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Meeting safety goals
VIEWPOINT
7 | Safety isn’t an extra step; it’s the foundation of manufacturing
By incorporating safety into every aspect of a facility, manufacturers can ensure quality in their products and people.
INSIGHTS
8 | VFD and VSD experts offer can’t-miss advice
Our experts deliver must-have advice for variable frequency drives and variable speed drives.
SOLUTIONS
12 | Achieve safety goals using digital tools in a manufacturing plant
“Safety first” can achieve zero recordable incidents when digital tools are implemeted.
16 | How to conduct periodic maintenance for fall protection
Understand the types of inspections and experts responsible when managing a fall protection program.
20 | How smart asset management unlocks energy efficiency in air compressors
Air compressors are among the most energyintensive systems in industrial facilities, but companies can slash energy consumption.
24 | How to apply self-service analytics to monitor plant energy efficiency
The growing adoption of advanced analytics is improving data availability, process insights and operational decision-making.
30 | New OSHA guidelines reset the arc flash safety standards
OSHA’s new guidance highlights a risk that many still underestimate: serious arc flash hazards can happen at voltages as low as 120 V.
36 | Design software can maximize efficiency, efficacy in a plant
Design software plays a critical role in optimizing efficiency within manufacturing.
39 | Powering Progress: Meet the 2025 Engineering Leaders Under 40
Celebrating 35 engineering professionals who are driving transformation, mentorship and excellence across the industrial landscape.
AMANDA PELLICCIONE, Marketing Research Manager A Pelliccione@WTWHMedia.com
EDITORIAL ADVISORY BOARD
H. LANDIS “LANNY” FLOYD, IEEE Life Fellow
JOHN GLENSKI, Principal, Automation & Digital Strategy, Plus Group, A Salas O'Brien Company
MATTHEW GOSS , PE, PMP, CEM, CEA, CDSM, LEED AP, Senior Vice President, CDM Smith
CONTRIBUTORS WANTED
Are you a subject matter expert in one of these topics? Would you like to write an article on one of the topics below? If so, please submit an idea to: www.plantengineering.com/contribute-to-plant-engineering
• Artificial intelligence in manufacturing
• Expert Q&A: Maintenance
• Expert Q&A: VFDs and VSDs
• Fall protection guidelines
• Lighting
• Lubrication
• Oils and lubrication
• Plant automation
• Preventive maintenance
• Safety and PPE
• Valves and seals
WTWH Media Contributor Guidelines Overview
Content For Engineers. WTWH Media focuses on engineers sharing with their peers. We welcome content submissions for all interested parties in engineering. We will use those materials online, on our website, in print and in newsletters to keep engineers informed about the products, solutions and industry trends.
The link below gives an overview of how to submit press releases, products, images and graphics, bylined feature articles, case studies, white papers and other media.
* Content should focus on helping engineers solve problems. Articles that are commercial in nature or that are critical of other products or organizations will be rejected. (Technology discussions and comparative tables may be accepted if nonpromotional and if contributor corroborates information with sources cited.)
* If the content meets criteria noted in guidelines, expect to see it first on the website. Content for enewsletters comes from content already available on the website. All content for print also will be online. All content that appears in the print magazine will appear as space permits, and we will indicate in print if more content from that article is available online.
* Deadlines for feature articles vary based on where it appears. Print-related content is due at least three months in advance of the publication date. Again, it is best to discuss all feature articles with the content manager prior to submission.
LEARN MORE AT: www.plantengineering.com/contributeto-plant-engineering
Safety isn’t an extra step, it’s the foundation of manufacturing
By incorporating safety into every aspect of a facility, manufacturers can ensure quality in their products and people.
Irecently visited a large Midwestern manufacturing facility. With hundreds of employees and three shifts, the plant generated an abundance of large products. At this facility, small-scale products were not flying off the assembly line; each product took many minutes or hours to complete — and, in some cases, days to finish.
Amara Rozgus, Editor-in-Chief
As a visitor, I was given the royal treatment. Tour options and a look at the office space really gave me a full view of how the technical, management and administrative teams worked together.
Before stepping onto the floor, every visitor underwent a thorough briefing. This in-person safety briefing was held in conjunction with the safety video I’d just watched en route to the plant. Every visitor had to wear the standard safety glasses and a bright, obvious safety vest. Walking paths were clearly marked, protective gear was mandatory and layered safeguards — from automatic shutoff systems to overhead signage indicating which line was active — were woven into the daily rhythm.
It was impossible not to notice how deeply safety was embedded in
the operation. At one station, multiple checks and balances ensured tools were calibrated correctly. At another, sensors monitored temperature to prevent overheating before an operator ever had to step in. These were not signs of slowing down production. They were signs of an organization that understood its most critical output is not just the product itself, but people going home without mishaps at the end of the day. Too often, manufacturers talk about safety as though it is a box to be checked. But safety allows everything else to happen. Without it, the best machinery, the smartest automation and the most efficient workflows collapse — a plant can crumble under the weight of risk. Cutting corners might save minutes, but it never saves costs in the long run.
The plant I toured was a reminder that safety is not just compliance — it’s strategy. It creates stability. It builds trust. And it reinforces the truth that the core of manufacturing is about creating value in ways that protect products and peoples. For manufacturers, whether they oversee safety directly, the message is the same: more safety is never wasted effort. PE
VFD and VSD experts offer can't-miss advice
Our experts deliver must-have advice for variable frequency drives and variable speed drives.
Question: What are the latest trends in variable frequency drives and variable safety drives?
Andrew Fischbach: The market is moving toward using permanent magnet motors to further drive efficiency. These are more efficient than traditional induction motors. They are becoming standard, and they require VFDs to operate.
Benjamin Strong: Expanded support for permanent magnet (PM) motors including micro drives.
Question: What are the emerging trends you’ve seen in VFD interface and user experience (UX)?
Benjamin Strong: Internet of things (IoT) methods used to collect and display data directly from variable frequency drives (VFDs), rather than thru programmable logic controllers (PLCs). VFDs with integrated artificial intelligence (AI) are reducing time required to diagnosis VFD problems.
Question: What advantages is your organization seeing from VFDs or VSDs?
Objectives
• Discover the latest trends in variable frequency drives (VFDs) and variable speed drives (VSDs).
• Learn how VFDs and VSDs can help manufacturers save energy and be more efficient.
• Find out how VFDs and VSDs can be customized to meet certain needs.
Benjamin Strong: PM motors like electromechanical actuator (EMA) motors are replacing vector motors, accomplishing position or low-speed, hightorque applications without encoders.
Andrew Fischbach: The biggest advantage is efficiency/energy savings. Rotary screw air compressors are positive displacement machines and with added VFD technology, the compressor’s capacity is directly proportional to the speed of the air compressor. As the machine speeds up, it delivers more air and needs more power, and visa-versa. Given its flexibil-
ity to meet higher and lower desired output, in some instances, a VFD can save the end-user considerable money on their power bill.
Question: How are new VFDs and VSDs improving motor efficiency beyond the International Electrotechnical Commission’s IE4 standards for manufacturing?
Andrew Fischbach: In certain applications, the isentropic efficiency of a compressor driven by a VFD and an IE4 motor can exceed the energy efficiency rating of a compressor that only uses an IE4 motor. A VFD will not directly improve IE4 motor efficiency, however, at part load conditions a compressor’s isentropic efficiency can be improved by using a VFD.
Benjamin Strong: Our customers are using PM motors with higher pole counts to direct drive loads like fans, eliminating gearboxes and improving system efficiency and performance.
Question: How are drive manufacturers making VFDs more plug-and-play for OEMs?
Benjamin Strong: We are eliminating the “plug” in plug-and-play, allowing our customers to proceed directly to “play” by offering multi-Ethernet protocol drives. This eliminates the need to plug in separate field bus or network cards. Adopting CiA402 profiles on the drive side speed up implementation of VFDs on the control side.
Andrew Fischbach: Some drive manufacturers are offering an integrated drive and motor package which reduces the need for separate components and wiring. Also, the VFD manufacturers offer pre-pro-
grammed drives that allow for a faster installation and commissioning process.
Question: How are manufacturers customizing VFDs or VSDs for specific use cases?
Andrew Fischbach: Hitachi Global Air Power selects the most effective motor and drive combination for the required pressure and flow requirements.
Benjamin Strong: Mitsubishi Electric VFDs come with many application-specific functionality built into the drives. These easily configured functions are paired with pre-built human-machine interface screens that our users quickly modify to their needs.
Question: What’s driving the growth of VSDs in low-voltage versus medium-voltage markets?
Andrew Fischbach: Quite simply, there are far more 200 to 480V motors in use than higher voltages and therefore more companies compete in the lowvoltage space. In addition, there are fewer electricians qualified to work on medium voltage systems. Since fewer manufacturers offer drives above 600V,
and more electricians compete at 200 to 480V, the cost of implementing the drives is higher. Very few, if any, medium-voltage inverters are available. To use a VFD on a medium-voltage supply would require a transformer.
Benjamin Strong: Low-voltage drives are easier to implement, and there is a larger number of potential suppliers.
Question: How have VFDs contributed to reducing mechanical wear and tear on motor-driven systems?
Benjamin Strong: VFDs allow our customers to transition between unloaded to loaded states smoothly without shocks or larger disturbances to the mechanical or hydraulic systems.
Andrew Fischbach: A standard induction motor started by a full- or wye-delta starter can usually be started only six times per hour. The top causes of induction motor failure are motor bearings and windings. Every start imparts a considerable load onto the motor bearings and windings which can lead to premature failure. Conversely, a VFD motor can be started a virtually unlimited number of times,
‘ Quite simply, there are far more 200 to 480V motors in use than higher voltages and therefore more companies compete in the low-voltage space.’
Benjamin Strong Industry Marketing Manager, Drive Systems
Mitsubishi Electric Automation Charlotte, North Carolina
Andrew Fischbach Director of Product Management Hitachi Global Air Power Houston, Texas
FIGURE 1 : Variable speed drives, like this one from Hitachi Global Air, and variable frequency drives are driving efficiency and helping manufacturers save energy. Courtesy: Hitachi Global Air
North American
for
and the starts have a slower ramp up time which saves wear and tear on motor bearings and windings.
Question: What factors do you consider when selecting a VFD for a specific application?
Andrew Fischbach: We consider many factors when selecting a VFD for an air compressor, including optimizing system efficiency, vendor technical support, ease of installation and use, warranty and cost.
Question: How can a plant integrate PLCs or SCADA systems into VFDs for automation? What are the benefits?
Insightsu
VFD and VSD insights
uVariable frequency drives (VFDs) and variable speed drives (VSDs) can offer several advantages to the manufacturing floor.
uThere are ways in which drive manufacturers are making VFDs and VSDs more plug-and-play for original equipment manufacturers (OEMs).
uVFDs can maximize efficiency and minimize energy usage in plants.
Benjamin Strong: Facilities are using our solutions to minimize large VFD power consumption earn power company rebates during energy peak times.
Question: What role do VFDs play in your facility for optimizing variable load conditions for sustainability?
Andrew Fischbach: Rotary air compressors are positive displacement machines whose capacity is directly proportional to the speed of the air compressor. As the machine speeds up, it delivers more air and needs more power, and visa-versa. Since most air compressors are used at a 70%
duty-cycle, a VFD driven compressor motor can save the end-user considerable money on their power bill, thus reducing the amount of carbon needed to generate electricity. In addition, when sized and operated properly the VFD-driven air compressor can deliver a more constant pressure to the factory in a more efficient manner than a fixed speed machine that relies on a wide pressure band for control.
Sustainability Trends
Question: How are VFDs helping manufacturers meet carbon reduction or environmental, social and governance (ESG) goals?
Benjamin Strong: Our focus is on reducing the number of times a VFD must be replaced over the life a machine, leading to a reduction of electronic waste generated. Add this to operating pumps at the best efficiency point, returning regenerative energy to the grid and reduced energy consumption at startup, and VFDs are in integral part of carbon footprint reduction.
Question: How are electrification trends in industrial systems impacting VFD demand?
Benjamin Strong: Demand for VFDs will continue to grow, mirroring the growth of data centers in North America. PE
FIGURE 2 : VFDs and VSDs are improving motor efficiency beyond the International Electrotechnical Commission’s IE4 standards for manufacturing. Courtesy: Mitsubishi Electric Automation
FIGURE 3 : Demand for VFDs and VSDs will continue to grow to match
demand
data centers. Courtesy: Mitsubishi Electric Automation
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ENGINEERING SOLUTIONS
Marc Elliott, Eaton, Pittsburgh
Achieve safety goals using digital tools in a manufacturing plant
The mantra “safety first” can achieve zero recordable incidents when digital tools are put in place.
Putting digitalization to work provides a powerful lever to enhance electrical safety. The ability to bring information in, aggregate it in one place and make it available for personnel can reduce exposure to hazards. In other words, active digital correlation can help teams be better prepared when they need to interact with electrical equipment.
Learningu
Objectives
• Understand how digitalization supports hazard reduction by enabling safer equipment monitoring, diagnostics and real-time alerts that reduce worker exposure.
• Recognize the role of digital tools in advancing safety practices in accordance with NFPA 70B and NFPA 70E, particularly through datadriven decisions and virtual training.
• Grasp how integrated digital strategies improve both safety and productivity by minimizing unplanned work, enhancing situational awareness and informing PPE use and procedural readiness.
Safety is a foundational and operational concern for industrial facilities and manufacturers. Impacting safety requires the right education, training and controls to eliminate or reduce hazards. The hierarchy of controls from the National Institute for Occupational Safety and Health provides guidance in preferred order. Fundamentally, safety programs must seek to eliminate hazards and keep people out of harm’s way and digitalization provides vital tools to do just that.
Five
strategies moving the needle on
safety
Getting to zero total recordable incident or case rate requires the ability to identify potential issues and avert them. Here are five proven digital strategies that can reduce risk and avoid unplanned or irregular work:
1. Monitoring equipment: sensors as digital watchdogs
Watching for problems in electrical and mechanical systems is important and digital monitoring provides a powerful tool to understand assets and environmental conditions. Digitaliza-
tion allows this to be accomplished safely without exposure to equipment or environment — reducing risk and providing insights on changes to conditions and equipment performance.
Further, digital equipment monitoring helps reduce complexity and risk. Complicated repairs create added risk exposure and typically have greater potential for injury. For example, hoisting is a dangerous process from an environmental health and safety perspective.
However, if an electric motor can be repaired early because of motor health predictions from motor analytics software or health-related warnings from an intelligent motor starter, it may be a simpler repair. Otherwise, if a motor fails, it will likely need to be hoisted out for replacement. In other words, having information as a situation develops can help reduce the risk of injury.
2. Diagnostics: recognize unsafe conditions without walking into them
There is widely recognized value in keeping people out of harm’s way. It’s why NFPA 70B: Standard for Electrical Equipment Maintenance became a standard, not just a recommendation. This standard is considered the minimum requirement for safe electrical work procedures and Occupational Health and Safety Administration can use this as the basis for issuing citations.
Digital tools allow plant managers and safety experts to keep tabs on things that have traditionally gone unmonitored or only observed occasionally such as on a cycle, which can help
‘If an electric motor can be repaired early because of motor health predictions from motor analytics software or health-related warnings from an intelligent motor starter, it may be a simpler repair.’
meet NFPA 70B and impact safety. Specifically, condition monitoring systems allow plant and maintenance managers to make smarter maintenance decisions based on actual equipment and environmental data, which can help determine the root cause of a problem. Digitalization enables workers to identify unsafe conditions as they develop and detect problems in areas that are hard or unsafe to access.
3. Alerts and alarms are safety game changers
Don’t underestimate the value of the right notification at the right time to the right people. The root cause of many recordables or near misses is complacency, distraction, insufficient knowledge and lack of planning. Digitalization can provide the needed notifications to avoid these issues and enable teams to plan for various scenarios.
Given that there’s so much data available, how is a worker able to act on it at the right moment? Safety requires urgency and that’s exactly where alerts come in. Blinking red lights and horns are insufficient and trending data also misses the mark — alerts need to deliver tangible information at the right moment. Plant managers need to know when a situation reaches a certain threshold and immediate action is needed.
Importantly, alerts are modeled on a set of criteria, helping establish what action needs to occur well before a situation arises. In other words, setting alerts enables staff to act faster and smarter because it can better pre-plan what needs to happen in a variety of given situations.
provides real-time and historical insight into electrical and mechanical systems to help plant management teams keep a close eye on equipment performance and environmental conditions.
FIGURE 1: A digital maintenance dashboard can proactively flag safety risks and recommend appropriate personal protective equipment, or PPE, ensuring workers are prepared before beginning maintenance tasks. Courtesy: Eaton
FIGURE 2: Digital equipment monitoring
Courtesy: Eaton
ENGINEERING SOLUTIONS
3:
and alerts cut through the noise to deliver the right information needed to empower faster, safer maintenance decisions. Courtesy: Eaton
4. Informing the last line of defense
Ready access to the right personal protective equipment (PPE) requirements is not easy, especially as requirements will invariably change as conditions evolve. Sometimes, there is no sufficient level of PPE. Personnel need tools to avoid dangerous conditions and situations in the first place.
A digital dashboard view can flag safety issues and provide recommendations that reflect realtime conditions — whether it’s for the appropriate level of PPE or to avert exposure. And the needed PPE can be identified via an alert to help ensure personnel are prepared with the proper equipment before starting work.
Insights
Safety insights
uThis article highlights how digitalization enhances safety by reducing worker exposure through real-time monitoring, diagnostics and alerts.
uBy integrating digital tools into operations, facilities can strengthen safety programs, meet standards like NFPA 70B and 70E and improve both preparedness and productivity.
For example, in a situation with dangerous gases and a high-pressure environment, the need to detect exposure in real time is vital, before personnel ever enter the room. Digitalization enables a team to turn to planned, safe work practice responses, including wearing the right personal hazard detection monitor devices, if needed.
5. Hands-on learning in a safe environment
Digital tools can empower teams with experiential training and tutorials enabling familiarity with equipment and proper procedures to advance safety. For example, manufacturing teams can learn how to safely operate equipment in a virtual environment, getting a tutorial on how to open,
‘In a situation with dangerous gases and a high-pressure environment, the need to detect exposure in real time is vital, before personnel ever enter the room.’
close and rack circuit breakers and operating switches and more.
Further, digital solutions can support testing required for qualified workers per NFPA 70E: Standard for Electrical Safety in the Workplace. This provides team members with feedback on specific tasks required for procedures like lockout/ tagout, helping ensure that safety analysis, protective barriers, required PPE and verification for the absence of voltage are all conducted appropriately. In other words, digitalization also provides vital tools to help team members gain experience and get feedback to advance safety — helping protect people, equipment and processes.
Digitalization helps plant workers become better prepared from a safety perspective, getting a deeper and broader understanding of conditions that impact safety and whether a facility needs to update or change its strategy for a specific situation. It is important to note that digitalization has an important role to play across multiple key performance indicators — including safety, maintenance and productivity — so there are fewer accidents, improved quality and less rework and waste. The good news is that some of the things that make workers safer also make them more productive, and vice versa. PE
Marc Elliott is director – mining, metals, minerals, pulp and paper at Eaton.
FIGURE
Alarms
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ENGINEERING SOLUTIONS
Philip Jacklin, Diversified Fall Protection, Cleveland
FIGURE 1: A worker connecting a 6-foot shock-absorbing lanyard to a certified anchorage. Courtesy: Diversified Fall Protection
How to conduct periodic maintenance for a fall protection program
Understand the types of inspections and experts responsible when managing a fall protection program.
Nearly everything within the confines of a facility will require periodic maintenance for operational, productivity or regulatory compliance purposes. Fall protection programs are no exception to this truth.
In addition to identifying the fall hazards and implementing solutions to protect their workers, organizations must also regularly inspect equipment, authorize and train designated employees and maintain anchor certifications, among other things, to ensure their fall protection programs remain effective over time.
Fall protection equipment inspections
Occupational Health and Safety Administration (OSHA) requires two types of inspections for fall protection equipment: pre-use inspections and annual inspections.
OSHA 1910.140(c)(18) requires workers to inspect their equipment for any damage, defects or signs of prior deployment before each use. Employees must also verify that their equipment still bears the original manufacturer's markings to ensure valid regulatory compliance.
Pre-use inspections should follow a straightforward process. First, the worker locates the product’s tag or label. Unfortunately, a missing tag or label will cause the equipment to fail inspection because the manufacturer information and regulatory compliance standards cannot be confirmed.
Then, workers must confirm the equipment has not already been used to arrest a fall. Each type of fall protection equipment has different methods for indicating if it has experienced a fall. For example, most body harnesses contain a specially stitched part of the back strap that extends or deploys during a fall, often exposing a tag with text that communicates this information. Other pieces of equipment, like shock-absorbing lanyards, physically deform during fall arrest, so prior deployment is very easy to identify.
Fall protection equipment is only rated to arrest one fall and then must be discarded and replaced. It is important to destroy equipment before discarding so nobody can attempt to reuse compromised fall protection equipment. Best practices include cutting harness straps with scissors, disassembling anchorages and removing snap hooks from selfretracting lifelines (SRL).
Similarly, users should test the brake mechanisms on SRLs before using the equipment at heights. Workers can perform this test by firmly grasping the snaphook and pulling it quickly away from the SRL housing. Most users should be able to pull hard enough to activate the brake and lock the device. Gently retracting the snaphook back into the housing will reset the mechanism for normal use.
Finally, workers must inspect the equipment for any damage or defects that could affect performance during a fall. For example, because ultraviolet exposure damages harness webbing and reduces its elasticity, users should monitor webbing quality over time while checking for tears, cuts, holes or other signs of wear during the pre-use inspection. OSHA does not require pre-use inspections to be documented; however, employers are required to record one formal inspection of every piece of fall protection equipment annually. The inspection process is almost identical to the pre-use inspection, but the following information must also be recorded:
• Description (harness, lanyard, etc.)
• Manufacturer
• Model number
• Serial number
• Date of manufacture
• Date of inspection
• Inspector name
• Inspector signature
• Pass/fail indication
Annual inspections must be performed by the organization’s “competent person.” OSHA permits companies to outsource their annual equipment inspections, but the inspector must still be trained at a competent person level. Furthermore, inspection logs should be retained for the life of the equipment. Companies may struggle to prove compliance after a fall incident occurs if inspection logs are not readily available.
Training employees to use fall protection equipment
OSHA requires employers to designate and train workers before they can use fall protection equipment. After initial fall protection training, companies must document the authorized users and the
‘OSHA requires two types of inspections for fall protection equipment.’
Learningu
Objectives
• Understand the inspection requirements for fall protection equipment — including the differences between pre-use and annual inspections, how to identify damage or prior deployment and what documentation is required to maintain OSHA compliance.
• Recognize the training and certification requirements for workers and competent persons.
• Learn the criteria and recertification timelines for certified and noncertified anchors — including how anchor strength is verified and when a qualified person must be involved in the certification process.
ENGINEERING SOLUTIONS
FIGURE 2: An employee receiving a hands-on demonstration during a fall protection training.
Courtesy: Diversified Fall Protection
Annual inspections ensure faulty equipment is found and removed from the field.’
training must be performed by the competent person or an American National Standards Institute (ANSI)-accredited training organization. Industry consensus suggests that fall protection training should occur annually, but more frequent training will help keep fall protection awareness top of mind. Organizations must document which employees have been designated as their competent person and ensure their certification is valid; the certification must be refreshed every two years. Maintaining valid competent person certification is imperative because of their crucial role in the fall protection program. Organizations would benefit from having multiple competent persons — it provides more flexibility when emergency fall protection decisions must be made and can help share the many responsibilities the role entails.
Anchor certifications within fall protection programs
u
Insights
Fall protection insights
uMaintaining an effective fall protection program requires regular equipment inspections, thorough employee training and proper anchor certifications.
u By prioritizing these actions, organizations can improve safety outcomes and ensure their fall protection efforts remain compliant and effective over time.
Fall protection programs refer to anchors as either noncertified or certified. Noncertified anchors are installed and used by the worker according to the manufacturer’s exact specifications, as outlined in the instruction manual. OSHA requires workers to follow the manufacturer's instructions whenever operating equipment. If workers neglect those instructions, they not only risk OSHA violations but also risk equipment malfunction. Noncertified anchors have specific limitations regarding proper use and installation that must be followed to ensure the anchor functions correctly.
OSHA and ANSI require fall protection anchors to withstand a minimum load of 5,000 pounds; however, some potential anchor structures are not
rated to withstand a 5,000-pound load. In these cases, if another anchor location cannot be found, a qualified person such as a professional engineer can certify the anchorage if they can confirm the structure can withstand twice the anticipated maximum arresting force (MAF).
When calculating MAF, 1,800 pounds is commonly used, as it is the maximum amount of fall forces OSHA permits to be felt by users. However, MAF can vary between different connection devices. Certified anchors being used in active fall protection systems must be recertified every five years by a qualified person.
Anchor certifications are also required for suspended access work or exterior building maintenance (EBM), such as window washing. However, these anchor certification requirements differ from anchors used for conventional fall arrest purposes. Because these anchors will be used to suspend a worker or equipment from the building’s rooftop, they also must be rated for a continuous load.
Once installed, suspended access or EBM anchors must be pull-tested to 2,500 pounds and then verified by the qualified person or anchor manufacturer for an ultimate load rating of at least 5,000 pounds. Compliant OSHA systems will ensure anchors are installed no more than 12 feet apart from each other and workers will be able to stay within the safe working radius of 30 degrees. Suspended access and EBM anchors must be recertified every 10 years by a qualified person.
Establishing a successful fall protection program is one thing and maintaining that program over time is another. However, this work is well worth the effort and helps make the program more effective over time. Annual inspections ensure faulty equipment is found and removed from the field. In addition, employee training increases awareness and helps keep everyone safe. Anchor recertifications ensure continued equipment performance.
The maintenance required for fall protection programs helps make them more effective over time. Any effort put into keeping workers safe will always be worthwhile. Every organization should prioritize the safety of the worker above all else. PE
Philip Jacklin is continuing education program manager for Diversified Fall Protection.
When an opportunity for being better or the best at what we do is available, why wouldn’t we take it?
As Engineers, Technicians etc., we should and, need to know what we are doing. Having a better understanding of our role is something that we can accumulate as we perform our jobs, but sometimes things come along that are ‘out of the norm’, just different or more complex than we can educate ourselves on, or perhaps related to a subject you may have only briefly covered during your formal education.
On the job training is only as good as those we are learning from, sometimes we need to seek additional help especially with much of the newer technologies we see today. While we could read books, manuals and these days even watch videos on the subject they often lack the ‘hurdle’ component, that’s the bit where we need additional guidance when something just didn’t make sense.
Training from an expert not only walks us through the process but also enables us to ask questions that may arise while doing so; the ‘hurdle’ effectively need never exist.
While finding time to take advantage of these opportunities may be a challenge, we should take them when we can. Companies such as DEWESoft offer opportunities both in-house and a variety of locations around the country to provide that training from beginner to expert in a variety of different subjects, consider the advantage and ultimate time saving as well as possibly creating local experts so the future on-the-job trainings you give will truly cover the needs of the role.
“ Training from an expert not only walks us through the process but also enables us to ask questions that may arise while doing so; the ‘hurdle’ effectively need never exist. ”
Training session with Dave Gallop, Business Development Training Manager — Dewesoft
ENGINEERING SOLUTIONS
ENERGY EFFICIENCY AND MANAGEMENT
Jayme Leonard, Atlas Copco Compressors, Rock Hill, South Carolina
How smart asset management unlocks energy efficiency in air compressors
Air compressors are among the most energy-intensive systems in industrial facilities, but with the right asset management strategies, companies can significantly reduce energy consumption, improve reliability and support sustainability goals.
EObjectives Learningu
• Understand the role of air compressors in industrial energy use.
• Learn why air compressors can account for up to 30% of a facility’s energy consumption and how they impact operational efficiency.
• Explore smart asset management tools and techniques to learn how real-time monitoring, predictive maintenance and system audits contribute to energy savings and improved equipment reliability.
nergy efficiency is not a trend; it's a strategic necessity for industrial businesses. Air compressors are a prime target for optimization as one of the most energy-intensive systems in manufacturing, consuming up to 30% of a facility’s total electricity. The key to unlocking this opportunity lies in smart asset management. By systematically monitoring, maintaining and optimizing air compressor systems, companies can achieve significant energy and cost savings.
Understanding industrial asset management
In industrial settings, asset management is a strategic process that ensures equipment is continuously monitored, maintained and optimized throughout the life cycle. Increasingly, companies are turning to digital, data-driven solutions that enable real-time tracking, predictive maintenance and operational control through integrated platforms.
These systems allow manufacturers to compare production data with quality metrics, access live service updates and streamline maintenance
using mobile tools and cloud-based technology. By incorporating life cycle planning and energy performance tracking, modern asset management solutions improve productivity, reduce downtime and futureproof operations.
For air compressors, effective asset management includes life cycle planning, performance monitoring, predictive maintenance and operational optimization. Integrated platforms support real-time tracking, automated service alerts and data-driven decision-making, all of which are essential to maintaining uptime and improving energy efficiency.
Smart asset management strategies, such as system audits, leak detection, pressure optimization and energy recovery, can substantially cut energy waste and operating costs. Diagnostic tools that evaluate the entire compressed air network help uncover inefficiencies and offer actionable insights for continuous improvement. By adopting these strategies organizations can enhance reliability, reduce expenses and make meaningful progress toward sustainability goals.
The role of air compressors in industrial operations
Air compressors are foundational to industrial operations, powering applications from pneumatic tools and process equipment to automation systems. Compressors worldwide are specifically tailored to industries like manufacturing, food and beverage and automotive sectors where a continuous, clean air supply is essential for precision, reliability and safety.
Despite their utility, air compressors are often among the largest energy consumers in a facility and inefficiencies can significantly inflate operational costs. The challenge is addressed through
innovations like variable speed drive (VSD) technology, which can reduce energy consumption by up to 35% and monitoring systems that detect leaks and pressure drops early.
Common inefficiencies such as over-pressurization, poor system sizing and lack of maintenance are mitigated through proactive diagnostics and tailored service plans. These solutions not only enhance performance but also contribute to sustainability goals by minimizing energy waste and extending equipment lifespan.
Three key elements of air compressor asset management
There are three major components of asset management for air compressors.
1. Inventory and asset mapping
Effective asset management for air compressors starts with inventory and asset mapping. Cataloging all compressor systems, including their age, condition and usage patterns, provides a clear picture of operations. This baseline allows facilities to prioritize maintenance, allocate resources wisely and plan for future upgrades. Auditing tools can then be used to assess the entire compressed air system, from generation to distribution, identifying inefficiencies and offering actionable insights.
2. Data collection and monitoring
Monitoring and data collection are essential for sustaining performance and reliability. Most compressor manufacturers offer platforms that track key parameters such as pressure, temperature and power usage in real time. These internet of things-enabled tools give operators visibility into daily operations and support predictive maintenance by identifying trends and anomalies before they cause failures. For example, vibration, oil and thermal analysis can detect early signs of wear, enabling maintenance teams to act proactively and prevent costly downtime.
3. Performance benchmarking and life cycle management
Performance benchmarking and life cycle management complete a strong asset management strategy. By tracking key performance indicators (KPIs) such as specific power (kilowatts/100 cubic feet per minute), runtime efficiency and leak rate, companies can pinpoint underperforming units and make
informed decisions about retrofitting, upgrades or replacements. With tools like return on investment (ROI) calculators and energy efficiency rebates, organizations can invest wisely while also supporting sustainability goals by reducing energy use and carbon emissions.
Benefits of effective asset management for energy efficiency
By leveraging smart technologies like VSD compressors and real-time data assessment, companies can significantly reduce energy costs and lower their carbon footprint. These innovations not only optimize energy use but also contribute to improved uptime and reliability, as predictive maintenance minimizes unexpected breakdowns.
ing the ZH 630 oil-free centrifugal compressor
with an FD refrigerant dryer for efficient, clean air delivery.
FIGURE 2: A 3D view of a compressor room featur-
paired
Courtesy: Atlas Copco
FIGURE 1: The ZH 630 oil-free centrifugal compressor with FD refrigerant dryer in a fully integrated 3D compressor room setup. Courtesy: Atlas Copco
ENGINEERING SOLUTIONS
ENERGY EFFICIENCY AND MANAGEMENT
Additionally, connected equipment enables data-driven decision-making, allowing operators to fine-tune performance and extend the lifespan of critical machinery. This holistic strategy supports sustainable operations while maximizing productivity and cost-effectiveness.
How companies leverage smart asset management for energy efficiency
Various companies across diverse industries have successfully leveraged compressor asset management technologies to enhance energy efficiency and operational performance. For instance, a glass ceramics manufacturer optimized its compressor room using Atlas Copco’s Optimizer 4.0 system. This centralized control platform allowed the company to balance compressor loads more effectively, reduce idle running and fine-tune pressure settings. As a result, the manufacturer achieved annual energy savings of approximately $39,000, demonstrating how intelligent control systems can deliver immediate financial returns.
In the fast-moving consumer goods sector, another company conducted a comprehensive system audit. By identifying inefficiencies in compressor sizing and pressure settings and implementing targeted upgrades, the company realized $23,000 in yearly energy savings. These improvements not only reduced operational costs but also enhanced system reliability and lowered the risk of unplanned downtime, which is critical in a sector where production continuity is essential.
A cardboard packaging company also achieved a 20% reduction in energy use through a combination of leak detection, system redesign and the integration of VSD compressors.
Similarly, a food manufacturer implemented a heat recovery system that captured waste heat from compressors and redirected it to support boiler operations. This innovation significantly reduced both energy costs and carbon emissions, aligning with the company’s sustainability goals.
Meanwhile, a South American bearing manufacturer adopted a holistic asset management
strategy that included compressor monitoring and predictive maintenance. The result was an 18% reduction in energy consumption and a carbon footprint reduction of 263 tons of carbon dioxide equivalent, underscoring the environmental and economic impact of smart compressor management. Whether through centralized control, predictive analytics or energy recovery, companies are achieving measurable improvements in efficiency, sustainability and profitability.
Technologies enabling smart asset management in compressed air systems
Smart asset management tools are designed to reduce energy consumption, enhance equipment reliability and streamline maintenance operations through automation and data-driven insights. One key innovation is the use of remote monitoring platforms that connect air compressors and related equipment to the cloud. These systems provide real-time visibility into performance metrics such as pressure, temperature and power consumption. By enabling continuous monitoring, companies can generate performance reports, receive automated alerts for anomalies and schedule maintenance proactively thus preventing small issues from turning into costly downtime.
Some platforms are modular, offering features such as service tracking, energy reporting and uptime analytics. These capabilities allow operators to optimize system performance under real-world conditions and make informed decisions about servicing and upgrades.
Many industrial firms are adopting centralized asset tracking platforms. These systems give organizations the ability to monitor equipment location, status and history, which can be especially important for facilities with assets distributed across multiple sites. Centralized tracking supports life cycle management, regulatory compliance, such as the International Organization for Standardization’s ISO 50001 and predictive maintenance, reducing operational disruptions and extending the lifespan of critical machinery.
Another area of advancement is the integration of artificial intelligence (AI) and machine learning into diagnostic systems. AI-powered analytics can detect abnormal behavior in compressors such as
FIGURE 3: Operator monitoring compressor performance using SMARTLINK on both mobile and desktop devices for real-time insights and proactive maintenance.
Courtesy: Atlas Copco
‘When staff are well-versed in interpreting this data, they can respond quickly to anomalies, schedule preventive maintenance and make informed decisions that enhance system reliability and uptime.’
changes in vibration, oil quality or thermal performance long before a failure occurs. These tools help maintenance teams prevent breakdowns and extend equipment life. Some systems also include realtime air quality monitoring in accordance with ISO 8573-1 standards, alerting operators to deviations and offering actionable guidance.
Cloud-based asset management platforms further enhance visibility and control by consolidating performance data, maintenance history and predictive alerts into a single interface. This allows for more strategic planning, timely interventions and better alignment with energy and sustainability goals.
To support mobile workforces, companies are also turning to smartphone apps that provide production insights, quality metrics and predictive alerts directly to operators and engineers. These apps enable faster decision-making and reduce response times when problems arise on the shop floor. In high-precision environments, this realtime responsiveness helps maintain product quality, reduce scrap and optimize throughput.
Overall, by adopting these smart asset management technologies, companies are not only improving operational performance but also taking major strides toward greater energy efficiency.
Two ways to improve air compressor energy efficiency
There are two best practices for bolstering energy efficiency in air compressors.
Routine energy audits: Conducting routine energy audits is one of the most effective ways to identify inefficiencies and uncover opportunities for improvement in compressed air systems. Many air compressor manufacturers offer comprehensive audit tools to help evaluate the entire compressed air network from generation to distribution. These audits help detect leaks, pressure drops and improper equipment size, all of which can lead to significant energy waste. By routinely assessing system performance, companies can implement tar-
geted upgrades and operational changes that reduce energy consumption and improve overall efficiency.
Asset management training: Training staff in asset management tools and technologies is another must when it comes to improving energy efficiency in air compressors. Emphasizing the importance of empowering operators and maintenance teams with the knowledge to use monitoring platforms. These tools provide real-time insights into compressor performance, maintenance needs and energy usage. When staff are well-versed in interpreting this data, they can respond quickly to anomalies, schedule preventive maintenance and make informed decisions that enhance system reliability and uptime.
The benefits of improved air compressors are clear — reduced energy costs, lower carbon emissions, improved uptime and longer equipment life. Real-world case studies show that organizations across sectors are already achieving measurable results by adopting remote monitoring technologies and by following best practices such as regular energy audits and KPI tracking. These strategies not only improve operational performance but also align with broader goals like ISO 50001 compliance and long-term ROI.
Start by assessing a plant’s current compressed air system, identify inefficiencies, evaluate maintenance practices and explore the digital tools available to support smarter asset management. With the right approach, air compressors can become a cornerstone of an energy efficiency success story. PE
Jayme Leonard is a marketing communications professional at Atlas Copco Compressors.
FIGURE 4: Atlas Copco’s Optimizer 4.0 system features advanced centralized control for maximizing compressor efficiency and energy savings. Courtesy: Atlas Copco
Insightsu
Air compressor insights
uSmart asset management best practices include inventory mapping, key performance indicator (KPI) tracking and energy recovery.
uData is a critical component for reducing energy usage in air compressor systems.
uWorker training programs are a significant factor in maintaining energyefficient air compressor systems.
ENERGY EFFICIENCY AND MANAGEMENT
Christopher Chin, Seeq, Seattle
How to apply self-service analytics to monitor plant energy efficiency
The growing adoption of advanced analytics is improving data availability, process insights and operational decision-making, driving energy efficiency and more sustainable production.
Energy efficiency is a critical driver of operational excellence, sustainability and regulatory compliance across industrial sectors. According to the International Energy Agency, energy improvements in the industrial space could deliver over 40% of the emissions reductions required to meet global climate goals by 2040.
However, despite widespread deployment of sensors and monitoring systems, many plants still struggle to translate data into actionable insights due to siloed databases, delayed reporting and
other challenges caused by legacy software and monitoring systems.
Fortunately, modern self-service advanced analytics platforms address these and other challenges by enabling engineers and operators to directly access, analyze and visualize operational energy data without specialized programming expertise. For example, monitoring key performance indicators (KPIs) — such as specific energy consumption and energy intensity index (EII) — empowers plant personnel to detect inefficiencies in real time, promoting continuous improvement.
Traditional challenges in energy efficiency monitoring
Before the rise of self-service analytics, energy efficiency monitoring was largely manual and centralized, constrained by limited technology and access.
At one manufacturing company, a process engineer responsible for generating a monthly energy consumption report spanning 20 global sites spent most of their time:
• Manually extracting process data from the historian
• Importing that process data into an Excel spreadsheet
• Requesting manual meter readings from each site
• Cleansing poor-quality data
• Validating anomalies with site personnel
This required determining whether issues stemmed from instrument failures, planned shutdowns or unexpected trips.
FIGURE 1: Energy equipment key performance indicators arranged in a global asset tree for 20 sites. Courtesy: Seeq
After adjusting the data based on site feedback, the engineer would apply KPI calculations and create visualizations, such as bar charts and tables, in Excel. These reports were finally shared with stakeholders, including plant managers and chief financial officers. Ad hoc requests, such as power consumption for a specific site, took several days to fulfill due to the manual and time-consuming workflow.
Pain points of manual energy consumption reporting
The engineering team at this company identified three primary pain points in this workflow:
• Manual data collection and utility billing: Energy usage was historically tracked via manual meter readings and monthly utility bills, providing delayed and low-resolution insights. Facilities sometimes employed interval data recorders — e.g., 15-minutes or hourly — but these still required manual download, analysis and meter and log updates. Monthly utility bills served as the primary data source.
• Spreadsheet-based analysis: Data collected was typically entered into spreadsheets, like Excel. This procedure was time-intensive, error-prone and lacked real-time insight capabilities. Following data entry, users needed to manually calculate KPIs, such as EII and cost per output unit.
• Delayed insights and reactive decisions: Most decision-making was reactive, with little real-time feedback or forward-focused projections to reference, due to limited report frequency, such as just once per month. Ad-hoc reports were typically unavailable and even when they were, they lacked self-service features, forcing users to rely on analysts or information technology (IT) teams for detailed information.
Before self-service advanced analytics, plant personnel were limited by:
Courtesy: Seeq
• Slow insights
• High technical dependency
• Limited anomaly detection
• Low accessibility for nonexperts
• Missed energy-saving opportunities
Bolstering energy analytics with integrated data systems
Modern day self-service advanced analytics platforms integrate all data sources into a single, centralized software environment, empowering users to analyze plant- and enterprisewide data. This is particularly useful in industrial settings where information is often scattered across various systems and tools.
When data from multiple sources — such as historians, energy meters, supervisory control and data acquisition systems and maintenance databases — is consolidated into a unified platform, subject matter experts (SMEs) gain instant access to the indispensable information needed to perform advanced analytics and generate meaningful insights. This places the data required to create energy monitoring and other reports readily at their fingertips, eliminating delays caused by navigating disparate systems or relying on IT teams to extract and share information.
Within this unified environment, SMEs can build structured asset trees and organize equipment and systems into logical hierarchies. This framework empowers teams to efficiently identify and isolate specific information among thousands of signals, streamlining navigation and improving productivity.
Objectives Learningu
• Identify the primary challenges and key pain points of legacy energy efficiency monitoring efforts, such as reliance on manual data collection, spreadsheetbased analysis and the resulting delayed/reactive decision-making.
• Learn how modern self-service analytics platforms improve energy management, highlighting the core features of these platforms, including data integration, the use of asset trees for organization and the ability for nonprogrammers to standardize production calculations and cleanse data within a unified software environment.
• Describe the key organizational benefits of adopting a self-service analytics approach, focusing on the resulting impacts of empowering subject matter experts to independently generate insights, providing near-real-time monitoring and fostering faster, datadriven decisions to improve operational performance.
FIGURE 2: Comparative analysis in Seeq, a self-service advanced analytics platform, before and after implementing energy optimization initiatives.
ENGINEERING SOLUTIONS
FIGURE 3: A business intelligence dashboard displays nearreal-time self-service analytics key performance indicators.
Courtesy: Seeq
More importantly, standardized KPIs such as energy intensity, efficiency ratios and baseline comparisons can be embedded directly into the asset trees. These KPIs can then be replicated and scaled effortlessly across all sites within an enterprise, ensuring consistency in performance monitoring and benchmarking.
Advanced analytics for data preparation
In addition to analysis and reporting, advanced analytics platforms ease essential data preparation tasks, such as data cleansing and alignment across sources. Whether values are missing, outliers are present or timestamps are unsynchronized, these software systems automate data conditioning, eliminating the need to move information among external tools, like spreadsheets. This endto-end capability within the single platform pro-
‘Ultimately, this integrated approach optimizes the entire analytics workflow, empowering SMEs to take ownership of their insights, respond to issues in real time and continuously drive energy usage and operational performance improvements throughout the organization.’
vides SMEs with full visibility and control over data workflows.
Ultimately, this integrated approach optimizes the entire analytics workflow, empowering SMEs to take ownership of their insights, respond to issues in real time and continuously drive energy usage and operational performance improvements throughout the organization.
Asset tree design, KPI calculation and dashboard validation
In a recent project by the previously referenced company, a plant SME with no coding knowledge used a point-and-click self-service advanced analytics platform to align signals across all 20 global sites, create KPI calculations and share insights with stakeholders, all within a month. The resulting real-time energy dashboard replaced static Excel reports, empowering faster and data-driven operational decisions.
The site SME collaborated with the central data team to develop a global asset tree using a self-service, point-and-click tool designed for nonprogrammers, intuitively empowering the SME — despite having no Python or coding background — to contribute effectively to the setup process. They started by engaging site teams to ensure accurate selection of historian signals, requiring around 10 working days of extensive
‘This one-time setup proved invaluable, providing key stakeholders with near real-time access to critical energy data, enabling faster data-driven decisions to improve energy use across the organization.’
back-and-forth communication across the 20 plants to validate the correct data sources to use for each energy system.
The asset tree was structured in three tiers (see Figure 1). The first level consisted of all the sites, while the second level categorized core energy equipment at each site, including boilers, electrical systems, steam systems and turbines. The third level housed the specific KPI signals and their calculation logic, mapped directly to each asset.
How built-in analytics address data quality
Data quality issues — such as invalid points, noise and inconsistent units — were addressed using built-in analytics functions, ensuring clean and standardized data for analysis. The KPI calculation setup took approximately three working days.
Once the calculations were configured, the SME compiled them into a centralized workbook and shared the URL with plant managers using access control features to provide read-only access. This facilitated easy collaboration and validation.
Feedback and corrective actions were documented within the workbook’s journal feature, streamlining communication and supporting online review meetings. This enabled SMEs to perform comparative analysis before and after implementing energy optimization initiatives (see Figure 2).
The central data team then integrated the verified KPI signals from the asset tree into a business intelligence tool to develop near-real-time dashboards (see Figure 3).
These dashboards provided visibility into power consumption and energy efficiency across all sites. However, the validation process took a while, approximately two weeks, due to the need to build stakeholder confidence in the shift from traditional Excelbased reporting to real-time digital dashboards.
Although the full project took roughly a month from initial setup to stakeholder validation, the SME successfully accomplished most of the work via independent initiative leveraging the self-service analytics platform. This one-time setup proved invaluable, providing key stakeholders with near-real-time access
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Insightsu
Self-service analytics insights
uAdvanced analytics platforms ease essential data preparation tasks, such as data cleansing and alignment across sources.
uSelf-service analytics help organizations unlock hidden inefficiencies, reduce technical dependency and accelerate digital transformation.
uUnified platforms enable subject matter experts to build asset trees, standardize key performance indicators and perform data cleansing in a single environment.
to critical energy data, enabling faster data-driven decisions to improve energy use across the organization.
Self-service analytics pave the way for artificial intelligence (AI)-driven insights
Organizations must prioritize self-service analytics adoption to unlock hidden efficiencies, reduce technical dependency and accelerate digital transformation. Widespread adoption of self-service analytics is paving the way for AI-driven insights, continuous optimization and a more agile and energy-efficient future.
For example, Pfizer’s Puurs, Belgium, facility reduced energy consumption by 20% through enhanced heating, ventilation and air conditioning monitoring. Meanwhile, BASF’s Ludwigshafen site improved utility efficiency by over 12% by optimizing steam and compressed air systems. And Nestlé achieved a 15% reduction in energy use per ton of product by embracing predictive analytics.
Traditionally, energy monitoring relied heavily on centralized teams, manual data handling and delayed reporting, which resulted in many missed opportunities for savings and operational improvements.
However, self-service platforms are empowering SMEs to access, analyze and act on energy data directly, without relying on — but creating collaboration opportunities with — IT and data science teams.
By consolidating data sources like historians and individual meters into a unified platform, SMEs can build asset trees, standardize KPI calculations and perform data cleansing in a single environment. This streamlines workflows, eliminates spreadsheet inefficiencies and ensures realtime visibility into energy performance across sites throughout the enterprise. PE
Christopher Chin is a principal analytics engineer at Seeq, focused on the oil and gas and energy sectors.
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ARC FLASH AND ELECTRICAL SAFETY
Herbert Post, TRADESAFE, Las Vegas
New OSHA guidelines reset the arc flash safety standards
OSHA’s new guidance highlights a risk that many still underestimate: serious arc flash hazards can happen at voltages as low as 120 V.
Can something as common as 120 volts (V) really cause an arc flash serious enough to send someone to the hospital or worse? Surprisingly, yes. And that misunderstanding is one reason Occupational Health and Safety Administration (OSHA) issued a major update in November 2024, its first significant shift on arc flash personal protective equipment (PPE) guidance in nearly 20 years.
Learningu
Objectives
• Understand OSHA’s updated expectations for arc-rated personal protective equipment (PPE) use at 120/208 volts.
• Know which job roles and environments are affected, including motor control centers and shared electrical spaces.
• Be able to review and revise PPE programs, lockout/tagout (control of hazardous energy) procedures and training to meet current enforcement priorities.
The updated guide applies broadly across general industry, commercial facilities and maintenance operations, especially in environments like motor control centers (MCCs), where energized work is frequent and often shared among multiple trades. It reinforces existing requirements under OSHA standards, particularly 1910 Subpart S, while aligning with best practices already outlined in NFPA 70B: Standard for Electrical Equipment Maintenance and NFPA 70E: Standard for Electrical Safety in the Workplace.
Importantly, this guidance does not change the separate rules that govern utility transmission and distribution work under 1910.269 and 1926 Subpart V, though it closely aligns with principles already established in NFPA 70E and 70B. But it does sharpen expectations, most notably around arc-rated PPE use during low-voltage tasks and corrects persistent misunderstandings that have long shaped field practices.
OSHA’s arc flash PPE guidance
For a long time, many teams treated anything less than 240 V as low-risk, almost routine. But
OSHA’s 2024 guidance calls that out. It states plainly: even low-voltage tasks can carry serious arc flash hazards. The new emphasis isn't on the voltage but on exposure.
If someone is working near exposed energized parts, even at 120 V, the risk is real. And that means arc-rated PPE is expected. Here’s what’s changed or clarified:
• Arc-rated PPE applies to low-voltage work — yes, even 120/208 V — if there’s any exposure to energized components.
• OSHA directly addresses a widespread assumption: that equipment under 240 V “can’t arc.” That idea is no longer acceptable, nor is it safe to assume.
• The focus shifts from voltage to task conditions: available fault current, enclosure type, worker proximity all matter more than the number on a label.
• Environments like MCCs are called out for their high exposure potential, even at common voltages.
Another major point is what qualifies as “de-energized.” OSHA doesn’t leave this vague. If the task doesn’t meet full lockout/tagout (LOTO) or electrically safe work condition (ESWC) requirements, it must be treated as energized, even if the breaker’s off. That’s in line with 29 CFR 1910.147 and 1910.333.
In short: Flipping a switch isn’t the same as verifying zero energy. And assuming otherwise is no longer something OSHA’s going to overlook.
While this isn’t a new regulation, it does tighten the practical expectations under the General Duty Clause and PPE standards (1910.132-138). It fills in the gaps that outdated training or misread standards left behind.
‘It states plainly: even low-voltage tasks can carry serious arc flash hazards. The new emphasis isn't on the voltage but on exposure.’
Who this arc flash guidance applies to
This guidance is aimed squarely at general industry, where energized work on low-voltage systems is common and often misunderstood. It addresses the everyday environments where arc flash risks have historically been downplayed: commercial facilities, light industrial plants, maintenance shops and multitrade electrical spaces. Who’s clearly covered:
• General industry workers involved in electrical installation, diagnostics, maintenance or servicing
• Electricians working in commercial, residential or industrial contexts
• Facilities staff and operators who interact with or near energized panels, disconnects or MCCs
• Shared workspaces where multiple trades work around the same energized equipment
What about utility workers? Workers involved in electric power generation, transmission and distribution are governed by separate OSHA standards, namely, 29 CFR 1910.269 (general industry) and 1926 Subpart V (construction). These rules already contain detailed arc flash protection requirements. However, here’s where it gets nuanced: Even nonutility employers may have workers who fall under 1910.269 if those employees perform “utility-type work,” such as managing electrical distribution throughout a facility or industrial campus. So, the distinction isn’t based solely on job title or employer type. It depends on the nature of the work and the hazard exposure involved. If ener-
Table 1: Outdated beliefs and correct practice for arc flash
120 volts can’t cause arc flash
Turned off = de-energized
Low-voltage work doesn’t need PPE
Quick diagnostics aren’t high-risk
Arc-rated PPE is required when energized exposure exists, even at low voltages such as 120 V
A system is only de-energized when LOTO and voltage verification are complete
PPE must match the risk of the task, not the voltage label
Any task near exposed energized parts requires protection and procedure
TABLE 1: Comparison of outdated beliefs versus correct arc flash safety practices. Courtesy: TRADESAFE
gized electrical exposure is present and the task doesn’t fall under the utility framework, this new guidance will likely apply.
Implications for mechanical, electrical system managers
One of the most immediate and visible impacts of the updated guidance is the expectation for expanded PPE use even during tasks many teams still consider routine. That shift brings a very real question to the table: Are your current budgets and inventories aligned with OSHA’s clarified expectations?
FIGURE 1: Infographic checklist of recommended arc-rated personal protective equipment for low-voltage arc flash work. Courtesy: TRADESAFE
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‘PPE needs to be suited not just to the voltage, but to the task, the equipment condition and the environment.’
The answer, in many cases, is probably not.
Arc-rated PPE, once reserved for high-voltage or utility settings, is now explicitly recommended for lower-voltage energized work. That includes common activities performed at 120/208 V, where energized exposure hasn’t been eliminated through full LOTO.
For managers reviewing PPE needs, especially in areas where energized work at lower voltages is routine, it helps to have a clear picture of what’s commonly recommended. Figure 1 highlights several types of gear that many teams are putting in place as part of their arc flash program.
Special attention is warranted in MCCs or other confined energized spaces. These are high-risk zones where arc flash exposure is both more likely and potentially more severe due to the proximity of workers to live parts.
PPE needs to be suited not just to the voltage, but to the task, the equipment condition and the environment. That makes upfront investment in PPE planning and procurement necessary. Treating arc-rated gear as optional for low-voltage work is no longer defensible under OSHA’s current position.
Arc flash safety policy and procedure overhaul
Upgrading PPE is just the start. The bigger challenge and arguably the more consequential
one is reworking safety policies that still rely on outdated assumptions. OSHA’s guidance signals that too many programs treat electrical safety as static, when risk conditions shift with every energized task.
To help close the gap, OSHA has made it clear that several common field beliefs no longer hold up under current expectations (see Table 1).
Policies must extend beyond assumptions and enforce procedural rigor, especially when energized diagnostics or servicing are involved. For system managers, this means:
• Rewriting procedures to reinforce that the power-off does not equal de-energized.
• Emphasizing LOTO and ESWC protocols at every level of work planning, not just for high-voltage or “high-risk” jobs.
• Eliminating language in policies that downplay the need for PPE below 240 V. Lower voltages can pose the same risks depending on the frequency of the task and exposure to hazards.
• Requiring field verification of deenergization (test for absence of voltage) before work begins.
This also applies during troubleshooting, voltage testing or simple resets, tasks often assumed to be “quick and safe.” If energized exposure hasn’t been eliminated, then PPE and procedural controls are nonnegotiable.
For example, resetting a breaker with an internal fault can trigger an arc flash even at 120 V. If the defect goes unnoticed, the worker still faces hazards. Limited experience or training and a false sense of security about “low-risk” tasks can leave employers unprepared for the consequences.
Training and supervision
Technical policies are only as strong as the training that supports them. And even the best-written procedures won’t hold up if workers fall back on assumptions, especially around what’s energized and what’s not.
OSHA’s 2024 guidance pushes supervisors to step in more actively, not just during onboarding,
FIGURE 2: Infographic summarizing the actions needed to align with OSHA’s 2024 arc flash guidance. Courtesy: TRADESAFE
but during day-to-day work. The goal is to make sure safety practices match the actual risks in front of workers.
To stay aligned with the updated expectations:
• Training should focus on identifying energized exposure, especially during diagnostics or panel work.
• PPE use must be reinforced during routine jobs (no exceptions based on voltage alone).
• Supervisors should monitor how procedures are being followed.
• Retraining should be scheduled, not reactive, based on the frequency of exposure, not incident history.
Supervisors are often the last chance to catch a gap before it turns into an incident. That’s why this
Table 2: Assessment factors for protective planning
What you assess Why it matters
Available fault current Indicates how severe an arc flash could be
Equipment condition and enclosure type
Worker distance and task type
Labeling accuracy and system updates
Poor maintenance increases arc likelihood
Proximity and energized contact raise risk
Incorrect or outdated info misguides decisions
part of the program needs just as much attention as equipment checks or PPE budgeting.
Hazard assessment and maintenance coordination
Even though OSHA’s latest guidance doesn’t mandate arc flash risk assessments, it strongly encourages them. The complexity of modern electrical systems means risk can’t be judged by voltage labels alone.
What it affects
Determines minimum PPE rating and boundary size
Drives cleaning, torque checks and inspections
Influences safe approach practices and PPE use
Triggers relabeling and study recalculation
TABLE 2: Table of key assessment factors and their influence on protective-planning decisions. Courtesy: TRADESAFE
• The available incident energy at specific locations.
• The correct arc-rated PPE needed for that exposure.
• Whether existing safety boundaries are adequate.
Without this data, teams are left to guess and guessing leads to either overprotection or under-protection, neither of which builds trust or reliability.
In practice, these decisions are shaped by a range of conditions. There are several common assessment factors connected to protective planning (see Table 2).
But hazard assessment doesn’t stop with calculations. Coordination between electrical and mechanical teams is just as critical, especially during scheduled maintenance or troubleshooting. Tasks
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overlap, trades mix and the risk increases when one team assumes another has verified safety conditions.
To strengthen your program:
• Coordinate assessments across departments.
• Review existing labeling and ensure it reflects current system configurations.
• Tie hazard assessment results directly into written work procedures and PPE selection.
• Make arc flash studies part of your update cycle after system changes or upgrades.
• Evaluate potential engineering solutions (e.g., panel-mounted devices that indicate voltage presence, current or fault conditions).
Maintenance is also equally important. Equipment that’s neglected can cause unexpected failures and elevate incident energy. OSHA references 1910.334 here: maintaining gear in good condition is one of the best
ways to lower the odds of an arc occurring in the first place.
Closing arc flash compliance gaps
With OSHA’s guidance reinforcing expectations around low-voltage arc flash hazards, the next step is verifying. Many facilities already have safety policies in place, but that doesn’t mean they align with what’s now clarified.
OSHA’s 2024 guidance doesn’t change the written standards, but it does change how clearly those standards are being interpreted.
If your team is still using “under 240 V” as a reason to skip arc-rated PPE or shortcut lockout procedures, this is your warning light. The guide reinforces what was already in place: if there’s energized exposure, it needs to be treated like any other hazard (even at low voltage), with engineering, administrative and PPE controls evaluated in the hazard assessment.
Here’s what matters:
• Workers can still become injured, burned and experience life altering injuries, even when working with only 120 V.
• OSHA can still issue citations using the General Duty Clause if a known hazard isn’t addressed.
• PPE expectations in 1910.132-138 still apply even if the voltage is low.
• The moment energized work happens without full LOTO or an ESWC, compliance depends on PPE and procedure.
Plant managers and safety experts don’t need to rewrite your safety manual from scratch. But facilities do need to make sure what’s written matches what’s happening in the field, especially in MCCs, control panels or anywhere energized work is routine.
If the risk is real and the controls are known, OSHA expects teams to act accordingly. PE
Herbert Post is the VP at TRADESAFE.
Insightsu
Arc flash insights
uThis article walks through what the update says and what safety managers should be checking for regarding their policies, procedures and training.
uOccupational Health and Safety Administration’s new personal protective equipment guide resets the arc flash safety standard.
ENGINEERING SOLUTIONS
ASSET MANAGEMENT
TJ Tatum and T.J. Kusnierek, Bosch Rexroth, Charlotte, North Carolina
Design software can maximize efficiency, efficacy in a plant
Design
software plays a critical role in optimizing efficiency within manufacturing.
FIGURE 1: Digital design tools can help to create effective aluminum framing solutions for workers, as seen in the digital image. Courtesy: Bosch Rexroth
The health of manufacturing operations relies on the plant floor running efficiently and flexibly — always adapting to keep up with ever-changing customer demands. What is on the plant floor can either be a hindrance or can empower employees to meet those demands and send quality products out the door.
Design software can maximize the design and use of various aspects within a manufacturing plant. There are many ways a plant manager can employ design software in an industrial facility.
framing can mean more than sticks, bundles and components. While the classic t-slotted aluminum sticks are often the most recognized when the words “aluminum framing” are brought up, it isn’t the only option.
Within the square and rectangular and “L” shaped profiles category, a supplier can have both metric and inch series. While using one versus the other can be a matter of preference, both are beneficial to have in a single portfolio.
Next, tubular framing systems are a lightweight option, often used to achieve lean production goals. Like its square counterpart, tubular framing is versatile, cost effective and creates high-quality plant floor solutions at a lower weight. Compared with steel, it can be as much as 30% less weight.
Objectives
• Learn how design software is playing an increasingly important role within manufacturing.
• Understand that aluminum framing has a variety of applications that can improve efficiency including in work stations, flow racks and safety guarding.
• Review two case studies of both design software and aluminum framing impacting productivity.
A robust aluminum framing portfolio and experienced design engineer can employ design software and similar tools to fulfill the plant’s needs. With its sleek look and seemingly simple function, aluminum structural framing is an unsung hero of the plant floor. It’s versatile, easy-to-use and practical in many applications; aluminum framing offers numerous advantages across multiple facets of operations. As a bonus, its durability makes it reconfigurable — enabling outdated structures to be reassembled and given new life for a different function within the plant.
Effectively using aluminum framing starts in the design phase — before a physical extrusion is even in your hand. With the right design tools and aluminum framing system, you can turn any vision into a reality with the portfolio that provides everything to build anything.
What is a robust aluminum framing portfolio?
Before diving into the applications, it’s important to understand the breadth of products a robust portfolio of aluminum framing products can include. With a well-rounded supplier, aluminum
Finally, the protector of the plant floor, safety guarding, rounds out the portfolio nicely. Used to create barriers around noncollaborative machines and enclose areas of production, safety guarding is a necessary component for any safety-conscious plant.
Simplify the design process with digital design software
Without the ability to easily conceptualize and customize your solution, aluminum framing is just a pile of profiles and connectors. Compatible, easy to use design tools are a critical part of an aluminum framing product offering — allowing design engineers to create fully customized solutions for their unique applications.
With aluminum framing, thinking outside the typical manufacturing box is encouraged. The versatility of aluminum framing allows it to be used in a wide range of applications and industries. Even applications from industries as strict as medical manufacturing are no challenge for the right aluminum framing system.
Continuing outside the standard manufacturing environment, aluminum framing can also be integrated into other aspects of business. Extrusions
and connectors can easily be assembled to create sturdy ladders, platforms and more for maintenance applications.
Designing with software to provide extraordinary support
Ergonomic workstations are a staple of any plant floor operation — providing a comfortable and customized work environment for employees to complete their tasks. The benefits of ergonomically designed workplaces for workers have been proven in many studies and the results speak for themselves: increased motivation and satisfaction, better performance, efficiency and work quality and fewer absences due to injury.
Ergonomic workstations: To effectively integrate ergonomic workstations into production systems, careful and comprehensive planning are key. Designing workstations to meet ergonomic requirements is often a costly complicated undertaking. But this is where design software can provide valuable support.
Another software feature to look out for that supports ergonomic workstation design is the ability to optimize designs for human use. The bottom line: Ergonomic workstations provide a significant improvement in productivity, increased efficiency and a decisive edge over the competition — thus ensuring lasting success for your company.
Flow racks: Flow racks play a critical role in reconciling lean production concepts and in optimizing efficiency, cost effectiveness and ergonomics on the plant floor. Whether they’re integrated into picking stations, shuttling materials to workstations or used as a first in, first out (FIFO) station, flow racks are a versatile champion for employee efficiency.
Flow racks also complement the ergonomic workstations mentioned previously. By implementing a dockable material shuttle, the workstation can be quickly adapted to changing products and assembly processes to optimize workflows and efficiency. Another example is placing a flow rack at a workstation to supply containers of components to workers, helping ensure FIFO principles without slowing the workflow.
Effectively designing flow rack systems requires knowing which materials will be supplied in what quantity and in which containers. The load capacity
of the flow racks will ultimately be decided by these selected parameters, as well as the setup, frame dimensions and the shelves and conveyor tracks used. Factors such as the container weight, type of activity involved and the overall strain placed on a worker during a shift are the additional considerations for ergonomic flow racks designs.
Flow racks can be designed using standard metric aluminum profiles or with a tubular framing system. Using a lighter-weight alternative, leverages proven principles such as Poka Yoke, Kaizen and Lean design to offer a well-rounded and cost-effective design for a variety of industries and applications. Racks can be designed to meet the high technical requirements of the manufacturing industry, while still emphasizing ergonomic design.
Safety guarding: As automation and robotics sweeps through the manufacturing industry, safety guarding is becoming increasingly important. Safety fences can be found in nearly every factory. They serve as safety barriers for entire production lines or enclosures for individual machines.
Regardless of the size of the system, however, one requirement applies: the protective equipment must be planned and built quickly and cost-effectively. Flexible conversion options are also required in variable production environments. Regulations and standards must always be met. PE
TJ Tatum is Digital Sales Specialist, Assembly Technology at Bosch Rexroth. T.J. Kusnierek is the Sales Product Manager, Shopfloor Solutions at Bosch Rexroth.
FIGURE 2: Aluminum framing plays a critical role in safeguarding process like battery recycling. Courtesy: Bosch Rexroth
Insightsu
Design software insights
uDesign software transforms aluminum framing from basic components into highly efficient, customized solutions that enhance productivity and safety on the plant floor.
u By streamlining the design of ergonomic workstations, flow racks and safety guarding, these tools help manufacturers optimize layouts, improve workflows and adapt to changing demands with ease.
Powering Progress: Meet the 2025 Engineering Leaders Under 40
Celebrating 35 engineering professionals who are driving transformation, mentorship, and excellence across the industrial landscape.
Amanda Pelliccione, Marketing Research Manager, WTWH Media
The future of engineering is in capable hands. The 2025 class of Engineering Leaders Under 40 showcases 35 early- to mid-career professionals whose work is accelerating progress in automation, controls, energy, infrastructure and beyond. These individuals are not only delivering technical breakthroughs—they’re also redefining what leadership looks like in modern engineering environments.
This year’s honorees represent a rich diversity of disciplines and backgrounds, but they share a common vision of using their expertise to solve real-world problems, supporting their communities and elevating their teams. From building gigafactories and digitizing frontline workflows to commissioning renewable facilities and mentoring young engineers, their stories highlight the ingenuity and resilience shaping today’s industrial workforce.
In addition to technical excellence, these leaders are passionate about mentorship, lifelong learning and making engineering more inclusive and future-focused. Many balance high-stakes responsibilities with impactful volunteerism, family life and personal passions that ground and energize their work.
We’re proud to honor these standout professionals who embody the values of innovation, service and human-centered leadership. As you read their stories, we hope you’re as inspired as we are by the energy, optimism and purpose they bring to engineering—and to the world.
Learn more about this program and how to nominate a colleague for 2026 at www.plantengineering.com/events-andawards/engineering-leaders-under-40. Nominations open April 1, 2026. PE
Hannah Bonaguidi, 27
Project Manager
Catalyx
Warminster Heights, PA
—Hannah is a rising leader in process automation and analytical technology. She has led more than 40 projects, demonstrating technical skill, adaptability and clear communication. Whether collaborating with experienced engineers or guiding teams unfamiliar with automation, Hannah ensures effective outcomes. Her expertise spans PAT systems, virtualized controls and GMP compliance, making her a trusted, forward-thinking project leader.
Johnnie Burness, 39
Engineering Manager – Factory Systems and Test
Verdagy
Newark, CA
—Johnnie leads high-impact projects at the forefront of modern manufacturing. From gigawatt-scale electrolyzer production at Verdagy to launching Tesla’s Model 3 Drive Unit line, he blends control systems expertise with big-picture strategy. As a licensed PE with an MBA, Johnnie delivers innovative, scalable solutions in complex industrial settings.
Fun Fact: Hannah has tattoos of “L” and “R” on her hands to help with navigation—and a husky named Tankus Pankus afraid of toasters.
Fun Fact: Johnnie didn’t fly until age 22—but now his engineering work takes him around the globe.
Jason Cary, 29
Senior Manufacturing Engineer
ContiTech USA LLC
Wahpeton, ND
—Jason is known for his hands-on engineering and deep process insight. A sub-lead at ContiTech, he’s driven improvements in safety, throughput and quality. Self-taught in rubber extrusion and a subject matter expert in polymer processing, Jason leads initiatives that boost performance while sharing knowledge across facilities.
Fun Fact: Jason restores classic cars with his dad and fosters rescue dogs with his wife.
Brady Darrough, 28
Automation Engineer
Huffman Engineering
Lincoln, NE
—Brady is quickly becoming a go-to expert in SCADA systems and legacy PLC conversions. His work spans utility and industrial projects, from flood recovery efforts to advanced system upgrades. With certifications in Ignition and Rockwell Automation platforms, Brady brings humility, technical rigor and genuine care to every engagement.
Fun Fact: Brady is a cross-country coach, marathon runner, and former agricultural drone pilot for Bayer Crop Science.
Hugo Dozois-Caouette, 33
CTO and Co-founder
MaintainX
San Francisco, CA
—Hugo is transforming industrial maintenance through AI and mobile-first tools. As CTO and co-founder of MaintainX, he built a platform used by more than 11,000 global facilities, improving data visibility and uptime. His passion for intuitive design and team mentorship fuels innovation that supports frontline workers in essential industries.
Danny Dylong, 37
Director, Manufacturing
The RoviSys Company
Aurora, OH
—Danny brings energy, strategic insight and technical depth to automation projects worldwide. From co-op student to director at RoviSys, he’s led teams across 12 countries and multiple sectors. Now driving growth in markets like aerospace, EVs, and defense, Danny is building a dynamic and people-focused engineering culture.
Fun Fact: Hugo is a rock climber, tennis player and long-time contributor to the open-source React-Bootstrap community.
Fun Fact: Danny is a serial hobbyist—he scuba dives, fishes, golfs, and also advocates for causes like leukemia and Parkinson’s research.
Chris Edwards, 37
CEO
Sensory Robotics
Cincinnati, OH
Chris pioneered 3D point cloud safety technology—replacing traditional safety devices with reconfigurable, vision-based systems for robotics. As CEO of Sensory Robotics, he self-funded and led the team to a working MVP and multiple pilot installations. His patented work bridges VR, AI and industrial safety with human-centered design.
Christen Egan, 33
Engineering Manager General Control Systems
Albany, NY
Fun Fact: Chris performs improv comedy in Cincinnati and preserves Civil War–era family properties through his Heritage Stewardship Committee.
Christen brings strong leadership and technical excellence to semiconductor and industrial control projects. A licensed PE in four states, she manages projects and engineering policies at GCS’s headquarters. Known for mentoring and innovation, Christen is also active in industry groups and professional certification programs.
Fun Fact: Christen is a Swiftie who attended four Eras Tour concerts in two countries and three cities.
Christopher Evans, 30
Project Engineer
The RoviSys Company
Houston, TX
Christopher is a versatile engineer who has shaped the growth of RoviSys's Texas office. A leader in power and energy projects, he brings curiosity, adaptability and deep technical know-how across multiple platforms. His self-driven learning—from home labs to AI systems—fuels innovation company-wide.
Fun Fact: Christopher sings in a local choir, hand-forged his wife’s engagement ring, and recently took second place in a strongman competition.
Michael Fazzini, 34
Director of Operations
Actemium Avanceon
Exton, PA
Michael blends technical engineering with strategic business leadership. Rising through the ranks at Avanceon, he now oversees operational performance, team development and revenue growth. Known for mentoring and creative problem-solving, Michael is a people-first leader driving transformation in the systems integration space.
Fun Fact: Michael and his wife married in Sorrento, Italy, and he’s a devoted dog dad to four pups and a passionate Philly sports fan.
Victor Foster, 40
Reliability Engineering Manager
International Flavors & Fragrances
Memphis, TN
Victor is a seasoned reliability leader who elevates maintenance strategy through measurable outcomes. He’s led CMMS installations, predictive maintenance integrations and multi-year performance gains, including a 50% drop in reactive work. A board member of the Reliability and Maintainability Center, Victor mentors co-op students and champions reliability as a mission-critical discipline.
Fun Fact: Victor is an Eagle Scout and Cubmaster who guides over 50 youth through character-building and leadership in Scouting.
Daniel Foster-Roman, 35
Industry Principal, Power & Utilities
Seeq
Seattle, WA
Daniel blends power-sector engineering with data science to transform industrial analytics. At Seeq, he leads AI-driven strategy for utilities and mentors teams across disciplines. Formerly with Ontario Power Generation, he earned awards for digital innovation in nuclear and hydro. A contributor to global AI guidelines via the IAEA, Daniel is shaping the future of smart energy.
Fun Fact: Daniel is a drummer who toured with a Canadian indierock band and now jams at home with his toddler daughter.
Mena Francis, 37
Project Manager
Applied Control Engineering
Newark, DE
—Mena is a standout in pharma and life sciences controls engineering, with expertise in medical device manufacturing, GAMP and ISO/FDA standards. A Six Sigma Black Belt and PMP, he drives measurable improvements in process performance while mentoring future engineers and championing continuous learning.
Fun Fact: Mena has traveled to over 30 countries, once competed in Greco-Roman wrestling and is passionate about chess and kayaking.
Prashant Ghadge, 39
Project Engineer
Compass Energy Systems
Houston, TX
Prashant blends mechanical and controls engineering to design high-performance compressor packages tailored to site and process needs. With experience across diverse compression technologies, he’s led innovations in hydrogen refueling and high-pressure gas systems. A published thought leader and industry advisor, Prashant is recognized for technical depth, safety advocacy and AI-forward thinking in energy systems.
Fun Fact: Prashant volunteers as an event photographer for local nonprofits and expresses his creativity through music, sculpture and stage design.
Michael Jagels, 37
Automation Engineer
CDM Smith
Columbus, OH
Michael leads SCADA system design, startup and commissioning for water infrastructure projects across Ohio. As a licensed PE and technical leader, he balances engineering rigor with 24/7 responsiveness, ensuring safe, reliable operations for public utilities. Passionate about training the next generation, he also mentors new engineers in fieldwork execution and client-centered design.
Fun Fact: Michael transformed his backyard into a native plant sanctuary to help manage stormwater runoff—both at home and in the field.
Luke Kellogg, 38
Senior Controls Engineer
Lectro Engineering
St. Louis, MO
Sharath Kumar Kanniyappan, 34
Sr. Controls Engineering Supervisor
Honeywell Intelligrated
Mason, OH
Sharath leads global warehouse automation projects with technical precision and strategic foresight. Rising from engineer to supervisor, he’s driven Honeywell’s digital transformation through emulation tools and Industry 4.0 adoption. His work bridges customer support, systems analytics and commissioning excellence, delivering value from design to deployment.
Fun Fact: Sharath plays the whistle flute—a talent he’s kept up since his school marching band days—and devours thriller novels on the go.
Luke is the backbone of controls design at Lectro Engineering, managing PLC/HMI programming, schematics and customer support. Rising from assembly tech to senior engineer, he’s led product innovations like vision and leak test machines that opened new markets. Self-taught and service-driven, Luke trains peers and builds machines from first concept to startup.
Fun Fact: Despite no formal training, Luke became his company’s top controls engineer—and now mentors youth through his church and community programs.
David Ladner, 32
Controls & Automation Process
Safety Engineer
Hargrove Controls & Automation
Mobile, AL
David tackles complex automation and process safety projects with calm confidence and technical mastery. From PLC programming to HAZOP studies, he supports clients across industries while mentoring interns and leading community STEM outreach. His custom LED driver design and startup leadership at Hargrove reflect both innovation and impact.
Fun Fact: David travels the globe to explore new cultures and cuisines—and is learning Spanish to connect deeper at work and abroad.
Jonathan Larnard, 31
Senior Automation Engineer
NeoMatrix
Portsmouth, NH
Jonathan is a trusted automation expert who leads high-compliance integration projects in pharma and GMP manufacturing. With nearly a decade at NeoMatrix, he’s known for platform versatility, attention to detail and end-to-end project execution. He’s also a dedicated mentor who models professionalism and continuous learning in every engagement.
Kyle Lick, 35 Automation Engineer CDM
Smith
Boston, MA
Kyle combines rare dual mastery in automation design and programming with an unwavering commitment to client support. A licensed PE and contributing author to NEIWPCC’s TR-16, he leads major SCADA upgrades while ensuring continuous operations. Calm under pressure, Kyle builds lasting trust across the water and wastewater industry.
Fun Fact: Jonathan is a lifelong soccer fan and avid traveler, and he balances work with tennis, snowboarding and gaming.
Fun Fact: Kyle once traveled to Kyle, Texas, to help break the Guinness World Record for the largest same-name gathering.
Patrick McKinley, 38
Project Engineer
Applied Control Engineering
Newark, DE
Patrick’s expertise in PLC platforms, team leadership and process startups drives success across control upgrades and greenfield builds. From steel plants to pyrolysis projects, he leads with curiosity, clear communication and hands-on skill. His mentorship and technical leadership are making lasting impacts in the automation community.
Fun Fact: Patrick owns a Pittsburgh brewery and applies his engineering know-how to beer-making and business operations.
Shankar Narayanan, 38
Technology Partnerships Manager
Amazon Web Services | Energy & Utilities
San Jose, CA
Shankar leads industrial innovation at AWS, scaling GenAI and cloud tools to modernize aging infrastructure across more than 30 sites. With a background at GE and Baker Hughes, he’s improved safety, uptime and emissions in energy systems. A mentor, author and startup advisor, he advances sustainable engineering at scale.
Muktar Ali Mohammad, 28
Industrial Controls Specialist
SymBioAITech
Farmers Branch, TX
Muktar designs advanced controls for Fortune 500 clients, driving efficiency and safety with PLCs, motion systems and industrial IoT. He mentors engineers, publishes research, and implements predictive analytics in high-speed logistics and food plants. A multilingual innovator, he brings smart automation to life.
Fun Fact: Muktar built a real-time home energy monitoring system—and a smart irrigation setup—just for fun.
Jasmine Nguyen, 27
Controls & Automation Engineer
Hargrove Controls & Automation
Birmingham, AL
Jasmine is a driven automation engineer with a background in chemical engineering and a talent for mastering diverse PLC and DCS platforms. She’s known for her leadership on migrations, onsite client support and mentoring in Hargrove’s co-op program. Jasmine is a versatile problem-solver whose technical excellence and collaborative spirit uplift both projects and peers.
Fun Fact: Shankar volunteers with energy-tech accelerators to guide startups in decarbonization and industrial AI deployment.
Fun Fact: A vintage enthusiast and recipe experimenter, Jasmine honors her Vietnamese roots through food and language.
John Pietras, 34
Project Manager 2
Matrix Technologies
Maumee, OH
John merges technical depth with project leadership, managing multimillion-dollar automation and digital transformation projects across manufacturing and chemicals. From OT networks to Industry 4.0 systems, he delivers results while mentoring younger engineers. A respected leader and strategic thinker, John’s efforts boost efficiency, safety and innovation.
Adi Prasad, 35
Co-Founder, Co-CEO NexiForge
Cambridge, MA
Adi led automation at Tesla, Apple and Rivian before co-founding NexiForge, where he’s compressing new-product introduction from 18 months to 18 days. He’s a pioneer in gigafactory design, AI-driven manufacturing, and yield optimization—delivering innovations that reshape global production. A hands-on leader, Adi mentors engineers worldwide.
Fun Fact: John is an Eagle Scout, avid runner and continues to mentor youth through leadership programs and community service.
Fun Fact: A certified Formula-style driver, Adi races electric cars on weekends and guest lectures at MIT on gigafactory automation.
Aravind Renganathan, 35
Services Growth Leader
Honeywell International
Richardson, TX
Aravind leads Honeywell’s services strategy, driving digital transformation and new revenue models across industrial sectors. A seasoned product and service innovator, he’s expanded portfolios and global footprints at companies like Flowserve and Amazon. He blends technical expertise with market insight to deliver scalable, customer-first solutions.
Fun Fact: Aravind is a trained Indian classical vocalist and a dual master’s degree holder who mentors early-career professionals.
David Smit, 37
OT Architect
Interstates
Sioux Center, IA
David is a driving force behind digital transformation in industrial environments. As OT Architect at Interstates, he bridges SCADA, MES and network infrastructure to deliver future-ready solutions. A trusted advisor and sought-after industry speaker, David leads strategic workshops, mentors peers and shapes innovation across client and partner landscapes.
Fun Fact: An avid cyclist and home automation enthusiast, David runs tech-tuning workshops and AV teams in his community.
Edgar Rivera Hernandez, 36
Regional Director
The RoviSys Company
Peachtree City, GA
Edgar’s leadership has propelled him from intern to regional director. At RoviSys, he built the Georgia office from 7 to nearly 50 engineers and launched the company’s Puerto Rico expansion. His mentorship, client focus, and commitment to high-quality execution have elevated teams and delivered major automation wins.
Fun Fact: Edgar credits his family—especially his wife, Lydia—for his success, and strives daily to lead by example for his three children.
Steve Solack, 37
Controls Engineering Manager
Mission Design & Automation
Holland, MI
Steve leads with vision and empathy, guiding the largest engineering department at Mission Design & Automation. With roots in custom automation, aerospace innovation and patented applications, Steve empowers his team to solve what is seemingly unsolvable. A mentor and motivator, he inspires the next generation through co-op programs and personal example.
Fun Fact: A punk rock fan and woodworker, Steve balances creative DIY projects with raising three daughters—and sharing great music.
Erik Sullivan, 35
Engineering & Maintenance Manager, Renewables
Tidewater Midstream and Infrastructure Ltd.
Prince George, BC, Canada
Erik brings hands-on expertise and decisive leadership to renewable energy operations. He has led major refinery turnarounds, improved reliability across rotating equipment, and played a key role in the launch of Canada’s first renewable diesel facility—all without lost time incidents. His engineering vision advances safety, efficiency and sustainability.
Fun Fact: Erik once tested wildfire sensors by starting a controlled forest fire in Northern Canada. He also builds car parts with 3D printing.
Greg Trujillo, 38
Engineering Manager
IDEC Corporation
Vista, CA
Greg combines deep mechanical expertise with people-first leadership. From aerospace to robotics to sustainability startups, he’s led high-impact projects and earned multiple design patents. Now at IDEC, he empowers engineering teams and mentors students, helping build the next generation of innovators.
Fun Fact: Greg is a first-gen college grad who loves deep sea fishing—early mornings on open water keep him grounded and inspired.
Laurent Trottier, 29
Senior Implementation Consultant MaintainX
Montréal, QC, Canada
Laurent has improved operations for more than 4,000 frontline workers across more than 350 global sites. A people-first digital transformation expert, he leads CMMS rollouts that slash downtime and maintenance costs. Laurent is a vibrant, cross-functional leader who shapes product strategy, mentors peers, and energizes teams with infectious positivity.
Fun Fact: Known for his intro—“You can call me Larry”—Laurent leads bike clubs, races up Mont Royal and inspires colleagues through fitness and fun.
Brice Williams, 40
Department Manager
Matrix Technologies
Cincinnati, OH
Brice blends technical excellence with team-focused leadership. From leading 24/7 system migrations in his early career to growing Matrix Technologies’ Cincinnati office, Brice has proven himself a versatile force in automation. He’s helped standardize PlantPAx systems and trains others in its use, all while fostering client relationships and team development.
Fun Fact: Brice is a Jeep offroading guide and pinball enthusiast who hunts for local machines during work travel—and always plays a few rounds.
Bill Warnke, 39 Senior Consultant Matrix Technologies Maumee, OH
Bill’s journey at Matrix began as a co-op in 2007 and has since evolved into a standout career as a Senior Consultant and company shareholder. Known for his versatility across industries and continents, Bill has led international implementations and created lasting impact in food and beverage, glass, pharma and other areas. A natural mentor and committee leader, he’s shaped best practices while fostering the next generation of engineers.
Fun Fact: Bill is a passionate runner and golfer, concertgoer and outdoors enthusiast who enjoys recharging with his wife and two daughters.
Engineering Leaders Under 40
Know someone who qualifies as an Engineering Leader Under 40? Help give them the recognition they deserve.
The Engineering Leaders Under 40 program recognizes manufacturing professionals under the age of 40 (as of Sept. 1, 2025) who are making a significant contribution to their plant’s success, and to the control engineering and/or plant engineering professions. Our research shows that finding, training and retaining workers is the biggest issue facing manufacturing today. The goal of the Engineering Leaders Under 40 program is to call attention to these successful young engineers in manufacturing and to show how manufacturers are recruiting and developing the next generation of manufacturing professionals.
See past leaders online at the website above, going back to 2010.
KAISHAN USA AND DIVERSIFIED AIR SYSTEMS SCORE A HAT TRICK WITH CUSTOM SEATING MANUFACTURER
CLIENT LOCATION
Precision Rehab Manufacturing Erie, PA
Scan the QR code to watch the video
THE SITUATION
Precision Rehab Manufacturing (PRM) custom molds seating for wheelchairs and other devices for people with disabilities. It relies heavily on compressed air to run computer numerical control machines, belt sanders and pneumatic equipment that manufacture its products.
“Our shop does not run if we do not have air,” said Nick Dinner, PRM’s vice president. “It is a lifeline for our business. We are super, super, super efficient.”
THE CHALLENGE
As the company grew and added two new CNCs, its existing 7.5-HP compressor wasn’t keeping up. The pressure was inconsistent—if both CNCs were running, the pneumatic equipment had to shut down. And he previously had problems with oil carryover from a reciprocating compressor.
So. he wanted clean, dry air and more consistent pressure, so that all his equipment had what it needed.
THE SOLUTION
It all started with hockey. Nick’s father, company president and CEO Todd Dinner, played pickup hockey with the son of Dave Henning, sales manager at Diversified Air Systems, an independent distributor of industrial compressed air and vacuum systems. Todd asked Dave for help.
Dave helped PRM select a compressor to handle the CNCs. Then, after conducting an audit of the facility’s flow and pressure demands, Diversified’s Dan Miller recommended a 20-HP KRSD direct-drive rotary screw air compressor equipped with a variable-speed drive for the main shop.
THE RESULT
The Kaishan unit handles both CNCs and the supporting equipment, maintaining a steady air flow at the pressure PRM needs. What’s more, with the VSD, there are definite gains in efficiency—energy costs are down 35%.
How strategic supply chain partners can enhance reliability in plant operations
From our experience in partnering with plants and their engineers, one theme is consistent: the services provided by value-added partners aren’t just transactional—they’re strategic. When you’re responsible for designing and troubleshooting critical systems, partners who deliver continuous strategic service become essential collaborators in your mission to keep operations running seamlessly.
A strategic partner understands your facility’s unique challenges and works with you proactively to prevent downtime, not merely reacting when issues occur.
The best suppliers go beyond simply selling a part in a box. They invest in building strong relationships, providing timely, insightful support and anticipating your needs before they become emergencies. Their teams are accessible, technically knowledgeable and committed to aligning their service to your operational goals. They can advise on best practices and emerging solutions. With this partnership, you gain a reliable resource that helps extend equipment life, optimize maintenance programs, and improve overall facility reliability.
Selecting partners with this commitment level transforms your supplier relationships into collaborative alliances that translate directly into smoother operations and less unplanned downtime.
Therefore, when evaluating suppliers, focus on long-term value. Prioritize those who demonstrate strategic service excellence. Dependable service is more than a benefit; it’s a critical factor that drives facility reliability and empowers you to deliver on your objectives.
has over 25 years of experience in the industry, sharing his technical and operations expertise with customers and teammates alike.
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