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MCI (P) 024/07/2015 | ISSN 0219/5615 | PPS 1561/06/2013 (022960)


pg 32

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Visit us on our website at www.iaasiaonline.com ISSUES & INSIGHTS


Industry 4.0 And The Connected Enterprise


The Internet Of (Secured) Things


Industry 4.0: The Evolution Continues


Laying The Foundation For Industry 4.0


Addressing IIoT Challenges Through Protocol Conversion

Industry 4.0 is a term that is being used extensively with regards to manufacturing in the modern era, also known as the connected enterprise, some of the benefits and strategies for realising such a vision will be discussed. By Tang Poi Toong, Rockwell Automation

The Internet of Things (IoT) presents many opportunities but also introduces some challenges around security and integration. Some of these considerations will be discussed. By Ang Thiam Guan, Cisco

Industry 4.0 is revolutionising the manufacturing sector with lower costs and increased efficiency and productivity. By Stefan Hensel, B&R

With the advent of IoT and Industry 4.0, factories and the sensors that occupy them are becoming more intelligent helping lower costs and increase productivity. Michael Kaspar, Sick


The Internet of Things (IoT) is changing many sectors and offers many varied opportunities. By Jeff Thornton, Red Lion Controls



Case Study: Simple Differential Equation

At the differential gear production plant of a Chinese auto parts supplier, Turck is showing how its IO-Link solution for signal connection is easy, fast and efficient. By Yu Gu, Turck (China)



MES – But Do It In The Right Way

Understanding the proper way of implementing a Manufacturing Execution System (MES) in the context of Industry 4.0 is important to gain the most benefits. By Sascha Graef, MPDV Asia



Feeling The Force: Singapore’s Newest Test Facility

IAA interviewed Dr Thomas Liew, executive director, National Metrology Centre; Lee Shih Mean, senior metrologist, National Metrology Centre; Sim Sem Peng, chairman, Malayan Daching; and Elton Tong, service manager, Malayan Daching, on the relationship between Malayan Daching and A*Star in setting up Singapore’s first 20 MN force measurement facility. By Mark Johnston




Energy Efficiency Is By Far The Best Way To Tackle Climate Change

Energy efficiency is of critical importance in reducing wastage and impacting climate change in a positive way. By Dr Ulrich Spiesshofer, ABB



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Buy Vs. Build: Advantages Of A Modular Design



A Primer On Additive Manufacturing


Upping The Gears Of Productivity

Additive manufacturing (or 3D printing) is revolutionising the manufacturing sector decreasing the cost of production and increasing productivity. By Chris Lee, Autodesk (ASEAN)

Robotic technologies are gaining popularity across the world, especially Asia, with their improving features and functionalities. Small and medium-sized enterprises are also gaining increased accessibility to these robots as they become more affordable and simpler to implement. By Shermine Gotfredsen, Universal Robots


What Is Next For The Wireless Industry?

Some of the top Wi-Fi Trends that may be seen in 2016 will be discussed. By Michael Lok, Ruckus Wireless


M2M Predictions For 2016


Doubling Up On Productivity




MCI (P) 024/ 07/2015 | ISSN 0219/5615 | PPS 1561/06/2013 (022960)



Some of the challenges and details associated with off-the-shelf embedded modules and how and where savings can be realised by opting for buying a pretested module instead of building a system from the ground up will be discussed. By Wolfgang-Heinz Fischer, TQ Group


Industry 4.0 | Manufacturing Execution Systems | Design & Test Integration | Semicon


February / March 2016

Connect with us at www.facebook.com/IAAsia



pg 32

COVER Sep15 (FINAL).indd 1

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The advent of the Internet of Things (IoT) and new M2M technology and approached offers many novel solutions to everyday tasks. By Justin Nelson, Vodafone Global Enterprise

Thanks to the implementation of a new line featuring robots, which was made possible by the collaboration between SIR, a system integrator based in Modena, and FCA Cento, production of new engine blocks for 3000cc V6 diesel engines has doubled. Contributed by Comau



Moving Into Industry 4.0: The Power Of PLM In Your Automotive Supply Chain


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Together we move the world The Schaeffler Group is a leading global integrated automotive and industrial supplier. The company stands for the highest quality, outstanding technology and strong innovative ability. The Schaeffler Group makes a decisive contribution to “mobility for tomorrow” with high-precision The Schaeffler is ina engine, leadingtransmission global integrated automotive and components andGroup systems and chassis applications industrial supplier. The company stands for the highest quality, outstanding as well as rolling and plain bearing solutions for a large number of industrial technology strong innovative network ability. The Schaeffler Group makes applications.and It has a worldwide of manufacturing locations, a decisive tofacilities “mobility tomorrow” withat high-precision research andcontribution development andforsales companies approximately components systems in engine, transmission and chassis applications 170 locationsand in 50 countries. as well as rolling and plain bearing solutions for a large number of industrial applications. It has a worldwide network of manufacturing locations, research and development facilities and sales companies at approximately 170 locations in 50 countries.

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February / March 2015 | industrial automation asia

Published By:

Spreading Awareness Of Industry 4.0 THE year ahead looks bright for the automation sector, with 2016 set to be a game changing year for the Internet of Things (IoT) and many other emerging trends in the technology sphere. Industry 4.0 has been a buzzword for some years now, but in 2016 and beyond we can expect to see a surge in new projects and a greater awareness of Industry 4.0 and what is required from companies looking to adopt such a strategy. The German government, when conceptualising ‘Industry 4.0’ as a strategy were betting on infrastructure becoming increasingly digital and manufacturing becoming increasingly connected. However, as discussed with some companies spearheading this initiative, there still lacks awareness amongst smaller companies and how it can benefit them. For instance, according to a survey published by the Centre for European Economic Research only 18 percent of entrepreneurs know what Industry 4.0 means, and only 4 percent of German companies have started digitally interconnected production or are planning to implement it in the near future. There is no doubt Industry 4.0 is growing in awareness, and with the rise of the Internet of Things (IoT) it is only a matter of time before a wider array of companies look to adopt and leverage connectivity to their advantage. In this issue, in addition to Industry 4.0, we also look at tracking systems, manufacturing execution systems, the setting up of a new 20 MN test facility in Singapore, module design in the electronics sector, and reducing energy consumption by way of instrumentation.

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Ang Thiam Guan, Stefan Hensel, Michael Kaspar, Jeff Thornton, Tang Poi Toong, Yu Gu, Sascha Graef, Dr Ulrich Spiesshofer, Wolfgang-Heinz Fischer, Chris Lee, Michael Lok, Justin Nelson, Shermine Gotfredsen, EDITORIAL CONSULTANTS

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tool tool Get Get Getthe the theresults results resultsthat that thatonly only only the the theright right righttool tool toolcan can cangive give give When When When you’re you’re you’re ready ready ready totoautomate toautomate automate your your your business, business, business, choose choose choose the the the automation automation automation tool tool tool that that that fits fits fits your your your needs needs needs exactly. exactly. exactly. Collaborative Collaborative Collaborative robot robot robot arms arms arms from from from Universal Universal Universal Robots Robots Robots work work work safely safely safely side-by-side side-by-side side-by-side with with with your your your employees employees employees atatlow atlow low ownership ownership ownership cost. cost. cost. These These These innovative innovative innovative tools tools tools are are are lightweight lightweight lightweight and and and easy easy easy totomove tomove move and and and programme, programme, programme, so soso you you you can can can optimise optimise optimise production production production for for for processes processes processes from from from assembly assembly assembly &&dissembling, &dissembling, dissembling, machine machine machine tending, tending, tending, polishing polishing polishing and and and grinding grinding grinding totopick-andtopick-andpick-andplace/ place/ place/ loading loading loading and and and unloading. unloading. unloading. Get Get Get the the the results results results that that that only only only the the the right right right tool tool tool can can can provide. provide. provide. Discover Discover Discover what what what robots robots robots can can can do dodo for for for you you you and and and book book book aademo ademo demo with with with us usus today. today. today.

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QuickBites Automation Industry Top News at a glance Dell Launches Its First Asia Pacific Internet Of Things (IoT) Lab In Singapore Singapore: Dell has opened its first dedicated Internet of Things (IoT) lab in the Asia Pacific and Japan (APJ) region.

Statoil Signs New Multi Year Agreement With Aveva For 3D Design Software Platform Cambridge, UK: Aveva has announced that it has entered a multiyear agreement with Statoil ASA for Aveva Everything3D (Aveva E3D).

AliCloud Launches One-Stop Platform For Big Data Products Singapore: AliCloud has announced the launch of the ‘Big Data Platform’ at its Computing Conference — 2016 Shanghai Summit attended by 3,000 industry representatives including AliCloud global partners, developers, entrepreneurs and government agencies.

Inmarsat Expands Presence In Singapore With Largest Facility In Asia Pacific Singapore: Inmarsat, has opened its new Singapore office, which is the company’s largest facility in Asia Pacific region.

Cognizant Takes Steps To Enable Clients To Accelerate Journey To Cloud And Improve Business Agility Singapore: Cognizant has announced that it has acquired privately-held KBACE Technologies, Inc., a global consulting and technology services company specialising in cloud strategy, implementation and integration.

February / March 2016 | industrial automation asia

Universal Robots Develops Robotics Solutions To Drive Local Industrial Adoption

Singapore: Universal Robots (UR) is embarking on a project involving their local distributor, Skymech Automation & Engineering (Skymech) to develop various new industrial robot applications that will showcase the ways in which Small and MediumSized Enterprises (SMEs) in Singapore can benefit from automation in the form of these robotic solutions.

With the support of the Singapore Economic Development Board (EDB) and SPRING Singapore, Universal Robots has partnered Skymech, a distributor of Universal Robots in Singapore, which will expand its range of robot applications, benefitting businesses across industries that intend to adopt and deploy these technologies. This collaboration seeks to spearhead the development of the robotic industry and promote enterprise development, through joint efforts between robot manufacturers and system integrators like Skymech to upgrade capabilities and develop scalable solutions for their customers. The first two applications that Skymech will begin developing include ‘vision pick & place’ as well as ‘machine tending’, which are two commonly used applications in the Precision Engineering (PE) sector. The vision pick & place application involves robots being equipped with cameras, or vision sensors, allowing them to pick parts in unknown orientations while the machine tending application enables robots to pick up raw materials and feed them to a Computer Numerical Control (CNC) machine (which is widely used in the PE sector), for example. Once the desired task has been completed, the CNC machine will send a signal to the robot for unloading. The deployment of these applications would help to improve the productivity of industry users handling precise parts and processes. Operators with no prior engineering experience will also be able to program the robots easily, thanks to an intuitive built-in interface. To facilitate the uptake of these applications, they will be showcased in UR’s Singapore office from January 2016 onwards. According to the project schedule, five applications are set to roll out after each cycle of 12 months. This project will also see the launch of a series of technical workshops and seminars that will be publicly open to those interested in learning more about new technologies and how to apply them into their everyday work environment.



February / March 2016 | industrial automation asia

The Institution of Engineers, Singapore (IES)


Er. Chong Kee Sen, president, The Institution of Engineers, Singapore; and associate professor Lim Tit Meng sign an MoU to intensify collaborations in promoting science and engineering to the public.

The Institution Of Engineers, Singapore Strengthens Collaboration With Science Centre Singapore To Elevate Promotion Of Science And Engineering Singapore: The Institution of Engineers, Singapore (IES) and Science Centre Singapore (SCS) have signed a Memorandum of Understanding (MoU) to intensify collaborations in promoting science and engineering to the public, especially the younger generation. Held in conjunction with the launch of SCS’s first Tinkering Studio, the MoU was signed by Er. Chong Kee Sen, IES President and Associate Prof Lim Tit Meng, SCS Chief Executive. Dr Vivian Balakrishnan, Minister for Foreign Affairs, graced the event as the guest-of-honour and witnessed the MoU signing at SCS. Through this MOU, IES and SCS, both champions in promotion of engineering, will build upon each other’s expertise, perspectives and

networks to set forth an exhilarating line-up of engineering-based promotional activities. They will also cross-share expert resources to support and enrich each other’s events as mentors and judges. The MoU will see to the joint organising of talks, forums, symposia and other forms of outreach events, including the F1 programme, robotics competitions and ‘Meet-the-Engineers’ sessions; nationwide events such as the National Engineers Day (NED) and the Energy Innovation Challenge (EIC); as well as a new engineering exhibition to be held at SCS. Both parties already enjoy a fruitful partnership in engaging the young in engineering, having jointly organised the inaugural EIC in 2015.

Richard Cheng

Microscan Welcomes New Regional Sales Director For Greater China Washington, United States: Micros-

can has announced the appointment of Richard Cheng to the position of regional sales director for Microscan’s Greater China region (including China and Hong Kong). In his new role, Mr Cheng will be responsible for all of the company’s sales and applications engineering activities in China and Hong Kong, reporting to Scott Summerville, president, Microscan. Mr Cheng has held increasingly responsible positions in sales leadership during his six years with the company and recently led the China sales team to reach peak sales in the company’s history serving the Chinese market.




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February / March 2016 | industrial automation asia

Dell Launches Its First Asia Pacific Internet Of Things (IoT) Lab In Singapore Singapore: Dell has opened its first dedicated Internet of Things (IoT) lab in the Asia Pacific and Japan (APJ) region. Based within the Dell Solution Centre in Singapore, the new facility, launched in collaboration with Intel, was unveiled by Glen Burrows, Area VP, Dell OEM, Asia Pacific and Japan and Prakash Mallya, MD, South East Asia, Intel. The lab features Dell and Intel IoT solutions with end-to-end platform facilities allowing customers to test the products and consult with Dell technical experts. This is the company’s third IoT lab globally, following the successful launch of its labs in Silicon Valley, US and Limerick, Ireland. Building on Dell’s and Intel’s strategy to support customers in their IoT projects, this facility will focus on enabling intelligent devices and gateways, speeding up the connection of legacy systems to the cloud and enabling end-to-end analytics to turn big data into actionable information. It will allow customers to build, modify and architect new IoT solutions on active bench space within the lab and have access to Dell technical experts, while capitalising on the company’s ability to span edge to the datacentre. Other partners within the IoT ecosystem, from developers to

The new facility will deliver a number of important benefits to the company as part of its IoT strategy.

Independent Software Vendors (ISVs) will also be able to benefit from the lab by having a working space to innovate using Dell and Intel IoT solutions. The new facility delivers a number of benefits to Dell customers including: • Ability to develop and test IoT proof-of-concepts (POCs) with some of the latest Dell and Intel solutions which includes the Dell Edge Gateway 5000 Series and IoT analytics solutions. • Access to Dell’s end-toend technologies, including servers, storage, networking and software solutions, allowing customers to test

the scalability of their IoT solutions. Significantly speeding up the time to market with new IoT and other OEM solutions.

In-line with Dell’s strategy to improve its offerings in the IoT space, the company also announced the formation of a division focused on bringing together enterprise end-toend IoT solutions that span hardware, software and services in May 2015. The subsequent efforts including launching IoT Labs, are streamlining the company’s focus on enabling enterprise customers with gateways, data centre solutions and analytics services.

Did you know?

The wearable device segment is expected to grow at the highest CAGR and dominate the IoT chip market between 2016 and 2022.





February / March 2016 | industrial automation asia

Statoil Signs New Multi Year Agreement With Aveva For 3D Design Software Platform Cambridge, UK : Aveva has announced that it has

entered a multiyear agreement with Statoil ASA for Aveva Everything3D (Aveva E3D). The Norwegian Energy owner operator has selected Aveva E3D to be its strategic 3D design software platform. Following the migration to Aveva E3D by a number of other companies, Statoil selected it as the natural upgrade of its existing design system, Aveva Plant Design Managememnt System (PDMS). Statoil will benefit from improved design efficiency and Aveva E3D’s simple migration from Aveva PDMS, means there will be no disruption to existing projects. This will give Statoil and its contractors the possibility of cutting project schedules and reducing rework during both the design and construction phase.

Did you know?

Asia Pacific emerged as the leader in IoT spending in 2015, contributing more than 40 percent of the worldwide total.

IoT Asia 2016: Closing The Gap Between Vision And Reality Singapore: Internet of Things Asia (IoT Asia 2016) returns with its third edition in 2016 with the theme of Closing the gap: From vision to reality. Jointly organised by the Singapore Industrial Automation Association (SIAA) and SingEx Exhibitions (SingEx), the IoT Asia 2016 conference and exhibition aims to go beyond addressing the benefits and promises of IoT in Asia and making it a reality. The event will be held from March 30-31, 2016 at the Singapore Expo Convention and Exhibition Centre. Delegates to IoT Asia 2016 will see the introduction of a new conference structure featuring five dedicated tracks to address the latest industry needs, and six thematic zones on the exhibition floor. There will also be new elements which will explore real and relevant technological developments and capabilities that businesses, governments and communities can tap on to make IoT a reality. The event serves as a platform for participants from a wide range of verticals — including healthcare, manufacturing, retail and transportation — to discuss key issues faced by the IoT industry and seek effective solutions. According to International Data Corporation (IDC), worldwide spending on IoT will grow from US$655.8 billion in 2014 to US$1.7 trillion in 2020. The analyst group also confirmed that Asia Pacific emerged as the leader in IoT

spending in 2015, contributing more than 40 percent of the worldwide total. At the two-day conference, IoT Asia 2016 aims to deliver critical industry-driven insights featuring over 80 international speakers and industry experts from 17 countries. The main focus this year is to provide a platform for participants to address the real nuts and bolts, issues and challenges of IoT implementation, and propel the industry forward. The revamped and expanded conference structure will present an array of forward-thinking keynotes and panel discussions across five focused tracks: Smart Cities, IoT Data Analytics, Design Applications, Wearables and Industrial IoT (IIoT).




February / March 2016 | industrial automation asia

Inmarsat Expands Presence In Singapore With Largest Facility In Asia Pacific (l-r) Andrew Lim, MD, business group, Singtel; Beh Kian Teik, executive director for space, technology and industry; Rupert Pearce, CEO, Inmarsat; and Ronald Spithout, President, Maritime, Inmarsat

AliCloud Launches One-Stop Platform For Big Data Products Singapore: AliCloud has announced the launch of the ‘Big Data Platform’ at its Computing Conference — 2016 Shanghai Summit attended by 3,000 industry representatives including AliCloud global partners, developers, entrepreneurs and government agencies. AliCloud also signed a strategic partnership with visual computing firm, NVIDIA at the Summit. Backed by AliCloud’s experience in data management, the Big Data Platform offers 20 new solutions covering all aspects of the data development chain, such as computing engine, data processing, data analysis, machine learning and data application. The company expects that it will partner with about 1,000 data developers on the platform in the next three years. During the Shanghai Summit, the company also announced its strategic partnership with NVIDIA. The two companies will collaborate closely around AliCloud High Performance Computing (HPC) to provide the first GPU-based cloud HPC platform in China. The partnership also plans to provide emerging companies support in areas of HPC and deep learning with comprehensive Graphics Processing Unit (GPU) computing.

Did you know?

Eighty-eight percent of organisations are using public cloud while 63 percent are using private cloud.

Singapore: Inmarsat, has opened its new Singapore office, which is the company’s largest facility in Asia Pacific region. The company’s investment in the 1,700 sq metre (19,500 sq feet) office in Toa Payoh, Central Region Singapore, sees its regional hub providing a new solutions lab, demonstration capabilities, training rooms, a knowledge centre and support centre, in addition to enhanced production and storage facilities. The opening ceremony was attended by Inmarsat’s CEO, Rupert Pearce, Beh Kain Teik, executive director, Office for Space Technology and Industry (OSTIn), Singapore Economic Development Board along with many of the company’s partners and customers. Singapore has been the company’s Asia Pacific headquarters since 2008. The company confirmed that its decision to invest in a new and expanded facility was driven in particular by Singapore’s outstanding infrastructure, its innovative culture and the deep pool of talent on which the company can draw as its expansion in Asia Pacific gathers pace. Coinciding with the opening of the new office, the company announced that it has signed an agreement with local partner SingTel for the provision of Inmarsat’s L-TAC services, enabling SingTel to provide Beyond Line Of Sight (BLOS) mobile communications to a broad range of government users in the Asia Pacific region. The contract enhances Inmarsat and SingTel’s relationship in the government sector. Key Singapore partners and customers of Inmarsat include: SingTel, Singapore Airlines, roKKi, AddValue, iDirect, ST Engineering, MediaCorp, Kemilinks International, Jason Electronics, EMAS, POSH and BSM.


February / March 2016 | industrial automation asia

CyberArk Appoints Vincent Goh VP Of Sales For Asia Pacific And Japan Singapore: CyberArk has announced that Vincent Goh has been named VP of sales for Asia Pacific and Japan. With more than 20 years of technology industry experience, Mr Goh was most recently VP, Asia Pacific and Japan for RSA, The Security Division of EMC. In this senior management role at CyberArk, Mr Goh leads sales and channel teams, and is responsible for growing the company’s customer base and channel relationships Vincent Goh across Asia Pacific and Japan. CyberArk continues to invest in expanding its business in Asia Pacific, with third quarter 2015 revenues in the region more than doubling year-over-year. In addition to driving growth for various business portfolios within RSA, Mr Goh chartered the transformation of RSA from an authentication-focused business to an intelligence-driven security provider in Asia Pacific and Japan. He consistently increased revenue for RSA in Asia Pacific during his tenure.

Johnson Controls Advances Environmental Sustainability Singapore: Johnson Controls is advancing its White House Council on Environmental Quality commitment by enhancing HFC product lines to be fully compatible with the non-flammable, low-GWP refrigerant — Opteon XP10 (R-513A) manufactured by The Chemours Company. York centrifugal and screw chillers ranging from 125 to 6,000 tonnes (440 to 21,100 kW) are compatible with R-513A. Chemours’ Opteon XP10 (R-513A) is a nonflammable (A1) azeotropic alternative to R-134a, providing 56 percent lower GWP and comparable performance. XP10 was commercialised as a part of a broad portfolio of Opteon refrigerants, which represent a breakthrough line of low-GWP solutions developed to help meet the current and proposed HFC regulations while maintaining or improving performance compared to incumbent products. While low-GWP refrigerants are important for the f uture, energy efficiency represents the greatest opportunity for true greenhouse gas emission reductions. Energy consumption represents as much as 95 percent of a chiller’s lifetime carbon emissions.

Accenture’s New Digital Portal Helps Product Developers And Engineers Accelerate Deliveries To Market

Singapore: Accenture has launched

a digital por tal that helps product developers such as engineers accelerate delivery of products to market at lower costs through greater efficiency. The Accenture Enterprise Product Information and Content (EPIC) Portal consolidates large amounts of product development data from multiple enterprise systems in a single, organised view, reducing the time needed for product developers to search for this data by up to 95 percent. Leveraging this portal, these professionals can use analytics to anticipate and solve problems, as well as develop insights and make betterinformed decisions. The company developed the EPIC portal for companies that design, engineer and manufacture complex

products in the aerospace, automotive, consumer products, electronics, industrial equipment, high-tech and life science industries. The portal features predefined integration with product lifecycle management, enterprise resource planning and a range of other applications used in product design and production. For example, a supply chain procurement engineer with an automotive manufacturer could use the EPIC portal to more rapidly ascertain the engineering status of automotive parts and avoid delays delivering products to market. Knowing this status also benefits numerous other corporate groups, including engineering, sourcing, quality, marketing, manufacturing and operations.




Cognizant Takes Steps To Enable Clients To Accelerate Journey To Cloud And Improve Business Agility Singapore : Cognizant has announced

that it has acquired privately-held KBACE Technologies, Inc., a global consulting and technology services company specialising in cloud strategy, implementation and integration. The Nashua, New Hampshire-based firm has one of the largest reference bases of Oracle Cloud Applications customers in the world and is a leading Oracle Cloud partner. The terms of the transaction were not disclosed. The acquisition strengthens and expands the company’s digital capabilities as more clients move critical business applications to cloudbased IT infrastructures to reduce costs and complexity and improve business agility. As part of the acquisition, approximately 400 KBACE consultants and implementation experts across industry and business functions will become part of Cognizant. The combined capabilities will further enable the company to help clients become intuitively digital by using the cloud to derive new insights, unlock new opportunities and lower costs through a subscription-based business model.

February / March 2016 | industrial automation asia

ABB To Strengthen Power network At World’s Busiest International Airport Zurich, Switzerland :

ABB will upgrade its Supervisory Control And Data Acquisition (SCADA) system for the power network at Dubai International (DXB), the world’s busiest international airport. The upgraded system includes replacement of the central computers and deployment of the latest version of the company’s Network Manager software. This will connect to the existing field devices (remote terminal units, bay control units and main distribution boards) and increase the operational reliability and efficiency of the power network to support a large-scale airport expansion plan. The company delivered the first SCADA system to Dubai International in 2004 and the monitored network has grown fivefold since then. In addition to augmenting capacity and offering, advanced features include highly efficient real-time alarm and event handling. The company’s SCADA solution provides a common power distribution automation system and today handles data signals from approximately 100,000 sources distributed over the entire power network at any given time. As part of the current system, field-based sensors continuously monitor detailed data related to the power network in real time, and provide the operator with analytics to support decision making processes and optimise operations.

Schneider Electric Gets Its Highest Score Ever In Sustainable Corporations World Ranking Singapore : Schneider Electric has been recognised as one of the

2016 Global 100 Most Sustainable Corporations in the World, coming 12th overall and 1st in its GICS Industry. It is the fourth year running the Group ranks among the top 15 corporations in the sustainability index by Corporate Knights, the magazine for clean capitalism, released every year at the World Economic Forum in Davos.



Companies who make the Global 100 ranking are the top overall sustainability performers in their respective industrial sectors, selected from a starting universe of 4,353 listed companies with a market capitalisation greater than US$2 billion on October 1, 2015. The Global 100 is determined using 12 quantitative sustainability indicators, as the amount of revenue companies generate per unit of energy consumed for example.

February / March 2016 | industrial automation asia

F5 Networks Appoints Vishal Singh As Regional VP To Drive Growth In ASEAN Singapore: F5 Networks recently announced the appointment of Vishal Singh as Regional VP for Sales for the ASEAN region. Based in Singapore, Mr Singh will be responsible for charting the company’s revenue growth and penetrating new markets. He reports to EmVishal Singh manuel Bonnassie, senior VP, Sales, for the Asia Pacific (APAC) region. Mr Singh joins F5 with over twenty years of experience, having held senior sales roles with technology industry players like Oracle and Microsoft. Most recently, he was VP, Sales (Network & Software) in ASEAN and ANZ for Oracle Communications Global Business Unit.

Did you know?

Data mining, pattern recognition, business analytics, business intelligence, and other tools are coalescing into an emerging field of supply chain data science. These new intelligent analytic capabilities are changing supply chains — from reactive operations, to proactive and ultimately predictive operating models.


DHL Supply Chain Launch White Paper Highlighting How Data Science And Supply Chain Management Are Driving The Predictive Enterprise Singapore: DHL has launched its latest white paper high-

lighting the untapped power of data-driven insight for the supply chain. The white paper reveals that most companies are sitting upon a goldmine of unutilised supply chain data that has the ability to give organisations a competitive edge. While this wealth of supply chain data already runs the day-to-day flow of goods around the world, the white paper documents a small group of trailblasing companies that are using this data as a predictive tool for accurate forecasting. ‘The predictive enterprise: Where data science meets supply chain’ is a white paper authored by Lisa Harrington, president of the lharrington group LLC that was commissioned by DHL to identify the opportunities available to companies to anticipate and even predict the future. It encourages companies to get ahead in their business and direct their global operations accordingly. Data mining, pattern recognition, business analytics, business intelligence, and other tools are coalescing into an emerging field of supply chain data science. These new intelligent analytic capabilities are changing supply chains — from reactive operations, to proactive and ultimately predictive operating models. The implications extend far beyond just reinventing the supply chain; they will help map the blueprint for the next-generation global company — the insight-driven enterprise. While supply chain analytics technologies and tools have come a long way in the last few years, integrating them into the enterprise is still far from easy. Companies typically progress through several stages of maturity as they adopt these technologies. The descriptive supply chain stage uses information and analytics systems to capture and present data in a way that helps managers understand what is happening. Descriptive tools have been effective in helping companies cut costs and eliminate waste in their supply chains, but leading companies are moving beyond the descriptive phase towards a more predictive supply chain. The predictive supply chain allows companies to start to sense and shape demand, streamline networks, and improve agility and responsiveness. Essentially, the predictive supply chain is a vital underpinning of a re-imagined, predictive enterprise.


INDUSTRY UPDATES PROFIsafe Is First National Safety Standard In China

& Economy Institute, P.R. China) in Beijing collaborated closely with the Chinese national standardisation committee SAC/TC124 Industry Process Measurement and Control.

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Successful Year For IO-Link PROFIsafe – the first and only communication-based safety standard – has been elevated to the status of a Chinese national standard.

Following successful standardisation of Profibus and Profinet in China, Profisafe — the first and only communication-based safety standard — has now been elevated to the status of a Chinese national standard. This is further evidence that the world leading PI technologies are highly regarded in China — not least because of their high quality but also based on their large installed base and reliable organisation. Functional safety has long played a very important role in production facilities in industrialised nations. The importance of functional safety in China has risen enormously in recent years. The use of fieldbus-based functional safety not only enables the setup of simple safety functions that initiate safe stopping of equipment under hazard conditions in order to protect humans and machines. It also offers intelligent methods for prevention of hazards without having to stop production with a shutoff device. An example of this would be to reduce the speed of robot motions or self-driving vehicles to an extent that people moving in their vicinity can easily evade them. Profisafe provides a very sound technological basis for this and supports these functions within the framework of profiles. After successful conclusion of all standardisation activities and votes in the national standardisation committee, establishment of a certification lab for Profisafe devices, and successful development and certification of an initial product by an original Chinese company, PI has met all requirements for the status of a national standard and is listed under designation GB/T 20830-2015. This was acknowledged in an official ceremony in the presence of more than 100 high-level representatives of the Chinese economy and universities in which PI Chairman Karsten Schneider participated. Leading up to this, experts from PI and the PI Competence Centre and ITEI test lab (Instrumentation Technology 24  industrial automation asia | February / March 2015

At SPC IPC Drives 2015, 39 members of the IO-Link member community presented 170 devices and components.

2015 ended successfully for IO-Link. At SPC IPC Drives, 39 members of the IO-Link member community presented 170 devices and components under the motto ‘Enabler for Industry 4.0’. The various sensors, actuators, masters and services illustrate the possibilities of high-performance point-to-point communication. More and more companies are convinced of the benefits. This is demonstrated by the member count, which increased by 36 percent in 2015 to 112 members, and by the increasing number of installed nodes, which is now well over the three million mark. At the end of 2014, there were only 2.19 million installed nodes. The interest in IO-Link is growing internationally as well. Evidence of this can be seen in Got a Question? the strong attendance numbers at Make An Enquiry. workshops held in 2015 in the US, ENQUIRY NUMBER the Netherlands, Poland, Milan, and Prague, among other locations. The IO-Link member community wants Turn to page 72a to enquire to continue its successful concept or log on to: www.iaasiaonline.com in 2016.


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CiA Exhibits At EmbeddedWorld In Nuremberg The CAN in Automation (CiA) international users’ and manufacturers’ group is as usual part of the EmbeddedWorld exhibition. The nonprofit association provides in hall 1 (stand 630) first-hand information about the recently released CAN FD standard (ISO 11898-1:2015). Additional information on CAN FD interface implementations (CiA 601-1) and ringing suppression (CiA 601-4) will be given. CiA will also provide the roadmap for CANopen FD making use of the enlarged payload (up to 64 byte). Another topic is the recently published standards IEC 61800-7-201/301:2015 specifying the CiA 402 CANopen profile for drives and motion control. “The EmbeddedWorld is one of our most important exhibitions,” said Holger Zeltwanger, MD, CiA. “It is a good opportunity to collect the latest information on CAN technology including CANopen and other higher-layer protocols and related device and application profiles.”

Ringing Suppression In CAN FD Networks CAN in Automation (CiA) has released the CiA 601-4 draft standard proposal specifying the ringing suppression in CAN FD networks. The basic idea is simple: The specified circuitry changes the overall impedance for a short time after the dominantto-recessive state change. The duration depends on the chosen data-phase bit-rate. In CAN FD networks using single-star or multiple stars or hybrid (star plus linear bus) technologies, the ringing on the bus-lines limits the maximal possible data-phase bit-rate. Therefore, the ringing suppression is very important. Most of the carmakers will migrate to CAN FD networks within the next few years. CAN FD standardised internationally in ISO 11898-1:2015 supports higher bit-rates in a part of the data frame. Additionally, the improved data link layer protocol features payloads of up to 64 byte. The Classical CAN protocol was limited to an 8-byte data field. The CiA 601-4 document is released CiA internally, but interested parties may request a personalised copy from CiA headquarters in Germany. The ringing suppression circuitry specified in this document can be implemented in ISO 11898-2 compliant transceivers or implemented Got a Question? Make An Enquiry. as a stand-alone circuitry.

CiA 417 Documents Updated CAN in Automation (CiA) has released new versions of the CiA 417 application profile for lift control, better known as CANopen Lift standard. After three years, the four-part specification has been updated. Part 1 (version 2.2.0) contains general definitions, which have been improved editorially. Part 2 (version 2.2.0) specifies additional parameters for program download purposes. The table of CAN-IDs used for lift controller 1 in part 3-1 (version 2.1.0) has been updated, too. Most of the changes are related to part 4 (version 2.2.0), which specifies in detail the application objects (process data and configuration parameter). Input and

output functions have been added. Other new parameters are related to the inverter virtual device, also know as car drive unit. The latest versions of the CiA 417 documents are accessible only for CiA members. Nonmembers can download free-of-charge version 2.0.0. New is the CiA 814 application note. Part 1 describes the boot-loader. It provides implementation hints for the boot-loader as specified in CiA 417 version 2.2.0. On start-up the boot-loader is executed first. It checks for a valid application program. If the application code is valid, this code is executed and the device resumes operating. When the boot-loader is called



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during runtime, it waits for commands received via the CANopen Lift network. This includes commands such as erase flash memory, flash a program, or verify the downloaded program. Non-members can download this application note from CiA’s website. An application profile specifies all CANopen interfaces in an application, eg: a lift control system, which may comprise different network segments interconnected by means of bridges or gateways. It is a virtual system approach. The interoperability of the connected devices from different manufacturers is one of the most important benefits of CiA 417.

ISA Publishes Book On The Application Of Foundation Fieldbus

The International Society of Automation (ISA) has announced the publication of Applying Foundation Fieldbus, a new ISA book that is designed to serve as a comprehensive and practical guide to the theory, engineering and implementation of Foundation Fieldbus in process control systems. The ISA has announced the publication of a new book that is designed to serve as a comprehensive and practical guide to the theory, engineering, and implementation of Foundation Fieldbus in process control systems.

The book, authored by Bharat Ratilal (B.R.) Mehta, Ph.D. and Jaganmohan (Y.J.) Reddy, Ph.D., examines: • The theory of the operations and basic concepts of the Foundation Fieldbus standards. • The different topologies and installation options available in Foundation Fieldbus standards and their applications for enabling engineers to design control systems for solving industry problems. • The critical factors to consider when using Foundation Fieldbus -based host systems and field transmitters. • The pivotal issues in Foundation Fieldbus from the perspective of an experienced practitioner at a leading company that was a major Foundation Fieldbus installation. “This book is aimed at providing the knowledge that engineering and maintenance teams require in applying Foundation Fieldbus,” explained Dr Mehta, senior VP at Reliance Industries, in Mumbai, India. “The technology benefits and areas for improvement Got a Question? are unbiased. And because the book Make An Enquiry. is written from a user’s point of view, ENQUIRY NUMBER it bridges the gap between theory and technician-level coverage on a practical basis.” Turn to page 72a to enquire Essential to the book, Dr Mehta or log on to: www.iaasiaonline.com explained, are its clear coverage of


concepts and applications, straightforward guidelines for implementing process control systems with Foundation Fieldbus technology, and real-world examples of deployments that have translated theory into practice. “The book offers a pragmatic approach to the subject, based on industrial experience and taking into account the latest technologies and professional practices,” he added. “It is suitable as an important introduction for junior-level professionals as well as an essential reference for more experienced practitioners.”

FieldComm Group Seeks Nominees For 2015 Plant Of The Year Award The FieldComm Group is actively seeking qualified nominees for the 14th annual Plant of the Year Award. End users and manufacturers from all world areas are encouraged to enter their plant or customer’s plant for this prestigious award. The FieldComm Group Plant of the Year is the only international award presented to end user companies in the process automation industry to recognise the exceptional and valuable application of Foundation Fieldbus and / or HART Communication technologies. Nominations will be accepted until May 16, 2016. Nomination forms and program details are available here. “Selection of the Plant of the Year is based on a plant’s use of our field communication and integration technologies - not on the size or location of the installation. We are seeking a plant that has taken the capabilities of Foundation Fieldbus, HART or WirelessHART enabled instruments beyond configuration and calibration,” said Ted Masters, FieldComm Group president and CEO. “Or, the plant that is using real-time device diagnostics and process information integrated with control, information, asset management, safety systems or any other system to lower operating costs, reduce unplanned downtime and improve operations.” This globally recognised award has been expanded to include all communication and integration technologies supported by the FieldComm Group. Previous recipients include Nucor Steel, Dow Chemical (USA), Monsanto (USA), Got a Question? Shell (Canada), MOL (Hungary), Make An Enquiry. Mitsubishi Chemical (Japan), ENQUIRY NUMBER P D V S A ( Ve n e z u e l a ) , S t a t o i l (Norway), Sasol (South Africa), Clariant (Germany), and DuPont Turn to page 72a to enquire or log on to: (USA).

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admeijer, Netherlands

EtherCAT Technology Group Events Draw Over 700 Participants In China

During the seminars, EtherCAT experts shared their knowledge about the opportunities and challenges of industrial Ethernet and demonstrated how engineers can use EtherCAT to specifically enhance devices and machines.

With the final ETG Industrial Ethernet Seminar for 2015, held in Hefei, China, the EtherCAT Technology Group (ETG) officially ended its successful 2015 seminar series in China. More than 700 engineers visited the EtherCAT Roadshows in 12 cities throughout the year. As the worldwide development of the ETG demonstrates, interest in EtherCAT continues to grow unabated, including in China where the local ETG office conducted 12 EtherCAT seminars in 2015. More than 700 engineers received information about EtherCAT, expanding knowledge about the technology within the Chinese industry and significantly increasing utilisation. Today almost 500 Chinese ETG members are active in research, implementation and application of EtherCAT, and already profit from the numerous beneficial features

of the technology. The ETG acted upon the increasing interest and demand for industrial Ethernet in general, and the technical details of EtherCAT in particular, by conducting EtherCAT Roadshows in numerous cities, including Suzhou, Hangzhou, Wuxi, Ningbo, Xi’an, Jinan, Shenzhen, Changsha, Chengdu, Chongqing, Beijing and Hefei. Sharing Of Knowledge During the seminars, EtherCAT experts shared their knowledge about the opportunities and challenges of industrial Ethernet and demonstrated how engineers can use EtherCAT to specifically enhance devices and machines. Thanks to the high performance, flexibility, openness and reliability of EtherCAT, users can make devices more efficient and easier to use while reducing overall costs.

The successful roadshow season in China demonstrated how well accepted EtherCAT is in the Chinese market today: More and more manufacturers involved in the automation industry actively participate in the development of EtherCAT. This movement is reason enough for the ETG to further promote implementation and application of EtherCAT, helping users increase the performance of their devices and machines to meet the requirements of Industry 4.0 and China Manufacturing 2025. Got a Question? Make An Enquiry.



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February / March 2016 | industrial automation asia

ARTICLE TAG Industry 4.0, Connected Enterprise, Smart Manufacturing



he launch of the fourth industrial revolution marked an inflection point for the manufacturing industry. Whether you call it the Smart Manufacturing Leadership Coalition (US), Industry 4.0 (Germany), China Manufacturing 2025, Manufacturing Industry Innovation 3.0 (Korea) or any number of other names, it is all about how the Internet of Things (IoT) is collecting and sharing information where and when it is needed to drive faster decision making, enhanced productivity, improved competitiveness, and, ultimately, maximised business value. It is estimated that IoT has the opportunity to create an incremental US$14 trillion globally in a combination of increased revenues and lowered costs by 2022 — with 27 percent of that monetary worth expected to come from industrial firms. One billion new middle-class consumers are predicted to spend US$8 trillion in the next decade, driving the requirement for more infrastructure, resources, and production. To meet these escalating user demands, savvy operators are expanding capacity and throughput with networked, secure, flexible and sustainable plants. The Essence Of The Connected Enterprise Intelligent production is based on the convergence of Information Technology (IT) and Operations Technology (OT) leveraged over a single, standards-based and secure EtherNet/IP framework. This common, smart foundation facilitates network-enabled plantwide devices to gather, analyse and communicate real-time, shop-floor insights with commercial teams throughout the company. Furthermore, to leveraging the union of IT and OT and

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the proliferation of linked in-plant and in-field sensors, contemporary industrial engineers are also using big data, cloud computing, analytics, virtualisation and cybersecurity to overcome hardware and software limitations. Moreover, mobility is giving remote workers in dispersed facilities the opportunity to interpret precise readings from a myriad of self-aware and system-aware devices, actuators, controllers and switches to unite people and processes across the organisation and the supply chain. Rockwell Automation coined the phrase ‘The Connected Enterprise’ to describe those unified firms that are distributing contextualised data seamlessly to stakeholders companywide to expedite time to market, raise asset utilisation, heighten yield, lower total cost of ownership, advance workforce effectiveness, as well as minimise corporate-risk management. A Guideline For Realising The Connected Enterprise The company pioneered a five-stage Connected Enterprise Execution Model, developed to aid manufacturers in their

Intelligent production is based on the convergence of IT and OT leveraged over a single, standardsbased and secure EtherNet/IP framework.

evolution towards becoming Connected Enterprises. The roadmap incorporates necessary steps and recommendations to ensure change in both technologies and organisational behaviour to pave the way toward harnessing the company’s most esteemed asset — its data. The path towards becoming a Connected Enterprise cannot be done all at once and usually begins with deliberately assessing, safeguarding and upgrading networks and controls. Next, operators should define and organise their information before running bigdata tools to deliver critical knowledge to boost strategic decision making. Lastly, they can apply analytics to amplify collaboration and attain the economic advantages offered by The Connected Enterprise. Every firm will enter and progress through the various phases of this passage at a pace determined by its own needs, infrastructure and resources. Establishing The Connected Enterprise is far more complex than simply connecting disparate systems with an open Ethernet/IP-based network; it requires designing a future-proof architecture with actual-time, multi-disciplinary control to forecast potential failures. Such a platform should include an integrated system complete with monitors, diagnostics, prognostics, analytics and optimisation functions. Optimised collaboration and continuous improvement depends on a cohesive commitment from senior leadership to embrace the necessary technical and cultural changes



needed to utilise knowledge throughout the whole firm, plot vital investments, and implement process-driven systems. Ultimately, organisations must be aligned so employees, along with the extended ecosystem of partners and suppliers, are empowered and rewarded for following the company’s vision and achieving a competitive edge. Benefits As A Connected Enterprise After taking many years to restructure its own facilities, processes and ecosystem, Rockwell Automation has now completed its companywide Connected Enterprise journey, with best practices driving centralised strategies across the board. Today, it is reporting the following quantifiable breakthroughs: reduced inventory (from 120 to 82 days); improved time to want (from 82 to 98 percent); 50 percent less PPM (enhanced quality and efficiency); better ontime delivery (from the mid-80s to 96 percent); 50 percent shorter lead times; 30 percent/year capital avoidance; and annual productivity gains of 4-5 percent. The organisation has also co-invented solutions with members of its PartnerNetwork to help customers realise their transitions to become Connected Enterprises and gain the resulting business value with high-performance, smart, safe, scalable and sustainable installations.


February / March 2016 | industrial automation asia


February / March 2016 | industrial automation asia

ARTICLE TAG IoT, Security, Manufacturing

Security is a critical element when using networking equipment.

The Internet Of (Secured) Things



he Internet of Things (IoT) is a topic that is beginning to gain quite a bit of steam lately, particularly when it comes to the security concerns that accompany it. Think about the billions of new devices, most of which are in insecure locations — You do not own them; oftentimes cannot see them; and you do not control them in any way, shape, or form. Yet, they are sending petabytes of data through your network and this is enough to make a security professional lose sleep for weeks at a time. However, while it is important to realise that there are security challenges that arise with the proliferation of IoT, there are also huge security benefits that can be derived from this trend and this comes in the form of IoT enabled security. Remember, IoT is not just about the devices themselves, it is about the network of devices — the benefits from having all of those devices work together to produce actionable intelligence. In a similar Got a Question? vein, securing IoT networks cannot Make An Enquiry. be about the individual security ENQUIRY NUMBER devices, but rather the network of security devices, so that they can work together to produce Turn to page 72a to enquire comprehensive, actionable security or log on to: www.iaasiaonline.com intelligence in near real-time —


increasing the organisation’s overall security posture with little or no human intervention required. The Importance Of Manufacturing The manufacturing sector in Singapore has also been a growth cluster that is set to gain importance. With the Singapore government looking to foster deep skills and innovation, advanced manufacturing will be aided by new technologies such as advanced robotics and additive manufacturing. In manufacturing, there are complex, fast-paced environments that present extraordinary safety and security challenges. IoT technology is already assisting to increase innovation and efficiency. Organisations can benefit from an interconnected factory environment where sensors, advanced robotics and other machines can all be combined to form a large comprehensive network. A typical factory floor consists of thousands of uncontrolled access points, and therefore requires multi-layer role-based security. Security controls need to identify the person and the machine to make a determination as to whether or not that person is authorised to operate that specific machine; they also need to validate that the person is who they claim to be, prior to granting access. Integrity of the safety system is also

Odan Jaeger



February / March 2016 | industrial automation asia

essential, so analytics need to play a major role to proactively recognise potential catastrophes.

Consider these IoT-enabled security responses for our connected factory example: •

By combining IP cameras, video analytics and sensors, intelligent, real-time decisions can be made about a person trying to gain access to sensitive systems or areas — by checking the picture on the ID badge and comparing it to the embedded ID sensor in the badge, the network-archived image of

the employee and the face of the person presently attempting access — access can be confirmed with a high level of accuracy. In the event that a breach is detected, those same systems can be disabled and an alarm state sent to security personnel for an appropriate human response. Sensors on machinery and across the factory floor can determine if there is an increased risk of an accident occurring and take proactive measures to avoid the incident. The integration of IP cameras with sensors across the factory floor that detect security-critical noises, machine failures, or other dangerous events enable the cameras to automatically zoom in on the precise location of the disturbance and begin recording; meanwhile, an alarm condition can be sent to trigger the required human response.

So while IoT certainly has its security challenges, it is important not to lose sight of the fact that if applied properly, those same IoT dynamics can dramatically improve safety and security capabilities, as well as response times.


Enhancing Security Currently, the various safety and security systems do not work together which limits visibility and control. It is one thing to know that a piece of equipment is at imminent risk of failure, but without the ability to shut that equipment down automatically, human intervention is required which can take too long to be effective. This is where IoT enabled security can help enormously. By combining numerous systems, including cyber security, cameras and sensors, IoT enabled security can improve employee safety and protect the entire system from the outside as well as the inside.




February / March 2016 | industrial automation asia

ARTICLE TAG Industry 4.0, Manufacturing, Data Analysis

Industry 4.0:



hat today is paraded under the banner of Industry 4.0 has been common practice at B&R’s own production facilities for nearly a decade. The smart factory in the Upper Austrian town of Eggelsberg has been fully networked since 2006 and is being upgraded all the time. For its latest project, the company optimised production of its industrial PCs. Using an online configuration tool, B&R customers assemble their PCs to their exact specifications. After verifying the feasibility of the configuration, the ERP system automatically generates a bill of materials with a unique serial number. 250 Billion Possibilities “Mathematically speaking, the customer has more than 250 billion different hardware configurations to choose from,” said Gerald Haas, head of global industrial management at B&R. That is without considering all of the software options. Most order quantities are in the two to three-digit range. “The way we are set up, order quantity is irrelevant,” said Mr Haas. “We can produce a one-off item with the same efficiency as a batch of 1,000.” The ERP system plans an optimised order processing schedule and ensures that the logistics run smoothly. Parts that come from the warehouse are delivered just in time. This is where one of the advantages of the company’s smart factory comes into play. The plant in Eggelsberg is completely networked – both horizontally and vertically. A Single, Homogeneous Network “What is special about our solution is that we do not have a collection of subnetworks that are interconnected with varying degrees of efficiency,” said Mr Haas. “What we have is a single, homogeneous network that incorporates every machine and every building automation component as well as the ERP system.” That is what gives the ERP system the ability to control the automated storage and retrieval vehicles in the high bay warehouse. The ERP system sorts the items in the high bay warehouse according to current and forecasted production volumes and triggers reorders when inventory is running low. Got a Question? By the time a PC order arrives at Make An Enquiry. a worker’s assembly station, all the ENQUIRY NUMBER necessary components are within reach. The worker is guided through the assembly of each PC by onTurn to page 72a to enquire screen instructions and light signals. or log on to: www.iaasiaonline.com Workstations are setup ergonomically


The company’s APROL process control system delivers parameters such as Overall Equipment Effectiveness (OEE) in real time

and the tables are easily adjusted to workers of different heights. Each and every PC is tested repeatedly during and after assembly. They are checked for correct assembly and the CPU and RAM are subjected to functional and stress testing. Only when all tests have been completed successfully does the ERP system release the PC for shipping. “After all, every product that our customers receive should work flawlessly,” explained Peter Gucher, GM, B&R Seamless Traceability “Functional testing is nothing we have invented,” granted Mr Gucher, “but what is fairly unique is the complete traceability we have for every single product.” Every step in production, every test and every significant component can be retraced at any time. This traceability extends throughout the entire lifecycle of the product. Even years down the road, based on nothing more than the PC’s serial number, you will be able to look up the results of every functional test ever performed on it and clearly identify every component it contains. “This gives our customers an added layer of certainty,” explained Mr Gucher. On its website, B&R provides a service portal where its customers can look up technical data and order-related information by simply entering their product’s serial number. This includes version information, delivery date, warranty status and much more. “We are able to save our customers a lot of time and effort this way,” added Mr Gucher. Real-Time Dynamics Communication throughout the networked factory works in every direction. “Our X20 modules are a good example of this,” said Mr Haas. Currently, there are 200 module types being produced on various lines. When a module reaches the fully automated station for assembly, testing and labeling, a realtime SAP query determines which tests are required. A fraction of a second later, the machine is busy putting the answer it received into action. This is only possible because every product

February / March 2016 | industrial automation asia

can be uniquely identified by its serial number. If an R&D engineer makes a note in SAP that a module has received a certain certification, and a module of that type happens to arrive at the labeling station only seconds later, the correct certificate mark will be laser printed on the housing. “That is smart factory technology at its finest,” said Mr Haas. Of course, fully networked intelligent production generates its fair share of data. On large systems, the collected data can quickly reach gigabyte or even terabyte levels. “Automated data processing and analysis is essential to reaching an informed decision,” said Mr Gucher. That is why the company collects and evaluates all of its production data using its own APROL process control system.

The company uses condition monitoring tools from its own portfolio, and is able to determine the ideal timing for maintenance work. This eliminates the waste of re-placing parts too early, as well as the risk of waiting too long and damaging a machine. If a key parameter moves out of its defined tolerance, an employee receives automatic email notification and can intervene before the aging component fails and causes an unplanned stoppage. Industry 4.0 As Usual “For B&R, networked smart factory production has been a reality since 2006,” said Mr Haas. “What for us is business as usual, has since been given a name: Industry 4.0.”


The company’s production halls are fully networked. The ERP system has direct control of the storage and retrieval vehicles in the high bay warehouse and automatically optimise production logistics.


OEE Parameters At Any Time In APROL, parameters such as Overall Equipment Effectiveness (OEE) can be viewed at any time and even compared between production lines, shifts or workdays. “With APROL we always have an eye on our energy consumption as well,” added Mr Haas, “so we can make immediate corrections when something is wrong.”


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February / March 2016 | industrial automation asia

ARTICLE TAG IO-Link, Industry 4.0, Predictive Maintenance

Laying The Foundation For Industry 4.0

WITH THE ADVENT OF IOT AND INDUSTRY 4.0, FACTORIES AND THE SENSORS THAT OCCUPY THEM ARE BECOMING MORE INTELLIGENT HELPING LOWER COSTS AND INCREASE PRODUCTIVITY. BY MICHAEL KASPAR, PRODUCT MANAGER, PRESENCE DETECTION, MARKETING & SALES, SICK system environments used in Factory, Logistics and Process Automation. In the context of Industry 4.0 in particular, this variability is the key to better investment security.


ith Industry 4.0 and an increasing number of communication-enabled sensors, transparency is on the increase, opening up new possibilities for both quality assurance and process optimisation in the production process. However, much more information is vital so that the right decisions can be made. One consequence of this is that higher-level systems find themselves faced with a massive flood of data. Sensor intelligence evaluates the data right away in the sensor and undertakes preprocessing accordingly: only the information that is actually relevant is forwarded. Whether raw data or preprocessed information: Without an appropriate industrial interface neither data transmission nor bidirectional communication is possible. At the same time new production and logistics concepts in the context of Industry 4.0 are demanding more and more communicationenabled sensors. Accordingly, there has been a tangible increase in demand for IO-Link-capable sensor solutions and the range of IO-Link devices offered is growing constantly. They are opening up the possibility of establishing complete transparency and monitoring down to the machine’s sensor / actuator level. In addition to the detection status these sensors are able to send for example process monitoring information via IO-Link. This information is important for predictive maintenance as well as for detection process optimisation to ensure a safe and Got a Question? rugged sensor operation. Even new Make An Enquiry. setup parameters can be transmitted ENQUIRY NUMBER via this route. IO-Link is a standardised communication interface for sensors Turn to page 72a to enquire and actuators, thus supported by or log on to: www.iaasiaonline.com almost all standard PLC and fieldbus


Complete With Intelligent Automation Functions Reliable data acquisition and the conversion of these data into application-relevant information directly by the sensor itself: This is what is at the heart of ‘Smart Sensor Solutions’ based on IO-Link. Smart Sensors with embedded intelligent Automation Functions allow managing subtasks of the overall machine process in a quicker, more precise or more efficient way. Raw-data analysis within the PLC is being reduced significantly. The potential advantages: • Predictive maintenance through active sensor selfmonitoring reduces or even avoids machine downtime caused by sensor malfunctions. • The process speed and thus productivity of the machine increases as the Smart Sensor directly provides the relevant process information beyond the detection state in real-time. • More efficiency from one end of the system to the other: Instead of large volumes of CPU-power and time-intensive big data transmission, preprocessed and selected information is sent to the controller. • Measured values are more precise, since the jitter caused by reading multiple pulses into the controller cyclically is no longer an issue. The sensor calculates the measured values independently and precisely. • The sensor takes over some of the tasks involved in data processing, as such relieving the load on the machine controller. More Transparency, More Control Full transparency of the sensor’s parameters and Automation Functions also improves control over the entire machine processes. In addition to the real-time information that is related solely to steer the machine process, Smart Sensors can supply additional information eg: for retroactive process monitoring and analysis. This information can be polled by the controller on demand, enabling faults to be analysed or a secondary process to be monitored simultaneously. For instance Smart Fork Sensors can be relied upon not only to detect labels securely at a high process speed but also to supply information about the actual number of labels on

February / March 2016 | industrial automation asia


a sleeve. As a result, deviations to the specified value can be identified and brought to the attention of the label supplier. Industrial Image Processing In The Context Of Industry 4.0 Solutions from the field of 2D and 3D vision are used wherever checking, measuring, localising, or identifying is the order of the day. Industrial applications have high expectations of these solutions: detection of the surrounding area, immediate data analysis, and immediate delivery of results so that specific action can be identified and taken, even under the most difficult of conditions. Alongside reliable image acquisition, efficient data processing directly in the sensor is decisive. Diversity Versus Efficiency? In the context of Industry 4.0, new challenges are arising all the time. Significant diversity of variants is a consequence of the desire for flexible, customer-specific production (‘batch size 1’), for example. However, high machine availability and production efficiency must also be ensured. 3D vision sensors in particular have a significant advantage in this context. Even if objects vary in size, height, or shape, the sensor can be relied upon to detect them and provide the necessary information about them. Once the parameters of a machine or plant have been configured, this process does not need to be repeated. In practice, production efficiency also means high through-put. Vision sensors with ever higher resolution, faster detection speeds, and maximum detection accuracy are essential if this is to be achieved. 3D Image Processing, Intuitive Operation Integrated image analysis makes configuration easy. On demand, the vision cameras can be supplied with precalibrated 3D data (output in millimeters). Intensity values are overlaid on the 3D data. This enables the sensor to reliably check the presence and position of labels or printed patterns. Those 3D vision cameras are thus a versatile stand-alone vision sensor for cost-effective 3D inspections such as checking the content of totes or quality control of consumer goods. Latest 3D Technology At A Glance The latest 3D vision sensors are offering innovative 3D snapshot technologies for use in industrial applications. The stereoscopy-based vision sensors are able to calculate the space and depth information for the objects located around it in real time (this even includes stationary objects). Thanks to intelligent data evaluation, these devices are ideal for assisting drivers in difficult off-road commercial vehicles such as those found in ports and mines or on construction sites. If an object is located in one of the two preconfigured alarm zones, the sensor will trigger an audiovisual alarm via the display if the situation is critical. The 3D Vision Camera supplies fully preprocessed information and digital signals with significant data

The latest 3D vision sensors are offering 3D snapshot technologies for use in industrial applications.

compression for this purpose. The sensor, the display, and the evaluation unit are a ‘turnkey’ total package: easy to configure, ready for operation in next to no time, and easy to use. Both high reliability for data acquisition and the mechanical ruggedness of the sensor head are ensured. The sensor also boasts a high temperature range. Tailor-Made: Data Quantity And Required Information For all manner of indoor applications the time-of-flight 3D Vision Camera delivers full flexibility: Based on time-of-flight measurement, the sensor provides depth information for every pixel in real time. Up to 30 three-dimensional images are made available per second. Whether in stationary applications or industrial vehicles, all 3D raw data or preprocessed information that is relevant to the application is delivered. Depending on the model the 3D vision sensor is able to calculate what information is actually needed directly in the device and, thanks to data reduction, is perfect for vehicle applications such as collision awareness, obstacle awareness, or navigation assistance. Alternatively, the 3D vision sensor delivers all of the 3D raw data for processing and evaluation item by item. The result: Tailor-made solutions that deliver precisely the information that is truly relevant to the application.




February / March 2016 | industrial automation asia

ARTICLE TAG IIoT, Protocol Conversion, Data Management



he Internet of Things (IoT) is a hot topic in the press today that is stealing many headlines. The reason for all this attention comes from the rapid growth expected in the IoT world. According to Berg Insight, the number of wireless IoT devices in automation networks is now forecast to grow at a Compound Annual Growth Rate (CAGR) of 27.2 percent to reach 43.5 million by 2020. However, the Industrial Internet of Things (IIoT) is more of a near-term reality, and many industrial firms are striving to take advantage of its benefits. There are many different terms for IIoT, including Industry 4.0. and the Connected Factory. Whatever you choose to call it, how can you take steps to ‘get in the game’ with IIoT? The Challenge — IIoT Readiness One might wonder how to get started with IIoT, especially when you look out at your organisation and see equipment from different manufacturers that is 5, 10 or 20 years old (or more). How can you solve the challenges of being IIoT ‘ready’ when you use legacy devices to operate many of your processes? Replacing equipment is not an option because of cost and integration time. You need to find a way to not only protect your existing investment, but also make it compatible with more modern equipment. This may seem to some like a ‘best of both worlds’ scenario. The Answer — Protocol Conversion Protocol conversion is a key first step in solving the multivendor and legacy equipment challenge. Wikipedia describes a protocol converter as ‘a device used Got a Question? to convert a standard or proprietary Make An Enquiry. protocol of one device to the protocol ENQUIRY NUMBER suitable for the other device or tools to achieve the interoperability.’ There can be many different Turn to page 72a to enquire devices on a manufacturing floor, or log on to: www.iaasiaonline.com with each one having its own


protocol, so organisations can have a situation where you need to handle several different protocols in order to gather data. The ability to provide protocol conversion in a Human Machine Interface (HMI) or other automation products across a multi-vendor environment is a great way to connect several different devices, with different protocols, and be able to aggregate that data collection. Protocol conversion allows you to collect data from different devices and different protocols and ‘translate’ those in a centralised device so that you can collect and compile data from all over the factory floor. Then, you can turn this information and data into useable, trend-related information and reports that help you to make informed decisions and do effective planning of your resources. Some refer to this as the mining and displaying of data for actionable intelligence, which gives you real-time visibility to help make operations more efficient. Connect — Speaking The Same Language You can benefit from bringing new and legacy equipment together on the same network. Some of the newer equipment on the factory floor may be ‘Ethernet ready’ while older equipment may use a serial connection and a legacy protocol specific to that vendor. By integrating different devices (and getting legacy devices talking with newer devices) you can get disparate equipment to communicate across multi-vendor environments. Industrial environments are embracing newer communication infrastructures such as cellular M2M, WiFi, Gigabit Ethernet, fibre and Power over Ethernet. These communication technologies help deliver and enable higherbandwidth applications that bring more information and intelligence to manufacturing environments. Monitor — Using Data To Visualise Processes Protocol conversion is also important for monitoring processes – collecting and analysing data to develop more


February / March 2016 | industrial automation asia

Industrial IoT is set to transform many industries.


Simon Shokry, Cairo, cairo, sn

Protocol conversion can help you integrate PLCs, PCs and SCADA systems to collect and process data in real-time to control devices and applications that directly affect operations.

efficient operations and reduce downtime. In particular, when protocol conversion is implemented in multi-vendor environments, customers can leverage visual management solutions to display Key Performance Indicators (KPIs) that can be used for tracking, assessing and analysing manufacturing processes. These performance measurements are commonly used to evaluate success in relation to goals and objectives. While KPIs tend to vary by organisation, common examples of KPIs in manufacturing include: count (good or bad), reject ratio, rate, target, Takt time, Overall Equipment Effectiveness (OEE) and downtime. Control — Increasing Operational Efficiencies Protocol conversion can help you integrate PLCs, PCs and SCADA systems to collect and process data in real-time to control

devices and applications that directly affect operations. Exercising control over operations could mean such things as having the ability to turn legacy serial-connected equipment on or off, or open or close valves regardless of location. In conclusion, addressing IIoT challenges through protocol conversion enables organisations to improve productivity and increase operational efficiencies through real-time device connection and data processing. With protocol conversion, you can get all of your devices — both legacy and new — communicating to provide a holistic environment view that allows you to plan more effectively and take action. By enabling disparate devices to communicate, you can now connect, monitor and control operations from a single platform. This type of data-driven monitoring and decisionmaking will get you on your way to IIoT readiness.

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February / March 2016 | industrial automation asia

ARTICLE TAG IO-Link, Multicore, Sensors





he automotive industry is a highly competitive sector. Nowadays, automotive plants in Asia, Europe and America are building very good cars, and the differences in quality between the particular vehicle classes are marginal. This competitive pressure is also felt by the auto parts supplier sector. Some manufacturers are renowned for the tough way in which they handle their suppliers. The positive side of this competitive pressure is the increased production efficiency that it has developed. Suppliers have to keep their production flexible and ensure that setups and modifications can be carried out quickly. To do this, they are increasingly relying on systemic production and products. Modular concepts enable larger quantities of individual components and shorter development and production times. Use Of Differential Gears One example of these developments is the production of axle differential gears for automobiles. Differential gears ensure that the wheels of a vehicle can move at different speeds. When a vehicle is cornering, an axle differential gear is necessary so that the outer wheel can cover a greater distance than the inner wheel. The differential balances out the different speeds of the wheels. For off-road driving, four-wheel drives have the ability to block single differentials or all of them in order to transfer the power from stuck wheels to all wheels. Four-wheel drive vehicles also have a central differential in order distribute the drive power to the front and rear axles. Got a Question? Make An Enquiry.

ENQUIRY NUMBER Many Sensors In Gear


Turn to page 72a to enquire or log on to: www.iaasiaonline.com

Production Several magnetic field sensors on the production line of the differential

gears detect the positions of pneumatic cylinders and clamps, while proximity switches detect components of the differentials themselves. There are also many actuators such as air valves, solenoid valves and other devices, which perform the commands of the controller. Multicore Cables And Passive Junctions Failed Initially, the customer wanted to connect the signals of sensors and actuators to the fieldbus gateways in the control cabinet using passive junctions and multicore cables. However, this solution did not meet all of the specified requirements. The costs of the cable lengths and the extensive wiring effort involved had a negative effect on the overall cost. Many cables for the passive junctions would have had to be prepared manually and then connected again to the I/O modules in the control cabinet. Commissioning would have been particularly prone to errors as well as being time consuming. The solution would also have been very expensive and difficult to maintain. Troubleshooting during cable inspection would have initially presented a lot of problems: As the types and models of the sensors installed are the same, the cable markings are also identical apart from one or two digits. Assignment errors were therefore bound to happen. The search for and rectification of wiring errors would in turn be very time consuming and complex. The customer recognised this before the solution was chosen and obtained further advice from Turck. IO-Link Solution Fast And Efficient Turck offered a space saving solution that simplified the wiring of the production workbenches and which nevertheless could be implemented cost effectively. The system also allowed the implementation of diagnostics right down to the sensor level. The customer used a Siemens controller with Profibus-DP. Turck consequently offered a BL20 Profibus gateway for the control cabinet in conjunction with IO-Link master modules. Turck’s IO-Link compatible TBIL junction boxes are suited for connecting the sensors and actuators in the field. These I/O hubs use IO-Link to bring up to 16 binary signals to the IO-Link master via a standard sensor cable. The 16-bit process signal of the IO-

Febraury / March 2016 | industrial automation asia


Besides hundreds of switching signals, two BL20 gateways also bring signals from RFID read/write heads and analogue signals to the PLC.

Link protocol is therefore not used for an analogue process value, but for transferring 16 individual switch signals for digital input or output signals. As the TBIL I/O hubs offer protection to IP67, they can be mounted directly in the field as close as possible to the sensors and actuators. IO-Link is a digital protocol that allows the use of standard three-wire cables, which eliminates the need for any expensive shielding and lengthy cable commissioning. Efficient And Transparent Network Structure This network structure, consisting of I/O hubs and Profibus DP gateways with IO-Link master modules, enabled the user to avoid the need for any time consuming wiring in the control cabinet as well as making savings in the terminals, expensive cables, and space required. The solution also provided a simple and clear network structure that prevented faults already at the installation stage. If any faults occurred later, however, maintenance was simple thanks to the use of IO-Link. The location of faults can be identified right down to the individual field device and differentiated between a wire break or a short circuit. The central configuration of the entire system from the controller ensures the central availability of all relevant information. This simplifies both maintenance and documentation. Space Saving And Flexible An IO-Link module on the BL20 gateway provides four IO-Link masters. This means that up to 64 binary signals can be connected with a single module. The flexibility of the overall solution is

always ensured. Additional IO-Link master modules or other I/O modules can be connected easily to the BL20 gateway. The customer was able to successfully complete the commissioning of the system quickly. As many identical sensors are connected and only TBIL I/O hubs were used as I/O-Link devices, the workload involved was manageable anyway. Analogue Signals Via IO-Link IO-Link i0s still unfamiliar territory for many customers. Some were initially skeptical, particularly due to the unusual set up in the controller. However, after an IO-Link installation is completed, most customers are convinced of the benefits. In the application described, the customer realised that he would also be able to connect all measuring sensors for pressure and temperature with IO-Link as long as they have an interface. Special analogue input modules are thus just as unnecessary as the expensive shielded cables for analogue signals. The analogue sensor could be connected directly next to the I/O hub to IO-Link master module of the BL20. The sensor parameters can then be set directly from the controller. The customer intends to examine this option with future projects. The project engineer for the customer is impressed by IO-Link: “We have good reason to believe that the IO-Link communication interface will be the top choice for the new generation of intelligent devices. Devices with IO-Link communicate data digitally and can thus exchange process values as well as configuration information and diagnostic data. The information exchange is transparent on the entire section from the sensor right up to the controller.�


Devices with IO-Link communicate data digitally and can thus exchange process values as well as configuration information and dianostics data.



February / March 2016 | industrial automation asia

ARTICLE TAG Industry 4.0, MES, Standards

MES – But Do It In The Right Way



n increasing demand for a state-of-the-art Manufacturing Execution System (MES) for Industry 4.0 clearly manifests itself. The functions and properties an MES system must have are detailed in the VDI guideline 5600. But is that relevant for Industry 4.0? The Future Concept MES 4.0 casts a light on the issue. Recommended action in order to prepare for Industry 4.0 could be: ‘Introduce an MES!’ But which one? Which properties and functions must an MES have in order to be a central information and data platform? VDI 5600 Guideline – Relevance For Industry 4.0 Looking into relevant standards like the VDI guideline 5600 (VDI = Association of German Engineers), published in 2007, gives an indication that apart from a wide range of functions, basic features like ‘Horizontal Integration’ and ‘Real-time Capability’ must be guaranteed. This also applies to industry 4.0. Therefore, MES systems already play an essential role in the practical implementation of Industry 4.0. Horizontal integration, which is defined in the VDI 5600 guideline, plays a central role even in the ‘VDI House for Industry 4.0’.

Got a Question? Make An Enquiry.



Turn to page 72a to enquire or log on to: www.iaasiaonline.com

Status Quo Current MES market reviews show that the market is quite diversified but only a few systems fulfil the requirements of the VDI 5600 guideline. Many systems have already implemented online capability but make sacrifices in their functional range and their horizontal integration. Many suppliers only partly cover the tasks and must supplement other functions with external products from partners. More and more suppliers extend their own portfolio of functions which verifies the relevance of VDI 5600. Avoiding interfaces, which is an essential requirement for horizontal integration, is normally not covered by increasing the number of functions. ‘Everything Under One Roof’: Horizontal Integration For the Future Concept MES 4.0 ‘Horizontal Integration’ is connecting all functions and data across the value chain and covering all tasks of an MES. Essential characteristics of the horizontal integration are avoiding interfaces and the modular structure of an overall system. It goes to show that in the workplace order postings (BDE) as well as quality inspections


February / March 2016 | industrial automation asia

Integrative data management — all collected data stored in a central database (source: MPDV).

MES systems are plentiful but a broad range of functions and a complete horizontal integration is only supplied with a few systems. (source: MPDV).

(CAQ) are carried out in the same shop floor collection terminal. Ideally both functions are represented in comparable dialogs. This makes it easier for the operator as the modules function on the same basis. The operator saves time as there is no need to go to a specific inspection station. It also makes it simpler for the administration of an MES system if the modules come from one software house. This is especially illustrated when the software is maintained and is considerably important concerning the life cycle management. Typically, using complex software systems not only small updates and error corrections routinely occur but also release and version changes. Thereby core software changes are also carried out. A horizontally integrated system can be used after a version change instantly as the modules and the functions are linked. This means the customer has time and cost savings. Horizontal integration is a requirement for the modular structure of an MES solution. That eases the successive introduction of the system which is significant for medium-sized companies. Also users can decide for themselves which functions are

complex manufacturing environments are the more significant correlating evaluations are in order to observe and operate processes efficiently. Only context-relating correlation of data can supply valuable information and therefore knowledge. Only by collecting comprehensive knowledge, processes can be optimised. This in turn is an important requirement to stay competitive - especially considering Industry 4.0.

No matter which manufacturing processes are presented by the MES in any culture or country, a modular, horizontally integrated MES solution fulfils all the requirements sufficient for their application case and can align their selection to their requirements. The software can be extended at any time. No matter which manufacturing processes are presented by the MES in any culture or country, a modular, horizontally integrated MES solution fulfils all the requirements. Despite that fact, several supplier campaign with ‘Industry 4.0 compliant’ products. If it is envisaged to use the system in the long term, horizontal integration is essential. Further Exploit Data: Correlating Evaluations Especially relevant for Industry 4.0 is that systems, incorporating integrative management, can process and evaluate data across all areas. The more

Here are some examples from real life: Keeping On Top Of Energy Costs In times of ever increasing energy costs and complex cost relief models, manufacturing companies need tools to collect and evaluate energy consumption. An integrated MES can correlate energy data with other information from production, ie: processed orders or machine status. Instantly energy intensive production steps or energy guzzling machine are detected. Optimised planning like avoiding peak times is one of the principal activities. In order to achieve the requested integrated solution relevant data from all areas must be linked.




February / March 2016 | industrial automation asia

Consumption Correlation — to know exactly how much energy is consumed with every order. (source: MPDV)

Shop floor data collection and quality management in one system. (source: MPDV).

Quality Made By MES The product quality is also significant in the era of Industry 4.0. By using an integrated MES inspection plans can be created simultaneously to production orders. When logging an order at the shop floor terminal the equivalent inspection order is instantly available. After a defined interval (based on time or cycle) due inspections are automatically identified and displayed on the shop floor terminal. Automatically collected quantities and the machine status can be evaluated. To further increase automation of quality inspection, collected process data can be used (ie: temperature, pressure, flow velocity, etc) which are now available if machines are connected. Therefore, quality levels improve. Preventive Maintenance An MES solution manages all

production resources in one system containing apart from machinery also tools and other production aids. A common database can plan and evaluate all resources across all sectors. Planning an order in the shop floor scheduling, it is straight away apparent which tools are available or if the tool needs maintenance during utilisation period. The central collection of cycles and utilisation times enables preventative and needsorientated maintenance. Therefore, utilisation of tools increases and idle times are reduced. From Planning To Controlling Systems, organised in a decentralised manner like required for Industry 4.0, require standards and to a certain extent planning or controlling. Direct connection to the shop floor enables to switch from true planning to a precisely accurate production control. Unforeseen events are detected instantly and the responsible members of staff can react in real time. If a machine breaks down, the graphical planning module in the MES system checks if there are alternatives available and how it affects the orders overall. The fully integrated MES solution can, apart from planning availability of tools and machines, also

Shop Floor Scheduling provides you with a multi-dimensional production planning and control (source: MPDV).

make allowances for resources like personnel, material stocks and energy consumption. Transparency achieved with the system safeguards the ability to react in production. Prospects: The Future Is Here The future vision, illustrated by Industry 4.0, seems to be more tangible with the realisation of the Future Concept MES 4.0. Growing networks which are presented by the horizontal integration of the MES environment, central data retention and the correctness of data are increasingly in the focus of production IT. Technical innovations ensure that obstacles are not insurmountable and successively disappear. Technical progress is unstoppable and therefore, the number of self-regulating systems at work is rising. An unrestricted access to relevant data is more important than ever. This goes to show that a Manufacturing Execution System (MES) is not only suitable to support Industry 4.0 but a necessary requirement. I It is also necessary for an MES to comply with the VDI 5600 guideline — completely. Remember not every system offered on the market is worthy being called an MES.




February / March 2016 | industrial automation asia

ARTICLE TAG Measurement, Standards, Heavy Industry

Feeling The Force:



ingapore in the past lacked the measurement capability to handle many of the heavy industry requirements that are necessary today. Until now that is. With the opening of Malayan Daching’s new force measuring instruments testing and calibration laboratory. This new facility, located in Singapore, is capable of testing force measuring instruments, load cells and hydraulic cylinders up to 20 MN. The testing capacity of up to 20 MN is among the highest worldwide.

Got a Question? Make An Enquiry.



Turn to page 72a to enquire or log on to: www.iaasiaonline.com

(l-r) Lee Shih Mean, Dr Thomas Liew, Sim Sem Peng, Elton Tong

Set up with the support of A*STAR’s National Metrology Centre (NMC) and SPRING Singapore. Like any such facility accreditation is important to give customers greater confidence in the laboratory’s test and calibration results and reports. Accreditation has been achieved for this facility under the Singapore Accreditation Council – Singapore Laboratory Accreditation Scheme (SAC-SINGLAS). Before this facility the highest measurement capability available in Singapore was 2 MN, offered by A*STAR. Now with this new facility applications such as those in heavy industries like oil & gas, marine and offshore, construction, or heavy engineering are now able to calibrate up to 20 MN locally rather than sending overseas, which is both time consuming and costly. Productivity is also expected to increase by more than 50 per cent, with workers being freed up for deployment

of other tasks. It is understood that aside from Singapore, only China and Germany have facilities of such testing and calibrating capability. Automating For Accuracy To effectively make use of such equipment and to ensure accuracy it is necessary to employ automation within the system. In regards to control, for us to exert a 20 MN force, it takes a while and if you do it the manual way the chances are you may not even control too well. Elton Tong, business development manager, Malayan Daching, explained: “In regards to control, for us to exert a 20 MN force, it takes a while and if you do it the manual way the chances are you may not even control too well.” Continuing, he said: “There is three stages of control. Firstly, if you want to go to 20 MN, the first stage of this would be to go to say 18 MN in a short

February / March 2016 | industrial automation asia

time. Once we reach 90 percent of our full capacity we then lower down into a medium control, which is a bit slower, but still fast enough to go to perhaps 95 percent. However, once we reach the top five percent towards our target we have this fine tuning to go up to 20 MN. These are the control mechanisms that we have.” Adding: “When we reach the target force that we want we have an automated system where we capture the reading once it reaches the target force. This process needs to be automated as our eyes will not be able to tell the exact force because once it reaches 20 MN the reading of this unit is always fluctuating. If you want to look at 20 MN exactly and take the reading chances are you will miss it by a fair bit. What we did was to have a capture system so when the indicator master shows 20 MN it will capture the units reading. On top of that there is also some controls related to the methodology on how not to overshoot your target range.” Additionally, the company developed customised software to enable the testing and calibrating of high capacity force measuring instruments, load cells and hydraulic cylinders. With a fully computerised system, the entire calibration process will be automated. Lee Shih Mean, senior metrologist (Mechanical Metrology) added: “One example of this is that when the force you are taking is a set point. In the case of taking a measurement we do not want the force to overshoot and then come back down. In terms of control, it is easier to control when you overshoot and then when you come down you let it hit the set point before you increase the force. This would be considered normal control. However, we do not want that to happen here, we want to go up and then increase slowly and then hit a set target before you go up to the next point. There should not be any kind of decreasing force when it is in an increasing phase. This is the advice we give people.


Collaboration With A*STAR When asked more about the collaboration with A*STAR, Dr Thomas Liew, executive director of the National Metrology Centre, remarked: “We are the national measurement institute within Singapore, so what we offer is the measurement science knowledge and also our understanding of measurement standards and references. We used this knowledge to work with Malayan Daching to develop this new machine that is capable of 20 MN. I would say, regionally, this is a one of its kind facility and is an expansion of our Singapore measurement capability, which has gone from 2 MN to now 20 MN.” He further explained: “We used our measurement knowledge to help in the selection of reference cells for this machine. We also used our capability as a measurement authority to ensure that the measurement machine that is constructed is measuring the force accurately, ie: traceable to national measurement standards or SI standards. That is our key role.” Operating Procedure Mr Tong explained more on what is

To meet the strict requirements of ISO 376 and ISO 7500-1, the team dedicated six months (instead of the usual two to three months). expected once a company contacts them and wants to make use of their new measurement capabilities: “If say a customer or client calls in for an enquiry the first thing we do is assess their equipment, for instance, what kind of equipment do they have? What is the capacity? Is it within our scope in terms of facilities and also the size of the load cell or the hydraulic jacks, and whether it can fit into our calibration frame. After we establish the suitability of the request, then we will talk to them more on the specification, such as what kind of accuracy they need, and what kind of sensitivity they need.”




February / March 2016 | industrial automation asia

The new 20 MN facility at Malayan Daching.

“If they are ok with our scope then we will probably go into a little bit more detail on what kind of indicator do they have, because if you have a load cell, the load cell will signal to an indicator. We need to understand how we can work with this indicator, and then if everything is fine and the engineers are happy then the job will be done,” he added. Integration And Standards Mr Tong expanded on the issue of integration and how this new service fits in with the company’s existing capabilities: “This new capability is a separate offering compared to what we previously had. From weighing of physical test kits to more measurement of load cells. We are ISO/IEC 17025 accredited since 1988 so our quality manual we can still make use of the same quality system that

we have been using and then on top of that our engineers who have all trained in the weighing business (the weighing calibration part), for them to learn on the new calibration for load cell force measurement is quite an easy transition. It impacts their productivity because for calibration we do not have every day where they are fully booked and they are fully utilised so with this new calibration services it is easier for them to work with us a bit and increase their time on work so I think that is a good increase.” To meet the strict requirements of ISO 376 and ISO 7500-1, the team dedicated six months (instead of the usual two to three months) to develop and troubleshoot a customised software that is able to control the calibration process to an accuracy level of 5 ppm (parts per million).

Force Transducer Calibration at The National Metrology Centre’s (NMC) in Singapore.



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February / March 2016 | industrial automation asia

ARTICLE TAG Energy Efficiency, Motors, Climate Change

Energy Efficiency Is By Far The Best Way To Tackle Climate Change




ne might think — after years of focus on global warming — that all the easy measures for reducing greenhouse gas emissions had been taken. And yet, as governments prepare for their 21st annual conference on climate change (COP21), some surprisingly low-hanging fruit remains. I do not mean small fruit, either. I am talking about big, high-yield fruit. Consider this: fitting energy efficient electric motors on all pumps and fans with devices to regulate their speed would save 3,338 TWh (3.3 million GWh), roughly equivalent to the amount of electrical energy produced in the EU in 2013.

Seizing The Opportunity The opportunity is Got a Question? so huge because Make An Enquiry. electric motors ENQUIRY NUMBER are among the biggest consumers of energy. They Turn to page 72a to enquire power all manner or log on to: www.iaasiaonline.com of equipment and


account for about 40 percent of all electricity consumed worldwide. In the European Union (EU), they are responsible for about 12 percent of total CO2 emissions, second only to space-heating products. In recent years the EU, along with several other countries, such as the US and China, has imposed new rules requiring older, energy-hungry motors to be phased out. These rules, known as Minimum Energy Performance Standards (MEPS), specify the minimum acceptable efficiency levels of a product, defining which products can be marketed and sold. Typically, these MEPS become more stringent over time. In the EU, for instance, rules requiring a higher efficiency class of motors came into effect in January 2015. MEPS in Europe and their equivalents in other countries will ultimately lead to the upgrading of the installed base of electric motors. However, at the current pace of implementation, and taking account

of loopholes and enforcement issues, they will likely fall short of the energy savings needed to achieve climate goals, especially given that global energy consumption is expected to increase by 30 percent over the next 15 years. One reason is that MEPS specify the efficiency of individual products, in this case electric motors, rather than the efficiency of motor systems. No matter how efficient a motor is, if it cannot regulate its speed according to load, it will always be operating at full throttle. Legislation is gradually changing to take account of this — for instance, EU rules that came into force in January 2015 specify that certain (less-efficient) motors must be able to adjust their speed. But only around 10 percent of motors in service worldwide are currently equipped with (variable speed) drives that allow them to do this, even though the energy savings can be substantial — up to 50 percent in some cases. Developing Common Minimum Energy Performance Standards Another challenge is to establish common MEPS globally. Again, progress is being made in this area, with more and more countries moving towards harmonised standards, but much remains to be done. A recent study commissioned by the European Commission concluded that, if the most stringent current MEPS for product energy efficiency were harmonised today, global final energy consumption

February / March 2016 | industrial automation asia

Baltazar Gabka, Kroscienko, Malopolska, la

would be nine percent lower, and energy consumption due specifically to products would be 21 percent lower. This would save 8,950 TWh of electricity, equivalent to closing 165 coal-fired power plants, or taking 132 million cars off the road. The clock is ticking on climate change. The weight of scientific opinion is that we do not have much more time to turn the tide on emissions, otherwise it will not be possible to limit global warming to two degrees above pre-industrial levels, which is considered the maximum temperature rise we can sustain without triggering potentially catastrophic climate events. Of all the actions that can and are being taken to limit carbon emissions and mitigate the effects of climate change, none holds out more promise than improving energy efficiency. There are numerous measures that can be undertaken immediately, without fear of harming economic growth; indeed, since most investments in energy efficient technology are paid back within a year or two through lower energy costs, they can significantly boost competitiveness and through the replacement of old equipment generate additional economic activity. Fruit does not hang much lower than this.

Of all the actions that can and are being taken to limit carbon emissions and mitigate the effects of climate change, none holds more promise than improving energy efficiency.





February / March 2016 | industrial automation asia

ARTICLE TAG Power Plants, Infrastructure, Software



mbedded modules, sometimes referred to as Computer-onModules (COMs), or System-onModules, (SOMs), are the building blocks of the embedded world. Using modules alleviates many of the challenges facing engineers and project managers when designing complex applications. Some of the obstacles and costs associated with designing complex computing platforms — certification, design and development time and production costs — can be overcome by using an off-the-shelf embedded module. Saving money, minimising risks and bringing a product to market faster are often at odds with reality. Technology is becoming more complex. It requires longer development times, and therefore more development resources, greater design risks and higher development costs. At the same time, however, development resources are being reduced or more and more employees are shifted to the software sector. The software part of a product makes up an ever growing share and often actually represents the core competency of the user or of the application. This situation is compounded by Got a Question? Make An Enquiry. the fact that a ENQUIRY NUMBER product’s 10 to 15 year life cycle has decreased to five to eight Turn to page 72a to enquire or log on to: years today,

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which means more products have to be developed or revised in a shorter period of time. In addition, it is becoming increasingly important to bring a product to market in a timely manner which, in reality, can only be achieved by using a modular design. The community of x86 users has relied almost exclusively on modules or standard boards for many years; integration is the absolute exception here. Selecting Modular over Integrated Designs The concern that a modular design is more expensive than an integrated design is usually unfounded or based on an incorrect understanding of modular design. When can a modular design be recommended, or when is it the only way to develop a product? Whenever in-house technical expertise or bandwidth is a reality (especially in the case of highly complex designs), the modular approach might be the easiest and most economical way to solve this problem — apart from outsourcing the

project entirely. A modular design can also help deliver the product on-time even with resource bottlenecks. Hardware And Software Time Savings Add Up A look at the individual steps in the design process quickly shows where a modular design is advantageous. The time saved using a modular design is of course essential — after all, the processor module is already completed and has already been tested and, as a result, a crucial component of the hardware design is already available before starting the project. This makes it easier to design the application board and it can accordingly be developed more quickly. Some parts of the circuit can be deduced from the reference design in the starter kit, which allows the application board to be designed even more quickly and reliably. Time can be saved on the software side as well. The key software drivers are delivered with the module already and can be used immediately — so software development can start on day one since the target platform is already available. Therefore, real parallel engineering can take place. Performance tests are often necessary before a final design decision is made. This, too, can usually be conducted with modules, further reducing development time.

Saving money, minimising risks and bringing a product to market faster are often at odds with reality.


February / March 2016 | industrial automation asia

Saving Money In Circuit Board Design As a rule, the circuit board is another significant cost factor. In this respect, it should be taken into account that the circuit board configuration is always determined by the most complex switching element or structural element. For example, a Freescale QorIQ processor with a speed of 1.2 GHz and a DDR3 memory requires a multilayer structure with microvia and at least 10 or 12 layers. In a modular design, the application or carrier board can usually be implemented more easily with two to four layers less due to a lower level of complexity. Assessing the costs of the additional plug in a modular design compared to an integrated design from this aspect alone, one can quickly calculate that costs can be reduced here as well, or that no additional material expenses are incurred.


Pictured above: The differences between an integrated and a modular design, showing the distinct advantages of the latter.

Key software drivers are delivered with the module and can be used immediately — so software development can start on day one.

Circuit Board Math The average price for a circuit board measuring 6.9 inches x 4.7 inches (175 mm x 120 mm) with 12 layers is about US$30 for medium quantities. Using a module allows the multilayer structure to be reduced to eight or less layers. The circuit board price for eight layers is about US$21 to US$23 for

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February / March 2016 | industrial automation asia

Integrated Design Reduce Time

Reduce Costs

Reduce Risks

Reduce Complexity

Modular Design the same quantities. A set of mating connectors for a TQ module with QorIQ processor is about US$7 to US$9 per unit; consequently, no additional material expenses are incurred by using a module. A less complex application board certainly presents a lower risk for a necessary redesign than a highly complex board. This creates not only additional costs but also a time delay — which can incur more costs. In terms of long-term availability, storage devices are the most critical components in a processor application today. For a product, this means that redesign will probably become necessary in the course of the life cycle due to discontinued memory modules. If modules are used, this is the responsibility of the module producer, hence further cost savings in the entire life cycle of a product. Interest On Investments If overall development costs decrease, the interest paid on these investments will be accordingly lower as well. If one expects to achieve cost savings of up to US$135,000 in development, an interest rate as low as five percent means additional costs of US$6,750 per year.

“In terms of long-term availability, storage devices are the most critical components in a processor application today. For a product, this means that redesign will probably become necessary in the course of the life cycle due to discontinued memory modules.”

Since the module will be used by many customers, each customer will benefit from the excess quantity produced by the module provider. And using a module in other products, that is, at higher quantities, results in additional room to negotiate a price. In addition to pure development costs, continued investments for the acquisition of the appropriate tools for development, manufacture and test equipment may be required. Risk Minimisation Another crucial factor affecting developments today is risk minimisation. Risk means time and costs. Since the design for the application board is much simpler in a modular design, the risk of eventual redesign is significantly lower. A redesign in the course of the life cycle usually becomes necessary for the embedded module only because this is where the memory modules are located. Less risk and timely completion of development can play a crucial role in contributing to a product’s commercial success. What this means in terms of dollars differs from one firm to another and from one market to another. In addition, the low complexity of the application board allows many developers to realise more and more ambitious designs — one more reason to use a modular design. A Design Calculator By choosing an example with concrete figures and closely examining the individual steps from idea to end-oflife of a product, you can determine the advantages of a modular design or discover up to what quantity modular design is an advantage in a given case. The example presented on these pages uses a Freescale i.MX6 processor for comparison. The Concept Phase In the concept phase, analysis of the components to be used, determination of long-term availability, DfX (Design for X) concept, feasibility studies, and time and personnel requirements come


February / March 2016 | industrial automation asia

Additional costs of total development and product qualification can quickly run up to US$250,000 to US$300,000 for an integrated design.

to approximately US$70,000 for an average design with an i.MX6 processor. With a modular design — the design of an application board — US$27,000 is generally enough to budget for the concept phase. Preparing A Circuit Diagram Preparing a circuit diagram for an application board costs about US$6,500, especially if you can draw on existing tested circuit plans from the starter kit. When the processor is integrated, the circuit diagram becomes considerably more complex and usually costs approximately US$25,000 to US$30,000. The Layout The differences are even more obvious when it comes to the layout. Since the application board is clearly simpler to put together with a modular design, US$13,500 to US$15,000 will usually suffice. With integration, however, costs can easily double. Prototype Creation For creation of prototypes, the values for modular and integrated designs are usually not very different. However, differences can be considerable here if new equipment needs to be procured.

Paying For Drivers In An Integrated Design The module is delivered by the manufacturer with certain drivers and BSPs included. If the drivers for an integrated design need to be created for the design itself, add a price tag of at least US$50,000. Controlling BOM Costs BOM costs are reduced by the costs of the parts in the module and a more affordable circuit board, but are increased by the costs of additional connectors. Testing And Testing Equipment The production costs themselves do not differ very much, but the case is very different for testing costs. As a rule, integrated designs require more complex testing equipment, and costs amount to US$60,000. Providing For Continued Product Availability One of the leading factors in deciding to go with an integrated design or a module is the question — if you go with an integrated design, will your components still be available 10 years from now?

Certification What is it going to take to get certification for a medical (DIN EN ISO 13485) or aviation (EN ISO 9001)? Buying a module that is already certified will save a lot of time and money in the development process. The Bottom Line The examples in this article demonstrate that additional costs of development and product qualification can quickly become US$250,000 to US$300,000 for an integrated design — not counting the costs of additional risks of re-designs in the course of the product lifecycle, varying quantities for product planning, and interest charges. The break-even point after which an integrated version appears to become more affordable can be calculated very quickly. Once you have decided that going with a module instead of an integrated design is the right approach, then you can begin searching for the right supplier and the modules to meet your needs.




February / March 2016 | industrial automation asia

ARTICLE TAG Additive Manufacturing, Productivity, Primer




e hear all about 3D printing, but what we do not hear about is how the technology 3D printing is being used, what its potential is, and of course, its challenges. Ford Motor, for example, has adopted 3D print technology in vehicle production, which allows prototypes to be made in hours instead of weeks. The new Ford GT supercar will have parts that are 3D printed — including the steering wheel, paddle shirts and door controls. The new Mondeo Vignale’s grille was also 3D printed. What then are the opportunities for this technology, both from a consumer and business perspective? Before we can even begin to answer those questions, we first have to understand the market, its history, and its potential.

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The History Of 3D Printing Stereolithography appeared in 1984 and by all accounts was the first type of 3D printing. The printer would print the object layer by layer and used a laser to cure and solidify the material. Early use was mainly for rapid prototyping, which allowed companies to test out a design before investing in more expensive and time consuming fabrication methods. We are now moving past prototypes and moving towards the ability to print final products. New uses for the technology appear every day, from lighter weight materials for the aerospace and automotive industry to different ways to design and fabricate jewelry and couture. But while 3D printing has been around for almost three decades, only 200K machines have been sold, mostly to industrial manufacturers. Only recently have consumers had the chance to purchase less expensive hardware with the advent of MakerBot.

The technology has a long way to go, as the average failure rate is up to 75 percent. That means you only have a one in four chance of having a successful print. That early start is not indicative of the future though. There is tremendous potential for additive manufacturing technologies to revolutionise how we design and create things. 3D Printing Market The 3D printing market impacts the entire global community. According to Gartner, 3D printer shipments will more than double every year between 2015 and 2018, by which time worldwide shipments are forecast to reach more than 2.3 million. Greater China, mature Asia Pacific such as Australia and New Zealand, and emerging Asia Pacific regions will lead the way during the coming years. Gartner also predicts that in mature Asia Pacific markets, which includes Australia and New Zealand, spending on 3D printers is forecast to reach US$1.4 billion in 2018, up from US$101 million in 2014. The Americas accounted for 42 percent of overall purchases, followed by EMEA at 31 percent, and Asia-Pacific at 27 percent. The 3D printing market generated revenues totaling US$3.3 billion in 2014, up 34 percent from 2013, as prices fall and more consumers make their first purchase in this segment. According to market researcher Canalys, nearly 133,000 3D printers were shipped globally in 2014, a 68 percent increase over the previous year. Revenue from the market included associated materials and services. Makers and entrepreneurs are boosting the industry alongside big business. Canalys estimated that three quarter of 3D printers shipped in fourthquarter 2014 were priced below US$10,000. In that


February / March 2016 | industrial automation asia

The Different Types Of 3D Printing Available Today Fused Deposition Modelling (FDM) is one of the most recognisable and common 3D printing processes. It was created by the Rep Rap initiative out of the UK with the goal of developing a printer that can print most of its own components. Stratysys, hardware maker and owners of the popular MakerBot desktop printers, then popularised FDM in the early 1990s.

Bilal tries out his design.

Strati, the Local Motors 3D printed car.

Most FDM prints use PLA, a plastic filament that is then passed through a heated extruder one layer at a time onto a build platform. Each new layers bonds to the previous layer and hardens. FDM is a highly applicable process and can be used for anything from small scale applications, like toys, to rapid prototyping. Local Motors, a company that design and fabricates a range of vehicles, used a derivative of FDM to be the first company to 3D print a car. They used a machine similar to an FDM printer by taking a 6.5’ x 13’ foot bed laser cutter adding


quarter alone, total market revenue exceeded US$1 billion for the first time in one quarter, with some 41,000 3D printers shipped worldwide. This represented a 24 percent climb over the previous quarter. Makers like Bilal Ghalib are helping that growth. Using free software, Bilal travels to the Middle East to scan and print better fitting prosthetics for amputees. Much of the growth will come from the healthcare and aerospace industries, and we have not even begun thinking about the developing world and how 3D printing can help bring innovation to resource scarce regions or provide lower cost alternative solutions to developing nations.




February / March 2016 | industrial automation asia

Slice Labs’ 3D printed molds. Ford elastomer grommets, 3D printed using CLIP (Source: Ford).

The Space X SuperDraco engine chamber made of Inconel. Printed using direct metal laser sintering (DMLS). (Source: SpaceX)

custom hardware to transform it into a massive 3D printer. The company used Autodesk Spark to connect automobile digital design information to the 3D printer in a streamlined way for easier visualisation and optimisation of 3D prints. In contrast to FDM, Digital Light Processing (DLP) uses photopolymers that react with a light source to cure the resin into the final design. The resin is held in a clear, movable tray and the light source is directed across the resin surface that then hardens on the build platform above the tray. The final design is built layer by layer in this fashion. DLP has the capability to produce pieces needing high resolution and precision. SliceLab, a jewelry company, uses DLP technology for their intricate designs. Co-founders Diego Taccioli and Arthur Azoulai use Autodesk Ember to create 3D printed molds, which are then used to cast metals such as sterling silver. Their intricate pendant, earring and bracelet designs could not be completed on lower resolution printers due to the complex geometry involved. Moving from plastics and resins, Laser Sintering (LS) uses powdered materials such as metal. A laser fuses the powdered materials together at an extremely high heat to create a solid design. Once each layer is complete, a roller flattens the design on the build platform to ensure the layers properly bond. LS produces parts that are much stronger than DLP, however it does require a completely sealed build chamber to ensure the temperature is constant to the melting point of the powdered material. Additionally, due to the high temperatures, pieces need extensive cooling time. The process is mostly used for industrial applications and is currently the only process capable of printing in metal. Space X, the Elon Musk founded company that designs and manufactures advanced rockets and spacecraft, uses the process to create parts for their payload rockets. General Electric also uses LS to produce light-weight titanium jet engine turbine blades. One of the newest forms of 3D printing is called continuous liquid interface production or CLIP. In 2013, a company called Carbon 3D created the new process that is 25 to 100 times faster than the processes currently available today.

The process involves adding a layer of oxygen to the resin that stops the resin in the bottom of the tray from hardening as UV light is passed through it continuously. Unlike other SLA printing where you are only projecting a layer at a time, CLIP projects a continuous image as the platform is moving vertically meaning that you never stop printing. This has the ability to create more structurally sound objects as well as higher resolution objects because you are no longer building in slices. The part actually comes out closer to an injection molded part than a traditional 3D printed part. Ford is one of the first companies to announce their adoption of CLIP in their prototyping process. The automotive giant is using the process to produce prototypes for elastomer grommets, which are used in the space between the body of the car to protect wiring from being damaged by internal pieces of sheet metal or other sharp edges. What Is Next? As the technology becomes cheaper and easier to use, we will continue to see applications appear in new and unexpected industries as it ushers in a new era of design and manufacturing. For example, fashion designers have been 3D printing hard shells to add onto their designs for years, and even all sorts of variations on chainmail, they are consistently looking to make 3D printing softer and able to flow with the way that we move. Thus we are seeing a rise in 3D Loom technology, a type of additive manufacturing where instead of using polymers they are using organics, gels and fibers. This is also a growth area in architecture where they are using additive robots to print large structures with carbon fibre, cement and even steel. The true future of additive manufacturing is in the creation of stronger lighter forms that were previously impossible to create. Generative design software is helping to create these impossible forms by using complex algorithms that can take in data like desired weight and pressure per square inch and structural analysis to output hundreds of design options to complete the project the most efficiently. With its potential for innovation, 3D printing is poised to be one of the most disruptive technologies of our future.


February / March 2016 | industrial automation asia

ARTICLE TAG Robotics, Automation, Productivity





he rise in global demand for robots is a strong indicator that manufacturing industries are growing highly competitive. Asia currently sits at the top spot for being the fastest growing market in the world with the number of robot units sold forecasted to double by 2018. As the robot adoption rate continues to accelerate within the region, staying ahead will require manufacturers to be more efficient and productive than before.

Challenges In Manufacturing Manufacturers that cater to either domestic or export demand today, face stiff competition with bilateral and multilateral free trade agreements becoming increasingly common. Major trade agreements such as the ASEAN Economic Community (AEC) and the recent TransPacific Partnership (TPP) are also exacerbating competition between companies and brands. To stay ahead, manufacturers are looking to optimise their production, enhance output quality and maximise their resources. In addition to global competition, manufacturers also face production challenges with product life cycles growing shorter over time. The constantly shifting marketplace of goods is becoming the norm across many industries. To keep up with today’s “High Mix, Low Volume” manufacturing environment, reducing time-to-market is crucial in gaining a competitive advantage. Increased Quality Standards To stand out among competing goods, manufacturers need to be able to deliver quality products consistently. This is especially crucial for products that require high-precision assembly and careful handling, such as solid formed embossed parts manufactured by Germanybased Ferd. Wagner Profile is an example where the company deployed two industrial robots to take over the complex soldering and

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welding process, which involve feeding metal components into a tack-welding machine and a highfrequency soldering station. Robots equipped with customised gripping tools are fine-tuned to handle these parts as these components have fragile decorative surfaces and any damage renders them unusable. By employing the same torque and pressure each time, robots can ensure high quality output with minimal human errors made. As a result, there is reduced wastage of raw materials, leading to lower overall production costs. Reduced Time To Market Factories operating at optimised productivity are not only able to reduce time-to-market but also stand to gain from lowered production costs. For example, robots can be assigned to automate the process of machining aluminium castings into hubs. The robotic arm takes unfinished castings from a bin onto the lathe, removes them after machining and then hands them over to an automatic broaching machine where the groove is cut. Deploying robots to perform such assembly applications that involve tending to two machines at a time can accelerate feed input and shorten the time taken to replace the machine parts. Manufacturers will ultimately benefit from savings in production costs and increased capacity.



FEATURES Built For Speed In an ever-shifting landscape of goods and services, time is becoming a pivotal factor in the production line. Industrial robots today are built in consideration of this, with the average initial set-up time including unpacking, mounting and programming spanning less than a day. Manufacturers deploying robots for the first time can be assured that downtime will be minimal, although there could be an initial settling-in period of customising the right gripper for the particular application depending on the end-user. Industrial robots are not only quick to set up, but also easy to program. The latest wave of robots includes built-in interfaces that are easy to operate with intuitive 3D visualisation available on the screen. This allows even operators with no prior programming experience to manoeuvre the control software easily. For example, to program a set of actions, the employee would only need to move the robot arm along desired waypoints or alternatively, use the arrow keys on the touchscreen. Features like flexibility and easy programming are especially important for manufacturers in the metal and machining industry as the production output for various components can range from small volumes to over a hundred thousand units per year. Easily programmable robots can be repurposed quickly across different production lines. Such manufacturing flexibility can provide businesses with a competitive advantage that differentiates themselves from their competitors. The user-friendliness of the robots also contributes to lower integration costs as workers can program robots independently with little reliance on external technical support. Built To Fit The size and weight of the robot are big factors that contribute to the ease of integrating robots into production lines. Robots have advanced from their bulky forms to the current modernised, lightweight model that is easily portable and occupies a relatively small footprint. For example, robotic arms with a payload of three kilograms can weigh as little as 11 kilograms while its footprint can be as narrow as five inches. Even with these robots, manufacturers will have the liberty to reconfigure machinery around the factory easily to find the best production flows. In some cases, manufacturers in the metal and machining industry operate on a “High Mix, Low Volume� basis as the component parts such as drive shafts, industrial gearboxes or drill bits are engineered-to-order. These units are produced

February / March 2016 | industrial automation asia

With the use of robots, human operators not only benefit from safer working environments but also from the creation of more jobs.

when required, to prevent a cluttering of the workspace and also because sales forecasts tend to be unreliable. Depending on the spare parts that need to be stocked, the lead-times and due dates can vary widely from a matter of days to a span of a few months. Having robots that can be easily shifted and easily fit along changing production lines will help manufacturers reduce time-to-market, which will be crucial in gaining a competitive advantage. The Robot-Human Collaboration Advanced technology has made it possible for robots to work side by side with humans today. In previous years, industrial robots in factories were usually fenced up to ensure the safety of the human operators. However, now the use of safety fences may be deemed to be unnecessary after prior risk assessments have been conducted. Automation with these robots would still be possible for factories with confined workspaces. Robots are now built with advanced force-sensing features that will trigger the machine to halt its action when it senses an obstruction in its path. Unfenced robots will be able to come into closer contact with workers and function alongside them in tight spaces. This will enable robots to perform a wider range of capabilities as they are better integrated into the production process. Safety First Metalworking manufacturing environments usually entail carrying of heavy materials or working with hazards such as welding fumes or flying shards. Apart from streamlining processes, robots also help create a safer and more attractive workplace for workers by liberating them from jobs requiring physical exertion, precision or repetition. This will not only greatly help reduce risk of accidents but also improve the motivational levels of these workers. Employees will be freed up and reassigned to focus on higher-level operation tasks, undergoing skills upgrading in the process. Human operators not only benefit from safer working environments but also from the creation of more jobs. According to a 2013 report by Metra Martech, over two million jobs will be generated in the next eight years because of industrial robots. These robots are predicted to be required mainly for industry expansion and downstream job development. Higher-skilled jobs have also become more acces-


February / March 2016 | industrial automation asia


sible as workers are reassigned to perform managerial tasks for example.

Embracing Change In a day and age characterised by volatile economic and financial conditions, it is imperative for businesses to stay ahead by securing competitive advantages for their operations. Companies are increasingly susceptible to fluctuating global demands and face challenges in the form of shortening product life cycles and increasing global competition. Similar to what computers are to humans, industrial robots are tools that the businesses can leverage to perform tasks better. Manufacturers looking to take their operations to the next level can turn to robots as a viable alternative with their ability to optimise factory productivity. Already, governments around the world have begun to recognise the benefits of robots with the number of grants made available to companies to encourage automation. Robots have been built to complement well with factory assembly lines, and will ultimately help contribute to the success of companies willing to adopt them.

In addition to global competition, manufacturers also face production challenges with product life cycles growing shorter over time.

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Strategic Investment Option The industrial robot has evolved technologically and functionally, culminating in a prototype that offers significant benefits to manufacturers and companies ranging from large enterprises to small medium enterprises (SMEs) worldwide. In addition, the process of integrating robots has become easier and quicker. The robot’s advanced safety settings also make it easier for companies to manage an employee workforce of a hybrid nature. Additionally, investing in robots will help factories achieve higher production stability, as robots are able to ensure consistent, high quality product output with its precise movements. This is especially important for production lines that require high accuracy or involve costly materials. These are points manufacturers can consider when deciding on investing in robots.



February / March 2016 | industrial automation asia

ARTICLE TAG Wireless, Trends, IoT



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i-Fi technology has become such a pervasive force that it has become hard to imagine what life will be like without wireless Internet access. The growth of smart mobile devices that feature new, data-hungry applications has undoubtedly shaped the wireless landscape as more users rely on these devices to perform more than just phone calls. On the enterprise front, the concept of the traditional office and work day has also evolved as more organisations adopt Wi-Fi to boost operational efficiency and productivity, allowing employees to accomplish tasks and collaborate with one another regardless of their location in the workplace. Given the changes in the way we live and work, no technology is better suited to address the everincreasing demand for data than Wi-Fi technology. In 2015, we saw 802.11ac Wave 2 Wi-Fi Access Points (APs) improve the overall Wi-Fi experience for

users. These APs support a new capability called Multi-User Multiple Input/Multiple Output (MUMIMO), which allows the simultaneous transmission of multiple client streams to different devices over the same frequency, enabling high performance Wi-Fi connectivity even in congested environments. However, in an industry that continuously changes, we can certainly expect further improvements in the coming months as organisations look for continued ways to take Wi-Fi connectivity to the next level. As we fetch our crystal ball to gaze into the year ahead, here is a look at how the wireless experience will change as we enter 2016 and beyond: Better End-User Experience Firstly, in the enterprise space, we predict that the end-user experience related to accessing BYODenabled enterprise networks will be easier and more secure through certificate-based device onboarding


February / March 2016 | industrial automation asia

solutions. According to a MicroMarket Monitor report, the Asia Pacific BYOD market is projected to grow from US$13.54 billion in 2013 to US$66.84 billion by 2019, driven by increasing consumption of mobile devices. Certificate-based device onboarding solutions will allow IT managers to deploy BYOD policies in a scalable and user-friendly manner while eliminating IT support costs and user frustration associated with passwords. On the homefront, whole home coverage will become a reality, and we expect people will be ‘showing off’ their home network capabilities at dinner parties using a smartphone app. Given that the smart homes market in Asia Pacific is projected to reach US$9.23 billion by 2020, one can expect to see more and more interconnected devices making their mark in the home. In the public realm, Hotspot 2.0 will become the de facto standard for public access and hospitality Wi-Fi, enabling end-users to seamlessly and securely roam on Wi-Fi networks. Now that we have Hotspot 2.0 support in all major mobile and laptop operating systems, Hotspot 2.0 deployments will accelerate by service providers and hotel brands. Carrier Wi-Fi calling, which allows users to make and receive phone calls using a Wi-Fi network instead of the traditional mobile network, will be one driver for this. Unlike services such as Skype and Hangouts that require users to download applications prior to making calls, Wi-Fi calling lets users use their actual mobile phone numbers to make and receive calls. This provides users the connectivity they require to make and receive calls where cellular coverage is insufficient.

The Asia Pacific BYOD market is projected to grow from US$13.54 billion in 2013 to US$66.84 billion by 2019, driven by increasing consumption of mobile devices. •

types and wireless protocols to provide business intelligence for enterprises and cities; and Continued virtualisation of networking services to enable service providers to more efficiently scale and more quickly roll out new services.

Innovations In Wi-Fi And Cellular Cross-Pollination The biggest innovation will be in the area of Wi-Fi + cellular cross-pollination and convergence (802.11ax, LAA, LWA). Wi-Fi and cellular are the two most successful wireless technologies in existence and have complemented each other for years. Now they seem to be getting engaged. And it could not come at a better time as demand for wireless capacity is at an all-time high.

Blurring Of Traditional Distinctions Many of the traditional distinctions in the wireless industry will be ‘blurred’ due to technology, regulatory and business advances. Blurring will happen between: licensed and unlicensed; service provider and enterprise; and, public versus private. Specific advances that will affect these include: unlicensed LTE, 802.11ax, Wi-Fi calling, enterprise IMS and WebRTC, CBRS, private LTE and Hotspot 2.0. New business models will evolve to monetise ‘free’ Wi-Fi. Traditionally, monetising free Wi-Fi meant charging for WLAN usage. In the coming year, we will see more organisations leveraging Wi-Fi and location analytics to monetise their wireless networks. Businesses can utilise these data to gather trends on customer behavior and Wi-Fi usage, which can drive business strategies. Web-scale content companies (social media, search, hosted services, and so on) will launch some very-large-scale Public Access Wi-Fi projects in developing markets. We also expect an acquisition or merger between a Tier 1 MSO and a Tier 1 MNO.

Other possibilities include: • Mainstream use of analytics to drive user experience, business process optimisation and monetisation; • Cloud interconnections and service chaining of networking services to seamlessly tie together best-of-breed technologies; • Secure, manageable and scalable IoT platforms that leverage multiple sensor

Enhanced User Experience For Customers As we move into 2016, we will continue to see technology innovations shaping the wireless industry. While these innovations relate to various aspects of managing and accessing Wi-Fi networks, ultimately, these result to enhanced connectivity and online experience for end users as a whole, as well as optimised business processes and monetisation models for enterprises.




February / March 2016 | industrial automation asia

ARTICLE TAG M2M, Predictions, IoT



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M2M Will Move Out Of The Back Office M2M has traditionally been used to automate internal business processes. Today, companies are evolving their M2M strategies to innovate, drive new customer experiences and increase revenue through more sophisticated, customer-facing

connected products and services. In fact, 66 percent of those already using M2M say that their strategy today focuses on external stakeholders, according to the Vodafone M2M Barometer 2015. As M2M moves outside the IT department and plays a larger role in customer experience and competitive advantage, we predict that by 2016, more than a third of businesses will describe their M2M projects as innovation projects, rather than IT projects. M2M Deployments Will Get More Sophisticated — And Will Deliver Greater ROI Businesses that are more sophisticated in their deployment of the technology, for instance linking M2M with cloud platforms and big data analytics, will see the greatest positive impact in 2016. While analytics has often been integrated in M2M solutions, it has now gone from a ‘nice to have’ to an essential part of a holistic M2M solution. Forty-nine percent of businesses in AMEAP, for example, are implementing M2M alongside a big data strategy, compared to 35 percent in Europe and 29 percent in the Americas. These types of solutions are leading to significantly greater returns, with 83 percent of the most sophisticated organisations seeing significant return, compared to 43 percent of the least sophisticated businesses. And, 69 percent of those most sophisticated organisations say that M2M has ‘fundamentally transformed’ their businesses. Going into 2016, organisations considering M2M will need to take a sophisticated approach — and vendors will be expected to deliver. IoT Will Become Vital To The Customer Experience Two-way communication is now enabling more sophisticated customer-facing applications. Users are starting to innovate and use M2M to drive superior customer experiences and increase revenue through customer-facing connected products and

Credit: renato cardoso, Amsterdam, Amsterdam, fi


n 2015, the Internet of Things continued to explode for both enterprises and consumers — and this will continue into 2016. In fact, Vodafone’s M2M Barometer found that more than a quarter of all companies worldwide are now using M2M technologies. In fact, companies in the Africa, Middle East and Asia / Pacific (AMEAP) region went further with an adoption rate of over 35 percent, outperforming other regions around the world. M2M is finding its identity as a vital business solution that touches everything from backend operations to customer experience. In countries across APAC such as Singapore, China and South Korea, governments are already pushing for IoT as a matter of national policy. Across developing markets in AMEAP, the rollout of foundational IT and communications infrastructure for IoT is already progressing. In 2016, we expect even greater growth and an increased focus on sophisticated and meaningful solutions. Below are my predictions for the APAC M2M market in 2016 and beyond.


February / March 2016 | industrial automation asia


In countries across APAC such as Singapore, China, and South Korea, governments are already pushing for IoT as a matter of national policy.

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There Will Be A New Focus On Connecting The ‘Things’ That Matter With all of the buzz around IoT, companies have rushed to connect almost everything. However, just because we can connect everything does not mean it makes sound business sense. As the market matures, we will begin to see a weeding out of the solutions that do not serve a true business or societal purpose. M2M vendors and service providers will focus on connecting the ‘things’ that really matter like — utilities and smart meters, heart monitors, fleet management and chronic healthcare management solutions. Just in South Korea alone, transmitting real-time data from SIM cards over wireless networks has enabled technology providers to monitor vehicle activity and reduce the risk of traffic accidents, as well as improve waste management with smart bins that alert collectors when they are ready to be emptied. These are simple yet innovative solutions that greatly improve our overall quality of life. It will be exciting indeed to see what other positive impacts will come in the year 2016.

M2M is finding its identity as a vital business solution that touches everything from back-end operations to customer experience.

Credit: iamwahid

services. Additionally, in 2015, M2M adoption in the retail sector grew an astounding 88 percent, as retailers and marketers began to realise the value of IoT for customer experience. Previously only used for solutions like smart vending machines, retailers now understand that M2M can strengthen the shopping experience through personalisation, smarter payment methods and digital signage — all while streamlining internal operations. Many businesses in AMEAP have expressed interest for M2M to enable real-time data exchange in order to monitor and better understand their customer experience processes. In 2016, we expect that the use of M2M and Internet of Things (IoT) applications for customer experience will go mainstream across industries.



February / March 2016 | industrial automation asia

ARTICLE TAG Robotics, Productivity, Manufacturing




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he goal was challenging: to double the production of the new V6 engine blocks made in Ferrara by FCA Cento. Yet the Modenabased system integrator successfully achieved the objective by designing and installing a line that puts two twin cells together and integrates them with the help of Comau’s robots designed to assist in the production floor. Since 1947, VM Motori has been known worldwide for the production of high-performance diesel engines destined to supply a wide variety of companies within the automotive, agricultural and naval sectors, as well as for power generation applications. The plant in Ferrara has a longlasting partnership with the Modena-based system integrator SIR SpA, through which they develop and supply high-tech industrial automation solutions. The integration with the FCA Group has allowed the company which is now known as FCA Cento, to further optimise its production. Following what is viewed as a sound manufacturing philosophy, the company is increasingly strengthening the strategic

Thanks to the new systems, the company has been able to optimise their production, ensuring even higher production capacities, which today are around 60,000 engine blocks per year for a single line. Comau Smart NJ 110, the machine used by Sir Automazioni to automate the FCA Cento Plant.

The new cell realised in the FCA Cento plant uses a robot with a high payload, 110 kg, suitable for lifting heavy engine blocks of about 21 kg each.

Comau Smart NJ 110, the machine used by Sir Automazioni to automate the FCA Cento Plant.


February / March 2016 | industrial automation asia

connection between the group’s design offices and working departments. Aligned with the perspective of a continuous implementation of its production capacity, and thanks to its long-time collaboration with SIR, the company installed a new automated line featuring the robots. The result is a significant increase in the production of crankcase panels for the new three litre V6 diesel engines. Ramping Up The Automated Lines The request made by FCA Cento to the system integrator was precise and clear — the creation of an automated plant that would be able to double the production rate of new cast iron engine blocks. An additional requirement was to utilise reliable machines, in terms of the mechanics and electronics, which would ensure good value for the money. “The company had an old robot cell for loading and unloading that was equipped with a machine tool and a Smart H2 robot,” explained Davide Passoni, Head of R&D at SIR SpA. “To meet the company’s needs, we optimised the existing cell by replacing the mechanical system with a new, two-spindle machining center and keeping the same robot that had been used for years to produce the engine blocks. We also created a new twin cell that was connected to the first and designed for the same operations. This new cell was set up with a similar machining centre and connected to a new generation Smart NJ 110 robot. This intervention has allowed FCA Cento to double the production of engine blocks that used to be carried out with a single robot cell.” The process involves a conveyor belt takes the

Comau Smart NJ 110, thanks to its outreach, carries out both the machine tending operations and any other movement required within the cell.

Another strong point of Comau robotics solutions is the ease of use, thanks to a simple and intuitive control unit management.

unprocessed pieces to the two cells where they are recognised by a sensor and loaded inside the machining tool centres that then implement, in parallel, the mechanical operations necessary for the production of the engine blocks. At the end of the cycle, the robots pick up the pieces and place them on a rotating table for a dimensional control and, if the pieces meet the parameters and tolerances required, they are transferred to an industrial washing machine to complete the process. Right Implementation, Greater Rewards Thanks to the new systems, the company has been able to optimise their production, ensuring even higher production capacities, which today are around 60,000 engine blocks per year for a single line. The operation implemented by SIR was developed in different stages, ending with the installation of the second robotic cell in January 2015. This automated system has presented several advantages over the last few months. By automating the loading and unloading of pieces with the robots, it was possible to convert the work of employees who were no longer needed for heavy and repetitive operations, and could be assigned to more specialised and less burdensome tasks, such as maintenance or general management of the line. Since the line is not expected to implement excessively strict cycle times — which last around 20 minutes per cell with the process divided in two phases at the end of which the piece is taken back — it was also possible to optimise the robots with




February / March 2016 | industrial automation asia

The 2015 production capacity of V6 engine blocks is 115,000 pieces per year, although the company is working to further improve their performance. particular attention to the care required for the handling of finished pieces such as the engine block. Reliability The Key For the automation of the second line installed was the Smart NJ110 model robot was used. With a payload of 110 kg, the robot can lift heavy engine blocks weighing about 21 kg each. Given that it also has a reach of about three metres, it can easily perform the machine tool tending operations as well as all the other handling operations required to carry out the production process as efficiently as possible. The system installed by SIR covers a significant part of FCA Cento’s production, which today serves clients such as Jeep, Chrysler, Lancia, LTI (London Taxis) and Maserati. The line is dedicated to the production of engine blocks and crankcase panels for new 3000cc V6 diesel engines which are mounted on vehicles such as the Maserati Ghibli and the Jeep Grand Cherokee, to name a few. Thanks to the 60-degrees V6 architecture, this engine is particularly compact and versatile, and can be customised to meet the customer’s requirements for both transverse and longitudinal applications. The engine is therefore ideal for sedans, SUVs and high-end vehicles for markets with EU 5 and NAFTA emission regulations. In addition to the new V6 diesel engine, FCA Cento is also developing new versions of V6 engines that can deliver even higher power and lower emissions. The 2015 production capacity of V6 engine blocks is 115,000 pieces per year, although the company is working to further improve their performance. This is accompanied by the production of the historical fourcylinder engine, which is also intended for the automotive market, with 15,000 units per year and, last but not least, engines for naval and industrial applications, with the production of an additional 15,000 pieces per year.



ith the introduction of openROBOTICS, partners Comau and B&R are opening up new dimensions of robotics integration for machinery and production lines. The solution is based on a full lineup of Comau robots that handle payloads ranging from three to 650 kilograms. “With completely uniform programming for every component in the line — including the robotics — our customers around the world gain the full benefit of holistic approaches to operation, diagnostics and maintenance,” said Tobias Daniel, head of sales and marketing at Comau Robotics. “You will not find another solution like this on the market.” Traditionally, robotics and machinery have always relied on separate controllers or gateways. Perfectly synchronised Comau robots all over the world can now be completely and seamlessly integrated into machines and production lines equipped with B&R automation components. “The customer simply selects the desired Comau robot in the Automation Studio engineering environment,” explained Walter Burgstaller, B&R’s European sales director. “With mapp technology, the robot can then be effortlessly incorporated in — and perfectly synchronised with — the machine’s automation software. Conventional solutions with cumbersome interfaces will never achieve this kind of usability and performance.”


February / March 2016 | industrial automation asia

Powering The Automotive Supply Chain Siemens PLM Software held an automotive supply chain seminar in collaboration with Industrial Automation Asia (IAA) and Asia Pacific Metalworking Equipment News (APMEN) on December 3, 2015. Syed Shah, senior editor discusses. Siemens PLM Software Date: December 3, 2015 Venue: Holiday Inn Kemayoran Country: Jakarta, Indonesia

AS Indonesia moves towards an age of increased digitalisation and connectivity, there is an increased expectation of the automotive sector to improve on its productivity and swing around an otherwise lacklustre 2015. At the ‘Moving Into Industry 4.0: The Power Of PLM In Your Automotive Supply Chain’ seminar co-organised by Siemens, Asia Pacific Metalworking Equipment News (APMEN), and Industrial Automation Asia (IAA), ideas on harnessing the power of Product Lifecycle Management (PLM) software were put to the GIAMM (Gabungan Industri Alat Alat Mobil & Motor) members who attended the event held at the Holiday Inn Kemayoran, Jakarta, Indonesia. Attendees ranged from OEM automotive parts makers to representatives from larger automotive corporations. During the seminar, Rajiv Ghatikar, VP and GM, ASEAN/Australasia, for Siemens PLM Software, brought up points with regards to managing increased complexity across the entire lifecycle of a vehicle in a cost effective and streamlined manner and how this is a crucial period in the economic cycle to increase productivity. This is where PLM solutions come in and these solutions are essential in today’s increasingly complex and digital world. Got a Question? Make An Enquiry.



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Yokogawa Management

“Indonesia is coming more into the light now for us because after the Jokowi administration took over, there has been more focus than ever in driving business. Aside from the somewhat sluggish second half of 2015 for the automotive sector in the country, the footprint that Indonesia has in the region is quite a distinct one that has the potential to grow,” said Mr Ghatikar. He further mentioned that it would give established players in the automotive market like Thailand competition because of advantages like having a low cost base, and has a good skillset for driving solutions across supply chains which could cater to export requirements too. As such, the Indonesian automotive market looks poised to grow much bigger in only a few years. Ir Hadi Surjadipradja who is the Secretary General of GIAMM and keynote speaker for the event mentioned: “The Indonesian automotive scene is currently experiencing a downturn but there are many opportunities in technology that we can be exploring in order to ride the uptick when it comes along. The key for us is not to be left behind and

The seminar ended on a lighter note with a lucky draw amidst more pressing matters like the need to invest in a PLM solution.

adopting PLM solutions to our existing processes is essential.” Mr Surjadipradja also added that the old mindsets of yesterday’s production are still prevalent but the need for a change in momentum has to come as quickly as possible. “What we do not want is to lose our competitiveness and it is true that only the most flexible and efficient manufacturers out there will survive.” The Road To PLM Adoption During the seminar, Mr Ghatikar stressed that people need to be prepped for the technology. Touching upon the maturity of the Indonesian market, he remarked that there is still a lot of catching up to do. After the event Mr Ghatikar mentioned that he believes the Indonesian automotive




February / March 2016 | industrial automation asia

industry is not ready for mass adoption of PLM solutions because of a lack of local knowledge and expertise in this area. Events such as this one aim to set off the wheels of innovation about the importance of innovating change because the automotive industry elsewhere is changing and they need to keep up with the global tempo. From Siemen’s point of view, PLM is the answer and they are equipped to provide the solutions to take companies to the next level. However, the infrastructure needed to support such technologies could be an issue in a country like this. But Mr Ghatikar believes that this is just a minor hurdle that can be easily overcome. “I believe that our solutions can be connected even on different architectures and some can do without connectivity — installed locally and then run. One might face an issue with connectivity when implementing cloud solutions down the road but right now I do not think that is the main concern.”

“Teamcenter is one of the modules that we offer and one of the reasons why companies should adopt us — the collaborative aspect of the solution that allows people to work across locations simultaneously. While connectivity is important, it is also varied in a sense that you can connect people on a wide variety of platforms today and could be as sophisticated as a multi-site Wide Area Network (WAN), a broadband based one or even a cloud based one,” remarked Mr Ghatikar. Continuing he said: “All these provide a platform depending on the client’s needs and objectives — in this day and age, one can get connected one way or the other to enable collaboration to happen. While the issue of the infrastructure to support the connectivity might not be as stable as let us say a fully developed economy like the US, in the connected world we live in now, the need for connectivity in the manufacturing world, I think that Indonesia will upscale itself quickly enough to meet these needs.” Another concern of automakers is the migration of design platforms. In response to this, Mr Ghatikar explained that the NX product has all the elements of the base design like CAD/ CAM/CAE simulations that one needs. “In addition we have the most open architecture. We take that as a core philosophy of the company and are happy to accommodate any environment that the customer wants to operate on which means our solutions can co-exist with other solutions and this, I believe, gives us the competitive edge.”

Collaborative Platforms To Power The Automotive Sector When asked about what is one of the most critical elements in the automotive supply chain, Mr Ghatikar mentioned that collaboration in an increasingly fast paced environment where quicker and better products are to be churned out is highly important. In order to do that, critical information sharing is paramount.

PLM & The IoT Since the global manufacturing sector is moving towards the ‘smart’, ‘connected’ factory floor, solutions in the factory space look to be on board this trend. Mr Ghatikar explained that the Internet of Things (IoT) phenomenon is essentially about making everything within an ecosystem become a smart object and getting them connected. He gave the example of an object playing

a role in a production process, there should have a way to increase the intelligence of the overall system that can then be designed to give feedback on certain metrics or performance criteria that says it is performing its functions faithfully as to what it was originally planned to do. “This means that in the IoT, if objects are to be smart, then there is a need to digitise them smartly in a way that they can interact, give feedback and in other ways become intelligent enough to, for example, pre-empt the user to potential issues that might arise in the process through monitoring. PLM on the other hand is a process that can seek to connect these smart objects and can work hand in hand with the IoT concept. To have a ‘smart’ PLM implies that there is an IoT system in which the PLM solution operates,” explaining where and how the PLM solution fits into the whole IoT setup. The Rationale For The PLM Solution The obvious takeaway at the end of the seminar is that the local automotive manufacturers need to look at being able to project where one’s business needs to be in two to three years’ time. They also need to stay informed of the major global market trends in the manufacturing sector to stay competitive on the global scene, in terms of innovation, effective cost management, and productivity. Mr Ghatikar’s parting advice was that: “If you do not have a PLM system, then it is time to get one! Those who have not come on board yet should not be afraid because the adoption of PLM is a journey that could take years to adapt to. But the most important thing is to be on that journey. It is like the stock market — if you want to reap the benefits of a good stock, you first have to buy and invest in it. So the message is embark on the journey and we at Siemens will help you along with your Return-On-Investment (ROI) planning to make sure that the investment in PLM will be paying out.”



February / March 2016 | industrial automation asia

ANCA Machine Tools: Linear Motor

AspenTech: Engineering Software

The LinX Linear Motor from ANCA Machine Tools overcomes all problems related to flatbed linear motors with its cylindrical design. The machine’s design eliminates attractive forces between the forcer and shaft, reducing the loading requirement on support bearings, and allows an impressive standalone thermal stability because of its thermal barrier design that separates and removes heat from the motor. This reduces power usage and saves on space as a chiller is not required. The simple construction offers improved and efficient performance at a lower cost.

Aspen Technology has announced the availability of new enhancements to aspenONE Engineering Version 8.8 software. Developed for firms in the Oil, Gas, Refining, Chemicals, Engineering & Construction and other process industries, aspenONE V8.8.2 includes updates to the Aspen Economic Evaluation and the Aspen Exchanger Design and Rating (EDR) product families. The latest upgrades deliver integrated workflow and costing improvements that allow leading global firms to minimise capital expenditures, improve project design efficiency and boost operational profitability. This release of Aspen Capital Cost Estimator (ACCE) software includes the annual Cost Basis update for 2015, which is integrated into the entire Aspen Economic Evaluation suite of products.



B&R: Line Control & Monitoring

CyberArk: Cloud-Based Privileged Account Security

With just a few mouse clicks, a convenient line monitoring system can be implemented using the APROL process and factory automation system from B&R. The solution is based on OMAC’s PackML standard, which can be applied to virtually any machine. To remain competitive, owners of machinery and equipment must eliminate all sources of inefficiency. A line monitoring system provides the information they need to identify and eliminate problems early on. The increased efficiency in turn boosts production output. The standard PackML machine data interface in APROL contains control modules for machines and lines that provide convenient access to relevant details. Faceplates and sub-faceplates display key data and important details.

CyberArk has announced new capabilities for CyberArk Viewfinity that deliver privileged account security to the endpoint. With CyberArk Viewfinity v5.5, customers can benefit from an enhanced, single privilege management and application control solution to reduce the attack surface while being able to block the progression of malwarebased attacks, and balance business user productivity and enterprise security. Following the acquisition of Viewfinity in Q4 2015, CyberArk Viewfinity is now available as part of the CyberArk Privileged Account Security Solution. With this release, customers can gain greater privilege management and application control features in an on-premises or Softwareas-a-Service (SaaS)-based offering.





Delcam has introduced the R2 ArtCAM Pro, with improvements that include creating structures for 3D Printing, easier designing with vectors, more design options with real-time updating and faster machine simulations. The accuracy will also be enhanced due to the addition of rulers in the 3D view to aid in creating more precise artwork and positioning elements of the piece. There are also two new options available in the 3D offset strategy. The abilit y to spiral from the outside in or from the centre out, reducing tool wear and giving better surface finish, and on-surface links that reduces machining time. ENQUIRY NO. 1906

Emerson: Level Measurement Emerson Process Management has enhanced its range of level measurement devices. A number of new functions and certifications will help to minimise maintenance, enable easy integration and expand the range of suitable applications. Supporting manufacturers’ need for improved inventory control, the Rosemount 5708 Series 3D Solids Scanner, which uses acoustic measurement and 3D mapping technology to provide accurate continuous level and volume measurement, is now suitable for a broader range of applications. The device is now ATEX/IECEx certified for installation in areas with potentially explosive atmospheres, often found in solids measurement applications.


February / March 2016 | industrial automation asia

E2S Warning Signals: Strobe Beacons E2S Warning Signals will launch its new GNEx GRP Xenon strobe beacons, on Booth W1002E at CIPPE 2016 in Beijing, China from March 29-31, 2016. The new products add visual signalling to the explosion proof and corrosion resistant GNEx family. Suitable for all Zone 1, 2, 21 & 22 hazardous location applications the GNEx beacons have extended temperature range with IECEx and ATEX Ex d approvals. For high ambient light or long distance signalling the GNExB2 beacon is available in 10, 15 and 21 Joule variants producing up to 902cd — a very high output Xenon strobe. The smaller sized GNExB1 is available for where a 5 Joule (up to 117cd) unit meets requirements.


Exxon Mobil: Multi-Purpose Grease The Mobilith SHC Series are greases designed for a wide range of extreme-temperature applications in various industries. They are designed to have an excellent proprietary additive system that provides anti-rust and anti-corrosive protection. Their low internal friction and their base fluids’ high natural viscosity improves mechanical efficiency, leading to prolonged bearing and grease life and low-temperature pumpability. These help reduce maintenance costs and improve profitability. The Mobilith SHC 220 is a multi-purpose, NLGI 2 grade extreme pressure grease, recommended for heavy-duty automotive and industrial applications. It has an ISO VG 220 synthetic base with a lithium-complex thickener that operates at a wide temperature range of -40 deg C to 150 deg C.




February / March 2016 | industrial automation asia

Fluke: Clamp Meter Fluke Corporation had introduced the Fluke 902 FC True-rms HVAC Clamp Meter, a wireless Fluke Connect enabled meter that improves the productivity of HVAC technicians in the field. With this product, technicians can document measurements, email results to customers, and collaborate with colleagues in real time directly from the job site. The rugged CAT III 600V / CAT IV 300V rated meter performs the essential measurements of HVAC systems — microamps for testing pilot light sensors, resistance up to 60 kilohms, AC current, AC/DC voltage, capacitance and contact temperature — eliminating the need to carry multiple tools. As part of Fluke Connect the 902 FC can transmit measurements to a smartphone or tablet for later, detailed analysis. ENQUIRY NO. 1910

Infineon Technologies: Microcontrollers The XMC4300 and XMC4800, from Infineon Technologies, are the industry’s first microcontrollers with integrated EtherCAT node on an ARM Cortex-M processor with on-chip flash and analogue/mixed signal capabilities. Both series enable compact designs because they require no additional components such as dedicated EtherCAT ASIC, external memory or a quartz clock generator to start up the EtherCAT slave controller. An integrated PLL supplies the EtherCAT IP with the necessary 25-MHz clock. Code is executed from the Cortex-M4 processor at 144MHz from the integrated RAM or flash memory. The XMC4300 and the XMC4800 offer an elegant solution for implementation in mixed networks with CAN and EtherCAT. They allow a gateway from CAN to EtherCAT to be efficiently established through DMA transfers.


Hradil Spezialkabel: Offshore Control Cables Hradil Spezialkabel is offering the new HB44 offshore control cables in a wide range of configurations from 3 x 1.5 mm2 to 36 x 1.5 mm2. Customised configurations such as 2 x 2 x 0.75 mm2 are available upon request. Hradil has replaced commonly used mica tape with special ceramicised silicon. The flame-retardant, halogen-free and non-hygroscopic special compound is inserted into the cable by means of pressure extrusion. All cable cores and shieldings are completely embedded so that all capillary spaces within the cable are filled. Regardless of the cable length and the type and pressure of gas, combustible gases can no longer flow into or spread within the cable. The company’s HB44 offshore control cables are suitable for applications with extremely high explosion protection requirements, such as in the petrochemical industry or for maritime applications, especially in the offshore sector. ENQUIRY NO. 1911

Luxion: Engineering Software

Luxion has announced the release of KeyShot 6.1, which continues the focus of improved workflow efficiency and enhancements to this software’s 3D rendering features. KeyShot 6 introduced new features with interior lighting mode that brings more possibilities and faster rendering in the creation of product, automotive and interior architecture visuals. Pro users gained advanced material creation with the new Material Graph and a smoother workflow with geometry editing and multi-layer PSD output. With Animation now included with KeyShot Pro, users were able to create advanced DOF, Panorama and Camera Path animations in addition to standard parts and camera animations, and see the results in real-time, as they are create ENQUIRY NO. 1913


PRODUCT&SERVICES Multi-Contact: Modular Connector System Swiss connector specialists Multi-Contact has added a 10 Gbit module to the CombiTac modular connector system for CAT6A high speed Ethernet communication. CombiTac combines power up to 300A, signal, thermocouple, coaxial, fibre optic, pneumatic and hydraulic connections in a single modular connector system, and is the expert choice in applications that require all-in-one space saving modular connectors that guarantee long life performance under the most demanding mechanical and environmental conditions. The addition of the 10 Gbit module meets high speed CAT6A Ethernet needs in industrial applications such as data communication from machines/equipment to manufacturing control networks, machine-to-machine communications (M2M), and real time data sharing between facilities. ENQUIRY NO. 1914

Siemens: Data Management Software Siemens has upgraded its data management software for Process Analytical Technology (PAT) with Simatic Sipat version 5.0, which allows users to monitor and control the quality of their products in real-time during manufacturing. The latest version features a new configuration concept that further increases user friendliness and shortens implementation time. Moreover, the new Dynamic Data Alignment (DDA) optimises data management for continuous manufacturing. The main applications of Simatic Sipat 5.0 are in the pharmaceutical, food & beverage and fine chemicals industries.


February / March 2016 | industrial automation asia

Polycom: Collaboration Infrastructure Software Polycom is introducing an industry-first software solution that provides customers of all sizes with simple, powerful and cloud- ready collaboration technology. Polycom RealPresence Clariti is designed to be simple, powerful, and cloud-ready collaboration infrastructure software with support for the broadest selection of collaboration ecosystems and a streamlined licensing model that now includes subscription and perpetual models. Customers will have multiple options for deploying the RealPresence Clariti solution, including on-premises, through hybrid or hosted Internet as a Service (IaaS) offerings from partners, or directly in their own cloud networks.


Siko: Actuators The new AG26 actuator, from Siko, is the same as the AG06 as far as electric motor and gearing are concerned. In addition to the data interfaces that it has offered for some time, the company has added the industrial Fieldbus interfaces Ethernet/IP, Profinet and EtherCAT and Powerlink. These allow flexible design of a wide range of line and ring topologies. Via the additional digital inputs and outputs, further signals from external proximity switches or limit switches, pulsers and control devices can be detected, and actions can be initiated or they can be sent to signal units.


Calendar Of Events 2016 MAR 1-3 Propak Vietnam Saigon Exhibition & Convention Centre (SECC) Ho Chi Minh City, Vietnam Singapore Exhibition Services Email: events@sesallworld.com Web: http://propakvietnam.com/

8-10 SIAF Guangzhou 2016 China Import and Export Fair Complex Guangzhou, China Guangzhou Guangya Messe Frankfurt Email: sps@china.messefrankfurt.com Web: http://www.spsinchina.com/

21-23 Power & Electricity World Asia 2016 Suntec International Convention & Exhibition Centre Singapore Terrapinn Email: yeelim.tan@terrapinn.com Web: http://www.terrapinn.com/exhibition/powerelectricity-world-asia

APR 13-14 Power & Electricity World Asia 2016 Pullman Central Park Jarkata, Indonesia Terrapinn Email: enquiry.sg@terrapinn.com Web: http://www.terrapinn.com/exhibition/powerelectricity-world-asia/index.stm

20-21 Cards & Payments Asia 2016 Suntec Singapore Convention and Exhibition Centre Singapore Terrapinn Email: sunny.wilson@terrapinn.com Web: http://www.terrapinn.com/exhibition/cardsasia/

26-28 Facilities Management Solutions Expo 2016 Sands Expo And Convention Centre Singapore Sphere Exhibits Pte Ltd Web: http://www.fmse.com.sg

26-28 Semicon (SEA) 2016 Spice Arena Penang, Malaysia Semi Email: semiconsingapore@semi.org Web: http://www.semiconsea.org/

MAY 25-28 Metaltech 2016 Putra World Trade Centre Kuala Lumpur, Malaysia Singapore Manufacturing Federation Email: tzekhang@smfederation.org.sg Web: http://www.metaltech.com.my/

31-Jun 2 Biomalaysia 2016 Kuala Lumpur Convention Centre Kuala Lumpur, Malaysia Email: biomalaysia@myevents.com.my Web: http://biomalaysia.com.my/

JUNE 1-4 Asean Sustainable Energy Week BITEC, Bangkok Thailand UBM Asia (Thailand) Co. Ltd Email: asew-th@ubm.com Web: asew-expo.com

21-24 Automatica Germany Messe Munchen Trade Faircentre Messe Munchen Email: mmi_sg@mmiasia.com.sg web:http://www.automatica-munich.com/en/home

29-30 SCM Logistics World Asia 2016 Singapore Suntec Convention Centre Terrapinn

JUL 5-8 MTA Vietnam 2016 Saigon Exhibition & Convention Center (SECC) Ho Chi Minh City, Vietnam Singapore Exhibition Services Email: william.lim@sesallworld.com Web: http://mtavietnam.com/

AUG 2-5 MTT Expo Indonesia 2016 JIExpo, Kemayoran Jakarta, Indonesia ECM International Email: info@mtt-indonesia.com Web: http://mtt-indonesia.com/

31-Sep 2 Medical Manufacturing Asia 2016 Marina Bay Sands Singapore Messe Duesseldorf Asia Email: mdafairs@singnet.com.sg Web: http://www.medmanufacturing-asia.com/

31-Sept 3 Taipei International Industrial Automation Exhibition 2016 Taipei World Trade Center Taipei, Taiwan Chan Chao International Email: automation@chanchao.com.tw Web: http://www.autotaiwan.com.tw/

SEPT 14-16 3W Expo Thailand Bangkok International Trade & Exhibition Centre Bangkok Thailand TechnoBiz Communications Email: enquiry@3w-expo.com Web: http://www.3w-expo.com/

14-16 Electric & Power Vietnam 2016 Saigon Exhibition & Convention Centre (SECC) Ho Chi Minh City, Vietnam Hong Kong Exhibition Services Email: exhibit@hkesallworld.com Web: http://electricvietnam.com/

OCT 24-28 Singapore International Energy Week Marina Bay Sands Singapore Energy Market Authority Tricom Events Pte Ltd Email: siewenquiries@tricom.com.sg Web: www.siew.sg To be considered for inclusion in the Calendar of Events, send details of event (name, date, venue, organiser contact) to: The Editor IAA Eastern Trade Media Pte Ltd. 12 Hoy Fatt Road, #03-01, Bryton House, Singapore 159506 Tel: (65) 6379 2888 Fax: (65) 6379 2885 Email: iaa@epl.com.sg




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