industrial network: fieldbuses and especially proprietary networks, it is critical to test to the point of failure. These failure points can be associated with the number of Ethernet port connections, the size and frequency of data being managed, as well as data addressing in the PLC. The PLC addresses used in data collection, if not contiguous or near contiguous, can cause excess read/write cycles to the PLC. Some PLCs can only provide X number of devices in one read. If that number is 1k (1024 devices) and you attempt to read the values of coils 250, 1400, 5000 and 6500 in one cycle, it can actually create four separate read requests. This results in performance issues and missing data. Think of the impact if you want to read 250 values! FMEA (Failure Modes and Effect Analysis) is a great tool to aid in trying to identify what can go wrong.
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Six things to consider when you get down to the network details
4. Avoid subnetworks. When selecting fieldbus or
network architecture, avoid the use of subnetwork systems or expandability features that require configuration of expansion modules or field devices separately from the PC or PLC. Subnet components add an additional burden for end-user support and complexity in software (re-tagging/programming) when the subnet I/O count or type changes. stand a chance of disproving this. Make sure high-quality network analyzers are available, and the real root cause of the problems will show up very quickly: very often it is application software. A network engineer without a network analyzer is like an electrician without a multimeter: clueless.
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Machine builders also need to consider how their equipment will impact the factory LAN once the customer installs the equipment on the factory floor. Many OEMs now use Ethernet as their communication protocol within the machine and provide an Ethernet switch to network the devices in the panel and to provide a link to the factory floor. Several of the industrial protocols on the market today use multicasting between devices in order to streamline communication. This feature can save bandwidth within the machine by allowing a device to send one packet to several
devices at once, but can cause problems with the factory network if not handled properly. If an OEM puts an unmanaged switch on the machine and the customer connects the machine to the factory LAN, this multicast traffic will be broadcast throughout the factory because an unmanaged switch will turn that multicast traffic into broadcast. The solution is to use a managed switch that supports both IGMP and IGMP snooping on the machine. This will prevent the multicast traffic from reaching the factory LAN.
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Four tips for dealing with wireless latency and bandwidth issues
More and more, systems engineers are taking advantage of industrial wireless technologies to reduce the amount of cabling in their designs. There are some issues to be aware of, however, when replacing dedicated connections with wireless links: multicast traffic coming from PLCs or producer devices. Multicast traffic is handled differently than unicast traffic by wireless access points. Multiple devices can receive multicast traffic, while unicast is destined for only one device. Wireless access points transmit multicast traffic at a minimal rate to ensure that all listening clients will be able to receive the traffic. This results in low aggregate bandwidth over the wireless AP as it has to lower its transmit rate down from the maximum.
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Four tips for dealing with wireless latency and bandwidth issues
4. Dont take shortcuts with wireless. Consider
the entire system design and the support lifecycle of the system before choosing technology and vendors. Time spent up front on site surveys, path loss calculations and fade margin will pay dividends when it comes time for installation. Design in fade margin. Wireless is very reliable when well designed, but if you dont design in appropriate fade margin youll have problems in the future.
Our expertise in automation, both electric and pneumatic, can solve all your motion challenges
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Let Graybars team of Industrial customer-focused sales professionals and automation and control technical specialists help you: Increase Output improve throughput with improved process control improve quality with improved process control Reduce Costs select the right automation and control products for lower equipment and system maintenance online monitoring and predictive diagnostics to reduce costs Safety select sensing and signaling solutions to provide a safe production environment intrinsic safety solutions
technology is that it can operate without using electricity. This minimizes the risk of fire or explosions from sparks or arc flash events. This technology is particularly useful in a plant making edible oils or hydrogenating oils or when using flammable gases in the production process.
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controllers and systems. This embedded approach to robotics integration brings the robot module directly into the control platforms chassis. It keeps machine and robot
control separate, but helps drastically reduce the machine footprintby up to 50 percentbecause there are fewer control boxes on a machine.
emergency maintenance never happens, and temporary, suboptimal, rigging ends up hurriedly being used.
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experience. Witness marks on joints can fall off, and having an independent means to establish the coordinate system is a major time saver.
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consistency and reduced scrap rates. Robots deliver limited production loss and lower error rates compared to manual operations. Speedincreased production rates and reduced wait time for operators. Robots have negligible downtime in situations where there is high demand for the manufactured product. Flexibilityreduced training and changeover time. Robots can also be set up to multi-task.
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425.745.3229
Every Machine Needs the Human Touch
www.maplesystems.com
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NT24k
Introducing the ultimate in network exibility. With all Gigabit and versatile connectivity options, Red Lions new N-Tron NT24k modular switch series delivers the conguration exibility to meet all of your industrial networking needs. From factories to extreme remote environments, NT24k enables customers to connect, monitor and control across a broad range of industries.
Mix and Match Copper, Fiber, Fast Ethernet and Gigabit Modules
proper calibration and document it in the software changes in the DCS. A built-in display unit for local monitoring of process data is recommended. Follow selection guides and material. Install the sensor in a proper rack/enclosure if the dust level is high. Put proper tags at the site to guide servicing. After commissioning, put the instrument on continuous monitoring/trending to make sure readings are correct and the calibration is accurate before handing it off to operations personnel.
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3. Are the sensors mounted outdoors? It is important to know the maximum and minimum temperatures to which the sensor will be exposed. For extreme environments, an internal or external heating or cooling unit may be necessary. Sometimes a heating unit is advantageous to reduce frost or fog buildup on the exterior of the lens. 4. Will the sensor be exposed to wash-down conditions? Choose an enclosure with the appropriate NEMA/IP
enclosure rating. Consider hygienic requirements in sensor selection, since these are becoming more popular in the food and beverage industry. 5. Is the sensor exposed to direct sunlight? During sunset or sunrise, for example, the sun might shine directly into the receiver of a sensor and give a false output. Reduce the risk of this happening by using a hooded bracket to minimize interference.
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10 questions to ask
Whether you are new to machine vision or an experienced user, consider the following 10 questions when selecting a stand-alone vision system: 1. Does the vision system make it easy to set up applications, create custom operator interfaces and administer vision system networks? 2. What is the importance of part location tools, and how can you assess their performance? 3. Does the vision system have a complete set of image preprocessing tools? 4. What should you look for in character reading and verification capabilities? 5. How can you determine the repeatability of a vision systems gauging tools? 6. How do you evaluate industrial code reading tools and what are some specific features to look for? 7. What networking and communications features are available? 8. What should you know about vision system accessories? 9. Does the vendor offer a wide range of hardware options? Are they rugged enough for your environment? 10. Does the supplier provide the support and learning services you need?
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SECTION THREE:
APPLYING TECHNOLOGIES TO IMPROVE OUTCOMES
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3. Involve production, not just facilities management. Involve people responsible for production
processes in energy management activities, since up to 90 percent of energy is consumed by production equipment. They will help you ensure that proper steps are taken to understand how process energy consumption can be reduced without affecting the productivity of expensive production assets. The primary reason most companies focus their energy-saving activities on the facility is that facility management personnel are often given the responsibility for reducing energy costs. Not only is the facility in their comfort zone, but its often the only area where they have the institutional authority to make changes. By involving production, you can address all the areas of your operation that consume energy.
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Where am I likely to find quick returns? What key metrics should I put in place? How can I encourage ongoing improvements?
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BOA products are highly integrated vision systems in a tiny smart camera package specifically designed for industrial use. Complete with choice of application software embedded, BOA offers new and experienced users alike, an easy-to-deploy cost effective vision solution.
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13 ways to get the most out of OEE and lean manufacturing disciplines
Overall equipment effectiveness (OEE) and lean manufacturing have won many converts. These two disciplines are frequently linked because they provide a systematic way to design manufacturing processes, measure their efficiency and identify problems. Here are some tactics to get the most out of your lean and OEE initiatives: rework, thereby increasing throughput in quality. Before building a lean cell, talk to your operators, quality people, manufacturing engineers and process engineers. Get their input, hold meetings and keep them in the loop throughout the project. They are the main stakeholders who will eventually approve of your cell.
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13 ways to get the most out of OEE and lean manufacturing disciplines
down, but you will be making more product in a shorter period of time. fine-tune the flow of your product.
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13 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 factors: availability, performance and quality. Heres how each of these factors is calculated: Time / Total Pieces). Ideal Cycle Time is the minimum cycle time that your process can be expected to achieve in optimal circumstances. It is sometimes called Design Cycle Time, Theoretical Cycle Time or Nameplate Capacity. Since Run Rate is the reciprocal of Cycle Time, Performance can also be calculated as: Performance = (Total Pieces / Operating Time) / Ideal Run Rate. Performance is capped at 100 percent, to ensure that if an error is made in specifying the Ideal Cycle Time or Ideal Run Rate, the effect on OEE will be limited.
CONTINUED ON PAGE 122
Availability
Availability takes into account Down Time Loss, and is calculated as: Availability = Operating Time / Planned Production Time.
Performance
Performance takes into account Speed Loss, and is calculated as: Performance = Ideal Cycle Time / (Operating
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13 ways to get the most out of OEE and lean manufacturing disciplines
Quality
Quality takes into account Quality Loss, and is calculated as: Quality = Good Pieces / Total Pieces.
OEE
OEE takes into account all three OEE factors, and is calculated as: OEE = Availability x Performance x Quality. It is very important to recognize that improving OEE is not the only objective.
OEE = Availability x Performance x Quality OEE = B x D x F A C E
Availability
Speed Losses
UNO-2483G
Intel Core i7/i3/ Celeron RegularSize Automation Computer w/ 4x GbE, 3x mPCIe, HDMI/VGA
FieldBus iDoor
PCM-26D1PB
DI/DO iDoor
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Communication iDoor
PCM-24D2R2/PCM-24D2R4
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13 ways to get the most out of OEE and lean manufacturing disciplines
9. Meaningful reports. Data
capture is quite easy. Reporting the data in a manner that helps implement change can be challenging. Dont assume a single report is sufficient. Different users need different data. And that data must be presented to each user in a manner that is meaningful. Software selection plays only a small part in the OEE process, but that is where customers spend the most time upfront. Operator involvement, the quality of the integration partner and the ability of the controls hardware to collect data are what truly make an OEE project successful.
12. Efficiency tool. OEE has to be automated to be successful. The data needs to be driven from machine status, not humans inputting the status. Any manually derived OEE system can be fiddled with to produce the expected 85 percent efficiency rate. Improving systems and automating OEE measurements may bring into question the accuracy of historical OEE data. To avoid internal politics, put an amnesty in place and promote automated
OEE in-depth
For a detailed discussion on calculating Overall Equipment Effectiveness, go to
http://awgo.to/022
Source: Automation World
data as a new way of measuring OEE. On the other hand, the only reason to use OEE is to help drive an improvement process to increase operational efficiency.
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13 ways to get the most out of OEE and lean manufacturing disciplines
If that isnt a widely embraced priority, then save yourself lots of time, money and effort.
13. Improving uptime. OEE can help you identify opportunities to improve your total uptime. First, understand the categories that OEE represents. Next, determine what things you want to track and how specific you want to be. There isnt a set rule as to what that may be. An example may be that under your performance efficiency category, you list specific pieces of equipment in an assembly line to track. By breaking down your categories you will have better opportunities to make improvements. The last hurdle is how to capture the data used to calculate OEE. Keep it simple and train your people in how to capture the data you need, what it is and why its important.
usa.siemens.com/tia-portal
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http://awgo.to/023
Source: Siemens
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Modernizing manufacturing
To learn more about the digital manufacturing initiative sponsored by the National Center for Manufacturing Sciences and other resources for modernizing American manufacturing, visit
http://awgo.to/024
Source: National Center for Manufacturing Sciences
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http://awgo.to/017
Source: Siemens
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$afety Pays
The OSHA website has an application designed for small businesses called $afety Pays that can help make the case for implementing safety systems. It gives scenarios based on lost time (litigation is not included) from the insurance industry, which can demonstrate the effect of severe injuries on sales and profits.
http://awgo.to/015
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openSAFETY
Looking for a safety solution that supports more than one TUV-approved protocol for industrial Ethernet? Consider using vendors that support the openSAFETY standard, which is vendor neutral with regards to fieldbus and supports safe operations with interoperable technologies. For more information, visit
http://awgo.to/019
Source: Ethernet Powerlink Standardization Group Source: Ethernet Powerlink Standardization Group
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http://awgo.to/016
Source: International Electrotechnical Commission
Safety modules independent from the logic solvers. By choosing safety systems with these features, availability has been estimated as high as 99.9999 percent.
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Consider also the stop time of the entire system. Realize that the stop time may include more than just the stopping of the machine. The time it takes for the scanner to react, for the stop signal to travel to the machine, for the machine to actually come to a stop and any other delays must be considered. These delays may be small, but can have an impact on the overall size required for the safety field.
The stop time of the machine will also be used in calculating the safety distance. By implementing this calculation into your design of a safety laser scanner, you will be on your way to properly complying with standards and achieving greater employee safety.
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http://awgo.to/020
Source: Tofino Security
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could be caused by a breakdown in security. Dont skimp by using cheap security software. A hack or virus in a system can cause the entire business to be compromised. External access is only one security consideration. What if an outside interest gained access to your operation solely for the purpose of accessing your information without your knowledge? Gaining access to your product manufacturing process, your supply chain and other aspects of your production could provide invaluable information to an unscrupulous competitor. All of these factors and potential threats should more than justify the cost of implementing a security plan for your facility.
In addition, there are security threats from within the facility. These can be as innocent as an accidental modification to a production program or as intentional as a disgruntled employee. While many security issues can be solved by better human behavior, theres no way to guarantee that the behaviors threatening your facility will actually change. Take all of these threats into account when developing a security plan. Considering the risks to your business, it shouldnt be difficult to justify implementing a security plan for your facility.
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7. Optimize firewalls to protect the right protocols. Firewalls should be optimized to secure SCADA
protocols such as Modbus and OPC, rather than email or web traffic, which have no place on a plant floor system. Products that inspect email and web traffic simply add cost and complexity to the security solution. Design your security system to handle very wide power ranges, since the plant floor often has dirty power.
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Nine ways to get the most from simulation and CAD/CAM software
Simulation software and CAD/CAM systems have helped transform the design of machines and automated systems by reducing design engineering time and costs. Here are some tips for getting the biggest bang from your software investment: anyone said, We performed too much simulated testing.
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Nine ways to get the most from simulation and CAD/CAM software
5. Verify performance. CAD/CAM simulation helps the
programmer and engineer to know about the working of a machine before its built and for troubleshooting as well. Its also useful for research. Before applying any hardware ideas, a programmer or engineer can simulate to verify the results to the nearest real-world values. simulation give you a good image of the problem to solve. Have a mental model to make sure digital version mimics the real world.
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be specific when discussing and documenting software requirements, methods and objectives.
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Use templates to save a lot of time. Use IEC 61131-3 for programming machine behavior. Be sure to enlist the experience of all those who will come
in contact with the workflow that you are trying to model or diagram. Ensure proper channels of workflow. A proper design is essential to avoid delays in a workflow project.
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Advantech
Automation Controllers
Advantechs Programmable Automation Controllers (PAC) combine a PLCs ruggedness with PC-based technology, an open architecture, high performance CPU, rich I/O modules and power software.
Automation Software
Advantechs automation software lineup includes SCADA software, SoftLogic programming tools, OPC WEB RESOURCES Server, and other user-friendly VIDEO programming tools and utilities.
awgo.to/200
WHITE PAPER
How has the recent strides in automation changed the factory floor? awgo.to/201
PRODUCT
awgo.to/202
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Advantech
With more than 6,000 talented people, Advantech operates an extensive support, sales and marketing network in over 20 countries worldwide. In addition, we cooperate closely with our partners to help provide complete solutions for a wide array of applications across a diverse range of industries.The Advantech Industrial Automation Groups Intelligent Automation, Seamless Integration mission statement looks forward to the contribution that Advantech, together with its partners, can make to this new era of intelligent automation. Whether in public safety, building energy efficiency, environmental monitoring, industrial monitoring, smart transportation, smart grids, smart homes and other areas with our expertise and experience we can provide the best solution to create better tomorrow.
ADDRESS: 11380 Reed Hartman Hwy, Cincinnati, OH 45241 WEB: www.advantech.com Return to contents
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Festo
Pneumatic and Electric Drive Technology for Factory & Process Automation
Festo is a leading global manufacturer of pneumatic and electromechanical systems, components and controls for process control and factory automation solutions, with more than 55 national headquarters serving more than 180 countries. With over 40 years of innovation in the United States and over 80 years globally, Festo has continuously elevated the state of manufacturing with innovations and optimized motion control solutions that deliver higher performing, more profitable automated manufacturing and processing equipment. Our dedication to the advancement of automation extends beyond technology to the education of current and future automation and robotic designers with simulation tools, teaching programs, and on-site services. Festo is globally recognized as a symbol of expertise in factory automation and process control. We can help decrease process costs by engaging Festo as an extended workbench and benefitting from our expertise with regard to pre-assembled pneumatics, customized product designs, and system solutions. Festo enables its partners to obtain more intelligent automation
COMPANY: FESTO
solutions from a single source. In addition to tried and tested pneumatic drive units, Festo also provides both servo-pneumatic and electric drive units. Our intelligent systems for status monitoring and machine diagnosis (condition monitoring solutions) are made up of sensors, software, controllers, and visualization. These solutions can greatly reduce maintenance and servicing costs. With a comprehensive line of automation components, custom components and complete WEB RESOURCES electromechanical and pneumatic motion controlled multi-axis systems. For more information about Festo Corporation: Festo can support your most complex automation requirements. FESTO ull Range of Standard and F Customized Products With a comprehensive line of more than 30,000 automation products, Festo can support the most complex automation requirements.
CORPORATE OVERVIEW
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awgo.to/139
SOCIAL MEDIA
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Festo
engineering, design, assembly, documentation, validation, and production. Engineering & Design Handling & Custom Assembly Control Systems
Our dedication to the advancement of automation extends beyond technology to the education of current and future automation and robotic designers with simulation tools, teaching programs and on-site services. Festo Didactic is the knowledge and learning division of Festo Corporation. Didactics charter is to provide automation technology training for manufacturing employees at our industrial customers worldwide. From basic training packages to the planning, control and handling of complex networked CIM systems and complete, fully equipped learning centers we can create a customized offer to suit your personal requirements for efficient learning and guaranteed results.
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Graybar
GRAYBAR: Your nationwide resource for automation, networking, electrical, safety and security solutions.
Graybar has high quality electrical, automation and control products common to the factory floor or automation processes. Graybars experience and alliances in automation and control products can provide a value to help your company get critical data from the shop floor to the top floor. Let Graybars team of Industrial customer-focused sales professionals and automation and control technical specialists help you boost output, reduce costs and increase safety. Graybar is uniquely positioned to provide the solutions needed from the factory floor to the corporate boardroom, including:
Software
A wide range of easy-to-use software programs that will help you easily migrate to newer platforms.
Operator Interfaces
The latest technologies in the human-machine dialogue field to help machine builders and industrial users meet new control system standards.
Industrial Networking
Ruggedized industrial Ethernet products designed specifically to network in tough environments, support the industrial protocols transmitted across these networks, and accommodate the environmental rigors of the location.
Enclosures
Industrial enclosures and enclosure solutions that isolate critical controls from harsh environments and help ensure reliable performance in a range of extreme conditions.
Wireless
Wireless data communication solutions for indoor and outdoor applications that offer reliable transmission, low maintenance and increased system availability.
Power Supplies
Industrial-grade power supplies for demanding applications and harsh environments.
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Graybar
Power Monitoring
Power management systems designed to help manage real-time conditions, isolate problems, study trends, and control loads and generators.
Sensors
Technical specialists to help you select the right sensor for your application, including proximity sensors, electronic pressure sensors, photoelectric sensors and limit switches.
Services
A wide variety of services to support our customers facility needs in power, lighting, networking, energy management, security and more. Our technical specialists help customers in all these areas today and continually expand their knowledge and skills to master new technologies.
Safety
Plant-wide safety audit provisions, lockout/tagout provisions, arc flash analysis, and personal protective equipment (PPE) to help avoid electrical hazards that can result in serious injury or death.
KEY COMPANY CONTACT Brett Felton, National Marketing Manager PHONE: (314) 573-9200 LOCATION: St. Louis, MO EMAIL: brett.felton@graybar.com
COMPANY: Graybar
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We help customers build superior automated machines that are easy to use, install and integrate.
Omron Automation and Safety is a leading global supplier of automation systems serving industrial customers for more than 80 years. Our comprehensive product lines and application expertise are delivered via a well-trained distribution channel. They work with you to solve demanding automation challenges and apply the advanced technology built into Omron products. WEB RESOURCES We support machine builders and OEMs across the United States, Canada Find Omron Automation & Safety on and Latin America with sensing and control technologies that help you deliver more capable and profitable machines in less time. We strive to be your trusted partner in automation. Leverage our industry expertise and powerful yet simple solutions in your next project.
LINKED IN
http://www.linkedin.com/ company/omron-electronics
FACEBOOK
https://www.facebook.com/ OmronAutomationSafety?ref=hl
TWITTER
https://twitter.com/ OmronProduct
YOUTUBE
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Primary Industries Served Automotive Food/Beverage Semiconductor Electronics and Small Parts Assembly Pharmaceutical/Cosmetics Automation Expertise Packaging & Material Handling Measurement & Gauging Inspection Track & Trace Quality Improvement
Omron Facts 80 years in the controls business, founded in 1933 $6.5 billion sales (USD, April 2012) 40% of our sales come from industrial automation; electronic components, social systems, automotive electronics and healthcare make up the balance 35,411 employees worldwide
COMPANY: Omron Automation and Safety PHONE: (847) 843-7900
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Opto 22
groov interface works on virtually any authorized, web-enabled device regardless of manufacturer or screen size: smartphones, tablets, and more. Gauges, buttons, labels, even live video all scale to match the device youre using, but never become too small to use. Simplicity. With groov, all you need to build interfaces is a web browser. No plugins; no extra software. And theres no coding or programming. Just drag and drop WEB RESOURCES touchscreen-ready indicators and controls onto the screen, then tag them VIDEO from your own tag database. Interface Simplify your job with a groov mobile interface. updates are simple, too. No user or device keys; no reinstallations. Just have http://awgo.to/166 users refresh their screens. WHITE PAPER Connectivity. What system do you 14 ways to build an operator interface have: Allen-Bradley, Modbus, Siemens, that works. Yokogawa, ABB? Now it doesnt matter. http://awgo.to/167 With groov, you can build mobile PRODUCT interfaces to all of these and many groov makes http://awgo.to/168 Return to contents
mobile simple. Get your free trial.
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Opto 22
complete control over quality. We do no statistical testing: each I/O module or solid state relay is tested twice before its shipped to you. Thats why we can afford to guarantee most I/O and SSRs for life. About Opto 22. Founded in 1974 by engineers who designed a better solid-state relay, Opto 22 has built reliable controllers, I/O, SSRs, and automation software for 40 years. With our flat structure, we can respond quickly to customers needs and develop cuttingedge products fast. All our products are based on open standards; all products are manufactured and supported in the U.S.A.
Easy-to-use software, reliable hardware, and people you can talk to: thats the Opto 22 difference. Call today: 1-800-321-6786 or 951-695-3000 KEY COMPANY CONTACT Selam Shimelash Systems Engineer PHONE: (800) 321-6786 ext. 3085 LOCATION: Temecula, CA EMAIL: systemseng@opto22.com
ADDRESS: 43044 Business Park Drive, Temecula, CA 92590 WEB: www.opto22.com Return to contents
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WEB: www.redlion.net
E-MAIL: info@redlion.net
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In addition, Red Lion now offers an industrial networking portfolio that includes:
WEB: www.redlion.net
E-MAIL: info@redlion.net
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Siemens
The worlds leading supplier of innovative and environmentally friendly products, solutions and services for industrial customers.
The Siemens Industry Automation Division supports the entire value chain of its industrial customers from product design to production and services with an unmatched combination of automation technology, industrial control technology and industrial software. With its software solutions, the division can shorten the time-to-market of new products by up to 50 percent. www.usa.siemens.com/automation The Siemens Drive Technologies Division is the worlds leading supplier of products, systems, applications, solutions and services for the entire drive train, with electrical and gear motors components. With its products and solutions, the division enables its customers to achieve productivity, energy efficiency and reliability. www.usa.siemens.com/drivetechnologies The Siemens Customer Services Division provides product-related services as well as services to improve the availability, reliability and productivity of industrial processes. A wide-ranging portfolio of environmental solutions helps industrial companies to use energy, water and equipment efficiently, reduce emissions and
COMPANY: Siemens Industry, Inc
comply with environmental guidelines. www.usa.siemens.com/services Industry Automation Portfolio Process and Batch Control Strategies SCADA, Process Controllers, HMI, Fieldbuses and Networks Discrete/Machine Control Strategies PLC, Motion Control, Logic and Programming Software, Discrete I/O, Sensors, HMI, Networks Asset Management Asset Optimization, Maintenance, Fieldbuses, Instrumentation, Power Supplies Information Management Networking, Ethernet Safety Strategies Process, Machine Energy Management Sustainability, Energy Management Software, Variable Frequency Drives, Motors, Motion Control Operations Management Production Management, Performance Management, Security
ADDRESS: 3333 Old Milton Parkway, Alpharetta, GA 30005 EMAIL: info.us@siemens.com Return to contents
WEB: www.usa.siemens.com/industry
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Siemens
An extensive infrastructure of local expertise and global support ensures you benefit fully from Totally Integrated Automation along the entire production process. Additional TIA productivity benefits are accomplished through common system characteristics across the entire Automation System: Integrated Engineering Industrial Data Management Industrial Communication Industrial Security Safety Integrated Our revolutionary TIA Portal engineering software provides the framework! TAKE A TEST DRIVE!
Request a trial copy of TIA Portal software and experience first-hand a single engineering framework that allows you to combine all automation tasks in one environment, reducing engineering costs up to 30% usa.siemens.com/tia-portal-trial-license
Lower cost in design, commissioning & maintenance Reduced downtime Faster time-to-market Greater flexibility
COMPANY: Siemens Industry, Inc
ADDRESS: 3333 Old Milton Parkway, Alpharetta, GA 30005 EMAIL: info.us@siemens.com Return to contents
WEB: www.usa.siemens.com/industry
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Teledyne DALSA
WEB RESOURCES
VIDEO
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ON DEMAND WEBINAR
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PRODUCT
PHONE: 978-670-2000
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Teledyne DALSA
Teledyne DALSA vision solutions provide a full suite of vision tools and capabilities for performing the following inspection tasks: Positioning Guide robotic handlers or adjust vision tools for part movement Identifying Identify product for verification or traceability Verifying Verify parts for correctness, assembly or packaging Measuring Measure parts for dimensional accuracy Flaw Detection Check part surfaces for scratches and other defects
ADDRESS: 700 Technology Park Drive, Billerica, MA 01821 WEB: www.teledynedalsa.com Return to contents
PHONE: 978-670-2000
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Thank you for downloading Automation World's Factory & Machine Automation Playbook! Now that you've had a chance to review it, we'd love your feedback. Share your thoughts!