Automation World December 2020 by PMMIMediaGroup

DECEMBER 2020 / www.automationworld.com

30 AUGMENTED REALITY GETS TO WORK 24 08 34 23 13 40

A New Kind of Connected Factory How Artificial Intelligence Works in Quality Control Drones Map and Inspect Energy Operations Trends in Adoption of Remote Access COVID-19 Accelerates Industrial AR/VR Use The Increasing Value of Cloud for OEMs

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2 CONTENTS

AW DECEMBER 2020

DECEMBER 2020 | VOLUME 18 | NUMBER 12

A New Kind of Connected Factory

Augmented Reality Gets to Work

As a pandemic forces social distancing, manufacturers are using technology to stay connected, creating a new vision for how data is aggregated, shared, and acted upon to unite factories and people.

In both discrete and process manufacturing, augmented reality technologies are proving to be an operatorâ&#x20AC;&#x2122;s best friend by helping to decrease repair times in the plant and in the field, improve accuracy, increase situational awareness, and boost safety.

Map and Inspect Energy Operations 34 Drones California Resources Corp. is growing its drone program with the use of DroneDeploy software for mapping and inspecting operations.

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4 CONTENTS

AW DECEMBER 2020

EDITORIAL

ONLINE 6

Exclusive content from AutomationWorld.com: videos, podcasts, webinars, and more

INDUSTRY DIRECTIONS 8

How Artificial Intelligence Works in Quality Control

BATCH OF IDEAS 10

The Long-Term Effects of Remote Access

PERSPECTIVES 12

Automating Continuous Improvement of Manufacturing Processes COVID-19 Accelerates Industrial AR/VR Use Influences on Automation What Is Machine-Centric Robotics? Why ABB Recycles Its Robots

David Greenfield Director of Content/Editor-in-Chief dgreenfield@automationworld.com / 678 662 3322 Stephanie Neil Senior Editor sneil@automationworld.com / 781 378 1652 Aaron Hand Editor at Large ahand@automationworld.com / 312 222 1010 x1180 David Miller Senior Technical Writer dmiller@automationworld.com / 312 205 7910 Jim Chrzan VP/Content and Brand Strategy jchrzan@automationworld.com / 312 222 1010 x1470 Kim Overstreet Content Strategist koverstreet@pmmimediagroup.com James R. Koelsch, Lauren Paul, Jeanne Schweder and Beth Stackpole Contributing Writers

ART & PRODUCTION

Filippo Riello Art Director friello@pmmimediagroup.com / 312 222 1010 x1200 George Shurtleff Ad Services & Production Manager gshurtleff@pmmimediagroup.com / 312 222 1010 x1170

NEWS 19

Asset Performance Management Developments for Oil & Gas Microsoft Extends Industrial Focus with Expanded Rockwell Automation Partnership New Edge Computing Platform Combines Data, Analytics, and Control Autonomous Mobile Robot PMMI News

NEW PRODUCTS 36

ADVERTISING

Kurt Belisle Publisher kbelisle@pmmimediagroup.com / 815 549 1034 West Coast Jim Powers Regional Manager jpowers@automationworld.com / 312 925 7793 Midwest, Southwest and East Coast

AUDIENCE & DIGITAL

Thermal Mass Flowmeters Industrial Application Platform Update Single-Phase Soft Start Compressors And more...

David Newcorn Senior Vice President, Digital & Data Elizabeth Kachoris Senior Director, Digital & Data Kelly Greeby Senior Director, Client Success & Media Operations Jen Krepelka Director, Websites & Digital Design Strategy

PMMI MEDIA GROUP

ENTERPRISE VIEW 40

Kurt Belisle Publisher kbelisle@pmmimediagroup.com / 815 549 1034 Jake Brock Client Success Manager jbrock@pmmimediagroup.com / 312 222 1010 x1320 Sue DaMario Director of Marketing damario@pmmimediagroup.com / 312 222 1010 x1710 Amber Miller Marketing Manager amiller@pmmimediagroup.com / 312 222 1010 x1130 Sarah Loeffler Director, Media Innovation sloeffler@pmmimediagroup.com / 312 205 7925 Janet Fabiano Financial Services Manager jfabiano@pmmimediagroup.com / 312 222 1010 x1330

The Increasing Value of Cloud for OEMs By Brian R. May

INDUSTRY VIEW 41

Moving to a More “Open” Environment By Dick Slansky

INTEGRATOR VIEW 42

Use Remote Upgrades to Prevent Software Obsolescence By Jason Anson

KEY INSIGHTS 44

All Automation World editorial is copyrighted by PMMI Media Group, Inc. including printed or electronic reproduction. Magazine and Web site editorial may not be reproduced in any form without the written permission of the publisher.

Automation World | PMMI Media Group 401 N. Michigan Avenue, Suite 300, Chicago, IL 60611 Phone: 312 222 1010 | Fax: 312 222 1310 www.automationworld.com PMMI The Association for Packaging and Processing Technologies 12930 Worldgate Dr., Suite 200, Herndon VA, 20170 Phone: 571 612 3200 • Fax: 703 243 8556 www.pmmi.org

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6 ONLINE

AW DECEMBER 2020

PODCAST SERIES What Factors Are Influencing Automation Technology Today? In this episode, we connect with Justin Kolbe of Henkel to learn how economic and technology factors are affecting the development and use of industrial automation technologies.

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AUTOMATION WORLD TV Automation World’s YouTube site offers relevant videos on the latest industrial automation insights, trends, and news. Check out our videos and subscribe to keep up with the latest technology and application developments.

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THE AUTOMATION PLAYBOOK The Automation Playbook is a useful source of information as you look for guidance in how to approach the Industrial Internet of Things, communication protocols, controls implementation, safety, asset management, predictive maintenance, the mobile workforce, and much more.

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AUTOMATION WORLD E-BOOK Tips and Tactics for Tackling Industrial Cybersecurity

Moving into a more digital space requires organizations to have strategies, tactics, and insights to protect its digital assets. In this e-book, you’ll find articles covering topics like: making sense of the ICS cybersecurity market, the growing demand for ICS cybersecurity specialists, keeping your cybersecurity documentation current, and more articles to help your organization stay secure.

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ON-DEMAND WEBINARS Industrial Communication and Intelligent Valve Solutions: Using the Advantages of Decentralized Process Automation

Watching this webinar will teach you about the advantages of decentralized plant automation, how digital communication creates added value, important facts about IO-Link and AS-Interface, how to efficiently monitor your processes using intelligent control heads, and what decentralized solutions look like in practice.

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How to Implement a Cobot Vision System

In this webinar you will learn how to program one of Universal Robot’s collaborative robots and configure a Cognex camera so they exchange pertinent information. A live demonstration will be featured, showing a pick-and-place application. The skills demonstrated in this webinar can be applied to a variety of other applications.

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8 EDITORIAL

AW DECEMBER 2020

INDUSTRY DIRECTIONS

How Artificial Intelligence Works in Quality Control By David Greenfield

dgreenfield@automationworld.com Editor-In-Chief/ Director of Content, Automation World

ew areas of industrial technology today remain untouched by artificial intelligence (AI). From controllers to ERP to food safety and robots, AI is changing the technologies we use to run manufacturing and processing facilities in subtle and not-so-subtle ways. One application with a big potential to benefit from AI is quality control. The use of smart cameras and related AI-enabled software is helping manufacturers achieve improved quality inspection at speeds, latency, and costs beyond the capabilities of human inspectors. And the timing of the arrival of these smart camera technologies is fortuitous, given the social distancing requirements of COVID-19. Of course, manufacturers have been using machine vision in quality applications for many years now. But the addition of deep learning-enabled quality control software represents a departure from earlier machine vision technologies. To help understand how AI is changing machine vision, Anatoli Gorchet, co-founder and chief technology officer at Neurala (a supplier of AI vision software), explains the process behind traditional industrial inspection processes using machine vision. The first step involves an expert deciding which features (such as edges, curves, corners, color patches, etc.) in images captured by a camera are relevant to the inspection.

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Then, the expert creates a rule-based system that details, for example, how much “yellow” and “curvature” classify an object as a “ripe banana” in a packaging line. The resulting system, based on the expert’s input, automatically decides if the product is what it is expected to be. Though this method has been very effective, there are some cases in which it renders machine vision ineffective. “For example, instances where the difference between good and bad products is highly qualitative, subtle, or variable can be hard to detect,” said Gorchet. This is where AI comes into the picture. Rather than having the machine vision system rely on the rules created by the expert, the AI-powered software can learn which aspects are important on its own and create rules that determine the combinations of features that define quality products. The type of AI model Gorchet is referring to here is known as “deep learning.” These deep learning systems, such as deep neural networks (DNNs), are trained in a supervised fashion to recognize specific classes of things. In a typical inspection task, a DNN might be trained to visually recognize, for example, a ventilator valve, based on pictures of good and bad ventilator valves. “Once these pictures are collected, a typical deep learning system has a training regimen that, when fed a good quantity and variety of data, trains a model that ends up being really good at coming up with precise, low error, confident classifications,” said Gorchet. Of course, if the line switches to a different part or product, the data collection, training, and deployment must be conducted again to develop a new model. To streamline this process, a new type of DNN is being explored for industrial quality inspections. These DNNs are known as “continual” or “lifelong” learning DNNs (L-DNNs). These L-DNNs, according to Gorchet, separate feature training and rule training to add

new rule information on the fly. “Like conventional DNNs, they need a slow learning of features based on a large balanced set of data—which includes equal amounts of images of good valves as well as every possible type of defective valve; but unlike conventional DNNs they do not include rule learning at this stage and therefore do not require images of all known valve defects,” he said. “In fact, the images do not even need to be of valves as long as they possess the similar features: curves, edges, surface properties. This data set can be quite generic and does not have to be industryspecific. This means that the model creation can be done once by the L-DNN provider and does not need to concern the manufacturers at all.” (Editor’s note: Neurala is a supplier of L-DNN technology.) This means that manufacturers only need a small set of images of good valves for the system to learn a set of rules of what a good valve is. L-DNNs, explained Gorchet, can learn on a single presentation of a small dataset using only good data and then advise the user when an atypical product is encountered. “A training regimen of an L-DNN can go over a set of tens of images, build a prototypical understanding of the object, and be ready to be deployed and reconfigured if and when production changes,” he said.

“...AI is changing the technologies we use to run manufacturing and processing facilities in subtle and not-so-subtle ways.”

11/30/20 11:18 AM

AW DE E ER 2020 ADVERTORIAL

Segmenting your factory floor network improves operations hen talking about an industrial enterprise, the term IIoT (Industrial Internet of Things) is always mentioned and is often overused. However, nearly everyone can agree that there always is a benefit to getting the “right” data in a “sustainable” fashion from “edge” devices to individuals who can use the data to make better business decisions. A risk is that too much data collection, without proper foresight, can create a situation where a plant Ethernet network can be rapidly overwhelmed due to poor design.

It pays to collect data from the factory floor

• Real-time downtime analysis from one location (“A Single Pane of Glass”) can show instantly where resources need to be applied to increase productivity. Long-term analysis of this data can point to maintenance trends, staffing shortfalls, or process bottlenecks. • Older assets can be connected to the network and improve process uptime. Even older machines with just relay logic controls can be monitored with the right equipment. • Gathering data isn’t just about the traditional cycle time reporting issues. Predictive maintenance information such as monitoring the vibration on motors has been proven to reduce costly downtime.

Managing Network Traffic is more important now than ever

Over the years, the number of devices on the factory floor has exploded. Often, networks were augmented as an afterthought without regard to problems that would occur down the road. Currently, many large networks have bottlenecks due to speed issues and the continued existence of unmanaged switches. Multicast protocols often initially meant for a small cell can inundate and overwhelm a network without the proper managed switches in place.

The Convergence of IT and OT

The IT world (Information Technology) and the OT world (Operational Technology) are coming together rapidly. Both sides have the same goals, but often go about the process in different fashions. Both sides always agree that a good balanced and segmented network is critical. Sometimes this is achieved via a “top down” design by having versions of the office switches down to the factory floor, where special

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Figure 1 – Problems will occur if multiple machines with the same IP address allocation pattern were simultaneously plugged in to a plant network. consideration must be made for environmental factors such as heat and vibration.

Industrial Routers can provide effective segmentation and connectivity

How does an organization handle networking equipment which can come from the outside? It is quite common now for machinery to come in from an outside vendor or OEM. Is it asking “too much” to be able to keep the original IP address scheme? An industrial router or switch with NAT (Network Address Translation) capability may be a solution.

The multiple machine cell case

Consider that an OEM over the years has delivered 20 machines consisting of a PLC, HMI, and a VFD (Variable Frequency Drive). Because they were manufactured originally as individual machines, the OEM used the same IP address allocation pattern. 192.168.1.1 for the PLC, 192.168.1.2 for the HMI, etc. (Figure 1)

What happens when all 20 machines need to be connected?

In the example above, if all machines were simultaneously plugged in to the plant network, IP address conflicts would happen. Some of the problems are documentation headaches, sudden introduction of multicast protocols into the greater network, and extra unexpected reprogramming of individual assets.

A device which has NAT capabilities (Network Address Translation) will help

Employing a switch or router with NAT capabilities means that a factory floor automation

engineer can design a table which gives a one-to-one correspondence from an internal address to an “external” plantwide address. That way nothing needs to change on the edge while maintaining security and uniqueness at the plant network level.

Add security with firewall rules

Often another advantage with these types of devices is the fact that one can add firewall capability for even more security. For example, if there is a SCADA machine on the plant network that needs to just talk to the PLC only, rules can be made to restrict all other communications except for requests from the SCADA computer. Routers and switches with NAT (and Port Forwarding) capability are only one way that networks can be segmented and made more secure. Many organizations have implemented VLANs (Virtual LANs) to segregate traffic. Make sure that you consult professionals on both the IT side and the OT side about working solutions to help improve the operation of your network and enhance security as your enterprise grows.

By John Kan, Motion Industries John Kan is Connectivity Product Manager with the Mi Automation Solutions Group/ Braas Division at Motion Industries. MotionIndustries.com

10/29/20 11:37 AM 11/23/20 3:22 PM

10 EDITORIAL

AW DECEMBER 2020

BATCH OF IDEAS

The Long-Term Effects of Remote Access By Stephanie Neil

sneil@automationworld.com Senior Editor, Automation World

rom the way manufacturers work to who they hire, the need for remote access due to the pandemic has altered more than just how information is gathered. To that end, moving forward, manufacturers will put more emphasis on partnerships with machine builders and technology suppliers as a new set of issues arise that relate to the added automation now in place. That was one message that came out of Rockwell Automation’s Automation Fair At Home—the company’s virtual version of its annual event featuring technical discussions, interactive labs, and segment-specific forums for automotive, chemical, food and beverage, life sciences, oil and gas, and more. One track focused on OEMs, and one session titled “Ready or Not, the Remote OEM Future is Here,” caught my attention, as it took a closer look at how COVID-19 has been a catalyst for industry change across the board. Specifically, manufacturers have been forced into “digital acceleration,” which has required OEMs to pivot and adapt to new ways of selling, designing, commissioning, and servicing equipment. The panel discussion featured speakers from Cama North America, a one-stop source for integrated robotic, cartoning, case packing, and sleeving machines; SaniMatic Inc., a maker of sanitary process cleaning systems for the food and beverage and pharma industries; and Hirata Corp., an

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OEM and system integrator in the automotive, semiconductor, and home appliance sectors. And, while all three agree that customer needs are the same today as they were before the pandemic, the digital transformation has been fast-tracked because problems can’t be solved by putting more people on the job. Now, there’s more automation involved to solve a problem—which causes its own set of issues. “If you have automation, how do you use it, how do you maintain it, and how will the OEM provide access,” said Bryan Downer, Sani-Matic’s vice president of sales and marketing. “Everything is changing drastically, and a lot of people are just trying to figure out how to do this.” Similarly, machine builders are using new augmented reality and virtual reality (AR/ VR) tools that require a new skillset. That means OEMs might need to hire people with expertise in these areas, but more likely it will require training. “This is where [partners] like Rockwell can provide that leadership,” Downer said. “If they can provide a platform and template for a centralized way of interaction for all of the different tools and software, I think that would be an opportunity for us as move into the future.” Interestingly, the barriers to adoption that were prevalent in the past—namely cybersecurity concerns—have faded away under the current circumstances. “The initial barriers are starting to be perceived as gone, and now we can start moving forward in full force,” said Billy Goodman, managing director at Cama USA. “The pandemic has pushed us forward light-years in a very short amount of time.” It has also introduced new obstacles to overcome. “The playing field has changed,” Goodman said, referring to servicing equipment. “It used to be we’d get someone out there in 24 hours, now there’s an immediate expectation of the OEM who has had to

step up to ensure customers are running efficiently during the pandemic. Those expectations will carry over after the pandemic, which puts greater stress on us.” Yet, that stress also gets OEMs thinking outside of the box to deliver new kinds of products and services. Downer said that SaniMatic recently mapped out the customer journey to identify different touchpoints and how it impacts virtual engagement through the machine’s lifecycle. “There is more we can do now as we have connectivity to the system, like providing OEE monitoring to help them understand where to optimize the system, or on-demand training with virtual tech support. I see a vast amount of opportunity for both the OEM and the customer once we embrace and understand what [the technology] can do for us.” That connectivity helped launch the company’s SaniTrend product, a cloud-based software-as-a-service (SaaS) that provides automated, secure data acquisition and reporting of critical cleaning cycle information for any automated cleaning system. Cama’s Goodman said the digital twin, too, is an area of opportunity for OEMs. Using simulation to show how a machine will function helps with machine design and end user education, as well as overall risk assessment, using simulations to test speeds and cycles that ensure the machine is set up for longterm success. New OEM products and services, however, will require close partnerships—as much of the technology required to deliver all of this is outside of the OEM wheelhouse. “We will have to seek more innovative ways to make a better proposal for customers, and that happens in collaboration with Rockwell,” said Mika Ide, chief of sales engineering at Hirata Corp.

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12 PERSPECTIVES AW DECEMBER 2020

Automating Continuous Improvement of Manufacturing Processes By Stephanie Neil, Senior Editor, Automation World

anufacturers on a journey to make production processes “smarter” typically start by aggregating data from around the plant with the ultimate goal of optimizing systems and operations. Of course, gathering data from different systems—be it sensors, a historian, quality control, or a manufacturing execution system (MES)—is straight forward enough. But all that information lives in different data schemas, which means different structures for organizing and classifying that data, which also means someone has to knit it all together to make sense of it. That’s the hard part. Sight Machine, a provider of manufacturing analytics software, has been working to solve this problem. In 2018, the company introduced a cloud-based platform that enabled centralized management of multi-factory Industrial Internet of Things (IIoT) data using artificial intelligence (AI) and machine learning algorithms to work with structured and unstructured data. Earlier this year, the company launched its Manufacturing Data Platform (MDP) which provides scalable analytics to compare interdependencies between production lines, different facilities, and the supply chain. Now, with this month’s announcement of Dynamic Recipes, Sight Machine has added a way to continuously and automatically update machine settings to produce optimal performance based on a combination of conditions related to raw materials, the environment, and output—such as grades of paper, for example. “Operators know what to do to optimize processes based on their experience, and [they] form a judgement of what adjustments to make in order to set everything up to have minimal quality problems and to predict efficiency,” said Jon Sobel, co-founder and CEO of Sight Machine. “But there are variations in the conditions of the plant and in raw materials.” When faced with variations, it requires deep domain expertise to make adjustments. Dynamic Recipes can automatically make the adjustments based on a range of parameters. “We announced the ability to flexibly set up the right recipe for production conditions based on what you determine the conditions to be,”

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Sobel said. “And every time you do this it goes back into the underlying data used to generate the rules, so it is constantly getting better.” To that end, Sight Machine has also introduced a new Productivity KPI Model that lets manufacturers optimize production according to their own preferred metrics. These metrics vary widely among companies, but typically include quality, uptime, and throughput. According to the company, Productivity KPIs give manufacturers consistent, applesto-apples metrics to track productivity of all lines and plants across the enterprise. In other words, manufacturers are able to track the performance of all their machines, lines, and plants using a uniform metric based on how well the asset is performing versus its maximum potential performance. “The second part of the announcement is super important,” said Sudhir Arni, Sight Machine’s senior vice president of business outcomes. “We launched a KPI model that makes it easy to set up a formula for any KPI…if you make any change to the data table it is reflected in the KPI, which makes it flexible and scalable based on what works best in the plant.” Dynamic Recipes optimize for any combination of targeted Productivity KPIs, such as minimizing cost and maximizing throughput. The prescribed recommendations automatically adjust as conditions change, and recipes automatically improve to reflect new top-performing production runs.

Operators in the control room or on the plant floor interact with the Dynamic Recipes using a new application called Operator Co-Pilot. Within Co-Pilot, they input current conditions (e.g. raw materials, desired output grade, humidity), make any adjustments to the targeted KPIs, and receive prescribed machine settings. Sight Machine can deliver these capabilities in real-world manufacturing environments due to the platform’s unique data modeling foundation which takes the dozens of incompatible data types generated by factory equipment and manufacturing software and generates a digital representation of the entire production process, including processes, production lines, downtime and defects. The platform also continuously models and analyzes all production data in real time, allowing manufacturers to monitor and improve current performance instead of only analyzing past performance. And while previous generations of the Sight Machine platform have been used primarily to help manufacturers understand how their factories are doing and analyze how to improve them using descriptive analytics, the new enhancements go beyond descriptive analytics to provide prescriptive analytics, proactively recommending the settings and processes needed to achieve the highest productivity under ever-changing conditions.

Credit: Getty Images

11/30/20 11:28 AM

PERSPECTIVES 13 AW DECEMBER 2020

COVID-19 Accelerates Industrial AR/VR Use By David Greenfield

Editor-In-Chief/Director of Content, Automation World

ince the spring of 2020, we’ve all been witnesses to how the COVID-19 pandemic continues to impact the manufacturing industries. From collaborative robots and supply chain management to social distancing technologies, every facet of industry is adjusting to the new realities of manufacturing amid the virus. One area of technology that had been gaining a lot of interest pre-COVID has been put to the test during the pandemic to help industry adjust to the impact on labor. According to Dijam Panigrahi, co-founder and COO of Grid Raster Inc. (a provider of cloud-based augmented and virtual reality platforms), “an increasing number of locations have begun to implement automation technologies that include augmented reality and virtual reality (AR/VR) as a way to speed efficiencies, lower costs, and minimize human touch points for social distancing.”

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Panigrahi noted a study from Aviation International News which showed that 42% of manufacturers in the aerospace sector are looking to implement AR/VR technologies (among other advanced automation technologies) in the next twelve months. Like many industrial sectors, the automotive industry was particularly hard hit by COVID-19. Panigrahi said that many car manufacturers completely shut down or scaled back their operations in March after the widespread outbreak of COVID-19. He added that the automotive industry faced a second blow in the summer as many plant workers decided to remain home for fear of catching the virus while working at the manufacturing facilities. According to Panigrahi, AR/VR technology, in particular, has been “showing great promise for auto manufacturers for a number of uses. The technology allows automo-

Dijam Panigrahi, co-founder and COO of Grid Raster Inc. tive designers and manufacturers to: conduct real-time 3D visualization and CAD for design and manufacturing; run faster training cycles; and enable professionals to work at drastically higher levels. In fact, some manufacturers report minimized errors using AR/VR through instructions overlay, remote assistance, better planning, and visualization. This has resulted in a more than 40% productivity increase in some instances. As more manufacturers look to implement AR/VR technology to address the labor issues created by COVID-19, Panigrahi stressed that operations managers should pay close attention to the technology infrastructure surrounding any AR/VR platforms they assess for use in their plants. “Choose a platform that is cloud-enabled,” he advised, “so that projects can truly scale when needed. Manufacturers are overcoming their growth limitations by leveraging cloud-based (or remote server-based) AR/VR platforms powered by distributed cloud architectures and 3D vision-based artificial intelligence. These cloud platforms provide the desired performance and scalability to drive innovation in the industry at speed and scale.”

11/23/20 2:47 PM

14 PERSPECTIVES AW DECEMBER 2020

Influences on Automation By David Greenfield

Editor-In-Chief/Director of Content, Automation World

o so long ago, the manufacturing industries—both process and discrete— experienced fairly predictable economic trajectories. The industries tended to rise and fall in response to commercial and consumer spending trends. But those predictable cycles in manufacturing are no longer so predictable, partly due to the influence of pervasive technologies like the internet and mobile computing on every market that manufacturing serves. And those effects impact the technologies manufacturers themselves use to respond to their customers. To better understand the factors affecting industry today and how those factors, in turn, impact the direction of automation technologies, we connected with Justin Kolbe, the head of power and industrial automation market strategy for Henkel, a global provider of adhesives, sealants, and functional coatings, for a recent episode of the “Automation World Gets Your Questions Answered” podcast series (http://awgo.to/KcMCn). Henkel’s role as a supplier and user of industrial products and technologies gives the company an interesting vantage point on automation, as the materials the company provides enable thermal management, reliable electrical function, and long-term sustainability to the power and industrial automation markets. “From a technology standpoint, what we’re seeing change most is the amount of data that's being processed and communicated between machines; it’s much greater than ever before,” said Kolbe. “And because

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industrial customers require reliability, we understand that downtime, maintenance, and production processes are critical. That’s why the designers of automation equipment have to think about reliability as job one—on top of all the other values they're providing. We’re also seeing the size of electronic devices continue to decrease, as space in manufacturing facilities comes increasingly at a premium. And because technology suppliers don't want the added capabilities of automation to require more volume, this has a number of effects on the overall design of automation technologies.” A detailed example Kolbe provided to explain this focused on how device designers historically used an air gap to provide the correct voltage insulation. Now they use solid insulation, like a potting or some other coating, to provide that insulation. Kolbe said the benefit to this change is that it increases the power density of the device, which is required as more functions are packed into a smaller space. “With these new insulation approaches, more power devices can be placed in a tighter space while maintaining safety agency creepage and clearance distances. In some cases the insulation can also be used as a conduction path to remove heat,” he said. From a higher-level point of view, Kolbe noted how manufacturing markets are capital expenditure-driven markets. This means that manufacturers are always concerned about the initial cost of a new device or piece of equipment. “But we are starting to see more

and more awareness and sensitivity to overall operational expense as well as increasing interest around some product-as-a-service models,” he said. “This means that technology suppliers are no longer just looking at the initial cost of implementing a solution, but the total cost of ownership their customers will face. And what they ultimately want to do is reduce the total cost of ownership or be able to provide more function, more convenience, more uptime, and more throughput—all at the same cost.”

Robotics

Considering the highly visible role of robotics in industry over the past several years, Kolbe pointed out how the COVID-19 pandemic has brought even more attention to collaborative robots. “Since these robots can operate with minimal human interaction, they can act as go-betweens in production cells and be thoroughly cleaned or disinfected between human interactions. This means that robots can provide for a much safer work environment by allowing for less human density in the inner production cell or elsewhere on the plant floor.” He also noted the role robots are playing in hazardous environments, which makes the use of protection technologies—like pottings or special coatings—so important, because they protect the robot’s electronics. “Another place where we see robots really continuing to increase their penetration in industry is in sensitive environments like semiconductor fabs or paint spray booths,”

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Kolbe said. “In these kinds of production areas, designers need to make sure that the construction materials they use won't contaminate the environment. An example of this would be the use of silicone-free or highly controlled silicone materials that don't leach out over time and potentially cause production process and yield issues.” Positional sensing is another trend in robotics Kolbe said is worthy of note in terms of influence on automation technology in general. This technology is often used in mobile robots. “These sensors are high power diodes that require accuracy and stability of placement,” he said.

Power

Since automation of any kind simply doesn't exist without power, the technologies associated with industrial power supplies are a major factor for any company looking to implement automation at any level, whether they're new to automating processes, or if they're adding to an array of automation technologies already in place. “Electric power conversion is a key aspect across many industrial automation applications,” said Kolbe. “And one application we’re seeing increasing customer interest in is in the use of battery-powered electric applications, such as warehousing robots. This means that charging is an area where we’re seeing an increase in interest around power conversion—in factors like fast charging and wireless charging of batteries.” Another automation area of focus around power in manufacturing is power factor correction. “Proper power factor correction allows the plant to use the power delivered to it in the most effective way, allowing the power system within the plant to work closer to capacity,” said Kolbe. “This also allows the plant to avoid usage fees from the state or utility based on poor power factor.” Referencing the semiconductor industry, which plays a major role in automation electronics, Kolbe pointed out how this industry is moving away from the use of silicon semiconductors and toward wide band gap semiconductors, like silicon carbide, for power modules or surface-mount components because of their ability to increase the power density of a device. “Wide bandgap semiconductors can provide much more efficient solutions, but in general they have a higher initial cost,” explained Kolbe. “But there are some applica-

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Justin Kolbe, head of power and industrial automation market strategy for Henkel. tions, like inverters for alternative energy or motor inverters for 24/7 operations, where these semiconductors can offer an acceptable return on investment.” “And by using wide bandgap semiconductors or silicon carbide, automation technology suppliers can decrease the space used by the power function,” Kolbe said. “Some of these new power electronics packages can provide electrical isolation, which allows for different cooling strategies, like doublesided cooling. And we're also seeing greater interest in baseplate-free power module designs. Historically, there has been a large copper plate placed on the back of a power module. But in the newer iterations of these designs, that copper plate is removed to reduce the weight, reduce the size, and reduce the cost of the power module.” All these automation power trends, require “new solutions in thermal management and packaging of the overall assembly to make the best use of the capabilities they provide,” Kolbe said.

Trends to watch

ing made by artificial intelligence. “Complex cognitive machine systems are not only changing what's possible to accomplish with automation, but they’re also changing automation design requirements due to their computationally intense processes that are going to require significant investments [from technology suppliers] in power utilization and software,” he said. Kolbe added that any differentiation in functionality offered by a technology supplier has to occur against “the backdrop of reliability.” Any new technology “should have a long service life and the ability to run continuously without quality issues or defects that can cause downtime and reduce capacity,” he said. Another factor to watch for in new automation technologies are specific increases in efficiency. For example, increasing voltages and decreasing current. “This is an area where efficiencies can really improve,” said Kolbe. “In older systems, where you would run a DC bus at six or 12 volts, the ability to push that voltage up to 48 or 50 volts and stay within intrinsically safe limits is a space where real improvements are going to happen.”

Clearly higher levels of device and system connectivity around IIoT and Industry 4.0 will continue to play a big role in automation for years to come. Beyond these trends, Kolbe stressed that industrial technology end users should be paying attention to the inroads be-

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�at s

ac ine

entric obotics

By David Greenfield

Editor-In-Chief/Director of Content, Automation World

n a demonstration at PACK EXPO Connects, Derrick Stacey, product manager at B&R North America, explained how machine-centric robotics (MCRs) can add flexibility and adaptability to production and packaging and operations. A key aspect of B&R’s approach to MCR is its merging of the robot controller into the machine controller so that users can manage servo control, I/O, and visualization from one industrial PC to drive ABB's portfolio of manipulators. The integration of ABB's robot manipulators with B&R’s control platform enables users to speed up cycle times, minimize dwell times, and eliminate extra hardware like external encoders for tracking, according to Stacey. (Editor’s note: ABB acquired B&R in 2017.) This integration of technologies “physically simplifies cabinet wiring and decreases the

footprint of electrical cabinets,” Stacey said. “Functionally, this eliminates communication interfaces, timing delays, and multiple programming interfaces while opening opportunities for real-time synchronization, recipe-driven changeovers, and simplified diagnostics.” Stacey explained that a key industry driver behind ABB’s and B&R’s pursuit of the MCR concept is that they are seeing more and more customers retrofitting machines once developed for a single product to accommodate additional SKUs developed long after the system was initially put into production. “These on-the-floor changes drive down the OEE of equipment and make for a repair and maintenance nightmare,” he said. “B&R sees integration of robots into a machine’s architecture as a way to help future-proof almost any system and can simplify the management

of the constant changeovers needed to run all the necessary SKUs to meet customer orders. This can be a crucial competitive edge as ecommerce becomes a larger share of almost all consumer packaged goods companies’ revenues and future growth.” With a single control architecture, the servo information can be shared over B&R’s PowerLink “real-time and deterministic Ethernet protocol at sub-millisecond speeds for fast, on-the-fly interactions with the robot without the need for any special compensation or homegrown algorithms,” Stacey said. “This can have a direct effect on productivity and push equipment OEE to a world-class level.” He added that the entire suite of ABB robot functionality is provided through B&R’s mapp robotics software—a set of standard function blocks to which B&R is constantly adding new

Machine-centric robotics is about merging the robot controller into the machine controller so that users can manage servo control, I/O, and visualization from one industrial PC.

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features and capabilities. The software can be programmed using industry standard languages like ladder logic and structured text as well as all the other IEC 61131 languages. “Setting up an ABB manipulator in Automation Studio—B&R's integrated development environment—is a single step drag-and-drop process,” Stacey said. “Select your manipulator from the toolbox and drop it into the system designer. Behind the scenes on the drives, configurations and parameters are brought in automatically so that users can be up and running and jogging the robot in minutes.” B&R’s MCR platform comes with a set of continuously updated process level components. Providing an example, Stacey said, “we have a pick-and-place component, where a user can configure the process and material flow for a range of pick-and-place use cases. This includes multiple robots, multiple products, and multiple conveyors all working in coordination to get orders filled.” Stacey also noted that having the added intelligence provided to the manipulator by the rest of the B&R control system means that “we can track wear on parts and add periodic maintenance to the growing list of jobs that the robot can perform without any operator interaction. Moving to a just-in-time maintenance scheme versus planned maintenance can increase the uptime for almost any system without increasing the risk of unplanned stoppages.”

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Derrick Stacey, product manager at B&R North America, explains the machine-centric robotics concept to the PACK EXPO Connects audience.

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�y

ecycles ts obots

By David Miller, Senior Technical Writer, Automation World

ecycling and refurbishment programs for old equipment have proven increasingly popular for a multitude of reasons. In addition to improving sustainability by shrinking the carbon footprint associated with manufacturing new machines, remanufacturing is desirable simply because it cuts costs. Often, refurbished robots and other pieces of industrial equipment are significantly less expensive, allowing small and medium-sized manufacturers to begin automating more easily. ABB’s buy-back service for previously owned robots provides these benefits, while also allowing those divesting themselves of outdated robots to ensure that their oncevalued piece of equipment does not become mere dead weight. After being repurchased and brought to one of ABB’s Remanufacture and Workshop Repair Centers, robots undergo a rigorous inspection, including a 16-hour test of their functionality, before becoming ABB-certified remanufactured equipment and being placed back on the market. Remanufactured robots include two-year warranties and support from local service teams, including assistance with installation and training. In addition to remanufacturing robots, ABB also refurbishes associated peripherals, such as controllers and manipulators. “Unlike third-party refurbishers, who only

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Robots being refurbished at one of ABB's Global Remanufacture and Workshop Repair Centers. fix faulty parts, we completely remanufacture our robots using original ABB design plans, specifications, and dimensional data. This guarantees that the robots offer the same levels of quality, performance, durability, and safety as a new ABB robot,” said Jan Borsky, sales manager of ABB’s Global Remanufacture and Workshop Repair Centers. “We have one of the largest inventories of pre-owned and reconditioned robots across the world,

with 400 robots of various types in stock for sale, and currently the demand for second life robots is so high that we have more than one robot leaving our Ostrava facility (in the Czech Republic) every working day.” The remanufactured robots can often be integrated with new software and controllers to unlock previously unavailable functionality. For instance, ABB’s SafeMove software, which allows robots to engage in safety-monitored stops as well as speed and separation monitoring for collaborative tasks, can be used with many of ABB’s older models once they are remanufactured. According to Borsky, remanufactured robots benefit a variety of different customers, including those looking to extend the lifetime and functionality of the robots they already own, those interested in a low-cost option for their first robot, and those who want additional robots for an existing production line but have found that the specific model they require has been discontinued. In addition to the Ostrava facility, ABB has remanufacturing facilities in Shanghai, China, and Auburn Hills, Michigan.

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Asset Performance Management Developments for Oil & Gas By David Greenfield

Editor-In-Chief/Director of Content, Automation World

onday, October 19, 2020, started out as a typical Monday covering industrial automation technology news—until just before noon eastern time. Then, within a period of two minutes, I received two significant news items, one from Siemens and one from Aveva, related to partnerships aimed at advancing asset performance management (APM) technology for the oil and gas industry. The first news item to arrive came from Aveva, announcing its development of a Digital Reliability Platform (DRP) in partnership with SCG Chemicals Business (a petrochemical company based in Thailand). This DRP, according to Aveva, is “a complete APM solution to predict equipment health, monitor performance, and enable advanced maintenance across its operations to eliminate unplanned downtime.” Aveva’s partnership with SCG was developed as part of SCG’s digital transformation plan to “become a data-driven organization to advance its position as a leader in the petrochemical industry” and to help Aveva deliver DRP technologies to market. According to Ravi Gopinath, chief cloud officer and chief product officer at Aveva, the “DRP solution integrates online and offline equipment data to visualize plant per-

Onshore and offshore operation areas in which Siemens and Bentley Systems APM4O&G can be applied. Source: Siemens and Bentley Systems. formance, enhance workforce efficiency, and apply artificial intelligence (AI) for predictive maintenance and resolution…to monitor critical assets, and predict failure towards achieving a goal of zero unplanned shutdowns.” The APM news from Siemens centered on the partnership between Siemens and Bentley Systems to deliver a new service for oil and gas industry companies known as Asset Performance Management for Oil & Gas, or APM4O&G. According to Siemens and Bentley Systems, APM4O&G combines Bentley’s AssetWise APM software technology with Siemens Energy’s technology and services.

APM4O&G will be part of Siemens Energy’s Omnivise digital technology portfolio to support maintenance activities across multiple assets, such as onshore compressor stations and gas processing plants as well as offshore production and floating production, storage, and offloading vessels. Laura Anderson, head of Siemens Energy Services control and digitalization business, said "APM4O&G adopts smart, conditionbased strategies based on predictive analytics to optimize maintenance schedules in compressor stations and gas processing plants, helping extend asset life and keeping maintenance costs down. Offshore, the solution helps operators reduce logistics costs associated with unmanned maintenance activities. Operators can also make the best use of limited laydown and storage areas offshore by holding just the right spare stock based on risk-based maintenance strategies. In addition to monitoring assets, the APM4O&G solution can run diagnostics and risk analysis scenarios that further optimize plant uptime, including failure mode effect analysis, operational health index of equipment, and a remaining useful life estimate for an individual component or a whole system."

SCG Chemicals plant in Thailand. Source: SCG Chemicals Business.

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Microsoft Extends Industrial Focus with Expanded Rockwell Automation Partnership By David Greenfield

Editor-In-Chief/Director of Content, Automation World

ne of the primary goals of digital technologies for industry over the past two decades has been to provide a single source of the “truth.” The ability for a company to aggregate, verify, and analyze the data from its numerous device and equipment sources is critical not only for production insights and optimization, but also for accurate planning, capacity assessments, and supply chain management. Historically, this push for one version of the “truth” in industry centered on the data within the confines of a specific facility, but Industry 4.0 and the Industrial Internet of Things has expanded the reach of this goal to extend from the edge to the cloud. And that’s what driving the recent partnership expansion between Rockwell Automation and Microsoft. The two companies announced a new five-year partnership expansion to “develop integrated, market-ready solutions that help industrial customers improve digital agility through cloud technology. By combining each company’s expertise in the industrial and IT markets, teams can work together more seamlessly, enabling industrial organizations to save on infrastructure costs, speed time-to-value, and increase productivity.”

Blake Moret, chairman and CEO of Rockwell Automation

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Credit: Getty Images

More specifically, Microsoft and Rockwell are focusing on edge-to-cloud-based systems to connect information between a manufacturer’s development, operations, and maintenance teams through a “singular, trusted data environment.” In their announcement of this new partnership, the companies state that customers using their applications will be able to “digitally prototype, configure, and collaborate without investing in physical equipment. This unified information environment enables IT and OT (operations technology) teams to securely access and share data models across the organization and with their ecosystem of partners as well.” As part of this announcement, Rockwell and Microsoft noted that they have co-developed more than 20 use cases using their combined technologies across the food and beverage, household and personal care, and life sciences industries. Tristan Hunter, general manager of automation and operational technology at Fonterra Cooperative Group Limited, a New Zealand-based dairy products producer, said, “Our team has seen the preview release of this new solution and are excited about the collaboration between Microsoft and Rockwell Automation. Moving data from our on-premise assets

securely with context and providing new workflows for us to analyze and drive better outcomes is important to maintaining Fonterra’s high standards across our many plants globally.” Manufacturers can access Rockwell Automation applications now via the Microsoft Azure Marketplace with more apps currently in development. The companies said that the next phase of co-innovation solutions will be made available to joint customers of Rockwell Automation and Microsoft in Q1 2021, with more details provided at the Automation Fair At Home event. “This partnership provides Rockwell Automation and Microsoft customers with a holistic, simple solution for IIoT development and operations and removes data silos that hinder industrial digital transformation initiatives,” said Blake Moret, chairman and CEO of Rockwell Automation. “By eliminating a core barrier to automation initiatives, industrial organizations can establish a digital thread connecting the entire enterprise, which in turn accelerates innovation, maximizes productivity, and optimizes operations.”

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New Edge Computing Platform Combines Data, Analytics, and Control By David Greenfield

Editor-In-Chief/Director of Content, Automation World

“

What we’re highlighting at PACK EXPO Connects this year is our ability to deliver scalable machine architectures, whether that's micro control systems, compact systems, large systems, or high availability systems (where PLCs need to keep running while software updates are made)," said Derek Thomas, vice president, sales and marketing for Emerson’s machine automation solutions. The company’s newest controller, previewed at PACK EXPO Connects, is an extension of Emerson’s PACEdge controller—acquired in Emerson’s acquisition of GE Intelligent Platforms in 2018. This controller is being expanded with technologies from Emerson’s acquisition of Progea in October of 2020. Progea is a provider of industrial internet of things (IIoT), plant analytics, human machine interface (HMI) and supervisory control and data acquisition (SCADA) technologies. The addition of Progea’s Movicon.NExT software capabilities to PACEdge enables

Emerson’s control to extend beyond individual devices or machines to complete line control. This soon-to-be-released controller will be known as PACEdge IIoT. Thomas said it is designed to create a comprehensive data, analytics, and control ecosystem. “With this controller, we now have a standard package which can be used to do 3D machine visualization or full line visualization as well as OEE calculations and energy calculations,” Thomas said. “Today, if you wanted to have a controller plus IoT plus OEE, you would have to have at least two different pieces of hardware and at least three different software packages from any company, we're the only one that can now do it all in one.” “Emerson is combining these technologies into one edge computing platform because the reality of sending large amounts of machine data to the cloud is neither practical nor affordable,” said Rich Carpenter, general manager, product management of machine automation solutions at Emerson Automation Solutions. “Especially when you consider that one piece of equipment can generate more data in one day than Twitter does in a full year.” Carpenter explained that, “when you bring

An example of OEE data provided by the Movincon.NExT software.

all that data down to the edge, you're making it more accessible to the operator, and that's how you're going to realize OEE (overall equipment effectiveness). By putting all this capability in one box, designed for industrial applications— from the hardware to the software—that makes a big difference. Other companies do this by using an industrial PC that they virtualize and run on a soft PLC on top of Windows. Running your production’s critical applications this way is not as optimal as doing it on one system that’s designed to have the reliability of a traditional deterministic control system.” Some of the specific functions Carpenter highlighted about the Movicon.NExT software and the capabilities it brings to the PACEdge IIoT system include: improving overall production efficiency, controlling equipment with better visibility to understand what’s happening in production, ability to easily see alarms that require maintenance, provide production reports to plant managers for help in continuously improving operations, and interfacing with mobile devices so personnel can access the system from anywhere.

Derek Thomas, vice president, sales and marketing, Emerson machine automation solutions.

Rich Carpenter, general manager, product management of machine automation solutions at Emerson Automation Solutions, demonstrates the capabilities the Movincon.NExT software adds to the forthcoming PACEdge IIoT.

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Autonomous Mobile Robot By David Greenfield

Editor-In-Chief/Director of Content, Automation World

t PACK EXPO Connects, Kate Cramer, automation engineer at Omron Automation, highlighted Omron’s newly released HD-1500—an autonomous, intelligent mobile robot that can handle payloads of up to 1500kg. In her presentation, Cramer explained the difference between autonomous mobile robots (AMRs) and autonomous guided vehicles (AGVs). Cameras used with AMRs enable them to navigate a facility without the need for facility modification (such as floor guides or tracks). She said that AMRs can also safely avoid obstacles without stopping through their use of cameras and

sensors. When traditional AGVs encounter obstacles, they may stop or stall until the obstacle has been removed. “The HD-1500 is specifically designed for industrial environments and allows for the movement of large payloads while reducing the need for forklifts,” Cramer said. “Typical applications include high-payload transporting of materials or finished products such as wrapped pallets, modular equipment, and subassemblies to and from the warehouse or from one location to the next.” Using Omron’s Fleet Manager software, the HD-1500 can calculate the best route for material transport while navigating safely around people and obstacles. Omron’s Fleet Manager can control up to 100 mobile robots of different sizes, configurations, and payload capacities, such as Omron’s other mobile robots—the LD-60/90 and LD-250.

Cramer added that the HD-1500 can also help reduce the potential spread of contaminants or pathogens due to operators no longer needing to move from one station to the next. The HD-1500 features safety-rated front lasers, safety-rated rear lasers, a front low laser, and a rear low laser to provide 360 degrees of safety coverage and allow for precise pick-up and drop-off of materials. Two optional side lasers give the unit “vertical awareness to avoid overhanging obstacles. These side lasers also create two light curtains for anti-collision detection,” said Cramer. The robot can operate for up to nine hours loaded or 12.5 hours unloaded and can be fully charged in less than 40 minutes.

Kate Cramer, automation engineer at Omron Automation, explains the features and functions of the new HD-1500 autonomous mobile robot.

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Trends in Adoption of Remote Access By Pat Reynolds, VP and Editor Emeritus, Packaging World

he report, Trends in Adoption of Remote Access, is based on a focus group and survey on the trends and issues consumer packaged goods (CPGs) manufacturers face in adopting remote access within their operations. Participants were asked to identify the top barriers preventing their company from taking full advantage of remote access technologies and how they are addressing these barriers. When asked about their current approach to remote access, 29% of CPG respondents indicated that they do not allow any remote access in their facilities. However, 27% of respondents allow certain OEMs or service providers to maintain a dedicated connection to specific equipment. Emergency situation access to equipment is allowed by 15% of respondents, and links to a computer where outside service providers are given access was cited by 13% of respondents. Only 6% said they use dedicated hardware that allows a cellular connection to specific machines. Remote access permissions cited by the remaining 10% of respondents included limited and approved outside connections to specific servers through a VPN as well as allowed exceptions for dedicated lines on new equipment installations during automation updates or changes. To download this free report, visit awgo.to/pmmiremote.

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AANew New Kind of Kind of Connected Connected Factory Factory As a pandemic forces social distancing, manufacturers are using technology to stay connected, creating a new vision for how data is aggregated, shared, and acted upon to unite factories and people. By Stephanie Neil Senior Editor, Automation World

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ntil about 10 months ago, Hugh Roddy, the vice president of global engineering and project management at Chobani, spent much of his time on the road traveling between the company’s plants in New York and Idaho, as well as periodically heading overseas to check in on the Australian factory. But his road warrior ways have been curbed by COVID19, and now—like many of his manufacturing peers—he has to manage the projects and operations remotely. As a result, Roddy has been turning to technology, including HMI (human machine interface) and SCADA (supervisory control and data acquisition) systems, the Industrial Internet of Things (IIoT), and augmented reality (AR) to remotely manage assets and troubleshoot machines. But he also needs visibility into how each plant is operating overall. A few years ago, that may have been a problem. But since Chobani’s adoption of Inductive Automation’s Ignition platform, which he describes as a modern day OT (operations technology) operating system, he’s been able to develop many different applications and

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dashboards, giving him and his team the ability to manage new projects, assist with the operations of current production lines, and gain an eagle’s eye view of individual plants from the enterprise level. “When I log into our Ignition system I can see New York, Twin Falls (Idaho), and Australia at any given moment in time,” Roddy says. “The plants are more connected to what is happening downstream and upstream...and at the enterprise level it allows plants to be highly integrated from the plant floor to the executive level and back down.” While Chobani adopted the Ignition platform years ago, other companies are just now starting their digital development journey—a process that has been put on fast-forward due to COVID-19. Now, every business, regardless of the industry segment, is finding new ways to stay connected.

People and processes

“The pandemic is accelerating the movement to digital and smart factories to keep operations running as efficiently as possible and to share [information] across cells in a plant,

lines in a plant, or plants in a network,” says Paul Wellener, a vice chairman at Deloitte LLP and the leader of the company’s U.S. Industrial Products and Construction practice. Deloitte, together with the Manufacturer’s Alliance for Productivity and Innovation (MAPI), recently published a report called “Accelerating Smart Manufacturing: The Value of an Ecosystem Approach,” which indicates that long-term partnerships in the form of an ecosystem can accelerate digital initiatives and drive results. According to the report, while the manufacturing industry was already on a digital transformation journey, it has historically been complicated by the complexity of digitally connecting assets that, in some cases, are more than 50 years old. The disruption and economic hardship caused by the ongoing pandemic have increased the urgency to accelerate smart manufacturing initiatives for future competitiveness. In a recent MAPI CEO poll, 85% of leaders agreed or strongly agreed that investments in smart factories will rise by June 2021. And, while economists predict

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that overall business investments could be low for the next three cycles, respondents in the study indicated they are directing a greater share of their factory investments toward smart manufacturing initiatives. So, while it may have taken a global pandemic to push organizations to find new ways to work virtually, the folks living in this new normal say the real revelation here is not how technology can create a connected factory, but how people use the technology and how it can standardize processes. “It’s not so much about digitization or IIoT devices,” Roddy says. “The transformational component is an organizational design that empowers the technology user. Connecting factories is about allowing people to see what is going on.” Indeed, industry experts agree that people and processes are the key to the connected factory. “Technology was never the barrier. It was always the people or the processes or the metrics in the organization that were the inhibitors or barriers to getting the benefits they were looking for,” Wellener says.

Because technology is the catalyst to connectivity, much of the work of getting plants connected in a practical fashion has to do with the data gathered and what operators do with it. And as cloud, analytics, and artificial intelligence technologies evolve, so do the way manufacturers work.

P&G’s progress

When manufacturers first think about connecting factories, a typical starting place is the manufacturing execution system (MES). That’s exactly where Procter & Gamble (P&G) went as it embarked upon its own digital transformation, finding that, of its 101 plants, 94 sites are using GE Digital’s Proficy MES, while those using other, homegrown system are actively transitioning to Proficy. P&G has more than 2,000 manufacturing lines and 45,000 operators, and according to Tim Rogers, P&G’s chief architect for manufacturing services, the company is currently trying to figure out how to deal with more than 100 plants, each of which has its own unique applications. “They tend to be big, they are local, and

people want the data, so we looked at what we could do differently,” Rogers said during a presentation at GE Digital’s user conference in October. “We have a lot of infrastructure at the facilities [and we thought] let’s get it out of the facilities. [Because] if we leave it there it will ultimately drive increased cost to maintain and support it.” That resulted in a pilot program with GE Digital to test its Predix Manufacturing Data Cloud (MDC), as a way to move manufacturing data to the cloud and apply analytics. According to GE Digital, Predix MDC enables the consolidation of three data sets required for process optimization and analytical applications: asset data, ERP data, and manufacturing data. In addition, the cloud structure is secure-by-design and managed 24/7. It ingests incremental data automatically without having to rely on human intervention and its edge technology includes monitoring and remote configuration. Bringing data to the cloud resulted in an 80% reduction of onsite infrastructure at P&G, which also increased performance because there was less data for applications

P&G’s Tim Rogers, chief architect for manufacturing services, and Beth Scheid, associate director of information technology, global business services, discuss a move to GE Digital’s Manufacturing Data Cloud.

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GE Digital’s Predix MDC consolidates data sets for process optimization and analytical applications.

to wade through. “At the same time, we have so many people accessing this information and they are starting to do more advanced analytics or prognostics or predictions of what might be happening in our plants, or what we could do differently,” Rogers said. “And now that this information can be used centrally across the plants, it can be correlated with other information in the company to do more machine learning and advanced analytics as well.” To that end, GE Digital is positioning its product portfolio around three areas: the connected worker, enterprise scale and visibility, and lean continuous improvement. “[Technologies] like MDC allow enterprise scale visibility and the ability to aggregate actionable data at new levels,” says Richard Kenedi, general manager of GE Digital’s digital plant business.

Testing grounds

While GE Digital is working closely with cus-

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tomers like P&G, others—including Deloitte, Rockwell Automation, and Schneider Electric—are building their own proof-of-concept smart factories. In September, Deloitte launched The Smart Factory @ Wichita, located at Wichita State University (WSU). Deloitte and WSU are constructing a new 60,000 square foot facility that will include a full-scale production line, dedicated space for select ecosystem sponsors, and experiential labs for exploring smart factory capabilities using AI, IoT, and robotics to manufacture products. The purpose of the facility, which will be open to the industry in 2021, is to create a dialogue about how companies can accelerate their journey toward scalable and sustainable capabilities. Rockwell Automation embarked on its own internal digital transformation, which led to numerous lessons learned and the launch of its Connected Enterprise consulting organization. This organization includes the acquisition of Kalypso, a firm specializing

in digital transformation. Based on its own experience, “we created a new and thoughtful approach, thinking not just about technology, but also about the process and first and foremost about people and the organizational dynamic,” says Bob Murphy, senior vice president of enterprise change management at Rockwell Automation. “We found [people] to be the most essential ingredient in making something happen in terms of connected factories.” Similarly, about three years ago, Schneider Electric launched a smart factory in the U.S. in Lexington, Ky., a build-out that took place in a brownfield factory that had been around for 60 years. The goal was to create a standardized smart factory program integrated with lean manufacturing practices. “MES was the first investment, but there’s been a couple of investments since then in different technologies,” says Luke Durcan, Schneider Electric’s EcoStruxure director. “We’ve got multiple automation solu-

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Inductive Automation’s Ignition Perspective can be accessed from mobile devices and as well as centralized computers.

tions, robots, drives, recipe management, and we’ve also invested in novel technology around augmented reality.” The company developed AR for wearable devices that connects to a PLC or the electrical infrastructure of a machine, giving users a number of potential recourses when a failure occurs and walking them through the steps required to execute a repair. Chobani’s Roddy is also a big fan of AR, especially since the start of the pandemic, as it has allowed the company to continue to lean on technology suppliers and machine builders for virtual support while empowering operators to solve problems. “A maintenance person with AR goggles can show someone thousands of miles away what is going. That in itself allows us to be more connected,” he says.

Understanding the data

Collecting data to connect factories is one thing. Understanding what the data means is another. That’s where companies like TrendMiner and Sight Machine come in.

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TrendMiner works with time series process and asset data coming from machine sensors that is typically stored in historians, as well as quality, maintenance, and batch records from other business applications. Typically, historians are slow to search and analyze data. But TrendMiner’s pattern recognition and search tools can access multiple years of historian data to search for patterns within a split second. “Just like Google provides search on the web, we have indexed the data so there’s that same value proposition,” says TrendMiner product manager Rob Azevedo. “TrendMiner works like Google in the way that we provide a cache on top of all that data to make it searchable and available for analysis in seconds. And just like Google, where you have one entry point where you can launch your data search and it searches every website from there, the same happens in TrendMiner. You have our single application that caches all of your data sources and provides the tools and search capabilities to analyze all of your data, regardless of where it comes from.”

In addition, since it’s available as a cloudbased software-as-a-service, TrendMiner can access different time series sources from different factories around the world to generate insights from a central level while sharing with the people onsite, Azevedo says. “The key differentiator is that we analyze time series data, but we also bring in the contextual universe and link to that data. This allows the subject matter experts to analyze what has happened, quickly find the root cause, and monitor to avoid certain behavior in the future.” Manufacturing analytics software provider Sight Machine is also focused on turning data blended from multiple sources into useful information. The company’s unique data modeling capability can take dozens of incompatible data types generated by factory equipment and manufacturing software and generate a digital representation of the entire production process, including production lines, downtime, and defects. “We stream data as it’s generated, restructuring it from whatever schema it’s in and organizing it around generalized concepts like unit of

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fore they want data at their fingertips—which is what they are used to. And, now, especially with people working from home, data has to come to them easily. “For us, Perspective is critical to getting data to the different people who need it. The more connected people are, the more they work together.”

So, while there’s a lot of discussion around the “connected factory” these days, the truly transformational aspect of digitalization is the ability to connect people securely and seamlessly.

| AT11-18USA |

work by a machine,” says Sudhir Arni, Sight Machine’s senior vice president of business outcomes. “Everything is associated with a part or a piece of material as it’s moving through production.” In addition, the company’s Dynamic Recipes feature continuously and automatically updates machine settings to produce optimal performance based on a combination of conditions related to raw materials, the environment, and output. “This is the ability to set a recipe every time you do a production run based on current conditions,” says Sight Machine CEO Jon Sobel. “That level of precision and flexibility has been the domain of expert judgement, never quantified or repeatable.” But now it is, he says, and it can be extended across manufacturing assets, plants, and possibly even entire supply chains. “If we can compare two plants in the same company, why not get everyone in the supply chain connected.”

The distributed servo system with One Cable Automation: AMP8000

The key to connectivity

For technology to be adopted it has to be accessible, easy-to-use, and accepted by the user. Roddy calls Inductive Automation’s Ignition software an OT operating system for the manufacturing floor because it is providing many applications beyond traditional HMI and SCADA systems. “It has given us the ability to, at any given moment, see what is going on in the plants from the HMI control standpoint or plant dashboard,” Roddy says. “And that data can be delivered to whoever needs it at any given time.” But when it comes to getting more, useful data into the hands of whoever needs it, Ignition offers a very useful option—an unlimited licensing model. “Connectivity is key, and from the beginning, the one thing we’ve tried to do is have a different licensing model,” says Travis Cox, co-director of sales engineering at Inductive Automation. “If you have an unlimited approach, it opens more doors of innovation.” The company also spent a lot of time building out its mobile module called Ignition Perspective, which is a web-based HTML5 visualization tool that provides monitoring and control of processes directly from a mobile device, desktop, or touch panel. With this tool, users can visualize data in a way that they’re familiar with. “If you make it hard [to access] and have to license it [individually], then it won’t be as effective,” Cox says. Everyone’s lives are hectic and there-

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www.beckhoff.us/amp8000 Eliminate and shrink control cabinets while expanding dynamic motion control: The AMP8000 Distributed Servo Drive System from Beckhoff integrates a servo drive directly into a servomotor. A unique benefit of the AMP8000 series is that servomotor power ratings* and installation sizes remain virtually unchanged. Proven One-Cable Automation in the EtherCAT P standard delivers real time communication and industrial power on one cable, and an innovative IP65-rated supply module powers multiple motors in the field. As such, the AMP8000 minimizes space requirements, installation effort, material costs and motion system footprint in a big way. sizes remain almost identical to standard AM8000 servomotors from Beckhoff no changes in existing machine designs required same high power ratings as before despite drive integration* TwinSAFE drive safety technology built into every servomotor *Compared with a combination of servo drive and servomotor

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In both discrete and process manufacturing, augmented reality technologies are proving to be an operator’s best friend by helping to decrease repair times in the plant and in the field, improve accuracy, increase situational awareness, and boost safety. By Lauren Gibbons Paul, Contributing Writer, Automation World

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n the world of manufacturing, augmented reality (AR) is one of those technologies that has been eagerly anticipated for years but isn’t yet widely used due to a lack of numerous commercial application examples. That’s starting to change as several forward-looking companies in the discrete manufacturing and processing sectors are publicly discussing their use of AR technology to decrease repair times, increase efficiency and safety, and seamlessly share knowledge across locations. At Bühler Group, a $3.3 billion Swiss equipment manufacturer, plant floor operators use Schneider Electric’s EcoStruxure Augmented Operator Advisor (AOA) to access targeted information on handheld devices which is overlaid onto the actual equipment via the mobile device’s camera. AOA provides Bühler Group operators with access to real-time, asset-specific data including manuals, CAD drawings, safety information, and production checklists,

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greatly reducing human error and mean time to repair (MTTR). The ability to visualize everything from manuals to standard operating procedures (SOPs) to maintenance schedules and asset health information has enabled the company to dramatically reduce downtime. According to Dr. Holger Feldhege, chief operating officer of manufacturing, logistics and supply chain at Bühler, the advantage of using AR to leverage Internet of Things (IoT) data lies in how it provides useful, targeted information to users where and when they need it—a huge improvement over the paper forms the company used to use. On the market for about a year now, AOA has proven its viability at Schneider Electric’s own 500,000-square-foot Lexington, Ky., facility, where workers use the app to keep fabrication of its Square D Load Center line of products running. Preston Lockwood, maintenance manager at the Lexington facility, says the first step was to document all of the operators’ task lists and create videos that showed how to execute these tasks correctly. With those videos uploaded, implementation with AOA was fairly straightforward. “All of my mechanics and technicians have tablets in house and they can access them through the AOA app,” Lockwood says. AOA shows them which preventive maintenance activities need to be performed, giving the technician the option of tapping to see a video or access a broad set of materials. With AOA providing support and backup, Lock-

wood finds it easier to schedule his staff of 30 technicians across three shifts. “AOA gives me flexibility to put any resource I have on a task regardless of their specific knowledge. That helps avoid unplanned downtime and speeds correction of issues. That’s the biggest benefit,” he says.

Virtual visibility protects operators

Better safety is another win users are seeing from AR. When performing reactive maintenance and troubleshooting, it’s not always easy to pinpoint blocked sensors. “These machines are fairly big and there’s a lot of tooling and equipment moving around that gets in the way. You can’t necessarily see a sensor that gets blocked,” Lockwood says. If one station does not complete its cycle, all the other stations are kept waiting. Before using AOA, an operator would have to go back to an HMI to try to figure out what was going on, a process that might take several minutes if he could even find out what’s wrong using those technologies. “AOA lets us see what the PLC is doing in real time. We can see the sensors, if they are being activated or not; we can see if the valves are being energized or not. I can have a technician pull up AOA and they can go through the overlays and see what is happening without having to lock out to find where the problem is,” he says. Previously, technicians would have had to open the gate and lock out the machine

Workers access equipment information, overlaid on the image of the equipment, on a mobile device using Schneider Electric’s EcoStruxure Augmented Operator Advisor.

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to see if the sensors were operating properly. Exposing all the automated equipment inside also poses an inherent risk, even if the machine is locked out. Using AOA means the team doesn’t necessarily have to put up danger tape, don PPE (personal protective equipment), and clear out work areas to assess the situation effectively. “AOA gives us much more information. We can go right to where the problem is. The less time we spend in the machine, the less risk to safety,” Lockwood says. Of course, as with any new technology, there is a learning curve with AR, Lockwood says. Some people take it to it faster than others. Lockwood focused on little wins that helped drive overall buy-in. Now, he estimates AOA has helped the Lexington factory reduce MTTR by an impressive 20%—enough to get everyone’s attention and enthusiastic endorsement.

Pointing the way

Emerson Automation Solutions recently debuted its Plantweb Optics Augmented Reality, part of its Plantweb Optics platform, which is designed to help process manufacturers manage critical asset performance in the field. One of the simplest and most powerful AR applications is to help the operator locate an asset and get directions to its position on the floor. This is especially helpful for contract workers or new workers trying to find a device, according to Vineesh Kapoor, product management director for Plantweb, Emerson Automation Solutions. “They can enter the name and the app will provide a route to that specific device with directions like ‘look down,’ ‘look up’ etc. This is very helpful in plants that have a lot of equipment,” Kapoor says. Instead of the worker having to climb a tower or a column on the hunt, the app helps pinpoint the exact location. Thanks to integration with IoT devices in the plant, Plantweb Optics AR helps process companies make better decisions faster, Kapoor says. “Engineers can bring up the app on the tablet, see the equipment data, and make a decision without having to have any additional, unnecessary conversations.” In the process industries, AR’s killer app is collaborations in the field. A technician can call a combined video and audio session depending on who is available to help with the problem. The expert can look over the

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Device operation status overlayed on images of the device using Emerson Automation Solutions’ Plantweb Optics AR. technician’s shoulder virtually and provide advice on how to fix an asset, faster and safer than before. One Emerson client, a food and beverage manufacturer, is preparing to use Plantweb Optics AR to help establish more efficient, consistent operations—a significant benefit for process operations where variability is the enemy of quality. The food and beverage manufacturer will store its procedures and documents in Plantweb Optics so they can be accessible in the field via the AR app. This helps ensure that technicians follow sanitation procedures. Historically, these procedures were kept in paper binders in the plant. Now they can be easily accessed by workers anywhere in the plant. Engineers will also be able to quickly access step-by-step guides to numerous procedures. If troubleshooting is needed, the engineer can ask for help from a remote expert using Plantweb Optics AR. The expert can then walk them through the maintenance

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or repair procedure using printed instructions and annotations overlaid on the equipment via the AR app. Kapoor says Emerson is “pleasantly surprised” about the pace of uptake on Plantweb Optics AR. In addition to the food and beverage company mentioned above, Emerson also counts a liquid natural gas customer and a life sciences company as early adopters. Emerson Automation Solutions also offers an ROI calculator to help companies estimate the payback period of the AR tool and gauge how much money they might save by reducing the number of field trips. The quickest ROI comes in cases where there are lots of trips to the field, according to Kapoor. “We see [an increase in field trips] occurring more and more as senior members of the operations organization retire. They know everything about the facilities and were able to do a lot,” Kapoor says. “We see many of our customers transitioning to outsourced maintenance to manage some assets, in addition

to bringing in fresh talent from engineering or technical schools. The new people need time to learn about the equipment and how it is operated in the plant.” VR enhances the learning experience and also tends to make it more compelling for learners. And if AR can help those organizations cut a trip to the field, that’s a lot of hours saved. For example, take a small work order in a chemical plant. Assuming no expert help is required, that work order might typically take four hours to finish, requiring the engineer to get out the binder containing the SOP, walk over to the asset, inspect it, go through the steps in the work order, check the work, and then close out the work order. Now, the technician can call up the Plantweb Optics AR app and move through the steps much more quickly, saving at least three hours. “These are the kinds of cases where you are seeing a huge benefit from AR,” Kapoor says.

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Drones Map and Inspect Energy Operations California Resources Corp. is growing its drone program with the use of DroneDeploy software to save hundreds of thousands of dollars a year mapping and inspecting operations and enabling proactive asset management. By Aaron Hand, Editor at Large

ince the plunge in petroleum prices began in early 2015, the oil and gas industry has been turning increasingly to automation to help optimize production to maintain profits. Long gone are the wildcatting days that paid little heed to efficiencies—where producers could strike it rich if they just kept drilling. Though the use of drones in any manufacturing operation might still seem fanciful, it has already proven its benefit to energy companies. California’s largest oil and natural gas producer, California Resources Corp. (CRC), started incorporating drones along with DroneDeploy software in 2018 and has

seen clear benefits in its operations. In its two years of drone use, CRC has been able to improve safety, promote communication, and improve production efficiency and reliability. Reducing the cost of inspections by eliminating the need for expensive manned aircraft, the company estimates the financial impact of using the technology in the hundreds of thousands of dollars while also reducing the risk to personnel.

Covering ground

CRC holds the largest privately held mineral acreage in California, consisting of 2.2 million

CRC deploys drones daily to help save time and money, and to improve operational efficiencies.

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net acres spanning the state’s four major oil and gas basins. Implementing drones into its operations made it possible for the energy producer to construct a more accurate digital property record. Currently operating with 26 licensed drone pilots—with plans to expand that to 100— CRC found a way to cover its vast expanse of land. But it also needed a way to pull all that data from drones in the field into a centralized location. This would help address CRC’s issue of having only about 5% of the company’s assets in a centralized database. “We were looking for an elegant solution for automated aerial imagery, mapping, and program management,” says Alvin Rentsch, transformation architect for CRC. DroneDeploy software gave CRC a process to allow the right people to have access to all aerial visuals while analyzing the images remotely. It could send out a team of pilots to fly several different areas of land and upload those captured images, videos, and panoramas to the cloud, enabling its analysts to work from accurate maps and models without the need for radios or similarly faulty communication techniques. CRC could also automatically collect detailed flight logs for all drone flights, filter through specific projects and timescales, and create custom pre-flight checklists with responses automatically recorded against the flight record. This enhanced visibility into their operations across the entire team by maximizing data capture—making sure pilots were using the most precise flight plans without doubling up on work. These capabilities

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CRC uses DroneDeploy to fly and map thermal imagery and conduct thermal inspections.

allowed CRC to scale its program without delays, mistakes, or extra costs, enabling them to capture all of their assets, across the millions of acres of land, in a much shorter amount of the time.

Detailed inspections

The energy industry has certainly caught on over the past couple years to how useful drones can be for quick, safe, effective inspections of everything from flare stacks to pipelines—not to mention renewable assets on solar and wind farms. In CRC’s case, inspections are used to detect dangerous methane or hydrogen sulfide leaks, ground subsidence of well pads, or flare stack anomalies. Using drones rather than manual inspections, CRC has been able to move from a reactive maintenance scenario to proactive. For example, CRC used DroneDeploy to monitor anomalies that could otherwise be missed by human inspectors, who cannot always detect the minute cracks on the ground surface. A tiltmeter—a sensitive incli-

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nometer designed to measure very small changes—was one alternative used by CRC, but it was an expensive one, sometimes costing as much as $7,000 each. It also had to be installed deep underground, adding several hours to the production schedule. Drones, on the other hand, can run regular flights to detect any anomalies. By using drones and thermal imagery, not only could CRC detect such instances accurately, maintenance personnel could act on that information faster, saving both time and money. Using drones also reduced the overall effort normally needed to perform such inspections. With pipelines often spanning thousands of acres, it can take days or weeks for a team to complete its examinations. One of the largest areas that CRC is required to monitor is more than 22,000 square acres. Within that area, more than 30,000 wellpoints need to be assessed. Manually and visually inspecting each and every wellpoint is impractical. And if workers could not drive or walk to some pipelines, CRC had to rent helicopters.

Flying further

By logging 100% of its drone flights through DroneDeploy, CRC realized more than $205,000 in savings over its previous process in the first half of 2019, with an estimated $500,000 in savings by the end of the year, according to Maurilio Espinoza, CRC’s process excellence lead. Those savings are all attributed to inspections, surveillance, mapping, and reliability, he adds. The company has also reduced the time for all inspection workflows by 40%. Looking to the future, CRC plans to expand its drone reach—putting a drone in every one of its field vehicles. The energy producer would also like to have up to six pilots per operational area. The plan is to continue to grow the program to address maintenance issues more efficiently than annual checks, and to cut unnecessary staffing hours.

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Thermal Mass Flowmeters

Endress+Hauser, us.endress.com The Proline t-mass F/I 300/500 flowmeters are designed for measuring pure gases and gas mixtures. Even when process and ambient conditions significantly fluctuate, t-mass ensures high measurement accuracy (±1.0%) with excellent repeatability (±0.25%). T-mass F and I can operate at process temperatures up to 356°F and pressures up to 580 psi. The t-mass 300/500 measuring system has been developed in accordance with IEC 61508, SIL 2 and can be used in safety-related applications. The measuring system is equipped with a “Gas Engine” software model to calculate the mass flow of a gas under current process conditions. The Gas Engine also calculates flow velocity, reference density, corrected volume, and energy flow for current operating conditions, provides exact measurements, and offers dynamic corrections.

Industrial Application Platform Update

Inductive Automation, inductiveautomation.com Ignition 8.1 is the latest update to the Ignition industrial application platform with tools for building human-machine interface (HMI), supervisory control and data acquisition (SCADA), manufacturing execution systems (MES), and Industrial Internet of Things (IIoT) systems. With Ignition 8.1’s new Perspective Workstation, users can deploy native applications to any HMI, desktop, workstation, or multi-monitor configuration without a third-party web browser. Screens can be displayed in full-screen kiosk mode with no distractions from the underlying operating system. Perspective Power Chart allows users to create runtime-configurable time series charts from tag historian data. Power Chart also adapts automatically for mobile screens.

Single-Phase Soft Start Compressors

Carlo Gavazzi, gavazzionline.com The RSBS Series compact, single-phase soft starter is designed for single-phase compressors in single-phase voltage networks prone to voltage fluctuations. The RSBS uses a current limiting algorithm to reduce compressor start current by more than 50% when compared to direct online starters. Its control algorithm automatically detects when the compressor reaches full speed to ensure that the internal bypass relay switches on when the current is at an optimum level. The RSBS can limit inrush currents up to 45 amps under balanced conditions with a maximum ramp-up time of 600 ms. Its HP function ensures the compressor receives enough starting torque by allowing a maximum current of 80 Amps. Features of the RSBS Single-Phase Soft Starter include: single-phase 195.5 to 264.5 V AC, 50/60 Hz operating voltage range; rated operational current: 37 amps; 4.4 kW/5 HP rating at 40°C; diagnostics for detecting voltage dips and other problems; and anti-short cycling function with built-in delay between starts.

Modular Linear Motors

Beckhoff, beckhoffautomation.com The AL8000 series modular linear motors, developed in cooperation with Fertig Motors, is based on a modular system design consisting of linear motors and magnetic plates. Users can choose between three widths: 50mm (AL8x2x), 80mm (AL8x4x) and 130mm (AL8x6x). Each width category offers a range of different linear motor types in terms of length, winding type, and cooling type. Depending on the size of the linear motor, peak forces of 120 to 6,750 N are possible as well as maximum speeds of up to 12m/s. The symmetrical structure of the linear motors means there are uniform intervals between the mounting holes throughout the AL8000 series. This makes it easier for machine builders to construct the machine slide and ensures consistent force and temperature distribution within the motor.

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Remote Access Platform

Red Lion, redlion.net The Secure Remote Access Platform centralizes the management of routers. These routers are industrial-grade gateways that offer optional LAN, WAN, serial, USB, Wi-Fi or 4G LTE connectivity. To simplify deployment, Red Lion’s remote access routers offer Simply.Connect technology. This enables the setup of routers in less than two minutes, facilitating small or large deployments, using only a smartphone. Once configured, routers can be deployed anywhere, providing real-time, secure, and seamless connectivity to remote assets or sites. The foundation of Red Lion’s remote access platform is RLConnect24, a remote service portal that provides a centralized site to monitor and manage deployed assets and users. RLConnect24 provides data visualization, geographic mapping, data logging, and alarms based on operational or system-generated data.

Embedded Vision Kit

Allied Vision, alliedvision.com The Embedded Vision Starterkit offers an entry into industrial image processing on embedded vision platforms. Users are provided a package of hardware and software that includes: Alvium 1500 C-120c color camera with S-mount and open housing, Allied Vision lens S-6-F1.8-5MP-T1-2.5IRC, 420mm CSI-2 flex cable, CSI-2 adapter board for Nvidia Jetson Nano/Xavier NX Dev Kit, Alvium tripod mounting plate, PCB Triangle for demo applications, MVTec Halcon machine vision software, MIPI CSI-2 driver, and preconfigured SD card image. The practical demo triangle keeps various applications ready for users with matching, reading of bar and data codes, pose estimation, and deep-learning-based classification.

Power Over Ethernet Switch

Antaira Technologies, antaira.com The INJ-C200G-bt-T is an industrial high-power IEEE 802.3bt Type 4 Power over Ethernet (PoE) injector switch that provides up to 97 watts of power. This compact PoE injector is backwards compatible with IEEE 802.3af/at standards and provides two gigabit Ethernet ports for data. The injector is IP30 rated, DIN-rail and wall mountable, and supports an extended operating temperature range of -40°C to 75°C. This industrial switch series provides high EFT, surge, and ESD protection to prevent any unregulated voltage and can support the power redundancy feature using a dual-power input design. There is also a built-in relay warning function to alert maintenance when power failures occur.

Edge Programmable Industrial Controller Update

Opto 22, opto22.com Version 3.0 of the groov EPIC (edge programmable industrial controller) platform introduces centralized user management via LDAP (lightweight directory access protocol) and improved maintenance and troubleshooting capabilities for remote installations. With LDAP, rather than defining user access profiles repeatedly for individual network devices, IT administrators can define permissions once and manage them centrally across an organization. Version 3.0 also includes: Node-Red upgraded to version 1.1.3, with improvements to the editor and core nodes plus support for Websockets connections for data-rich client-side apps; standalone PID capability for groov Manage, allowing for control of up to 96 PID loops without any programming in PAC Control or CODESYS; and enhanced MQTT/Sparkplug B support with the ability to publish more tag properties.

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Power-Limited Tray Cables

Helukabel, helukabel.com The Profinet Type A, Type B, and DP cables from Helukabel have earned a Power-Limited Tray Cable–Exposed Run (PLTC-ER) certification. The original PLTC certification allowed the products to extend outside of the cable tray by 6 ft (1.8 m). With the upgraded PLTC-ER certification, these products can extend up to 50 ft (15 m) outside of the cable tray without additional protection, such as conduits or armoring. Each of these cables is rated Category 5e and can be used in environments that vary in temperature between -40°F and +176°F (-40°C to +80°C). The cables are also UL recognized under PLTC-ER 75°C according to UL 13 for the U.S. and listing type CMG 75°C according to UL 444 for the U.S. and Canada.

Wireless Sensor System

Swift Sensors, swiftsensors.com The Series 3 wireless sensor system incorporates BLE5 technology with Nordic nRF52840 system-on-chip cryptography, multiprotocol communication, and power management features to increase the sensor range up to 300 feet, increase the number of sensors that each gateway can securely support, and extend sensor battery life to six to eight years. The Series 3 sensors also include a predictive vibration sensor that adds peak-to-peak, RMS, and crest factor monitoring. Other improvements include: a water-resistant (IP 67) sensor; one-touch sensor activation for immediate measurements with zero configuration; an internet status LED that shows if the gateway is connected to the internet, connected locally, or not connected; enhanced web app and LED indicators that simplify gateway Wi-Fi setup; and an optional USB cellular network module for deployments where Ethernet and Wi-Fi are not available.

Chassis for Embedded Computing

Elma, elma.com This new rugged ATR (air transport rack) chassis is compliant with VITA 48.4 for liquid flow-through cooling. The backplane in the chassis is designed for data rates up to 10 Gbps and can handle 300 watts per slot. The new chassis features configurable front I/O connectors on a removable panel and a filtered power input connector. Individual card coolant flow rates are adjustable with selectable orifices. The backplane features eight 6U slots on a 1.2-inch pitch, including two VITA 62-compliant power supply slots, four 6U slots, and two 6U payload slots populated with all J1-J6 connectors. Clockable guide pins are included at each slot to allow for easier keying (angle rotation), without having to deal with the removal of the backplane from the chassis.

Dual Display Digital Panel Meter

Otek, otekcorp.com The NTM-8 smart meter is a direct form, fit, and function replacement for the Foxboro 257, Bailey 775, or any other 6- or 7-inch analog meter. Available in a metal housing, the NTM-8 has industry standard dimensions of 2.785-inch width x 6.35-inch height. Able to offer a dual display, the NTM-8 can house anywhere from two to four channels, with four digits and an automatic tricolor bar display with intensity control. It can be powered by the current loop, the AC signal or an external power source. Additional features of the NTM-8 include an input failure alarm with run time stamp that alerts the operator in the event of a dead or lost signal, self-diagnostics, isolated serial I/O or USB/RS485, math functions, four relays or open collector transistors, optional 4-20mA/30V output, and a configurable bar direction.

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Robot-Based Press Automation

ABB, abb.com The IRB 760PT is a flexible press tending system offering 25% faster cycle times compared to other robot-based press automation systems. It features a revised design that reduces the interference in the robot’s fourth axis. This allows the robots to move freely without colliding with equipment such as press clamps, with no compromise to the working area or the robot’s freedom of movement. It is capable of handling loads up to 450kg and can automatically change tooling. The IRB 760PT features a 3.18m reach, which—when coupled with a linear seventh axis or with the Twin Xbar system—avoids the need to reorient parts between consecutive stamping operations.

Industrial PC for Edge Computing

Phoenix Contact, phoenixcontact.com The BL2 BPC 1500 is a compact industrial PC for rugged environments with limited space. This box IPC is designed for entry-level automation, small machine control, and IIoT applications such as edge/fog computing or decentralized data collection and processing. It features a fan-less design, solid-state mass storage, and heavy-duty metal housing. The standard version measures 97mm wide, 92mm high, and 46mm deep. An extended version is 63mm deep, with the same width and height. Additional features include 32 GB eMMC internal mass storage, 12V DC to 30V DC wide-voltage operation, and DIN rail mounting. Select models offer an additional 64GB or 128GB m.2 solid-state drive.

Mass Flow Controller for Gas

Bürkert, burkert.com The Type 8742/46 range of mass flow controllers/meters (MFC/M) for a range of gas applications now features analog communications onboard and includes an integrated Profibus-DP option. The Type 8742 handles low- to mid-flow, with a nominal range from 0.010 lN/ min to 160 lN/min. The Type 8746 is designed for high-flow, covering 20 lN/min up to 2500 lN/min. The latest release adds analogue communications interfaces including 4-20mA, 0-20mA, 0-10V or 0-5V. The new Profibus-DP variant features onboard CANopen, which enables integration with all leading Ethernet-based networks and fieldbus. The digital option can support up to 32 MFC/M on one fieldbus gateway.

Sensor Network-to-Cloud System

SignalFire Wireless Telemetry, signal-fire.com The integration of SignalFire’s wireless sensor network with Machfu’s industrial IoT gateway delivers a secure sensor-to-cloud system. Operating the SignalFire Edge application on Machfu’s Edge gateway, users can wirelessly bring all sensor measurements from a SignalFire sensor network into their cloud application. The IIoT gateway automatically communicates with the SignalFire gateway to discover wireless nodes in a network, collect measurements from sensors, and transmit them over cellular, Wi-Fi, or Ethernet connections. Features include: MQTT/SparkPlugB support to integrate with SCADA monitoring applications; SignalFire Toolkit remote connectivity to monitor and troubleshoot SignalFire nodes; remote connectivity to HART instruments using software like PactWare; and flexibility of on-premise or cloud connectivity.

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40 ENTERPRISE VIEW AW DECEMBER 2020

T�e ncreasin o loud or O Brian R. May

brian.r.may@accenture.com Managing Director, Industrial North America, Accenture

loud, the popular metaphor for a group of on-demand and computerpowered services, has largely played a support role for industrial operations in recent years. Today, however, the scaling flexibility of cloud can provide industrial companies optimized IT cost, agility, and a platform for growth, which are critical to their future success—and with good reason. From the start of 2020, industrial companies faced a challenging outlook. Revenue growth and profitability were slowing due to a progressing global economic downturn and a significant drop in industrial production. Many were focusing on efficiency improvements, restructuring, and reshoring the production chain, already making the flexibility that comes with cloud technologies a necessity. Then COVID-19 struck, significantly altering the industrial value chain and fundamentally changing everything from consumer behavior to the path to market. Now, companies must also navigate an uncertain economic recovery, emerging competitive threats, new ways of working, and a new set of customer expectations in an era of profound societal change. In other words, industrial reinvention is needed now more than ever. Using cloud capabilities can play a pivotal role in the reinvention journey when focused on three critical areas; a “fit for purpose” cost structure—enabling growth in a new business environment—and smart products and services innovation. For example, cloud digital applications are changing the way customers engage, empowering new growth models. As product portfolios continue to expand to include services and greater digital engagement, there is a need to accelerate speedto-market to remain competitive. As part of

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alue s

the acceleration, e-commerce platforms can be set up quickly for customer engagement through the cloud to facilitate digital connectivity across multiple customer channels. Cloud connectivity also enables a shift to a leaner and flexible operating model by integrating processes, platforms, and ecosystems. It supports real-time customer insights through analytics and provides the flexibility to adjust infrastructure capacity to quickly respond to new customer expectations.

Making the journey

Here is a more in-depth look at actions industrial companies can take to optimize cost, enhance growth, and increase speed-to-market using cloud technologies: 1. Fit for purpose—Industrial companies must prioritize cost management to boost profitability and invest in reinvention. To accelerate cost optimization, companies need to leverage the benefits of data, analytics, automation, cloud, and other digital technologies at scale. This will help ensure a lean organization focused on differentiation and growth. Moreover, analytics-driven inventory right-sizing will drive sustainable gains for manufacturing and operations. 2. Growth: Industrial companies will need to retool their approach to growth. This means shifting from B2B to B2C, using direct-to-customer and digital-go-tomarket models. According to Accenture research, by 2025 online sales alone are expected to reach 20% to 25%, an increase from 10% today, with up to 50% of sales being online induced. There also will be a need to diversify revenue sources by focusing on adding a portfolio of services, many of which will be digitally enabled. This shift, among other benefits, will result in greater stability during uncertain economic times. 3. Smart, connected products and services—These portfolio additions will require industrial companies to increase agility and flexibility across the entire value chain to differentiate market position and enable new revenue streams. This includes sensing,

forecasting, and anticipating changing demand by both customer segment and geography, while simultaneously applying digital manufacturing to ensure faster response times. It also will require developing a roadmap for creating more resilient supply chains based on extensive data, customer collaboration, automated operations, and a digitally enabled workforce.

Maximize value

As part of the cloud journey, industrial companies will need to balance speed and value. Cloud can be both transformational and disruptive for the better, offering breakthroughs, scalability, flexibility, responsiveness, efficiency, resilience, and security. This new environment underscores the need for companies to seriously consider expanding the use of cloud technologies to maximize value and future success.

T�e scalin e ibility o cloud tec nolo ies can provide optimi ed T cost a ility and a plat orm or rowt all o w ic are critical to uture success.

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INDUSTRY VIEW 41 AW DECEMBER 2020

Moving to a More “Open” Environment By Dick Slansky Senior Analyst, ARC Advisory Group

he expansion and proliferation of open source organizations such as the Linux Foundation and the OpenStack Foundation attest to how much open source projects have become mainstream. The overall architecture of the digital transformation and the technologies, products, services, and business strategies that define it are gelling. ARC observes some distinct delineations in this digital transformation environment: • The cloud enterprise infrastructure of platforms, servers, and networking; • The edge computing environment of private cloud servers, networked appliances, gateways, and firewalls; and • The far edge of IoT endpoints, intelligent devices, and automation and controls. Much of the openness in these areas is being accomplished through open source projects and by the suppliers and users that are developing solutions for the Industrial IoT. To operate successfully in this landscape, industrial organizations require an understanding of open source software’s benefits, limitations, and how to leverage the value proposition of an open source development environment. For the most part, open source software and the Industrial IoT development community adhere to the open standards movement that evolved along with the software. Open standards are often a requirement for doing business; open source, in turn, is a choice made by users.

Edge architecture and open source frameworks

An IoT solution is an amalgamation of hardware, software, and networking capabilities.

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Edge computing is required for virtually any IoT solution to succeed. Various open source frameworks are available in the IoT space. Cloud service providers also offer rich services for IoT solutions and edge computing. Data is the heart of an IoT system and should be processed as quickly as possible to allow the system to operate efficiently and as designed. The huge amounts of data generated from IoT devices or sources can easily consume the available network bandwidth and require excess data storage. It is crucial to aggregate and digitize the data at the periphery of the system, which can then be communicated to back-end systems. Today, with the emergence of AI (artificial intelligence) algorithms embedded in computing hardware, processing can take place at the edge, significantly reducing the need to transport data to edge computing server layers. Edge computing handles this, helping reduce the amount of data transported across cloud computing infrastructure. These edge computing systems reside close to the IoT devices/data sources and enforce the required security. A major benefit of edge computing is that it improves the time to action, reduces response time, and optimizes the use of network resources. It also helps reduce latency and network bottlenecks.

ment platforms can be expensive; set of available standard features don’t always fit all business needs; and • Open source IoT platforms are not for the casual developer.

• The

Computing at the edge

Currently, the Linux Foundation and the OpenStack Foundation serve as umbrella groups for a wide range of OSS industrial IoT projects. Taken together, the Linux Foundation and the OpenStack Foundation OSS market is huge. The development cost of the top 100 Linux Foundation projects exceeds $16 billion with one million developers enrolled in OSS training. The OpenStack market is projected to reach $7.7 billion by 2023. Computing at the edge will drive much of the OSS market, with IoT architectures, edge devices, intelligent edge processors, and edge computing server layers defining the edge environment. OSS will provide the flexibility, the broad developer base, and a single purpose to improve and enhance the software. The goal of the Linux Foundation is to bring all edge computing players under one umbrella with a single technology to create a software stack that unifies a fragmented edge market around a common, open vision for the future of the industry.

Driving IoT implementation

Unlike proprietary software, open source technologies are completely customizable and scalable. Because the code is open, it can be adjusted and modified to the business’s needs. Assuming the necessary toolkit is provided, open source software (OSS) allows developers and enterprises to move between different frameworks without complications. With a great number of automated protocols and functions, open source frameworks can save time for IoT engineers and tech professionals. While data privacy and security are primary concerns of any business, companies need to be aware of some remaining challenges when using OSS. These include: • “Open” means free access, i.e., contributors are not always specialists; • Maintenance security can be vulnerable; • Data privacy can involve legal issues; • Some of the better open source develop-

Data should be processed as quickly as possible to allow the IoT system to operate e ciently and as designed.

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42 INTEGRATOR VIEW AW DECEMBER 2020

Use Remote Upgrades to Prevent Software Obsolescence Jason Anson Automation Manager, Interstates

id you know that software companies introduce new operating systems every 5-7 years? These new operating systems come with a plethora of new features and added security. But maybe you haven’t had the time or don’t want to make the switch due to financial or safety concerns during a pandemic. So, do you really have to make the change? Technically, maybe not right away, but when software companies release new software, they typically stop supporting the old systems—they call this end of life. If you aren’t sure when your plant’s systems will reach their end of life, you’re not just missing out on new functionality. Failing to update will leave you vulnerable when patches and critical security updates are no longer available. The bad news is that putting off updates will leave your plant susceptible to increased downtime and lost productivity. The good news is that these essential updates can be done remotely and for less money if you find the right company to help you. Before deciding on whether or not to move forward with an upgrade, there are a few things you should take into consideration.

Determine your risk

At a certain point, hardware must be updated or replaced alongside software. As operating systems become more sophisticated, they need compatible computers. If the PC that runs your HMI breaks while running an obsolete OS, you cannot purchase a new computer with that same OS. You need to stay up to date with software so that, in the event of computer hardware failure, you can replace it and be up and running again with minimal downtime. The difference between a two-hour downtime fix and one that

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takes two days is significant. Consider these questions: • How much is your product worth? • How much availability do you have in your production schedule if downtime occurs? A plant that runs 24/7 making a high-value product can’t afford to be down for very long. Scheduling your downtime is a lot more cost effective than waiting for something to break. Many plants don’t run at night or on weekends, so it’s easy to schedule obsolescence replacements without disrupting production.

Planning and implementing upgrades

An upgrade requires the plant’s process to be down so any old computer hardware can be replaced with new hardware. The new applications, which have already been tested offsite, will be installed and tested at the plant as production starts up again. Virtual computer systems, developed in the last 10-15 years, have improved the downtime window and are ideal for testing new systems. They allow programmers to turn off a virtual image or file that behaves as an actual computer and turn on the newly loaded and prepared image, which then runs on the new OS. It’s important to note that virtual images reduce the risk of upgrades. On a virtual image upgrade, you power it down and power up the new, upgraded image and begin commissioning. In the event of issues, you are able to power down the new image and power back up the original image and then regroup if needed with little effort. Not every upgrade requires new hardware. With virtualized replacements, servers are used and have a longer life span. Additionally, some server hardware can be replaced while production remains running. Older systems and smaller production facilities running on a computer desktop and not a virtualized system generally require a computer replacement.

Remote upgrades

and application upgrades. If your plant doesn’t allow outside contractors on site or keeps visitors to certain, restricted areas, remote upgrades to combat software or hardware obsolescence are a smart choice. Engineers won’t have to travel to your location, avoiding lengthy quarantine protocols and saving money and time. Scheduling is more flexible with remote upgrades, as well. As long as you have “boots on the ground” or someone at your plant to facilitate the upgrades, the remote option is a good one. Make sure you choose a company that has targeted experience and longevity in obsolescence replacements. The entire point of addressing software obsolescence is risk mitigation. You need to weigh whether you can handle the risk of a piece of hardware going down and not being able to replace it. Don’t underestimate the benefits you’ll gain from the new functionality that comes with up-to-date software, either. Just like consumers upgrade their phones, plants need to upgrade to stay consistent with production and gain new functionality. In a day and age where this can all be done remotely, it’s simply smart business to keep on top of upgrades and avoid downtime.

T�e bad news is that putting oﬀ updates will leave your plant susceptible to increased downtime and lost productivity.

The pandemic has forced companies to adapt in many ways, including pivoting to remote work when possible. Programmers can use VPN access to offer remote support for process problems or small updates like remote OS

11/30/20 11:21 AM

ADVERTISER INDEX 43 AW DECEMBER 2020

COMPANY

TELEPHONE

WEBSITE

PAGE

AutomationDirect

800.633.0405

www.automationdirect.com/cmore

Beckhoff Automation

952.890.0000

www.beckhoff.us/amp8000

Digi-Key Electronics

800.344.4539

www.digikey.com/automation

Galco

888.526.0909

www.galco.com

Hammond Manufacturing

716.630.7030

www.hammondmfg.com

Inductive Automation

800.266.0909

www.demo.ia.io/automation

Motion Industries

800.526.9328

www.motionindustries.com

Opto 22

800.321.6786

www.opto22.com

PMMI PACK EXPO Connects

571.612.3198

www.packexpoconnects.com

Telemecanique Sensors

800.435.2121

www.tesensors.com/XXSonic

Tetra Pak

940.565.8800

www.gonature.tetrapak.com

Wago Corporation

800.DIN.RAIL

www.wago.us/touchpanel

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7 Cover-4

Automation World ® (ISSN # 15531244, USPS 22435) is a registered trademark of PMMI, The Association for Packaging and Processing Technologies. Automation World ® is published 14x a year by PMMI with its publishing office, PMMI Media Group, located at 401 N. Michigan Avenue, Suite 300, Chicago, IL 60611; 312.222.1010; Fax: 312.222.1310. Periodicals postage paid at Chicago, IL, and additional mailing offices. Copyright 2020 by PMMI. All rights reserved. Materials in this publication must not be reproduced in any form without written permission of the publisher. Applications for a free subscription may be made online at www.packworld.com/subscribe. Paid subscription rates per year are $105 in the U.S., $147 Canada and Mexico by surface mail; $250 Europe, South America. $325 Far East and Australia by air mail. To subscribe or manage your subscription to Automation World, visit AutomationWorld.com/subscribe. Free digital edition available to qualified individuals outside the United States. POSTMASTER; Send address changes to Automation World®, 401 N. Michigan Avenue, Suite 300, Chicago, IL 60611. PRINTED IN USA by Quad Graphics. The opinions expressed in articles are those of the authors and not necessarily those of PMMI. Comments, questions and letters to the editor are welcome and can be sent to: editors@automationworld.com. We make a portion of our mailing list available to reputable firms. If you would prefer that we don’t include your name, please write us at the Chicago, IL address. Volume 18, Number 12.

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44 KEY INSIGHTS AW DECEMBER 2020

Instead of selling a product as a one-time item, many companies are taking advantage of the growing demand for product-as-a-service offerings to fill the revenue gap. For example, a major tire manufacturer is offering customers the option of managing their tires as a service in addition to selling them. The organization is currently managing 300,000 truck tires of customers worldwide. Brian R. May of Accenture on industry’s shift to product-as-a-service. awgo.to/1112

Augmented reality and virtual reality technologies have been showing great promise for auto manufacturers for a number of uses. The technology allows automotive designers and manufacturers to: conduct real-time 3D visualization and CAD for design and manufacturing, conduct faster training cycles, and enable professionals to work at drastically higher levels. David Greenfield on the increased use of AR/VR in response to COVID-19. awgo.to/1113

If a food producer can document that it’s performing required tests, getting good results, and basically handling food safety the way it should, that would help provide confidence to a regulator or auditor that their time could be better spent elsewhere. Aaron Hand on improving traceability for food safety. awgo.to/1114

The platform’s unique data modeling foundation takes the dozens of incompatible data types generated by factory equipment and manufacturing software and generates a digital representation of the entire production process, including processes, production lines, downtime, and defects. Stephanie Neil on new additions to the Sight Machine platform. awgo.to/1115

According to a PMMI robot report, collaborative robots accounted for about 3% of all robot sales in North America in 2017; by 2025, that number is expected to increase to 34%. Anne Marie Mohan of Packaging World on how robots are driving a manufacturing revolution. awgo.to/1116

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Automation World December 2020

Articles inside

Augmented Reality Gets to Work