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FACTORY & MACHINE Automation Playbook 2 / 167
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FACTORY & MACHINE Automation Playbook 3 / 167
CONTENTS
7 Playbook Advisors
8 Contributors
11 Introduction
OEM machine designers (in addition to automation end users) will specifically find useful tips in highlighted articles.
FACTORY & MACHINE Automation Playbook 4 / 167
CONTENTS
Section 2: Selecting products to build your automated system
52 16 best practices for specifying PLCs, PACs or PC controllers
72 Seven considerations for applying servo drives, motion controllers and PLCs
77 Six things to think about when you get down to the network details
82 Four tips for dealing with wireless latency and bandwidth issues
OEM machine designers (in addition to automation end users) will specifically find useful tips in highlighted articles.
FACTORY & MACHINE Automation Playbook 5 / 167
CONTENTS
86 12 tips for selecting and sizing pneumatic and hydraulic components
1
01 Six critical considerations for successful machine vision applications
OEM machine designers (in addition to automation end users) will specifically find useful tips in highlighted articles.
FACTORY & MACHINE Automation Playbook 6 / 167
CONTENTS
119 13 ways to get the most out of OEE and lean manufacturing disciplines
128 Seven human factors to consider when developing machine safety systems
147 Nine ways to get the most from simulation and CAD/CAM software
PLAYBOOK ADVISORS
Thomas A. Doney Joe Martin
Senior Research Engineer President
Nestlé Martin CSI
CONTRIBUTORS
Michael Mikolajczak Jad Wehbe Abdulilah Alzayyat William Wang Kurt Wilde Tom Jensen
Bryan Sisler Automate, Lebanon - Jim Hulman DuPont China, China Henniges Automotive, USA Lenze, USA
ABB, USA Germany - Qatar Joaquin Ocampo
Bosch Rexroth, USA Tim Matheny Satish Samineni Stefano Linari
Alex Miller Rafael Arevalo Duque ECS Solutions Inc., USA Halcrow, Qatar Linari Engineering srl, Italy
ABB Robotics, USA Automatizacion Ingenieros Larry W. Ostrander
Especialistas sas, Colombia CADD Tech Support, USA Ed Nachel Tianshun Qiu Dan Perkins
Mike Berryman Elobau Sensor Technology IBM (China) Co. Ltd., China LINAK U.S. Inc., USA
Advantech, USA Peter van den Berg John F. Wozniak Inc., USA
Avans University of Applied CC-Link Partner Alexander Pinkham Jagjeet Paul
Wendy Jacintha Science, the Netherlands Association, USA Julian Martinez ICONICS, USA Little Systems, India
AFLAC, Canada Emerson Network Power,
Stanley Moses Johnny Sorensen Colombia Joel Albert Ken Lauer
Leslie Crothers Bahwan CyberTek Inc., USA Chr. Hansen, Denmark Industrial Networking Middough, USA
Almac, United Kingdom Roy Adams Solutions, USA
John Malinowski John Lewis ERA LLC, USA George Hockett II
Rob Cotner Baldor Electric Company, Cognex Corp., USA Josu Bilbao Miniature Plastic Molding
Anixter, USA USA Vikram Kumar IK4-IKerlan, Spain LLC, USA
Mohbat Tharani EZAutomation, USA
Carl Stelling Shawn Day COMSTATS Institute of John Wilson Deana Fu
Antaira Technologies, USA Henry Menke Technology, Pakistan John Holmes Integrated Automation, Bryan Knight
Balluff Inc., USA Festo Corp., USA Australia Mitsubishi Electric
Lonnie Purvis Hernan Gardiazabal Automation, USA
Apex Manufacturing Jeremy Jones ContrALL, Mexico Robert L. Fischer Sudhendu Banerjee
Solutions, USA Baumer Ltd., USA Fischer Technical Services, Instrumentation Ltd., India Stephen Chilton
Mike Cerda USA Monozee Ltd., United
John Coetzee Jingxu He Control M Automation, Majid Takabi Kingdom
Aristotle Consulting, South Bayer, USA Mexico Eric Esson JGC Co., Iran
Africa Frommelt Safety Products, Todd Desso
Mike Fahrion Sanjay Mishra USA Tom England Eddie Lee
Sujata Tilak B&B Electronics, USA COTMAC Electronics Pvt. Kollmorgen, USA Mike Werning
Ascent Informatics Pvt. Ltd., India Chris Alexander Moxa Americas, Inc.
Ltd., India Eric Byres Givaudan Flavors, USA Pierre Lampron
Mike Miklot Roy Greengrass KSH Solutions Inc., Canada Nelson South
Dave Robinson Belden, Inc., USA Del Monte Foods, USA Dr. Colin Harrison Nelson South Electrical,
Aurora Industrial Glasgow Caledonian Chris Weigmann Australia
Automation, USA A. Klemptner University, United Kingdom Lakeside Manufacturing,
DTE Energy, USA USA » CONTINUED ON PAGE 9
FACTORY & MACHINE Automation Playbook 9 / 167
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
FACTORY & MACHINE Automation Playbook 10 / 167
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
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
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.
SECTION ONE:
PLANNING AND IMPLEMENTING
AN AUTOMATION PROJECT
FACTORY & MACHINE Automation Playbook 14 / 167
continued
continued
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.
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.
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
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
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
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
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
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
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.
continued
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.
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
continued
425.745.3229
by signing a separate contract.
Every Machine
www.maplesystems.com
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FACTORY & MACHINE Automation Playbook 40 / 167
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
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
continued
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
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.
continued
continued
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
SECTION TWO:
SELECTING PRODUCTS TO BUILD
YOUR AUTOMATED SYSTEM
FACTORY & MACHINE Automation Playbook 52 / 167
continued
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
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
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.
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.
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
else should not be an alarm.
Get more vision.
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FACTORY & MACHINE Automation Playbook 61 / 167
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
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
continued
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.
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
» CONTINUED ON PAGE 69
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.
continued
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.
continued
Seven considerations for applying servo drives, motion controllers and PLCs
continued
Seven considerations for applying servo drives, motion controllers and PLCs
continued
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.
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
continued
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.
continued
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.
continued
continued
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.
continued
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
continued
continued
controllers and systems. This embedded approach to control separate, but helps drastically reduce the machine
robotics integration brings the robot module directly into footprint—by up to 50 percent—because there are fewer
the control platform’s chassis. It keeps machine and robot control boxes on a machine.
5. Tooling clearance. It is very important to have a clear, emergency maintenance never happens, and temporary, sub-
defined understanding of the type of end effector for your optimal, rigging ends up hurriedly being used.
application so that tooling does not damage in-order production
parts. Selecting a well thought-out end effector will also help 7. Get early feedback. Try and do as detailed a simulation
minimize the teach time on the final program to ensure the as early as you can and show it to the workforce involved in the
proper clearance to run the robot at the maximum speed. process in order to get feedback on possible operational issues.
You may find that there is more going on in the existing process
6. Plan for maintenance. For large robots, make sure than you knew about and that micro-management is necessary.
means for maintenance are included in the original project
scope. A monorail hoist designed in at the start of the project, 8. Zoning for product size. In a robotic pick-and-place
for example, is much cheaper and easier to install than one built system for thermoformed packaging trays, incorporate zoned
years later. Installing a hoist while running requires scheduling, suction cups that can be isolated or turned on and off, to allow
downtime, lost production, etc. Installing a hoist during for various tray sizes.
continued
425.745.3229
and sealing.
Every Machine
www.maplesystems.com
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FACTORY & MACHINE Automation Playbook 95 / 167
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
continued
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
continued
continued
3. Are the sensors mounted outdoors? It is important to enclosure rating. Consider hygienic requirements in sensor
know the maximum and minimum temperatures to which selection, since these are becoming more popular in the
the sensor will be exposed. For extreme environments, food and beverage industry.
an internal or external heating or cooling unit may be
necessary. Sometimes a heating unit is advantageous to 5. Is the sensor exposed to direct sunlight? During sunset or
reduce frost or fog 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.
continued
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
SECTION THREE:
APPLYING TECHNOLOGIES
TO IMPROVE OUTCOMES
FACTORY & MACHINE Automation Playbook 106 / 167
continued
continued
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.
continued
continued
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
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
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.
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
13 ways to get the most out of OEE and lean manufacturing disciplines
Calculating OEE
As described in World Class OEE, the OEE calculation is based 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 ON PAGE 122
continued
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.
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 »
FACTORY & MACHINE Automation Playbook 123 / 167
continued
13 ways to get the most out of OEE and lean manufacturing disciplines
continued
continued
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
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.
continued
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
continued
continued
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
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.
continued
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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.
continued
floor, use network equipment designed specifically for industrial accessibility, lockable PLC panels, server rooms), hazard protection
applications. (fire, floods, EMI, etc.), a disaster recovery plan and other features
as appropriate to the needs and concerns of your business.
3. Be on your guard. As with functional safety, the objects
involved in security are not only devices or equipment. There are 5. Defense-in-depth. In the past, industrial network security
human factors as well. Security is more challenging than safety, was accomplished through air gaps. Essentially, this relied on
because it’s always in a state of dynamic change. New malware, having physically separated or isolated systems to protect plant
viruses, worms and tools arise every day. Defenders need to be equipment and networks from the rest of the world. This type of
awake all the time. In an industrial environment, it’s more difficult security resulted in industrial systems with software that wasn’t
than in an office environment. The plant is not allowed to shut kept up-to-date with the latest security patches, as well as pockets
down its process. So policy, procedures and cooperation are very of unsecured networking equipment. Now these systems are
important in implementing an industrial security strategy. slowly becoming connected to public networks for the purposes
of remote administration, programming and monitoring, making
4. Develop a security policy. In addition to malware them vulnerable to many threats. In order to protect these
issues, implementation of a security policy should also include: networks, a defense-in-depth strategy should be deployed. This
an authentication mechanism, data backup procedures, off- type of defense protects in several places, such that bypassing a
site backup of electronic media, physical protection (such as single security device does not provide unfettered access to the
continued
continued
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.
continued
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
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.
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.
continued
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.
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
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FACTORY & MACHINE Automation Playbook 153 / 167
awgo.to/140
COMPANY: FESTO PHONE: 1 800 99 FESTO WEB: www.festo.com/us
YOUTUBE
http://www.youtube.com/user/
COMPANY: Omron Automation and Safety ADDRESS: One Commerce Drive, Schaumburg, IL 60173 OmronAutomationTech
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
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
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FACTORY & MACHINE Automation Playbook 159 / 167
COMPANY: Opto 22 ADDRESS: 43044 Business Park Drive, Temecula, CA 92590
PHONE: (800) 321-6786 WEB: www.opto22.com
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FACTORY & MACHINE Automation Playbook 161 / 167
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
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FACTORY & MACHINE Automation Playbook 162 / 167
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
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FACTORY & MACHINE Automation Playbook 163 / 167
COMPANY: Siemens Industry, Inc ADDRESS: 3333 Old Milton Parkway, Alpharetta, GA 30005
WEB: www.usa.siemens.com/industry EMAIL: info.us@siemens.com
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FACTORY & MACHINE Automation Playbook 164 / 167
COMPANY: Siemens Industry, Inc ADDRESS: 3333 Old Milton Parkway, Alpharetta, GA 30005
WEB: www.usa.siemens.com/industry EMAIL: info.us@siemens.com
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FACTORY & MACHINE Automation Playbook 165 / 167
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.
COMPANY: Teledyne DALSA ADDRESS: 700 Technology Park Drive, Billerica, MA 01821
PHONE: 978-670-2000 WEB: www.teledynedalsa.com
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167 / 167