Aw Factory Machine

2014 EDITION
FACTORY & MACHINE

AUTOMATION PL AYBOOK Mac
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HOW TO SUCCESSFULLY IMPLEMENT FACTORY & MACHINE AUTOMATION PROJECTS end
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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.
Also inside:
 Project Management Tips  Common Project Mistakes  Safety & Security Tips
 Energy Management Advice  Asset Management Guide  OEE & Lean Manufacturing
FACTORY & MACHINE Automation Playbook 2 / 167
SPONSORS
CONTENTS
7 Playbook Advisors
8 Contributors
11 Introduction
Section 1: Planning and implementing an automation project

14 12 points to consider before even beginning your automation project
17 Nine tips for automation project managers
20 Automation project management from a machine builder’s perspective
25 How to justify capital projects: Speaking finance gets results
35 Eight tips for selecting the right automation system components
37 How to properly select and vet a system integrator
43 12 common mistakes people make in automation projects
47 10 ways your automation project can fail and how to prevent it
OEM machine designers (in addition to automation end users) will specifically find useful tips in highlighted articles.
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
CONTENTS
86 12 tips for selecting and sizing pneumatic and hydraulic components
89 11 considerations for selecting and deploying industrial robots
93 A role for robots in lean
95 10 secrets to selecting and implementing sensors in industrial applications
1
01 Six critical considerations for successful machine vision applications
Section 3: Applying technologies to improve outcomes

106 Develop a strategy for asset management
107 Five best practices for more reliable asset management
109 Four considerations for monitoring equipment assets
111 Four tips for calibrating equipment
112 Nine strategies for achieving your energy management objectives
116 Nine recommendations for building effective manufacturing IT systems
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

PLAYBOOK ADVISORS
Thomas A. Doney Joe Martin
Senior Research Engineer President
Nestlé Martin CSI
Paul Brinks Jeff Miller, PMP

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

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

Senior Facilities Systems Support Technician Senior Automation Controls Engineer
Data Device Corp. MT&E - Machine & Automation Systems
Corning Inc.
Robert Lowe
Executive Director
Control System Integrators Association (CSIA)
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 9
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
Jose Gonzalez Valero Amy Peters Eder Mathias USA Yaskawa Motoman
PEMEX, Mexico Fatime Ly Seymour SEW-Eurodrive, Brazil Alejandro Pena Robotics, USA
Thomas Sugimoto Pat Gallagher Universidad Distrital,
Helge Hornis Rockwell Automation, USA Nesko Kontic Solar Automation Inc., USA Colombia Will Zurkan
Pepperl+Fuchs, USA SGS - Wind Energy Zurkan Solutions, USA
Mahendra Dissasekera Technology Centre, China Lewis Gordon Gary Phillips
Mark Buckley Ronan Engineering Co., Tangent Services, USA URS E & C, USA » CONTINUED ON PAGE 10
Phoenix Contact, USA USA Shamsol Shamus
Shamus Technology Ent., Peter Hook Bill Bobbitt
Rahul Aggarwal Sam Shorer Malaysia Tech Innovations LLC, USA Van’s Aircraft Inc., USA
Prekar Services & Solutions, SABMiller, South Africa
India Dr. Gyan Ranjan Biswal Dave Szurek Sachin Kumar
Andrea Sammartino Shiv Nadar University, The Mackubin Group, USA Vertex Automation System
Rafey Shahid Saipem Spa, Italy Noida, India (P) Ltd., India
Qanare Engineering, Assaf Beckman
Pakistan Steve Sarovich George Pease Tomatic, Israel Pradeep Soni
Sardee Industries Inc., USA Show-Me Machine Works, VSM Venture Control
USA System P. Ltd., Noida, India
CONTRIBUTORS
Individual Contributors, by Country
Algeria India Israel Pakistan USA Tim O’Brien
Nesrine Chaouche Rajesh Keswani Victor Zaltsman Faisal Mirzam Don Baechtel Tony Olivieri
Sarang Kulkarni Jim Brastauskas Tony Perna
Bosnia Senthil Kumar Lithuania Saudia Arabia Daniel Bruno Friedrich Purkert
Bojan Djurdjevic Arunnun Loganathan Genadij Nesterenko Ghulam Rasul Bruce Centofanti Ray Royal
Mukesh Negi Marc Emmerke Stephen A. Sajewicz
Brazil Avinash Patil Mexico Spain Greg Fairchild William Schmidt
Edson Gonçalves de Oliveira Naveen Kumar Ramasamy Jorge Loza Antonio Anton Irene Farquhar Accounties Smith
Babu Reddy T Miquel Vall Boladeras Marty Grimes Konstantyn Spasokukotskiy
Canada Netherlands Tony Guzman Joe Staples
Ed Kinakin Iraq R. Hulsebos Sri Lanka Daniel Hood Jim Tennant
Amer H. Rasheed Hindrik Koning Suren Stambo Joseph Kolo Suresh Vasan
Guatemala Rajendera K. Kapoor Leonard Walsh
Moises Yac Ireland Nigeria Taiwan Michael Kinziger Nick Wisniewski
Joe Burke Oladapo Akinbola Iyedupe Jin-Mu Lin David Lamb
Egypt Todd LaRoche Venezuela
Mahmoud Abdel Fatah Abo Ahmed Norway Hian Yong Leong Juan Nicolaidis
Rune Saetre John Nix
Thanks as well to the many contributors who preferred to remain anonymous.

INTRODUCTION
Manufacturers, machine builders and system integrators have how to justify an automation investment, how to select products,
been automating production systems for more than 30 years. systems and service providers and how to achieve your business
But as aging systems become obsolete, technology advances, and technology objectives.
competition becomes fiercer and priorities change, a new wave
of automation is changing the landscape of manufacturing. Our thanks to the more than 275 people from 40-plus
countries—from end-user companies, system integrators,
The drive for cheaper, better, faster has added another machine builders, educators and automation suppliers—who
element—the need to become smarter, not just about what’s have participated in the development of this playbook. They’ve
happening on the production floor but about how companies volunteered to share some of the things they’ve learned during
use resources, the skills they require of their workers and how their careers as a way to give back to this unique community.
they interact with their customers and supply chains.
In the following pages, we’ll share their ideas about the best
This edition of Automation World’s Factory Automation Playbook practices to follow and common pitfalls to avoid. We hope
will explore these themes, sharing guidance from your peers and this information will be useful, whether you’ve been doing
suppliers about how to plan and manage automation projects, automation projects for more than a decade or are part of the
» CONTINUED ON PAGE 12
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continued
Introduction
new generation of engineers just entering the field. The goal Automation is a tool to help people. Keep those people, the
of this playbook is to help everyone achieve more successful stakeholders, in the forefront of your mind as you go about your
factory and machine automation projects. work.“ 
Jeanne Schweder
Just as important, it is to remind all of us why automation
Contributing Editor
adds value to our world. As one of our contributors pointed
out, “Automation is not about technology—it is about people.

13 / 167
SECTION ONE:
PLANNING AND IMPLEMENTING
AN AUTOMATION PROJECT
12 points to consider before even beginning

your automation project
The first step in any automation project is the most critical one: 3. Helping people. Automation can do many things, but
Define your objectives. The more thorough and detailed this one must be aware that its purpose is to do real things in a
definition is, and the earlier in the process it can be achieved, given ecosystem. Keep in mind that the goal is to have systems
the greater the likelihood that the project will be completed engineered to serve humans, not the other way around.
successfully.
WHAT DO THEY REALLY WANT, AND WHY?
1. Visualize success. Try to visualize what a project would It’s essential to understand each person’s expectations before a project
look like if it were a stunning success. Take note of how it will starts. There are three parts to this definition process:
affect all the people involved and write down any others you
What outcomes or desired results does the project team want to
yy
think it might touch. Take all of these people and put them
achieve?
on a spreadsheet column. Now in rows across, write down the
attributes they need in the machine/process. Use this when What do they want the project experience to be like (for example,
yy
evaluating solutions and communicate shortcomings to those no production line shutdowns during the project or communicate
updates by email)?
affected. Come up with workarounds or throw out the idea if
the results won’t be acceptable. How will they define quality, such as on time/on budget or
yy
increased production volumes or zero downtime, at the end of the
2. What’s driving the project? You need to understand project?
what is the most important motivation for doing this particular Different people will have different expectations and they all have to
project and use that to guide your decision-making. be satisfied.

continued
12 points to consider before even beginning your automation project
4. Project definition is critical. Without doing true

TECHNOLOGY COMES LAST
engineering work, everything you learned in school and in your
career up to this point, you are not doing any project properly Never start by defining technology-driven objectives. Use the following
or professionally. By creating definition for the project and order:
then verifying that the project will answer the need, you are 1. Business objectives. What will the business gain from this project?
on your way to successful project management. It is only the
2. Operational objectives. How will this project impact operations—
start, but without a properly defined starting point, it is difficult
greater efficiency / better quality / compliance, etc.?
to complete (or defend) a meandering, ill-defined project
that is meant to resolve a problem, address a challenge or 3. Integration objectives. Can data generated by this system be used
complement your company’s engineering resources. by other systems?
4. People objectives. Skill development, ease in work pressures.
5. Start with the objectives. Don’t even begin to select Only when all of these have been defined can you establish the
suppliers and service providers until you’ve established a technology objectives.
project’s objectives. Make sure everyone on the team agrees on
what the project needs to achieve before it starts. If you don’t do it for free. If you bring them in at this stage, so that they
know where you’re going, you’ll never get there. understand the history of the project, they can contribute to
decisions that will improve the chances for a successful project.
6. Get a second opinion. It pays to get a second opinion
from an informed outsider like a system integrator or machine 7. Set rules for communication. Define what
builder before finalizing project objectives—they’ll often communications are expected at the start of the project—

continued
12 points to consider before even beginning your automation project
what is to be communicated, how it is to be communicated, the boxes, it becomes a Gantt chart. Putting all your objectives
what the milestones of the project will be and how often things (the completion of functioning subsystems, integration) into
should be communicated. one simple chart keeps those objectives clear to the whole
team.
8. Talk to everyone. Interview the stakeholders from
various factory disciplines, such as operations, maintenance, 11. Spell everything out. If you want drawings in
quality control, supply chain, shipping and management. They portrait vs. landscape mode, for example, or want certain
always have a stake in every automation project. brands to be used, such as for wire or PLCs or other
components, state that up front. If a requirement is not written
9. Never assume. Don’t make assumptions about the down, then it likely will not happen.
ground rules—spell everything out in advance and define who
is responsible for doing what. 12. Scope! Nothing is more important than a scope
that reflects both the well-defined areas of the project and
10. Create a chart to keep objectives clear. Define the gray areas of the project. The gray areas should have a
the expected performance for each subsystem, and the general framework put together by the customer and the
expected steps to get there. Use Excel to list the task steps, and implementer, with benchmarks that clearly indicate when
the hours/$ across a time matrix. Then that becomes a calendar project reassessment should occur. This way scope creep can
for the schedule, sort of a compressed MS Project. If you color be managed to the benefit of both parties. 

Nine tips for automation project managers

More than technical skills are required management skills.
to successfully manage an automation
project. It also requires communication 2. Welcome the bad news. Every
and organizational skills, along with automation project has things that go
the ability to motivate a team of people wrong, but the earlier you find out what
from a variety of disciplines and different the problems are, the easier and cheaper
departments. they are to fix. Nobody wants to hear or
deliver bad news, but it’s important not
Here are a few practical tips for to get defensive. Anybody on the team Looking for training?
automation project managers: needs to be able to push the stop button
There’s a source to help you learn
if a project has gone off the tracks. the ropes of project management or
1. Project management Otherwise, you’re just gambling that improve your skills. For more informa-
resource. There have been thousands things will come out all right at the end. tion, visit
of words written about project
http://awgo.to/028
management. If you think you need 3. Keep simplicity top-of-mind.
a refresher course, or expect to be Engineers tend to make systems too Organization: Project Management Institute
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.

continued
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 factory floor. Its objective is to prove that the equipment the team, creates confusion and fails to take advantage of
actually does work as designed and is producing product at the the unique expertise of the team members. Foster open
level required. Approve the testing plans early in the project communication and communicate frequently, so that everyone

continued
on the team understands the issues and 9. Make sure you have bench Close
is aware of any problems that need to strength. There’s nothing that delays Internal Lifecycle Methods
Kickoff Waterfall
be resolved. Establish a communications a project more than a team member who Agile
Spiral
Site
Requirements Design V Acceptance
roadmap for vendors; check with them gets assigned to another project and no Development
Other Test
Factory
soon into the project to make sure it’s longer has the time to devote to your Specification
Traceability
Acceptance
Test
working. project. Identify alternative resources Design
Subsystem Integration Test
early and have them ready to fill in if
Unit/Module Unit/Module Test
8. Don’t be a roadblock. As needed. That same rule applies to the Development
project manager, it’s your responsibility system integrator’s team; make sure
to respond to information requests and they’ve identified people with equivalent
approve various aspects of the project skills who can be assigned to the project
Project management “V” model,
in a timely fashion. Stay involved and if required. 
courtesy Control System Integrators
be responsive to prevent delays in the
Association.
project’s timeline.

Automation project management from

a machine builder’s perspective
By Paul Brinks, Chief Operating Officer, Koops Inc.
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
 S elect people for the team with Specification (Tech Spec) that lays out the  Operator duties
the right combination of skills and design parameters and the performance  Number of operators
attitudes. expectations for the system’s builder. The  Setup and changeover
following list will get you started on a  Repeatability
Technical Specification Form:

continued
Automation project management from a machine builder’s perspective
Machine Definition Project Management *

DEFINITION
 Operation sequence  Timeline development
 Guarding  Transportation Poka-Yoke is a Japanese term that means
 Ergonomics  Installation “mistake-proofing.” A poka-yoke is any
 Cycle activation  Warranty mechanism in a lean manufacturing
process that helps an equipment operator
 Frame configuration  Terms
avoid mistakes. Its purpose is to eliminate
 Size footprint
4. Justification. This may be a product defects by preventing, correcting
 Power requirements or drawing attention to human errors as
 Quality/Poka-Yoke* challenge. Management and the project
they occur. More broadly, the term can
team must be committed to the value
refer to any behavior-shaping constraint
of the investment. Companies will vary
designed into a process to prevent
Acceptance Criteria greatly as to how the justification is
incorrect operation by the user.
 Runoff requirements measured and how quickly a return on
 Safety review investment is required. Many common
 Poka-Yoke verification areas looked at for justification are:
 Training Capacity, efficiency, quality, personnel
 Documentation requirements reduction, safety, sales value, etc.

continued
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:

continued
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

Can your current control continued
platform deliver... Automation project management

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

How to justify capital projects:

Speaking finance gets results
By Gary Mintchell, Founding Editor, Automation World
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.

continued
How to justify capital projects: Speaking finance gets results
rewards at the justification stage. This person would be involved

in the analysis at all stages of the project, and will be well
positioned to translate benefits into the correct numbers.
Why is there such an emphasis on financial analysis these

days? Steve Loranger, area vice president for Emerson Process
Management, an Austin, Texas-based process controls
supplier, notes the changing value of automation over the last
25 years. “Automation drivers from the 1950s to 1975 went
from pneumatics to electronics by emphasizing speed of
operation and labor improvements with limited automation
improvements. Drivers from 1975 to 2000 were repeatability and
Technical managers may be sitting on a gold mine of cost quality. During this time, computers went mainstream, there was
detail that can be used to determine where the manufacturing improved control, and information integration became essential.
problems lie, as well as the crucial data that can be used to figure Now, drivers are economics and business optimization, due
out the best solution—and how to get through the financial to globally integrated manufacturing and activity-based cost
maze to approval. accounting.”
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

continued

this article provides several areas of improvement that can

result from the project. Some of the areas can be hard to
quantify, but it is essential to try to cost-justify as many as
possible.
For example, it may seem hard to quantify safety and

ergonomic improvements that result from improved
automation. But safety and insurance experts may be able
to help document savings that can include anything from
avoiding lost workdays to lower insurance premiums.
Boston-based Liberty Mutual released its 2003 Fall
Workplace Safety Index, and concluded that the financial
impact of workplace injuries in the United States is growing
faster than the rate of inflation.
Insurance premium savings are certainly welcome, but

a greater value to an investor is reducing risk to future
earnings. Failure Mode Effect and Criticality Analysis is a
powerful tool that can be used to demonstrate the risk of

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

continued
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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future cash flows to the investment outlay. The IRR assumes
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The hurdle rate is the minimum rate of return to justify an

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continued
the numbers don’t make the hurdle rate, then reevaluate the business objectives. So, when looking for projects with the
benefits. (Microsoft Excel has functions that easily calculate NPV highest probability of approval, make sure that they align with
as well as payback and IRR justifications). one or more of the objectives in the Profit Zone.
Emerson’s Loranger discusses the analysis from a slightly Train managers

different point of view. The balance sheet is where assets and Logic One’s Egert offers some additional tips on putting together
liabilities are tabulated and the income statement is where a justification package. “Get management trained on technical
income and expenses are calculated. The analysis entails aspects,” he states. “They have lots of knowledge and experience
comparing the Return on Invested Capital (operating earnings on finance and marketing, but not much on technical aspects.
from income statement divided by invested capital shown on
balance sheet) to the weighted average cost of capital, or hurdle A progressive, smart manager will have those technical
rate. The difference is the economic value added. people. A manager with technical skills will be able to see
some problems coming.” Another problem is management
Analysis is good, but often engineers looking at automation embracing new technology with no strategy for implementing,
projects become infatuated with new technologies and fail no urgency for training or no technical champion to embrace
to match the project up with business strategies. As Loranger and learn the new stuff.
shows in the Business Planning Framework graphic, technology
managers find their comfort zones in evaluating automation It’s not just a matter of providing training in some cases, but
technology alternatives. The profit zone for the business, whether the workforce has the basic background skills to make
however, lies in meeting or exceeding plant, production and training a practical option.

When EVERY minute of downtime continued
matters...choose Graybar How to justify capital projects:

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continued
Who are you competing with

internally for dollars?
Make sure your project proposal appeals to your company’s, sustainability officer should like your numbers better.
your business unit’s and your project stakeholder’s priorities.
After all, you are competing for the same capital as everyone  Will your proposed system save water, compressed air
else. This isn’t political. This is survival. Don’t let that “green usage, electricity, and/or floor space that must be lighted,
roof” win over your lean manufacturing improvements! heated and cooled? Most plants today face corporate
mandates to hit reductions in all these resources, and every
 Sustainable manufacturing—what will really do the bit helps.
most to reduce your “total system carbon footprint” Will
it be that green roof proposal or your production line  Consider distributed drive technologies that reduce the
improvements that produce less scrap and use less energy? heat buildup inside electrical cabinets and eliminate the
Lean production lines won’t make the same photo opp that need for costly air conditioning and filtration, along
goats munching turf on your plant roof will—but your chief with reduced floor space. To maximize energy efficiency,

continued
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. 

Eight tips for selecting the right

automation system components
Many factors come into play when choosing components or market and not the proprietary product of only one supplier.
systems for an automation project. Some companies reduce Components should be easily replaceable with another make
the complexity by limiting the number of suppliers they work when needed at any point in time. The system should have
with or standardizing on certain features or functionalities. the flexibility to expand in the future and should not become
Others want maximum flexibility and the ability to customize obsolete in the near future. Get a commitment from the OEM
solutions or select from multiple vendors. The growing use about planned system life.
of components built to industry standards is making both
approaches easier to implement. 3. Don’t forget power. Make sure you have all the needed
power requirements in the locations intended for your new
1. Flexibility required. The adaptability and flexibility devices for the instrumentation you are using. Don’t forget to
of components are critical. Make sure that open standards like update all prints to reflect your changes.
IEC 61131-3, PLCOpen and overall fieldbus communications are
supported. For OEMs, having equipment that communicates 4. Functionality. Make sure new components have all the
with more than one fieldbus is an advantage because they will functionalities that will be required, such as asset management,
not have to order different part numbers for different customer power integration, safety system integration and the load of the
requirements. CPU.
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

continued
Eight tips for selecting the right automation system components
best practices. Second, components must be consistent and

FIND A PARTNER
compatible with existing systems. Third, anticipate new trends in
automation to keep your system sustainable. Automation project managers need to find partners who they can trust
and rely on to be with them through every stage of the project, from
6. Systems thinking. Do not fail to think systemically, planning to implementation, from startup to long-term service and
including power, grounding, communications, control and support. If a problem does crop up, a good project manager needs to
environment. know that their chosen vendors can be trusted to do the right thing
in the heat of the moment to keep the project on track and make it a
success. There will be plenty of time later to analyze the cause of and
7. Look for support. Make sure to do the research and con-
blame for the problem. The important thing is to not let issues get in
sider the ease with which a system can be modified if needed. Al-
the way of the project schedule and ultimate success.
ways 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 equipment so you don’t need a spare parts room the size of a
a machine builder, look at the OEM’s track record and see how small plant. Go green wherever possible. Retrofit pneumatics,
often it advances to newer generations of equipment. for example, using electric cylinders instead; restrict the
number of stroke lengths to no more than three. Use similar
8. Simplify. Select from a specific and predetermined criteria to simplify selection for other product categories,
list of components during the design phase on any piece of whether it’s motors, servos or other components. 

How to properly select and vet

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

continued
How to properly select and vet a system integrator
3. Familiarity with standards. 5. Expertise. Focus on their

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

Graphic HMI | PLCs | Panel PCs | OITs

continued
Powerful Industrial HMIs How to properly select and vet

for Every Need... a system integrator
7. Stay involved. Has your system integrator done

4.3” to 15” Display Sizes something similar before? Chances are the pool of talent
isn’t all that big. Can you allocate any resources to working
• Connects to over 100 PLCs
with that integrator on a day-to-day basis? You will have
• High Resolution Graphics
to take ownership of the system, so you will need to
• SD & USB Expandable Storage know how to modify it and maintain it or you will be tied
• Cast Aluminum Enclosure into a system that might need unallocated cash to make
• Serial, Ethernet, & USB changes. Get involved at the zero level in the planning,
• Audio & Video simulation, detailed layout, software handling techniques
• Operating Temp: -20°C to 55°C and maintenance requirements as much as you possibly
can in order to get the biggest possible benefits and to
learn in excruciating detail how it all goes together.
At a fraction of the cost 8. Take a long-term view. Select an integrator

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

continued
Detail the requirements

1. One of the most important factors in selecting a system 4. Some system integrators take advantage of a poorly
integrator is his willingness to develop a good project written requirements document from a customer and
proposal. Avoid any integrator whose proposal is just one or present a very generic proposal, so the price might look
two pages long. attractive at the beginning. When the project is awarded,
then the customer has to face a series of change orders
2. Automation projects must have good system requirements because a requirement that might be obvious was not listed
from the customer, and the system integrator must list in his in the proposal. The customer ends up paying far more
proposal what requirements will be met and what will not. money for the project than originally estimated.
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. 

continued
How to properly select and vet a

system integrator
15. Do they have business skills? Look beyond
technology expertise or project experience to consider
an integrator’s commercial qualifications: Are they CSIA
certified? Do they have insurance? How many years have
they been in business?
16. Are they open? Select an integrator that is open to

your requests and ideas. Beware of someone that constantly
pushes back. If you hear the phrase “nobody does it like that”
or “this is how everyone does it,” you might want to consider
another integrator that is more open minded. You are paying
that integrator to get what you want and need—not just
what they are willing to build because it’s easy or they “always
do it that way.” Yes, you hired them for their experience and
would like their suggestions, but don’t discount your own
ideas just because this is your first time. Also allow for the
ability to make some changes—especially if your approach
is new and unconventional. Be open for changes and tweaks
as you go if it makes the end result easier to use and more
flexible. You need to stay involved throughout the whole
process. Don’t pass up the learning opportunity! 

12 common mistakes people make

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

continued
12 common mistakes people make in automation projects
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
Seven Automation Don’ts

1. Don’t over-complicate the solution. Keep the solution need to be corrected at heavy expense and effort.
simple.
5. Don’t forget the grounding.
2. Don’t program the machine first. Always program or
storyboard the HMI first. 6. Don’t propose a project without a good understanding
of the requirements. That guarantees scope creep.
3. Don’t neglect the communication protocols and
interface terminals when evaluating control products. 7. Don’t always believe what salesmen tell you. Do
your homework and make your own decisions for your
4. Don’t waste too much time planning without customer application. 
input. That could cause critical planning errors that will

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

10 ways your automation project can fail

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

continued
10 ways your automation project can

fail and how to prevent it
a giant breakthrough
in small readers project stakeholders from adding “capabilities” to the
process that can lead to both financial and timeline
strains, and ultimately to a failed project.
5. Skills mismatch. Many automation projects

are viewed as successful when the system is in the
development and testing stage, but it becomes an entirely
different scenario when the project is implemented in
the field. Errors begin to crop up. This is often due to the
different skill levels of the people who develop the project
compared to the people who are sent out to execute it in
the field.
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6. Poor planning. Most projects fail because of
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the complexity of the project and overestimate the
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enemies of any project. The project owner also needs to
establish the most important priorities for the team, such
Scan to Learn More
continued
10 ways your automation project can fail and how to prevent it
FIVE POINTS FOR FAILURE. frequently.
1. Failure to plan for and handle project resource changes.

8. Design misalignment. Failure often comes from
2. Failure to know or admit that requirements are not well defined. a lack of communication on the design of the project, from
3. Failure to address requirement definition problems in a timely component selection to the format of I/O tags, networks
fashion. and programming structure. Provide a scope prior to design
4. Failure to plan and execute design review and approval that allows all items of the design to be agreed upon. As this
milestones. document is created, members of the team or the integrator
can then point out potential pitfalls, such as using multiple
5. Failure to engineer the verification of project deliverables
networks or not selecting a common controller.
sufficiently, including lack of inspection and test planning.
9. Confusion. An insufficient amount of effort in the front-

as cost, quality, maintenance, training, stocking of components, loading stage, or subsequent budget cuts or direction changes
safety, etc. This will assure that decisions are aligned with the by management, will result in confusion for the project team.
project’s goals. It’s a standard recipe for failure.
7. Failure to manage expectations. Make sure all 10. Other reasons for failure.
stakeholders understand the trade-off between scope, budget  Unrealistic schedules are set.
and time frame. Communicate this deliberately, formally and
 Potential risks are not calculated and planned for.

continued
10 ways your automation project can

fail and how to prevent it
 E ngineers working on a project lack the necessary skill sets

or experience.
 Insufficient milestones to measure progress and identify
problems.
 Outdated/incorrect documentation in brownfield projects.
 Insufficient time in the schedule for third-party
communications or for developing a particular section of
the system.
M ismatch in the requirements of the project and the
solution given by the supplier.
M issing of the minute details pertaining to engineering
and scope of supply.
 F ailure to establish a clear schedule to finalize process and
equipment designs.
 L ack of training to enable plant personnel to operate and
maintain complex systems and new technologies. 

51 / 167
SECTION TWO:
SELECTING PRODUCTS TO BUILD
YOUR AUTOMATED SYSTEM
16 best practices for specifying

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

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

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

continued
WHAT ARE YOUR GOALS?
When selecting a control platform to automate a machine, you should veyor control, a PLC is a good choice. If high-speed electronic gearing,
first decide your end goals. Ask yourself: product registration or more complex motion is required, a dedicated
motion/machine controller is a better choice. If data handling is
1. Do I want increased productivity? Better repeatability? More con- required, then a more dedicated motion/machine controller would do
sistent accuracy? better.
2. Do I need servo or stepper motors? Servomotors will generally have 4. Will the controller do the job? Best to spec in a controller that can
better acceleration and top speed characteristics over a stepper. Step- handle more axes of control than you expect as you may need to add
per motors do better when holding a position without dithering. these capabilities later. Be sure the controller has the processor power
to perform all the needed functions. It’s common to “run out of gas”
3. What type of controller? Will a PLC work or do I need a more dedi- when performing multiple tasks simultaneously. Look for a fast pro-
cated motion and machine controller? For basic material and con- cessor, enough user memory and a lot of connectivity.
10. Get out of the code. Ask the people at the plant why process. On the flip side of the coin, after examining the code,
they are running the way they do. Sometimes what you might you often find people think a system is running in a particular
think is bad programming is really needed to optimally run a way, but the reality is that it is not.

continued
11. Document software. Use of programmable controllers 14. Prior experience. Do not use a controller for critical
offers significant advantages over analog devices. However, it applications in your plant without a successful prior use
brings a new set of issues. First, consider the control of multiple experience with a like product with the same revision level
function block parameters. It is a good practice to maintain components, firmware and software.
the software configuration control document that summarizes
all programmable/tunable parameters in one place. You will 15. Are micro PLCs an option? Micro PLCs with flexible,
use this document for any disaster recovery event, including “just enough” control may enable OEMs to differentiate their
cybersecurity issues. equipment, particularly in stand-alone machines. By developing
a range of stand-alone machines using the same controller
12. Think ahead. Don’t go for the cheapest option when platform, OEMs can reduce design time and lower their costs.
installing a PLC. Think five years ahead to accommodate factory Look for micro PLCs that include:
integration, peer-to-peer networking and data exchange
between controllers. The modern factory environment is  Flexible hardware configurations, like USB, up to six serial ports
becoming a network of integrated controllers. and Ethernet for communications.
 Up to three axes of embedded motion.
13. Don’t overcomplicate your solution. Keep it as  Plug-ins and 2085 expansion for I/O USB.
simple as possible. Don’t use a PC-based system when all you  Single programming software package that eases installation,
need is a little advanced I/O control. configuration, connectivity and maintenance.

continued
16. Single control platform. Customizing your controller

selection for each application may seem like a smart move, but
sometimes it pays to narrow down to a single control platform.
Survey your requirements and select a platform capable of
handling all current and near-future needs, from the simplest to
the most complex ones. Selecting a single control platform for all
of your automation control requirements, whether it is motion,
robotics, numerical control, C program or sequence control,
can reduce spare parts inventory, unify programming methods
Speed up controller
across all machine types and simplify training and maintenance
response
efforts. 
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response times by optimizing
subroutines, exploiting interrupt
programming and leveraging peer-to-
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10 steps to creating the perfect HMI

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

continued
the designer, once as the user and then invite at least two levels
of users who will be interfacing with the HMI. Doing this prior to
specifying equipment helps to identify the features that users
will want in the HMI station. It also avoids surprises at point of
commissioning.
5. Location, location, location. Real estate can be prime

in a busy production area. Locate the HMI in a practical place,
out of heavy traffic areas but accessible. Be aware of near-future
projects in the area. Guard the HMI location so others don’t park
or configure something else on top of the station.
6. Back up work periodically. Backups are especially

important before implementing upgrades or changes. Software
such as Norton’s Ghost Image can be invaluable to support and
maintain HMI systems.
7. Visualize the process. HMI graphics should illustrate the Use hardware that meets minimum requirements and keeps the
production process in the plant to provide better visualization to number of failure points low and assures high availability of the
the operators, giving them a sense of the action that’s required. system.

• Tightly Integrated Vision • Industrial Enclosures continued

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• Easy to use Embedded
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• Factory Style Connectors 10 steps to creating the perfect HMI
• Ideal for Single Point
• Sensor Resolution: Inspections
VGA to 1600x1200
8. Only essential data. Make control and monitoring
• Factory Communications
of the process simpler by selecting only the most essential
information from the process database for the historian. This
will reduce the load on the system and keep it from stalling
or failing. Don’t forget the need for maintenance and make
sure you schedule periodic backups.
9. Think about flow. It is essential to have a clear

design approach to the HMI. Decide how the display
blocks naturally flow and how sections need to be grouped
together for the operator. Do not blindly follow P&I
diagrams. The S88 functional hierarchy is a good place to
start. Make paper-based designs to get a feel for screens,
navigation and other requirements, and review with clients
prior to designing and making electronic screens.
BOA products are highly integrated vision systems in a tiny smart camera
package specifically designed for industrial use. Complete with choice of 10. Alarm strategy. Alarming needs to have a well-
application software embedded, BOA offers new and experienced users articulated strategy. Alarms must be used for conditions
alike, an easy-to-deploy cost effective vision solution.
that require intervention and must have a clear
corrective action associated with each one. Anything
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www.teledynedalsa.com Share article » Add comment » Return to contents »
continued
Alarming guidelines
The key aspect of an HMI display is the dynamic plant data. 12 men have some form of color-blindness, which can affect
There are two basic types of dynamic data: Alarms and the perception of red and green, color cannot be used as the
normal Plant Status data. sole indicator of alarms.
1. Alarm status for the overall plant, preferably organized into 3. Any color change must be supplemented with a pictorial
groups, should be visible on every screen and there should change and, if the alarm is critical, an audible alert. Pictorial
be a simple navigation route to access the screen containing changes could include shape changing, a change in the
additional details about the alarm. position of an indicator, having additional text or objects
appear on an alarm. Flashing of alarms that have not been
2. The alarm colors should follow the safety convention: Red accepted is very irritating and stressful and should be
= stop, prohibition, danger; Yellow = caution, risk of danger; avoided.
Green = safe condition; Blue = mandatory action. As one in » CONTINUED ON PAGE 62

continued
4. Similarly, automatic changing of displays should

be avoided—to 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
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Eight considerations for

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

continued
Eight considerations for I/O engineering success
distributed I/O in the facility until all equipment OEMs have

REMOTE I/O PITFALLS.
provided general arrangements. Provide the team with an overall
scope on what these cabinets are called by name, and what area There are many design pitfalls to avoid when developing
of the facility each will handle. Timing of this design phase with I/O systems. The options now available to the designer
the upfront engineering will save time and money. are limited mostly by hardware price point, once you
understand the purpose, location and lifecycle issues. Just
7. Leave room for expansions. Make sure your new because a thing can be done, however, does not mean
control cabinets have plenty of room for all I/O points needed in that it should. Remote I/O options, for example, are grow-
ing, which can reduce wiring and terminal block needs
that cabinet. Also allow room for expansions that will be required
in some cases by over 50-80 percent compared to what
for unanticipated changes and upgrades In the future. For I/O
was available just 10 years ago. But serious thought has to
wiring, plan to label the parts of the circuit wiring that connect
be given to proper documentation and training of plant
to the I/O points from that side of the devices with the program
personnel to repair and maintain the system and prevent
addresses. This will lessen the time needed for your techs to downtime. The documentation should include trouble-
troubleshoot issues with those circuits later on. The rest of the shooting methodology in addition to part number, manu-
circuit labeling should be based on the print line numbers. facturer, MAC address, etc. The control software should
also be integrated with the remote I/O layout to allow for
8. Diagnostics. Make use of the built-in diagnostic either remote troubleshooting or status information. If
information provided by most I/O systems. Good information for these simple things are not properly accounted for and
the operator can save you a lot of production time.  implemented, the actual usage of the remote I/O may not
be worth the savings.

11 recommendations for selecting

motors and drives
Motors and drives are two of the foundation components of any a hybrid contactor. Now you have the best of both worlds—
automated system. Here are a few tips and best practices for a programmable, intelligent overload that has motor load
achieving improved motor control: feedback (alarm back to operator as well as shutdown
parameters) with a hybrid contactor. The hybrid contactor
1. Think system. When doing an equipment upgrade, extends the time between end-of-life motor switching by a
think of the drive train as an integrated system and choose factor of 10. The intelligent overload will remain in service
components with similar efficiency ratings. It makes no sense to indefinitely.
couple a high-efficiency pump to an inefficient worm gear. The
motor used to drive the load could be half the horsepower with 4. Proper way to select motors. Selecting a motor
a more efficient gear reducer because of the reduced energy needs a bit more than just calculating the maximum rotational
losses. speed and torque. The best way to select a motor is by drawing
a speed-torque diagram of the load and the maximal allowed
2. Matching firmware. When changing a drive, make sure speed-torque diagram of the motor (as defined for continuous
the firmware of the drive or motion controller matches the one operation). If the diagram of the load characteristics is fully
you are replacing. enclosed by the diagram of the motor characteristics, the motor
is adequate.
3. Intelligence improves uptime. When you want
to improve uptime, think about replacing standard IEC 5. Manual mode. The manual mode, which allows
electromechanical starters with an intelligent overload with maintenance to check if one specific motor has a problem or

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

Can your current control continued
platform deliver... 11 recommendations for selecting

motors and drives
LOGIC 10. Drive failures. The reliability of the core

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

continued
Performance packed into

compact drives
Advancements in today’s AC drives, including compact there have been dramatic technological leaps in other areas.
drives, require that engineers more thoroughly review
how drives with new, performance-enhancing features can Similar to trends in consumer electronic products, compact
contribute to automation projects. drives now pack more intelligence and user-focused design
in smaller sizes. Engineers tasked with implementing an
Selecting a compact drive still requires an understanding of automation project need to understand the latest compact
the most appropriate control technology—volts per hertz, drive features and how the right mix of features can ease
sensorless vector, etc.—but while those control technologies data sharing, improve safety, minimize programming and
have remained relatively unchanged over the past decade, installation time, and, ultimately, lower total overall cost.

continued
To find a compact drive that can do more and maximize  Programming. Seek simple local and programmable
value, engineers should examine features in the following automation controller (PAC)-integrated programming to
four key areas: reduce development time. Features such as descriptive
scrolling text on LCD human interface modules (HIMs) and
 Communications. Seek compact drives with multiple intuitive software with standard connectivity help speed up
communication options, dual port connectivity supporting drive configuration.
ring topologies with device level ring (DLR) functionality,
and support for other open industrial networks.  Physical size. Seek compact, modular designs that
allow simultaneous configuration and installation while
 Safety. Seek embedded safety as a standard feature to offering flexible mounting options with small footprints,
help protect personnel and equipment, meeting ISO 13849- high ambient operating temperatures and low clearance
1 standards with ratings up to and including SIL 2/PLd Cat 3. requirements, saving valuable panel space. 

Four tips for improving

motion control systems
Technology advances, along with a systems approach to design running conditions, inertia, braking and deceleration, current
where all the components are working together in harmony, dissipation, back driving or on-site drive tuning—just to name
allow engineers to deliver improved performance in motion a few of the more common issues associated with motion-
control applications. Here are some tips and best practices to get control design. You’re the person responsible for ensuring you
the most out of your motion control solution: have thought of everything when dealing with motion-control
concerns. So instead of charging full force into a project, take the
1. Design for system. It is important to understand the time to first identify all the possible scenarios that your project
accuracy requirements of the entire electromechanical system may face before it starts. It’s important to document potential
when specifying servo drives. The control system, position trouble spots and anticipate appropriate solutions.
feedback sensing, the drives and final gears/mechanical links
have to be carefully chosen to work together so that the desired 3. Exceed machine specifications. The problem with
resolution of control can be achieved. It is important to work motion control is that speed does not necessarily equate to
with suppliers who strive to understand your needs and will throughput and motor resolution does not equate to system
provide knowledgeable technical support when complex control accuracy. You need to design the system to exceed the machine
strategies need to be implemented. specifications; this means from the drive point back to and
including the motor.
2. Plan for surprises. If you’ve ever designed motion
control systems or served as a project manager, chances are 4. Cubic splines. Use cubic splines for motion planning and
you’ve run into a few surprises during a project, such as over- for servo interpolation of position, velocity and acceleration. 

continued
Four tips for improving motion control systems
Don’t forget power, grounding

Proper system design is critical to the long-term success of inverters and converters to ensure adequate isolation,
your manufacturing system. Steps to remember include: impedance and grounding.
1. Power monitoring for energy management. 4. Grounding review for supply to drives, drives to motors,
motors to supply for high-frequency mitigation, as well as
2. Balanced and adequate power distribution for immediate safety or PE (potential earth) and adequate isolated TE (true
needs (in current and voltage range), as well as an allowance earth grounding) for control and communications.
for growth.
5. Cable selection, routing, management and access
3. Power supply review for variable frequency drives, design. 

Seven considerations for applying servo drives,

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

continued
Seven considerations for applying servo drives, motion controllers and PLCs
4. Over-sizing wastes energy, cost and panel entire trajectory?

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

continued
Seven considerations for applying servo drives, motion controllers and PLCs
6. Minimize vibrations. The latest vibration suppression

LOAD TO MOTOR INERTIA RATIOS—IMPROVE
algorithms in some servo drives can actually minimize vibrations RESPONSE TIME
from occurring on overhung loads and in the machine base
without additional sensors. These vibration suppression Calculating an inertia ratio is often overlooked by newcomers to servo
algorithms, combined with auto-tuning and filtering, can allow sizing, but is arguably the most important factor in determining the
for high-performance motion without complicated mechanical performance of a servo system. Inertia ratio is calculated by divid-
damping or heavy bracing. ing the load inertia by the motor inertia. Lower load-to-motor ratios
improve response times, reduce mechanical resonance and minimize
power dissipation.
7. Reduce wiring, space. By using common DC and/
or multi-axis servo drives, OEMs can reduce wiring, energy An inertia mismatch of greater than 10:1 can produce oscillations and
consumption and panel space. These systems use regenerative extended settling times. To prevent overshooting and oscillations with
energy to power other axes, rather than wasting this energy very large mismatches, the control gain may have to be reduced. A
as heat in the electrical enclosure. Panel space is reduced by motion system with a load-to-motor inertia less than 10:1 can reach
up to 30 percent, while wiring is reduced by up to 50 percent, a set speed or move into position in less time than one with a ratio
compared to a traditional single-axis servo system architecture.  greater than 10:1. Large inertia mismatches require higher current to
drive the motor, thus they dissipate more power. For example, a mis-
match of only 5:1 will dissipate six times more power, and it gets worse
as the load inertia increases.

Seven issues to think about before you develop

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

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

Six things to consider when you get down

to the network details
It all comes down to the details. That’s as true for networking as it fieldbuses and especially proprietary networks, it is critical to test
is for every other aspect of an automation project. Here are some to the point of failure. These failure points can be associated with
tips for making sure the details are covered with your industrial the number of Ethernet port connections, the size and frequency
network: of data being managed, as well as data addressing in the PLC. The
PLC addresses used in data collection, if not contiguous or near
1. Keep a list. Networked devices have addresses. It is very contiguous, can cause excess read/write cycles to the PLC. Some
important to keep a list that shows the assigned address, the PLCs can only provide X number of devices in one read. If that
product this address has been assigned to and the line/plant number is 1k (1024 devices) and you attempt to read the values
location where the product has been installed. It is very difficult of coils 250, 1400, 5000 and 6500 in one cycle, it can actually
to troubleshoot many systems because this basic information was create four separate read requests. This results in performance
not captured, leading to significant equipment downtime. Once issues and missing data. Think of the impact if you want to read
installed, these devices need to be labeled accordingly since 250 values! FMEA (Failure Modes and Effect Analysis) is a great
it is not uncommon to have several identical devices in close tool to aid in trying to identify ”what can go wrong.”
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.

continued
Six things to consider when you get down to the network details
4. Avoid subnetworks. When selecting fieldbus or stand a chance of disproving this. Make sure high-quality network
network architecture, avoid the use of subnetwork systems or analyzers are available, and the real root cause of the problems
expandability features that require configuration of expansion will show up very quickly: very often it is application software. A
modules or field devices separately from the PC or PLC. Subnet network engineer without a network analyzer is like an electrician
components add an additional burden for end-user support and without a multimeter: clueless.
complexity in software (re-tagging/programming) when the
subnet I/O count or type changes. 6. Everything’s networked. Nothing is not in the
network anymore. When you implement a new project or a
5. Need network analyzer. When a system using a new system, the networking criteria are a critical consideration.
fieldbus/industrial network does not work as expected, somehow Every device needs a communication port or ports, physical
the network is always blamed: too slow, too many flipped bits media, communication protocol and tools to configure, display,
due to EMC (electromagnetic compatibility) issues, etc. Without diagnose, analysis, etc. 
proper measuring equipment, a network troubleshooter won’t

Five considerations for implementing Ethernet

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

continued
Five considerations for implementing Ethernet for an industrial network
4. Learn Ethernet. Take the time to learn (through courses 5. Get ready for connectivity. It makes sense to
or self-taught) the art of Ethernet networking. It’s never going to implement all PLCs on Ethernet using protocol converters. This
go away. If you can seamlessly work through VPNs, port forward, makes your plant ready with data available on Ethernet for future
subnet masks and IP addresses, your job is only going to become connectivity with MES/ERP systems. 
more interesting.
Networking tips for machine builders

OEMs need to understand the big picture when selecting a In today’s factory, departments such as IT, operations and
network for a machine. Does the end user of that machine accounting will likely be involved in the project scope. You
need secure remote access, will IT be involved, is the need to understand their requirements when selecting a
machine standalone or will it be networked? How? What are network and how to provide value after the machine has
the requirements? been delivered.

continued
Five considerations for implementing Ethernet for an industrial network
Machine builders also need to consider how their devices at once, but can cause problems with the factory
equipment will impact the factory LAN once the customer network if not handled properly.
installs the equipment on the factory floor. Many OEMs now
use Ethernet as their communication protocol within the If an OEM puts an unmanaged switch on the machine and
machine and provide an Ethernet switch to network the the customer connects the machine to the factory LAN, this
devices in the panel and to provide a link to the factory floor. multicast traffic will be broadcast throughout the factory
because an unmanaged switch will turn that multicast traffic
Several of the industrial protocols on the market today into broadcast. The solution is to use a managed switch that
use multicasting between devices in order to streamline supports both IGMP and IGMP snooping on the machine. This
communication. This feature can save bandwidth within the will prevent the multicast traffic from reaching the factory
machine by allowing a device to send one packet to several LAN. 

Four tips for dealing with wireless latency

and bandwidth issues
More and more, systems engineers are taking advantage of multicast traffic coming from PLCs or producer devices. Multicast
industrial wireless technologies to reduce the amount of cabling traffic is handled differently than unicast traffic by wireless
in their designs. There are some issues to be aware of, however, access points. Multiple devices can receive multicast traffic, while
when replacing dedicated connections with wireless links: unicast is destined for only one device. Wireless access points
transmit multicast traffic at a minimal rate to ensure that all
1. Need latency tolerance. Today’s wired Ethernet listening clients will be able to receive the traffic. This results in
connections are full duplex. This means that each end device can low aggregate bandwidth over the wireless AP as it has to lower
both transmit and receive at the same time. On the other hand, its transmit rate down from the maximum.
wireless technologies such as 802.11a/b/g/n are half duplex.
This means that when any one device is transmitting, all other 3. Low bandwidth requirements. Make sure that
devices must wait. Make sure that your application is designed your application’s bandwidth requirements are low enough to
to be tolerant of the latency introduced due to the half duplex be satisfied by the lower rates. Many designers overlook these
nature of wireless. points and experience problems when moving to wireless
solutions. Being aware of the limitations of wireless technology
2. Control multicast traffic. When implementing wireless can ensure that your upfront design will work in a wireless
technology in factory automation projects, be aware of any deployment.

continued
Four tips for dealing with wireless

latency and bandwidth issues
4. Don’t take shortcuts with wireless. Consider

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

and pneumatic, can solve all your motion
challenges
For more information: Share article » Add comment » Return to contents »

Call: 1-800-463-3786
Global manufacturer of process control and factory automation solutions www.festo.com/us
How network management systems

aid firmware, configuration updates
As technology advances, automation projects today are can be a simple task to accomplish. When you have many
becoming more and more complicated. Many times engineers deployed, it can become challenging and time-consuming.
are focused on the design of the end application and fail to
spend enough time thinking about the ongoing needs of the The order in which the network devices are updated can make
network. a big difference in the connectivity of the network and needs to
be planned out as well. Another common problem is failure to
Today’s automation projects are always connected to some plan how configurations of your network devices will be backed
sort of network. A reliable network is an integral part of the up after changes are made. You want to ensure that when a
successful automation project. If you fail to plan for the growth device needs to be swapped out, its configuration can be quickly
of the network or plan the management aspect of it, the project installed on the replacement device with no ambiguity as to
is bound to run into problems down the line when it is too late which features to enable.
to change things.
Over time, as new functionality is added to the system,
Most network devices contain firmware and need to be updated changes may be required to the network topology as new
for security patches or increased functionality over time. devices are added. Unfortunately, hand-drawn documents of
Failure to plan for how firmware updates will be accomplished network diagrams are the last thing to get updated and often
in the running system can lead to misconfiguration and long get overlooked. This can lead to problems later on when new
downtimes. When you only have a few devices deployed, this systems engineers are assigned to maintain the project. In

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

12 tips for selecting and sizing

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

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

continued
12 tips for selecting and sizing

pneumatic and hydraulic components
The leakage often found with soft tubing is hard to detect in

a plant environment.
11. Inlet side flow control. In a pneumatic logic circuit

controlling a double-acting cylinder, place the flow controls
on the inlet side of your cylinder depending on the direction
of travel. Air is compressible and positioning will float if
controlled on the outlet. This will also create back pressure.
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11 considerations for selecting

and deploying industrial robots
As manufacturers embrace the business case for implementing cell doors have safety interlocks and light curtains as needed,
robots, engineers are challenged to design systems using today’s and make sure you make the robot aware of these safety devices
highly complex and increasingly sophisticated robot technology. so it can do the job better. When it comes to designing your
robot cell (electrical and mechanical layout) and programming,
1. Redefining robots. Too much focus on humanoid always consider safety as your top most priority. This aspect is
robotics is a misplaced definition of objectives. A robot is really even more important given all the codes and regulations for
a modular, autonomous platform combining measuring circuits, robotic safety. For more information on new safety requirements,
active RFID, RF, acoustic, laser and power technologies for in- visit http://awgo.to/026.
situ data processing and real-time communication. Distributed
architectures with this type of robot are revolutionizing 4. Complexity can be barrier. When implementing
industrial automation. robotics, engineers need to ensure the system is scalable,
will mitigate safety and security risks, and has built-in energy
2. Don’t fight the laws of physics. Adjust your management. The robotic system must provide personnel at all
expectations to what the robot is actually capable of doing. levels with access to prognostic and diagnostic data in the same
way discrete and process automation systems deliver operating
3. Safety first. Pay attention to the cell layout from the data. Unfortunately, the complexity of the design process can
operator’s perspective. Fence the area so the operator cannot often be a barrier to achieving the cost savings and efficiency
reach into the cell while the robot is in full motion. Make sure all gains expected with robots.

continued
11 considerations for selecting and deploying industrial robots
Tips for robotics integration

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

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
9. Electronic changeovers. Customization is only a

fraction of the normal line production, but the ability to create MECHATRONICS FOR OEMS
electronic changeovers between formats in a small footprint
The perception of robots in the industrial workplace follows a form
streamlines the customization process.
factor that leads users towards a limited amount of mechanical models.
This feels modular, but it’s not mechatronic. Changing the definition
10. Error codes. When you are programming a robot, many of robotics to coordinated axes synchronized by a single software and
lines of code are involved. If you build in your own error codes processor opens up conventional machine design to modular code and
in the program, it is easier to identify where in the program the mechanisms—or mechatronics. OEMs that have adopted this new out-
error has occurred and to diagnose the issue. If it is a new issue, look make robotic machines that are faster, smoother and more flexible,
add it to the list of your error programs. not by changing their mechanics but by changing their approach. The
choice for OEMs is even easier because they need only migrate their
11. Faster remastering. For a robotic cell, design in a control philosophy to those capable of true mechatronics.
location datum point into the cell. Having an independent
datum point outside of the usual work area (still within the robot
work envelop) will allow quick remastering of an axis or robot experience. Witness marks on joints can fall off, and having an
following maintenance. This is critical for users of just a few independent means to establish the coordinate system is a
robots, who don’t typically have a lot of robot axis mastering major time saver. 

A role for robots in lean

Lean manufacturing is a strategy for reducing waste—in Traditional production lines are designed to be an effective
materials, movement, waiting time, processing and defects. collaboration between man and machine. While the machines
While robots are not innately lean, since they could be used to (including robots) can be programmed for optimal performance,
automate a faster creation of waste, there are a number of ways people cannot. An efficiently designed automated robotic
that their capabilities can support lean manufacturing systems: station must take into account the human variable and not limit
the station ahead of time by creating an overly rigid structure.
 Repeatability and accuracy—improved product quality or
consistency and reduced scrap rates. Robots deliver limited Most important, the decision to use robots must be justified
production loss and lower error rates compared to manual by an ROI analysis. Planning is critical. Robots must be properly
operations. incorporated into the overall lean manufacturing environment,
 Speed—increased production rates and reduced wait time in the right applications, to get the desired results.
for operators. Robots have negligible downtime in situations
where there is high demand for the manufactured product. Standard industrial robots have a single tool mounted to a single
 Flexibility—reduced training and changeover time. Robots can arm. While more efficient than human labor, the lack of flexibility
also be set up to multi-task. is limiting. By incorporating tool changers, the robot can
perform multiple functions. This improved utilization improves
productivity and profitability.

Graphic HMI | PLCs | Panel PCs | OITs

continued
Powerful Industrial HMIs A role for robots in lean

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Another development that can advance lean
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Robots are heavily utilized in inspection applications using
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Needs the Human Touch Share article » Add comment » Return to contents »
10 secrets to selecting and implementing sensors

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

continued
10 secrets to selecting and implementing

sensors in industrial applications
adapt to changing product. In this case, consider capacitive

sensors, which are sensitive to more colors and materials
than others, and in many cases are less expensive than
ultrasonic sensors.
5. Select for technology, conditions. The

most common mistakes in sensor applications include
failing to select the most appropriate sensing principle/
technology for the task, and failing to consider the full
range of expected operating conditions. For example,
although a capacitive proximity sensor can detect metals,
in general an inductive proximity sensor would be a better
choice. Ambient light, temperature, dirt, vibrations or other
conditions can affect sensor performance. An example of
failing to consider operating conditions would be to install
a sensor rated for a maximum temperature of 70 degrees
C in an area where temperatures can reach 85 degrees C or
higher. In this case, the sensor may experience premature
failure or may exhibit unstable operation, such as locking

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

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10. More sensor tips. If changes are required, ensure

proper calibration and document it in the software changes
in the DCS. A built-in display unit for local monitoring of
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continued
Operating environment critical factor

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

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 buildup 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. 

Six critical considerations for successful

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

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

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
Test read rate performance

To evaluate industrial code reading tools, start by measuring run a more challenging read rate test to determine the
the vision system’s reading speed. To do this, present a well- impact of factors such as line vibration, variable lighting
marked code to the vision system and have it read the code conditions and extremely high line speeds on the vision
hundreds of times under pristine conditions to determine system’s reading performance in your application.
the number of reads per minute.
To test this, present a large sample of codes of good, bad
Make sure you have a 100% read rate under these optimized and marginal quality to the vision system. At the same time,
conditions, or you may face problems later when conditions simulate vibration and motion blur by shaking the part and
might be less than ideal. For example, at a production line sliding it back and forth beneath the camera as it acquires an
speed of 2,000 parts per hour, a read rate of 99.7 percent image.
would fail to read the ID codes on 48 parts in just one eight-
hour shift. This test will provide a good initial assessment of how well
the vision system’s read rate will hold up under real-world
After establishing the system’s reading speed, you should production conditions. 

105 / 167
SECTION THREE:
APPLYING TECHNOLOGIES
TO IMPROVE OUTCOMES
Develop a strategy for asset management

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

Five best practices for more reliable

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

continued
Five best practices for more reliable asset management
4. Take a balanced approach. There are many

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

Four considerations for monitoring

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

continued
Four considerations for monitoring equipment assets
bit toggle where the application sets or resets a bit. In any case, motor may not be required. In most applications it is acceptable
the communications link should be monitored and alerts created to monitor one rotating asset for a short period of time, say for 5
when they fail. The alert can be as simple as a line-side machine minutes, and then use the same transmitter to monitor several
alarm or sending an alert email to a group email for IT and other motors or pumps. With this arrangement you will still
technicians, or even to a centralized operations center monitor. need sensors on each piece of equipment, but they can share
Monitoring and notification do not need to be complex to be one transmitter, reducing costs. A system can be engineered to
effective. use several tandem piezo acceleration sensors wired through
relays so that the transmitter monitors one device at a time. Data
4. Shared transmitters. Using real-time vibration collection can be simplified by using a PLC with the transmitter
monitoring on large or critical rotating equipment can provide and relays in one node. The controller can switch the relays and
maintenance staff with valuable information on the health of collect the vibration information from the corresponding pumps
their assets. However, continuous monitoring of one pump or or motors. 

Four tips for calibrating equipment

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

Nine strategies for achieving your

energy management objectives
Whether your primary goal is to reduce operating costs or often cover all or part of the cost of those improvements, which
achieve your company’s sustainability goals, finding ways to makes it easier to get management and financial support for
reduce energy consumption requires good tools and good adding energy reduction activities to automation projects.
information.
3. Involve production, not just facilities
1. Choose the right tools. A comprehensive energy management. Involve people responsible for production
management program is quite challenging, since every aspect processes in energy management activities, since up to 90
of a manufacturing facility is an energy consumer (processing, percent of energy is consumed by production equipment. They
packaging, warehousing, utilities and even the building will help you ensure that proper steps are taken to understand
itself). A common mistake is to expect a traditional process how process energy consumption can be reduced without
or machine automation system to be pressed into service for affecting the productivity of expensive production assets. The
energy management applications (EMS). Instead, purpose-built primary reason most companies focus their energy-saving
EMS systems are designed to provide the right tools for energy activities on the facility is that facility management personnel
analysis and reporting. are often given the responsibility for reducing energy costs. Not
only is the facility in their comfort zone, but it’s often the only
2. Side benefit. Energy management programs that achieve area where they have the institutional authority to make changes.
the most significant savings are typically those whose original By involving production, you can address all the areas of your
goal was to improve control of production processes. The energy operation that consume energy.
savings achieved as a result of improved production processes

continued
Nine strategies for achieving your energy management objectives
4. Use interns to collect data. It’s fairly simple to

FIVE WAYS TO MANAGE ENERGY COSTS
identify viable energy management projects, but it takes real
Reducing energy costs from production processes requires managing engineering to develop the business case. Use interns from local
the five most important factors that determine both utility charges and universities to collect the actual data points needed to develop a
total energy consumption: well-founded business case.
1. Energy event management. Detection and analysis of process
changes that cause consumption to exceed forecast. 5. Avoid duplication. Many motor control devices now
2. Peak demand management. Minimizing peak demand, which have network connections that pass along energy data. There’s
triggers higher utility rates or penalties. no need to duplicate these data-generating capabilities by
installing power monitors over the top of intelligent motor
3. Scheduled demand management. Minimizing costs by shifting
control devices.
demand to lower-cost time periods.
4. Idle state management. Minimizing energy draw during idle
6. Take advantage of incentives. It can often be difficult
process conditions.
to find the funds to invest in projects that will reduce energy
5. Demand/response management. Offering energy capacity back consumption by your plant. Federal, state and local governments
to the grid on request in exchange for incentives. offer a range of incentive and rebate programs for energy saving
projects and using alternative energy sources.

continued
Audits provide holistic energy assessment

Energy assessments and audits can help companies identify energy for the organization. Recommendations may include
a wide range of changes they can make to help reduce their low-investment modifications, such as shifting maintenance
consumption. Audits can be simple, such as a walkthrough operations to non-peak times, or may be more involved,
of a building or facility to identify quick-hit opportunities, or such as programming changes to equipment. Evaluation
much more detailed efforts. These are not one-time projects, and prioritization of capital improvement opportunities can
but rather ongoing efforts to identify variables, such as also be included in the analyses.
how seasons might affect production costs and whether
previously implemented improvements are continuing to An assessment, regardless of scale or scope, should help
perform as planned. answer the following key questions:
Such assessments can help to establish the scope of an  Where am I likely to find quick returns?
effort to reduce energy consumption, define key metrics  What key metrics should I put in place?
and put resources in place that can take a holistic view of  How can I encourage ongoing improvements? 

continued
7. Be prepared. Before planning for any energy always correct, it is the

management purchase, it’s important to first gather your data. key to cost savings as it
It must cover the entire usage pattern of the equipment. Based is the perfect metric for
on the requirements, choose the technology (hardware and measurement.
software) that will help in analyzing a combination of parameters
instead of a single parameter. Monitor the results and associate 9. Track big
operational conditions with energy consumption. consumers.
Always make sure
8. Start with your power bill. Look for peak demand you have the means Energy-saving incentives
charges or power factor charges. If you have a shift come in and to track the energy
For information on the energy incen-
get the facility running from a dead stop, this can create a big performance of large tive programs available in your state or
grid load for a short time and lead to additional kw/hour charges energy consumers. region, go to
due to the short period amp draw. Work with your facilities to The term “large” can be http://awgo.to/021
stagger the starting of equipment and lights. When possible, determined by using a
Source: U.S. Department of Energy
use soft starts or VFDs on large-horsepower motors to reduce simple Pareto analysis.
large startup currents. Utilize lighting vendors and not just an Make a list of all of your
integrator or electrical contractor to create ROIs based on the energy users and section off the top 20 percent. This will identify
real-world numbers you can give them from your power bill and a large portion of your energy usage, as well as the focus of your
a walk-through of your facility. Although the power bill is not maintenance activities. 

Nine recommendations for building

effective manufacturing IT systems
Information technologies are giving manufacturers powerful 3. Virtual redundancy. Look to redundancy through
tools for improving their processes, productivity and profitability. virtualization. It is not just a concept that holds for office IT;
Here are some ideas for making manufacturing IT systems more it is very well suited to manufacturing IT. Backup, recovery,
flexible and reliable. simulation, external support (shipping the machine setup to a
supplier or specialist support) processes can all be improved
1. Data model. Most of these technologies are dependent with server virtualization.
upon a rigorous data model. So putting that model in place first,
and understanding the source, importance and use of the data, 4. Build a wall. It is imperative to separate production
is critical. For manufacturing IT systems, it’s setting expectations networks from office networks. This is because production
about what the product can and cannot do, how it can scale, systems do not need access to the Internet and the office
what performance and refresh rates should be, and what data environment does. If a connection must exist, it should be only
types and databases it can interface with. through a firewall gateway system.
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

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

• Tightly Integrated Vision • Industrial Enclosures

System
continued
• 360° Direct Mounting
• Easy to use Embedded
Software
• Factory Style Connectors Nine recommendations for building
• Sensor Resolution:
VGA to 1600x1200
• Ideal for Single Point
Inspections effective manufacturing IT systems
• Factory Communications
8. Programming languages. Focus on flexibility,

expandability and the opportunity to choose what high-
level programming language meets your company’s
needs. The industry has evolved to where manufacturing
programming languages are no longer the only solution for
automation. High-level languages such as C++, C#, Visual
Basic and MatLab, for example, can now accomplish this.
9. Powerful cellular. Many companies don’t

fully understand the capabilities of Industrial Cellular
technology. New cellular routers include standard features
such as I/O control, protocol converters, seamless network
integration, routing, NAT, firewall and cloud interface,
all with LTE speed. The major commercial hurdle is that
BOA products are highly integrated vision systems in a tiny smart camera
package specifically designed for industrial use. Complete with choice of cellular carriers don’t have solid relationships with control
application software embedded, BOA offers new and experienced users engineers, so major decision-makers are just ignorant of
alike, an easy-to-deploy cost effective vision solution.
the capabilities. Wireless Ethernet or wireless serial radios
certainly have their place, but a deeper knowledge of
cellular applications could be an industry changer. 
Get more vision.
www.teledynedalsa.com Share article » Add comment » Return to contents »
13 ways to get the most out of OEE and

lean manufacturing disciplines
Overall equipment effectiveness (OEE) and lean manufacturing rework, thereby increasing throughput in quality. Before building
have won many converts. These two disciplines are frequently a lean cell, talk to your operators, quality people, manufacturing
linked because they provide a systematic way to design engineers and process engineers. Get their input, hold meetings
manufacturing processes, measure their efficiency and identify and keep them in the loop throughout the project. They are the
problems. Here are some tactics to get the most out of your lean main stakeholders who will eventually approve of your cell.
and OEE initiatives:
3. Lean management. Lean manufacturing is a powerful
1. Accessing data. One of the great challenges when concept when employed correctly. The problem is that with
executing a project to gather and report OEE metrics is easy lean, along with other methodologies, one size does not fit all.
access to manufacturing equipment status. The obstacles may Managers can get caught up in how it improved this company
include islands of automation or even equipment that’s not or industry, and then try to implement it internally. What they
automated. Don’t expect that all equipment information is fail to do is penetrate the details of why it worked, what support
available via existing automation systems. Be prepared to install structure is required and how that translates to their internal
simple data acquisition systems to gather the necessary data to business. Lean is as much about management engagement in
track OEE. daily operations as it is about the methodology.
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
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 fine-tune the flow of your product.
of time.
7. Too lean? If you operate with vendors that are stationed in
5. Visual management. Visual management, including areas with a high potential for natural disasters, think carefully
large display screens on the factory floor, are an effective tool about being too lean with your supplies. You’ll need to plan
for OEE programs, letting both managers and workers easily for alternative routes and suppliers. Another area that has to
monitor the metrics of production lines and track KPIs. Displays be monitored is the amount of time for production to meet
harness natural human competitiveness. In one experience, customer need. Sometimes manufacturing is too lean and when
once data was displayed it started a race between shifts to drive there’s a sudden demand, the slow ramp to manufacture can
up OEE. Without any management intervention there was a 20 cost more money than producing stock.
percent increase in productivity. Among the most useful KPIs
to display: count (good or bad), reject ratio, operating speeds, 8. Business support. Make sure the business has
takt (cycle) time, downtime and OEE (availability multiplied by adopted and fully understands OEE. This can be a huge change
performance and quality) for determining resource utilization. management nightmare if not well-entrenched prior to the
project (or as part of the project execution). Lean manufacturing
6. Increase uptime. Lean manufacturing is a very important can also be applied to service disciplines, not just product
factor in a production plant. Just by placing materials at the manufacturing, mostly with only minor adaptations. Look
point of use within the production floor area, you can increase to these techniques and principles to streamline your own
production uptime. This is just one small adjustment that will processes and eliminate waste.

continued
Calculating OEE
As described in World Class OEE, the OEE calculation is based Time / Total Pieces). Ideal Cycle Time is the minimum cycle
on three factors: availability, performance and quality. Here’s time that your process can be expected to achieve in
how each of these factors is calculated: optimal circumstances. It is sometimes called Design Cycle
Time, Theoretical Cycle Time or Nameplate Capacity.
Availability
Availability takes into account Down Time Loss, and is Since Run Rate is the reciprocal of Cycle Time, Performance
calculated as: Availability = Operating Time / Planned can also be calculated as: Performance = (Total Pieces /
Production Time. Operating Time) / Ideal Run Rate. Performance is capped at
100 percent, to ensure that if an error is made in specifying
Performance the Ideal Cycle Time or Ideal Run Rate, the effect on OEE will
Performance takes into account Speed Loss, and is be limited.
calculated as: Performance = Ideal Cycle Time / (Operating

continued
13 ways to get the most out of OEE

and lean manufacturing disciplines
Quality
Quality takes into account Quality Loss, and is calculated as:
Quality = Good Pieces / Total Pieces.
OEE
OEE takes into account all three OEE factors, and is
calculated as: OEE = Availability x Performance x Quality. It
is very important to recognize that improving OEE is not the
only objective. 
OEE = Availability x Performance x Quality

OEE = B x D x F
A C E
Availability
A = Total Operative Mode Time
B = Run Time Time Losses
Performance
C = Normal Speed
D = Actual Speed dr Speed
Losses
Quality
UNO-2362G UNO-2483G FieldBus iDoor DI/DO iDoor Communication iDoor E = Product Output
AMD ® Dual Core Intel ® Core™ i7/i3/ PCM-26D1PB PCM-27D24DI PCM-24D2R2/PCM-24D2R4 Scrap
T40E Small-Size Celeron Regular- Hilscher netX100 Digital I/O, isolated OXPCIe-952 Isolated F = Actual Good Product Losses
Automation Size Automation FieldBus, ProfiBus, 16 DI/8 DO, 1x RS-232, 2x DB9, isolated
Computer w/ 1x Computer w/ 4x 1x DB9 DB37 RS-422/485
GbE, 2x mPCIe, GbE, 3x mPCIe, PCM-26D2CA PCM-24D4R2 / PCM-24D4R4
HDMI/DP HDMI/VGA SJA1000 CANBus, OXPCIe-954 UART, Non-
CANOpen, 2x DB9 Isolated RS-232, 1x DB37,
Non-isolated RS-422/485 Share article » Add comment » Return to contents »
continued
9. Meaningful reports. Data Software selection plays only a small

capture is quite easy. Reporting the data part in the OEE process, but that is where
in a manner that helps implement change customers spend the most time upfront.
can be challenging. Don’t assume a single Operator involvement, the quality of the
report is sufficient. Different users need integration partner and the ability of the
different data. And that data must be controls hardware to collect data are what
presented to each user in a manner that is truly make an OEE project successful.
meaningful.
12. Efficiency tool. OEE has to be au- OEE in-depth
10. Improvement tool. OEE can be tomated to be successful. The data needs
For a detailed discussion on calculating
a very valuable tool to identify problems to be driven from machine status, not
Overall Equipment Effectiveness, go to
within a process. Ensure that everyone humans inputting the status. Any manu-
http://awgo.to/022
understands what the three elements are ally derived OEE system can be fiddled
Source: Automation World
that make up OEE: availability, speed and with to produce the expected 85 percent
quality, and how to calculate each. Once efficiency rate. Improving systems and au-
processes are stabilized, use OEE to drive tomating OEE measurements may bring data as a new way of measuring OEE.
improvement. into question the accuracy of historical On the other hand, the only reason to
OEE data. To avoid internal politics, put an use OEE is to help drive an improvement
11. Software less important. amnesty in place and promote automated process to increase operational efficiency.

continued
13 ways to get the most out of OEE

and lean manufacturing disciplines
If that isn’t a widely embraced priority, then save yourself lots

of time, money and effort.
13. Improving uptime. OEE can help you identify op-

portunities 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.
usa.siemens.com/tia-portal There isn’t a set rule as to what that may be. An example may
be that under your performance efficiency category, you list
Up to 30% reduction in specific pieces of equipment in an assembly line to track. By
breaking down your categories you will have better opportu-
engineering effort for nities to make improvements. The last hurdle is how to cap-
faster time to market. ture 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 it’s important. 
Experience a more intuitive and efficient way of working using the TIA Portal
integrated automation software – a single engineering framework that
allows you to combine PLC, PC-based control, HMI, Network configuration,
Drives, and Safety in a single, proven engineering environment.
Request a trial license today!
usa.siemens.com/tia-portal-trial-license

Answers for industry.
Eight ideas for improving product

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

continued
Eight ideas for improving product lifecycle management
cost of the equipment is 2-5 percent of PLM software that is able to validate the
the lifecycle costs, while the rest is the production system in a simulated three-
cost to run and maintain the equipment. dimensional environment. This allows the
risks of failure to be identified in different
4. Keep it basic. Remember that parts of the process or equipment. The
hardware and software designs have a software can also be used to determine
direct impact on industrial productivity. the best way to lay out production lines
The most elegant and complex system in order to move material through the
design does not help a customer unless factory floor. Modernizing
it is faster, easier to maintain, uses less manufacturing
energy and, above all, can be understood 6. Is there a payback? Don’t be
To learn more about the digital manu-
by plant maintenance personnel. afraid to tell others when a system is at facturing initiative sponsored by the
Sometimes it is better to sacrifice elegant its end of life. Just because an outdated National Center for Manufacturing Sci-
and complex for basic and simple if system is running today is no guarantee ences and other resources for modern-
the result is a faster, easier-to-maintain it will be running tomorrow. Strive to izing American manufacturing, visit
manufacturing line. Those who care educate operations and management
http://awgo.to/024
about manufacturing productivity will that it’s important to upgrade as needed.
Source: National Center for
appreciate it. But don’t upgrade just to have the latest Manufacturing Sciences
technology if there is no real payback.
5. Validation essential. Choose

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

Seven human factors to consider

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

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

continued
change will be seriously impaired and, production due to an injury or downtime

even worse, unsafe conditions may arise. from faulty equipment.
Bringing their viewpoints into the design
review process will help eliminate costly 7. Is it needed? Make sure you are on
surprises during the testing or rollout the same page as the machine builder or
phases. By conducting proper meetings system integrator when making design
and maintaining clear communication decisions about machine safety. A lot of
with all impacted personnel, project money can go towards guarding, only to
management is demonstrated and find that the machine will be in a secure openSAFETY
confidence is instilled in the management area that cannot be accessed during Looking for a safety solution that sup-
of change. operation. On the other side, the end ports more than one TUV-approved
user should not cut costs by eliminating protocol for industrial Ethernet? Con-
6. Pay now, or pay later. Saving machine safety features just because sider using vendors that support the
someone from injury by paying for they don’t understand the need for openSAFETY standard, which is vendor
neutral with regards to fieldbus and
training courses is better than losing implementing safety systems. 
supports safe operations with interop-
erable technologies. For more informa-
tion, visit
http://awgo.to/019
Source: Ethernet Powerlink Standardization Group
Source: Ethernet Powerlink Standardization Group

continued
Safety standards online

Be proactive and try to stay ahead of regulation before Community Emergency Response
changes are mandated. The Internet is a great source of Plant Emergency Response
Physical Protection (Dikes)
information about current regulations and standards—and Physical Protection (Relief Devices)
what might be coming next. Automatic Action SIS or ESD
Critical Alarms, Operatior Supervision
and Manual Intervention
Apply LOPA for risks Basic Controls, Process Alarms
and Operator Supervision
Deep dive into Process Hazard Analysis (PHA) to identify the Process Design
risks underlying a process. Apply LOPA (layer-of-protection)

analysis to rate the SIL level and guide the SIF design
according to IEC 61508/61511. Understand all aspects of
the safety lifecycle before proceeding with design and LOPA chart courtesy of ABS Consulting,
implementation.  awgo.to/018

Eight tips for the technical side

of safety systems
From new standards for functional safety 2. Validate the safety code.
to making sure that an e-stop will actually Determine each failure mode and validate
stop everything on a machine, these that it fails to a safe state. Just because the
practical recommendations address the logic tells you to turn an output on or off
details of a safety system: when running, does not necessarily mean
it will return to the correct state if there is
1. Functional safety. Functional a fault. It needs to be verified.
safety, as defined in IEC 61508, is a totally
new methodology in automation. It’s 3. Key features for safety IEC 61508 explained
based on two main principles: 1. It’s a systems. Low PFD (probability of failure For a comprehensive look at functional
systems approach. Sensor - controller - on demand), equivalent to the long- safety and the IEC 61508 standard, visit
actuator, every component should have accepted TMR (triple modular redundant) http://awgo.to/016
the same SIL/PL. Otherwise, it makes no benchmark standards, in either simplex or Source: International Electrotechnical Commission
sense. 2. System/product lifecycle idea. redundant configurations. Low STR (steps
Today’s safety does not mean tomorrow’s to reproduce) that meets or exceeds the Safety modules independent from the
safety. Functional safety needs a TMR standard when implemented in logic solvers. By choosing safety systems
procedure to implement it continuously. dual configuration. Exceptional hardware with these features, availability has been
fault tolerance in dual configurations. estimated as high as 99.9999 percent.

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

continued
Don’t overlook safety distance calculations

The safety of a machine is not guaranteed by simply using the scanner plane may have to be mounted farther from the
a safety laser scanner in an application. A safety distance hazard, similar to a light curtain.
calculation needs to be considered to ensure the correct use
and functionality of the scanner device. More commonly, if it is mounted with a horizontal plane,
there may be a chance for reach-over, which would require a
The safety distance calculation will help determine the larger-sized safety field. These two possibilities are called the
size of the safety field or the distance a scanner plane is Depth of Penetration and are a part of the safety distance
mounted from a hazard. How will the device be mounted? calculation.
Will it be scanning vertically or horizontally? If it is vertical,

continued
Consider also the stop time of the entire system. Realize that The stop time of the machine will also be used in calculating
the stop time may include more than just the stopping of the safety distance. By implementing this calculation into
the machine. The time it takes for the scanner to react, for your design of a safety laser scanner, you will be on your way
the stop signal to travel to the machine, for the machine to properly complying with standards and achieving greater
to actually come to a stop and any other delays must be employee safety. 
considered. These delays may be small, but can have an
impact on the overall size required for the safety field.

Wiring, safety PLC programming

critical to machine safety performance
Some common pitfalls in machine safety have to do with not hardware setup change. Either way, you need to understand how
wiring devices correctly. Many devices today can cover a range safety works.
of safety levels, such as SIL 1 through SIL 3, but have different
wiring methods. Diagnostic coverage is extremely important Once you have designed your system, you must program it.
with safety and incorrect wiring or an incomplete understanding Pay special attention to what the controller allows you to do in
of the wiring requirements could lead to a lower safety level or a the safety code. A safety PLC can add many benefits that can
system that does not work at all. help the system be more flexible and increase production. On
the other hand, it has to be programmed and must be tested
Be sure to follow the manufacturer’s recommended wiring for correct operation during the machine’s commissioning
practices and understand the diagnostics that are performed on phase. This is a very important step and is often overlooked. Be
the circuit. Having two devices that perform diagnostics of the sure to inject faults into the safety system to ensure that your
same type may cause the system to not work. An example would configuration and code give you the desired response.
be cross-wire detection where the PLC card checks the circuit by
sending out a pulse on the wire and detecting that pulse back A safety PLC can add great benefits to the automation project,
on the input. If the device that it is wired to the PLC card does but it also can add scan time that may affect the response time
not pass the pulse through, then the I/O module may fault. This of the safety system. It is important to understand this and to
could be corrected by selecting the right devices or a simple select the right hardware. The response time is very important

continued
Wiring, safety PLC programming

critical to machine safety performance
a giant breakthrough
in small readers in safety and could make a machine that appears to have all
its safety bases covered not respond fast enough to a person
working in a highly dangerous area.
Make sure you document your safety system, from risk

assessment to the testing and checkout phase. Integrated
safety is very flexible and can give great benefits, but pay
attention to the wiring and configuration of the devices. And
remember, time is distance and the scan time may affect the
response of your system on a high-speed machine with close
approach boundaries. 
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Europe sets standards for safety design

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

Six strategies for creating a

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

continued
Six strategies for creating a secure industrial network
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
rest of the network. A defense-in-depth provide an in-depth defense against many

strategy should provide secure remote attacks aimed at industrial systems. Protect
access through the use of VPN gateways to your network at the site level, internal zone
provide encrypted access at the external and cell levels.
boundaries. The internal zone boundaries
should employ firewall and network 6. Prioritize your efforts. Every
address translation. This can limit the control system has one or more assets that
scope of access by an internal action such would seriously impact production, safety
as a phishing or a virus introduced by a or the environment if successfully attacked.
trusted device inside the network, such as These might be the SIS (safety integrated
Protecting control systems
accessing a malicious external website. It system) in a refinery, the PLC controlling For more information about protecting
industrial control and SCADA systems
can also provide critical device protection chlorine levels in a water filtration plant or
from security threats, download the
by isolating malfunctioning devices from the RTU in an electrical substation. Plant
white paper at
broadcasting packets to the entire network personnel know what really matters in an
and creating a denial of service. Employing operation. If these assets are aggressively http://awgo.to/020
an industrial VPN/NAT/firewall/router protected, the chance of a truly serious Source: Tofino Security
at multiple places in your network can cyber incident is massively reduced. 

continued
Security threats confront every

manufacturing plant
Network security is becoming a more important issue. which are planned and intentional. Now consider the cost
With manufacturing facilities becoming more wired and impact if the facility was maliciously shut down, or if only
automated, as well as accessible from outside the facility, one operation in the facility was disrupted. The cost could be
external security is becoming an issue that in the past was devastating.
typically not even a consideration.
With all of the eavesdropping and international espionage
Security, from both outside and from within the facility must in the news, it is becoming more important to secure the
now be incorporated as part of any automation project. automated facility and protect operations from outside
Consider how much cost is involved when the production interests (including foreign governments). Cost is becoming
facility is shut down for standard maintenance operations, less an issue when compared to the potential damage that

continued
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.

Seven details to remember when

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

continued
Seven details to remember when implementing network security
well as limit access to the network. Unmanaged switches do not protocols, any port can be connected with an Ethernet cable
provide any type of control and allow any device to be plugged back into another port on a switch and create a broadcast
into the network. Managed switches also allow the network storm. This can cripple the switch as well as the network. This
designer to disable any unused ports. This prevents unauthorized kind of problem can also be tricky to track down and flush out
devices from gaining access to the network. The ports can either of a network. Loop prevention protocols include the spanning
be disabled or be configured to use a central RADIUS server, tree variations such as rapid spanning tree. For industrial
which can control access to them using 802.1X. This requires a applications, these can be too slow, but optimized solutions
bit more configuration, but allows for all your network devices to such as TurboChain and broadcast storm prevention (BSP) can
have a single user database that is centrally administrated, rather provide response time in milliseconds to prevent network loops
than have to manage user names and passwords on individual from occurring. These features can be used to prevent a malicious
switches. Make sure you change the default admin password denial of service outage from occurring as well as prevent an
of the switch. It typically comes set to a default and many fail to accidental Ethernet cable loopback.
change it. It goes without saying that this is a big problem and it
should always be changed. 5. Look for redundancy and robustness. Having
equipment that is easy to disrupt makes an attacker’s job easier.
4. Guard against network loops. Many industrial All network components, including cabling, cabinets and active
networks are designed with redundant paths in the system and equipment, need to be industrially hardened, resilient and have
already employ a redundancy/loop prevention mechanism. This high mean-time-between-failure (MTBF) ratings because of
is also a feature of a managed switch. Without loop prevention the harsh environments found in an industrial facility. Active

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

Nine ways to get the most from

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

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

Five recommendations for

implementing workflow systems
Workflow software is a useful tool in many applications, from
enforcing standards and compliance to feeding into an MES. PHASE IT IN
Here are some suggestions for implementing workflow software:
It’s a good idea to implement workflow automation software in two
planned projects. Plan and execute the first workflow project within
1. Define your objectives. For workflow software, a limited domain, where the systems, responsibility and authority
you need to first discuss what you want to use the workflow reside in one group. Once there is proven success with this project, the
software to do. Do you want it to enforce compliance, for bigger projects that span groups can be tackled with knowledge and
example, or build a corrective action solution or provide confidence in the workflow tool. The challenge on a bigger project that
offshoot functionality for an MES? Are you using it to interface spans domains is selecting a project team and leader with the author-
plant-to-business applications? Workflow software needs to ity to make decisions and trade-offs efficiently, with buy-in from all.
enforce a standard procedure or series of procedures. If you
have processes that change all the time, workflow may be too be specific when discussing and documenting software
structured for you to benefit. But to facilitate standard responses requirements, methods and objectives.
to activities or events, workflow software is a good solution.
3. Document standard work. Ensure that the real
2. Define subsets. Recognize and define the expanding production workflow is accurately documented and understood
subsets of workplace software (for example, fixed programming, for all products and all variations before you start the project.
limited variability programming, full variability programming, And make sure you get the operators to agree and quantify the
utility software, embedded software, firmware, etc.) and “standard work” (if it’s available). If you don’t do this up front and

continued
Five recommendations for implementing workflow systems
get everything documented, agreed on and the “future state”  Use templates to save a lot of time.
well understood, then you will end up running in circles.  Use IEC 61131-3 for programming machine behavior.
 Be sure to enlist the experience of all those who will come
4. Improving code. When you ask for additional product in contact with the workflow that you are trying to model or
flexibility that will require workflow software code changes, diagram.
allow sufficient time for your programmer or integrator to make  Ensure proper channels of workflow. A proper design is
the changes. Pushing them beyond their work capacity with essential to avoid delays in a workflow project. 
unrealistic schedules can result in mistakes and project delays.
5. More workflow tips.

 Do not be overly analytical and make it unnecessarily
complicated.

VENDOR SELECTION RESOURCE GUIDE Advantech

Advantech, a pioneer in
Intelligent Automation Technology
With more than 30 years of Automation Controllers
experience in providing a full range Advantech’s Programmable Automation Controllers (PAC) combine a
of products to different vertical PLC’s ruggedness with PC-based technology, an open architecture, high
markets, the Industrial Automation performance CPU, rich I/O modules and power software.
Group of Advantech is a pioneer in
intelligent Automation technology. Automation Software
By combining connectivity, Advantech’s automation software lineup includes SCADA software,
flexibility, ruggedness and being SoftLogic programming tools, OPC
WEB RESOURCES
at the leading-edge of Internet of Things technology, Advantech’s Server, and other user-friendly
programming tools and utilities. VIDEO
Industrial Automation Group is proving to be a global leading Advantech –
Automation Product and Services provider. Major product lines include: Now and Beyond
Embedded Automation Computers awgo.to/200
Intelligent HMI Platforms Advantech offers complete line of
With a complete range of intelligent operator panels, touch panel embedded automation computers with
WHITE PAPER
computers, industrial automation panel PCs, and industrial monitors, rugged and cableless designs, including How has the recent
fanless box PCs and industrial control strides in automation
Advantech offers a wide range of human machine interface (HMI) changed the factory
products for industrial automation panel needs. In addition, an devices. With compact and multiple floor? awgo.to/201
integrated I/O and control feature with HMI/SCADA software enables IOs, multiple expansion solutions
PRODUCT
efficient integration. and multiple mounting methods,
Multi-touch wide screen
monitor with water-
proof M12 connectors.
COMPANY: Advantech Corporation  ADDRESS: 11380 Reed Hartman Hwy, Cincinnati, OH 45241 awgo.to/202
PHONE: (800) 800-6889  WEB: www.advantech.com
VENDOR SELECTION RESOURCE GUIDE Advantech
each embedded automation platform is suitable for a wide variety of With more than 6,000
automation applications in a wide range of environments. talented people, Advantech
operates an extensive support,
Distributed I/O Modules sales and marketing network
While the Internet-of-Things is rapidly becoming a reality, customers
in over 20 countries worldwide. In addition, we cooperate closely
can take advantage of Advantech’s machine-to-machine I/O modules
with our partners to help provide complete solutions for a wide array
(ADAM-2000 series), RS-based I/O Modules (ADAM-4000 series), and
of applications across a diverse range of industries.The Advantech
Ethernet-based I/O Modules (ADAM-6000 series) to monitor and
Industrial Automation Groups “Intelligent Automation, Seamless
manage field sites easily.
Integration” mission statement looks forward to the contribution
Data Acquisition and Control that Advantech, together with its partners, can make to this new era
Advantech offers wide range of industrial data acquisition and control of intelligent automation.
devices with various interfaces and functions. Based on PC technology, Whether in public safety,
from ISA to USB, and signal conditioning to graphical software tools, building energy efficiency,
Advantech’s industrial I/I products are reliable, accurate, affordable, and environmental monitoring,
suitable for many industrial automation applications. industrial monitoring, smart
transportation, smart grids,
Industrial Communication Solutions smart homes and other
Advantech’s Industrial Communication products provide reliable wired areas with our expertise and
and wireless communication for mission critical applications. Products experience we can provide the
include Industrial Ethernet Switches, Industrial Wireless AP/CPE, best solution to create better
Media Converters, Serial Device Servers, Cellular IP Gateways, Modbus tomorrow. 
Gateways, and Serial Communication Cards.
COMPANY: Advantech Corporation  ADDRESS: 11380 Reed Hartman Hwy, Cincinnati, OH 45241
PHONE: (800) 800-6889  WEB: www.advantech.com
VENDOR SELECTION RESOURCE GUIDE Festo

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

VENDOR SELECTION RESOURCE GUIDE Festo
• Pneumatic Drives engineering, design, assembly,

• Servo Pneumatic Technology documentation, validation, and
• Handling & Vacuum Technology production.
• Air Preparation, Pneumatic Connections and Tubing
• Valve and Valve Manifolds • Engineering & Design
• Sensors and Machine Vision • Handling & Custom Assembly
• Control Technology • Control Systems
• Electromechanical Components
Training & Consulting
Our dedication to the advancement of automation extends beyond
Industry Specific Expertise
technology to the education of current and future automation and robotic
Whether designing new machinery or modernizing existing designers with simulation tools, teaching programs and on-site services.
systems, Festo can provide the resources you need to meet your Festo Didactic is the knowledge and learning division of Festo Corporation.
unique requirements in every stage of industrial production and Didactic’s charter is to provide automation technology training for
manufacturing. manufacturing employees at our industrial customers worldwide.
• Automotive From basic training packages to the planning, control and handling
• Biotech/Pharmaceutical of complex networked CIM systems and complete, fully equipped
• Electronics/Light Assembly learning centers – we can create a customized offer to suit your
• Flat Panel/Solar personal requirements for efficient learning and guaranteed results. 
• Food & Beverage
• Lab Automation
• Printing, Paper & Converting
• Water/Wastewater
Complete System Solutions

Our experienced engineers provide complete support at every stage
of your development process, including: conceptualization, analysis,
COMPANY: FESTO  PHONE: 1 800 99 FESTO  WEB: www.festo.com/us

VENDOR SELECTION RESOURCE GUIDE Graybar

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

VENDOR SELECTION RESOURCE GUIDE Graybar
AC Drives and Soft Starts Power Monitoring

Technical assistance to help you commission your variable frequency Power management systems designed
drive (VFD) and provide the control for a more energy-efficient to help manage real-time conditions,
operation. Graybar’s automation specialists are certified by Schneider isolate problems, study trends, and
Electric for VFD stat-up and commissioning. control loads and generators.
Sensors Industrial Cables and Connectors

Technical specialists to help you A wide range of industrial data cabling solutions for all of your harsh
select the right sensor for your environment needs that will help you avoid transmission errors that
application, including proximity can lead to downtime or safety issues.
sensors, electronic pressure
sensors, photoelectric sensors Services
and limit switches. A wide variety of services to support our customers’ facility needs
in power, lighting, networking, energy management, security and
Terminal Blocks and more. Our technical specialists help customers in all these areas today
Interface Products and continually expand their knowledge and skills to master new
A comprehensive line of DIN-rail technologies. 
mounted products to choose
from, featuring an array of
termination methods that save time, space and money.
Safety KEY COMPANY CONTACT

Plant-wide safety audit provisions, lockout/tagout provisions, arc Brett Felton, National Marketing Manager
flash analysis, and personal protective equipment (PPE) to help avoid PHONE: (314) 573-9200 • LOCATION: St. Louis, MO
electrical hazards that can result in serious injury or death. EMAIL: brett.felton@graybar.com
COMPANY: Graybar  PHONE: 1-800-GRAYBAR (472-9227)  WEB: graybar.com/industrial

VENDOR SELECTION RESOURCE GUIDE Omron Automation & Safety

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.
We support machine builders and WEB RESOURCES
OEMs across the United States, Canada Find Omron Automation
and Latin America with sensing and & Safety on…
control technologies that help you LINKED IN
deliver more capable and profitable http://www.linkedin.com/
company/omron-electronics
machines in less time. We strive to be
FACEBOOK
your trusted partner in automation.
https://www.facebook.com/
Leverage our industry expertise and OmronAutomationSafety?ref=hl
powerful yet simple solutions in your
TWITTER
next project. https://twitter.com/
OmronProduct
YOUTUBE
http://www.youtube.com/user/
COMPANY: Omron Automation and Safety  ADDRESS: One Commerce Drive, Schaumburg, IL 60173 OmronAutomationTech
PHONE: (847) 843-7900 Toll-free: (800) 556-6766  WEB: www.omron247.com

VENDOR SELECTION RESOURCE GUIDE Omron Automation & Safety
Primary Industries Served

• Automotive
• Food/Beverage
• Semiconductor
• Electronics and Small Parts Assembly
• Pharmaceutical/Cosmetics
Automation Expertise
• Packaging & Material Handling
• Measurement & Gauging
• Inspection
• Track & Trace
Omron Facts
• Quality Improvement
• 80 years in the controls business, founded in 1933
• $6.5 billion sales (USD, April 2012)
• 40% of our sales come from industrial automation; KEY COMPANY CONTACT
electronic components, social systems, automotive electronics PHONE: (847) 843-7900 • Toll-free: (800) 556-6766
and healthcare make up the balance LOCATION: Schaumburg, IL • EMAIL: salesnet@omron.com
• 35,411 employees worldwide
COMPANY: Omron Automation and Safety  ADDRESS: One Commerce Drive, Schaumburg, IL 60173
PHONE: (847) 843-7900 Toll-free: (800) 556-6766  WEB: www.omron247.com
VENDOR SELECTION RESOURCE GUIDE Opto 22

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

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

Temecula, CA EMAIL: systemseng@opto22.com
COMPANY: Opto 22  ADDRESS: 43044 Business Park Drive, Temecula, CA 92590
PHONE: (800) 321-6786  WEB: www.opto22.com
VENDOR SELECTION RESOURCE GUIDE Red Lion Controls
Red Lion Controls

As the global experts in communication, monitoring and control
for industrial automation and networking, Red Lion Controls has
been delivering innovative solutions for over forty years. Our award-
winning technology enables companies worldwide to gain real-
time data visibility that drives productivity.
The following industrial automation products collect, present

and process data anywhere, anytime:
• Controllers: PID controllers, signal conditioners and data

acquisition devices for machine and process control
• Protocol Conversion: extensive protocol library connects
otherwise incompatible devices on wired or wireless networks
• HMIs: combine protocol conversion, data logging and web
server capabilities with visualization functionality for PLCs, • Visual Management: enables the display of real-time KPI data
motor drives and more and Andon messages on large televisions to drive productivity
• Panel Meters: a wide range of models and sizes with expansion • RTUs & I/O Modules: provide a simple yet powerful monitoring
capabilities that easily adapt to changing requirements and control system for remote sites
COMPANY: Red Lion Controls  ADDRESS: 20 Willow Springs Circle • York, PA, 17406 • USA
PHONE: (717) 767-6511  FAX: (717) 764-0839  WEB: www.redlion.net  E-MAIL: info@redlion.net
VENDOR SELECTION RESOURCE GUIDE Red Lion Controls
In addition, Red Lion now offers an industrial networking

portfolio that includes:
• Unmanaged Switches: compact IEEE 802.3 Layer 2 industrial

switches with automatic speed, duplex and cable sensing
• Monitored Switches: enable Layer 2 network performance
monitoring via N-View software
• Managed Switches: provide Layer 2 and Layer 3 networking in a
rugged package
• PoE Solutions: designed to transmit power and/or data
over an Ethernet network
• Wi-Fi Radios: IEEE 802.11a,b,g,n hardened radios
support data bandwidths up to 300 Mb/s
• Cellular M2M Routers: provide uninterrupted, secure
communication for remote sites
To learn more, call +1 (717) 767-6511

or visit www.redlion.net/together.
COMPANY: Red Lion Controls  ADDRESS: 20 Willow Springs Circle • York, PA, 17406 • USA
PHONE: (717) 767-6511  FAX: (717) 764-0839  WEB: www.redlion.net  E-MAIL: info@redlion.net
VENDOR SELECTION RESOURCE GUIDE Siemens

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

starts with efficient infrastructure of
engineering local expertise and
global support ensures you
Totally Integrated benefit fully from Totally Integrated Automation along the entire
production process.
Automation:
Efficiency driving
Additional TIA productivity benefits are accomplished through common
productivity system characteristics across the entire Automation System:
• Integrated Engineering
Efficient engineering is • Industrial Data Management
the first step towards • Industrial Communication
better production: faster, more flexible, and more intelligent. • Industrial Security
• Safety Integrated
Totally Integrated Automation (TIA) saves time in engineering as a
result of the efficient interoperability of PLCs, HMIs, safety, and drives. Our revolutionary TIA Portal engineering software provides the
framework! 
The result:
TAKE A TEST DRIVE!
• Lower cost in design, commissioning & maintenance Request a trial copy of TIA Portal software and experience
• Reduced downtime first-hand a single engineering framework that allows you to
• Faster time-to-market combine all automation tasks in one environment, reducing
• Greater flexibility engineering costs up to 30%
usa.siemens.com/tia-portal-trial-license
COMPANY: Siemens Industry, Inc  ADDRESS: 3333 Old Milton Parkway, Alpharetta, GA 30005
WEB: www.usa.siemens.com/industry  EMAIL: info.us@siemens.com
VENDOR SELECTION RESOURCE GUIDE Teledyne DALSA

Teledyne DALSA High Performance
Digital Imaging Solutions
Teledyne DALSA is an international leader in high performance Designed for single point inspection, Teledyne DALSA’s BOA
digital imaging and semiconductors with approximately 1000 products are highly integrated vision systems in a tiny smart
employees world-wide. Established in 1980, and acquired camera package specifically designed for industrial use. Complete
by Teledyne Technologies in 2011, Teledyne DALSA delivers with choice of application software embedded, BOA offers
industry-leading technology for digital imaging and specialized manufacturers a robust and flexible automated inspection system
semiconductor fabrication. With core competencies in CCD and that is easy to integrate and deploy on the factory floor.
CMOS imagers, high-performance electronic cameras, image
processing hardware and software, Teledyne DALSA is committed to For applications requiring multi- WEB RESOURCES
enabling industry and exploration through innovative technology. camera inspection, Teledyne DALSA’s VIDEO
embedded machine vision systems BOA Smart Camera
Demonstration
Teledyne DALSA’s industrial vision solutions are designed to are comprised of a centralized camera
awgo.to/155
meet the diverse needs of industry and end users alike. Designed controller that delivers low deployment
specifically for factory floor deployment and usability, our cost with high performance processing. ON DEMAND
innovative vision systems offer scalable solutions that satisfy a wide These vision systems are available WEBINAR
Machine Vision for
range of application needs from positioning robotic handlers to with choice of application software Factory Automation
complete assembly verification. These products are easy enough for and camera interface to suit a range of awgo.to/156
novices, powerful enough for professionals. application needs. PRODUCT
BOA Vision System
– Small, Smart and
Flexible
COMPANY: Teledyne DALSA  ADDRESS: 700 Technology Park Drive, Billerica, MA 01821 awgo.to/155
PHONE: 978-670-2000  WEB: www.teledynedalsa.com
VENDOR SELECTION RESOURCE GUIDE Teledyne DALSA
Teledyne DALSA’s vision systems are available in a range of cost- provides advanced
effective models to satisfy a broad variety of user requirements. functionality in terms
These include single 640 x 480 standard camera configurations of scripting, customization
to high-performance multi-camera models with 1600 x 1200 and support for 3rd-party tools.
color resolution. They support line scan technology to address
challenging large format or cylindrical unwrapping applications. Teledyne DALSA vision solutions provide a full suite of vision
tools and capabilities for performing the following inspection tasks:
Vision solutions are equipped with two distinct styles of
application interface to accommodate the differing needs and Positioning – Guide robotic handlers or adjust vision tools for
experience of end users: part movement
Identifying – Identify product for verification or traceability
iNspect Express software allows experienced users and 1st time Verifying – Verify parts for correctness, assembly or packaging
adopters alike to setup and deploy solutions with little or no prior Measuring – Measure parts for dimensional accuracy
machine vision knowledge. iNspect Express’ logical setup is built Flaw Detection – Check part surfaces for scratches
from the experience and algorithms that have been put to the test and other defects 
over the course of many years.
Sherlock software offers experienced vision integrators additional

flexibility, together with a rich suite of capabilities and options
that can be applied to the most challenging applications. Sherlock
COMPANY: Teledyne DALSA  ADDRESS: 700 Technology Park Drive, Billerica, MA 01821
PHONE: 978-670-2000  WEB: www.teledynedalsa.com
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2014 EDITION

FACTORY & MACHINE

Hands-on practical advice on selecting and implementing controllers, motion control,

Section 1: Planning and implementing an automation project

17 Nine tips for automation project managers

20 Automation project management from a machine builder’s perspective

25 How to justify capital projects: Speaking finance gets results

35 Eight tips for selecting the right automation system components

37 How to properly select and vet a system integrator

43 12 common mistakes people make in automation projects

47 10 ways your automation project can fail and how to prevent it

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

75 Seven issues to think about before you develop an industrial network

79 Five considerations for implementing Ethernet for an industrial network

84 How network management systems aid firmware, configuration updates

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

Section 3: Applying technologies to improve outcomes

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

125 Eight ideas for improving product lifecycle management

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

149 Five recommendations for implementing workflow systems

151 Vendor Selection Resource Guide

Paul Brinks Jeff Miller, PMP

Stephen M. Goldberg Howard Skolnik

Michael Hake Arthur C. Smith

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

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12 points to consider before even beginning

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12 points to consider before even beginning your automation project

4. Project definition is critical. Without doing true

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12 points to consider before even beginning your automation project

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Nine tips for automation project managers

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Nine tips for automation project managers

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Nine tips for automation project managers

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Automation project management from

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Automation project management from a machine builder’s perspective

Machine Definition Project Management *

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Automation project management from a machine builder’s perspective

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Automation project management from a machine builder’s perspective

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Can your current control continued