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Rockwell Automation Journal - April

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1. 34 THE JOURNAL APRIL 2009 WWW ROCKWELLAUTOMATION COM THEJOURNAL POC COOH HEE E HEHE EOE TOOHE EEO HSOT EE EEHHOEESOSOOOE OO OEHEO TEES OOTSE OO ESOT EE ESHOE EES OSEOE OS EOHOOT ES HOHETTOSETO TSO ES OSH SES OSEEE SE SOOSO TES HOOESS OSHS OS TOES OSHS EO OSEH EOE ESOHO EES HOOEESOSEHOT TS ET OHS ES OSEOTO SESH HOEESOSOSESOSEHOOESOTOOHEE TOSSES OE EEHSEEES ESOS O SEES e AN ELECTRONIC SUBSCRIPTION TO JOURNAL IS 1 CLICK AWAY THE From Rockwell Automation and Our Partners Life Sciences Update Cut Pneumatic Energy Costs Increase PI li Power Re It s that easy to get The Journal We keep you up to date on industry trends and help you increase productivity and profitability by getting the most from the technology and services offered by Rockwell Automation and its Encompass Partners and Solution Providers Get your e subscription today Visit www ROCKWELLAUTOMATION COM go tjsubscribe CUT ENERGY COSTS FOR PNEUMATICS New field devices for monitoring pneumatic systems let users measure compressed air consumption for comprehensive diagnostic and cost control By Dr Christian Boehm Manager Solution Engineering Center Festo Corp and Sean Schmelzer Power amp Energy Management Products Rockwell Automation gt gt Energy management and accounting systems can play a key role in reducing energy consump tion and carbon emissions Although compressed air is an expensive energy carrier tha
2. Accurate performance management helps you use planttloor data to create a productivity phenomenon that boosts your bottom line FEATURES Feeling the Pinch No Problem 14 Rockwell Automation Solution Providers are held to high stan dards so they deliver dependable systems integration services to help you through the tough times Pick the Right Partner 18 Discover how Rockwell Automation helps you find the right sys tems integrators for manufacturing information system projects Be Smart With Your Intelligence 26 Learn the difference between business intelligence and enter prise manufacturing intelligence and discover why they re criti cal for managing manufacturing operations Bridging the Digital Divide 28 Wyeth Pharmaceutical shares insights and expectations from its vision for establishing IT enabled manufacturing on an enterprise scale Adding PoP to the Process 32 An OEM used the Proof of Principle process and Rockwell Au tomation Integrated architecture to help its life sciences client to boost equipment speed and reliability Cut Energy Costs for Pneumatics 36 New field devices for monitoring pneumatic systems let users measure compressed air consumption for comprehensive diag nostic and cost control Is Reliability Enough 42 Learn how to detect the causes of voltage problems and help end power quality related downtime Recover Reuse 49 Life sciences companies can cut energy wa
3. item North America replaces painted welded steel with robust structural aluminum profiles and modular components for use in machine bases frames sub structures and assembly lines of any length Primary industries include medical packaging pharmaceuticals life sciences and research development item s in house engineering team will provide no cost engineering and design support to meet just about any machine building need Rockwell E ITA Automation shock vibration extreme temperatures or exposure to containments AMETEK Automation amp Process Technologies www rockwellautomation com go p ametek North America 925 Glaser Parkway Akron Ohio 44306 U S A itemsales itemamerica com Encompass Product Partner Americas www itemamerica com WWW ROCKWELLAUTOMATION COM THEJOURNAL APRIL 2009 THEJOURNAL 55 PRODUCT FOCUS gt gt Wireless Modem Rockwell Automation Encompass Product Partner ESTeem Wireless has released the Model 195Ed wireless modem It operates in the unlicensed 902 928 MHz spectrum with radiofrequency data rates from 1 Mbps to 54 Mbps It s suited for long range wireless networking applications with integral Ethernet and serial ports to support SCADA VoIP video and DFI protocol interface needs including wireless Remote I O ESTeem Wireless Modems www rockwellautomation com go p est gt gt Product Spotlight Production Control and Intorma
4. 5 PETROCHEMICAL MACHINE BUILDER PACKAGING OEM ASSEMBLY R Your Universe N Spectrum Controls ww s Universal 1 0 A ee Megaversal 8 p N N N Mix a variety of analog input te types voltage current resistance thermocouple and RTD on just one module Save money and optimize cabinet space So no matter what universe you occupy from machine builders to OEMs from oil refining to food processing Universal I O from Spectrum Controls gives you the ease of use flexibility and overall lower cost per point you need to stay competitive Call us today at 1 425 746 9481 to see how our All Spectrum Controls Universal modules use licensed Rockwell Megaversal solutions can help technology and include Rockwell technical support on us your automation universe aA s Tt i le f SACL E PLATT i tessa ee toa pm nk 1705 132nd Ave NE Bellevue WA 98005 USA Tel 425 746 9481 Global Email spectrum spectrumcontrols com www spectrumcontrols com VIEWPOINT JOURNAL JN Rockwell Automation and Our Partners APRIL 2009 VOLUME 16 NO 2 Putman Media Inc 555 W Pierce Rd Suite 301 Itasca Illinois 60143 630 467 1300 Rockwell Automation The Journal Executive Publisher Rockwell Automation Rebecca Archibald rkarchibald ra rockwell com Putman Editorial amp Sales Team Publisher Mike Brenner mbrenner putman net Executive Editor Theresa Houck thouc
5. Keith Nosbusch Rockwell Automation Chairman amp CEO We believe this forward thinking strategic part with the Hebei Provincial Develop ment and Reform Commission The agreement will allow both sides to cooperate on projects that help save energy reduce emissions protect the environment and achieve a sustain able economy First Vice Governor of Hebei province Fu Zhifang and Chairman and CEO of Rockwell Au tomation Keith Nosbusch partici pated in the signing ceremony We believe this forward thinking strategic partnership with the Hebei provincial government will lead to cleaner more modern and energy Metal Systems Becomes Lectrus Corp MSI Metal Systems a participat ing Encompass Product Partner in the Rockwell Automation PartnerNetwork and MSI Equipment Centers will now be known as Lectrus Corp Lectrus provides metal building production and expertise integrating complex electrical systems for the power oil and gas and other industrial markets Since 1968 Metal Sys tems has provided protection solutions for electrical equipment and personnel for markets that include custom manufactured equipment centers operator centers and custom electrical enclosures Lectrus Corp www rockwellautomation com go p lectrus efficient manufacturing and help give the province a leading position in sustainable industrial development said Nosbusch Under the agreement Rockwell Aut
6. SUSTAINABILITY CORNER a RECOVER REUSE By using on site solvent recovery life sciences companies can cut energy waste and costs while helping the environment By Trevor Mahoney Process Team Leader ProsCon Ltd A Rockwell Automation Company gt gt Paradigm shifts for finan cial decision making are occurring in all industries The life sciences industry faces special eco nomic challenges when drug patents expire For life sciences companies to sustain financial performance into the next decade they must also sustain their environmental perfor mance Solvent recovery solutions can help meet this challenge Solvent Usage In the life sciences industry solvents are essential to manufacturing They constitute a large portion of the raw materials consumed and the waste discharged Solvent use consistently accounts for 80 to 90 of mass utilization in a typical pharmaceu tical fine chemicals nonpolymer batch chemical operation Pharmaceuticals manufacturing can be divided into the Active Phar maceutical Ingredient API and the as acetone and ethanol to more must either be treated on site or sent Fill Finish processes The API process unique solvents such as tetrahydro off site for treatment formulates the active ingredient and furan THF and methyl tert butyl the Fill Finish process puts the API ether MTBE API manufacturing Old Fashioned Handling into pills or capsules outputs consist of bulk
7. on page 20 to learn how you can optimize your operations Until next time Theresa Houck Executive Editor WWW ROCKWELLAUTOMATION COM THEJOURNAL APRIL 2009 THEJOURNAL 7 1 NEWS amp NOTEWORTHY ROCKWELL AUTOMATION TO ACQUIRE RUTTER HINZ gt gt Rockwell Automation Inc has agreed to purchase the majority of the assets of engineering company Rutter Hinz Inc a wholly owned subsidiary of Rutter Inc a publicly held Canadian company Headquartered in Saskatoon Canada Rutter Hinz s annual sales are about US 35 million The acquisition includes Rutter Hinz s engineering and automation businesses in Canada and the United States but not its Newfoundland consulting engineering business or the assets of Rutter Technologies Inc These operations will continue as part of Rutter Inc With eight offices in Canada and two in the United States Rutter Hinz has engineering expertise in industrial automation process control and power distribution specifically for the oil and gas in dustry in addition to the pipeline utility mining forestry and food and beverage sectors The company s management team and approxi mately 220 employees will join the Rockwell Automation Systems amp Solutions business unit This acquisition accelerates the growth of Rockwell Automation s business and reach in Canada s heav y This acquisition establishes a robust delivery capability in a ma
8. Inc W Industries Inc River RoviSys Company Western Integrated System Rockwell Automation Copyright 2009 Rockwell Automation Inc All Rights Reserved AD RS2121 R2P B PARTNERNETWORK NEWS PICK THE RIGHT PARTNER Discover how Rockwell Automation helps you find the right systems integrators for manufacturing information system projects By Rob Windle Manager Information Solutions Partnering Program Rockwell Automation and Dan Hebert Contributing Writer The Journal gt gt Are you like many others trying to integrate the fac tory floor with enterprise informa tion systems to increase overall total supply chain visibility and agility but aren t sure where to start and who can make this goal a reality Are you finding that many of the tradi tional automation systems integrators aren t experienced at doing this Are you also finding that the traditional enterprise systems consultants don t really understand how your plant floor process operates Fear not Rockwell Automation has been working to identify and promote qualified companies with experience in deploying manufac turing production management systems and integrating critical information from the plant floor up and throughout the enterprises of companies just like yours While more and more compa nies are looking to achieve greater manufacturing floor visibility and integration to the greater enterprise the approach to a
9. To be recognized in any of the disciplines means that the Solution Provider s ap plications will be routinely audited A successful audit is measured through an audit of the installation by inter viewing the customer If the customer views the installation a success then Rockwell Automation will recognize that Solution Provider in that disci pline and be promoted accordingly Why is That Important to You It s all about mitigating your risk Involving third party organizations inherently adds risk to your success and risks can appear in many forms Ask yourself these questions e What third party organizations can help me achieve my goals e Who can help me determine if the goals are achievable How do I know who to trust e Do they have industry know how Where have they done it before e Are they going to be in business long term e Are they financially sound e Do they have the resources I need Bandwidth Scalable re sources Technology e What is their project manage ment methodology e How do they mitigate third party risk Our goal is to do the legwork for you and provide you with one place to look for all your solution delivery needs Whether you want to involve a third party for the first time or youre looking to expand into areas such as information solutions safety solutions or asset management Rockwell Automation and its Solu tion Providers are working to make it easier to find a h
10. e N m X La A Y P V V 2 Z A b b X V 2 N 7 N PED P IOJ A WY x X x 42 THE JOURNAL APRIL 2009 WWW ROCKWELLAUTOMATION COM THEJOURNAL facing manufacturers When calcu lating those five nines only power outages longer than two minutes are counted as a failure of service Short term voltage deviations are much more common The result is that poor power quality PQ causes more downtime than poor power reliability We ll examine PQ and see how to use PQ monitoring to identify the cause of voltage sags to help prevent PQ related downtime Power Reliability Doesn t Tell the Whole Story Brief voltage disturbances cause most power related downtime More than 92 of all power glitches are voltage sags lasting less than two seconds Voltage sags occur when weather animals equipment failure or human error cause a short circuit on the utility grid Sags are most commonly related to such grid events that are both unpredictable and beyond your control U S manufacturers even with premium power experience six to 10 voltage sags every year Many are hit by weekly voltage sags during the spring and summer storm seasons Although some voltage sags can cause the lights to blink they arent always so detectable Some sags are so short that the lighting flicker is im
11. gt What the Worldwide Shortage of ACN Means to You By Charles R McBride Process Technology amp Modular Construction ProsCon ltd A Rockwell Automation Company The worldwide shortage of acetonitrile ACN products is primarily related to the global economic downturn ACN is a by product from the automotive indus try that is widely used in the pharmaceutical industry for laboratory use and in Active Pharmaceutical Ingredient API processes Raw ACN is obtained as a by product in the production of acrylonitrile a plastic used in automobile com ponents and other products such as carpets and luggage As a consequence of the collapse in the automotive industry and the associated overall reduction of demand for acrylonitrile the supply of ACN has been significantly reduced This supply constraint will continue in the short to medium term with an ex treme shortage being anticipated for the first half of 2009 This is causing sharp price increases in some cases six to eight times that of the 2008 ACN price This increase is expected to remain for quite some time Benefits that you can realize by recovering spent solvent can include e Good payback period typically fewer than 15 months e Reduced solvent purchase and resulting protection against future solvent supply and cost issues e Reduced waste and disposal costs including the elimination of spent sol vent transport from site and associated risks e Redu
12. uses for its certifica tion process see sidebar on page 16 WWW ROCKWELLAUTOMATION COM THEJOURNAL APRIL 2009 THE JOURNAL 15 SPNEWS What Technology Experiences Do Solution Providers Offer Rockwell Automation recognizes the importance of keeping your facilities operating at peak efficiency Solution Providers have consistently demon strated their technical competencies in a successful implementation of Rockwell Automation products Solution Providers are best in class system integrators evaluated on competency especially with our control products To further help you reduce your risk we ve developed additional compe tencies to raise the knowledge of the Solution Providers in several manu facturing disciplines e Control Recognized Verified implementation of the Rockwell Automation Integrated Architec ture for improving manufactur ing processes eProcess Recognized Verified industry specific experience in delivering successful plant wide process automation e Information Recognized Verified delivery of manufactur ing information solutions using Rockwell Automation Facto rylalk technologies for plan ning scheduling quality and performance management This added dimension allows you to easily find the Solutions Providers that have experience with these tech nologies and it provides the Solution Provider the opportunity to differenti ate themselves among their peers
13. 16 THE JOURNAL APRIL 2009 WWW ROCKWELLAUTOMATION COM THEJOURNAL Rockwell Automation Solution Providers Partners in delivering solutions Best in class systems integrators providing industry and applications expertise in delivering automation and information solutions to manufacturing companies globally Proven trusted established organizations with extensive experience in design implementation project management and maintenance of your automation control and process solutions Our Solution Providers deliver innovative results to keep your facilities operating efficiently Rockwell Automation Solution Provider ABCO Automation Inc Applied Control Technology Automated Control Concepts Inc Bachelor Controls Inc Biehle Electric Inc Concept Systems Inc Electro Design Engineering Inc Elm Electrical Inc ESE Inc Grantek Rutter Hinz HK Systems Inc Horizon Consultants Inc Interstates Control Systems Inc Javlyn Inc JVH Engineering Inc L H Controls Inc Matrix Technologies Inc Millennium Control Systems Inc Naval Automation Group LLC Allen Bradley Rockwell Software Power Engineers Stone Technologies Polytron Inc Systems Interface Inc Precision Control Systems Taurus Power and Controls of Indianapolis Inc Technical Systems Inc PREMIER System Integrators Inc Tegron Pyramid Controls The Oilgear Company Reimelt Corporation TriCore AEA Revere Control Systems
14. 5831 or 858 278 2900 HARDY INSTRUMENTS WWW ROCKWELLAUTOMATION COM THEJOURNAL APRIL 2009 THE JOURNAL 45 Rockwell Automation Encompass Product Partner ENCOMPASS SHOWCASE Single Channel Weigh Scale Module This single channel weigh scale module features strain gage signal conditioning builtin tare and programmable gain and calibration tunctions It is available in 16 bit 1 millisecond update 10 000 count full scale and 20 bit 200 millisecond update 100 000 count full scale versions Applications for the HM 1734 module include batching filling process bulk weighing and level control Helm also manufactures strain gage modules for the 1746 1756 and 1769 I O platforms For more information call 419 893 4356 or visit www helminstrument com HELM INSTRUMENT CO INC Excel Reporting for Production and Management Finally a reporting solution that gives the informa tion you need in the form you want with absolutely no programming XlReporter turns raw process data into a polished report in worksheets Web pages or email If you are looking to combine the best of Microsoft Excel with a product that has industrial ro bustness fast data access integrated tag browsing LRepories Seay ma eye E Pete Pet ig hee T and firstclass support then this product is for you The product is compatible with RSLinx RSView OPC Servers OPC HDA Servers ODBC compliant da
15. Compatible Standard 1756 format plugs directly into ControlLogix rack RS 485 and Ethernet interfaces www fieldserver com slotserver 1991 Tarob Court Milpitas California 95035 USA Tel 408 262 2299 Fax 408 262 9042 TETE Toll Free 888 509 1970 Product Partner email sales fieldserver com FieldServer Technologies WWW ROCKWELLAUTOMATION COM THEJOURNAL APRIL 2009 THEJOURNAL 11 E NEWS amp NOTEWORTHY gards Creameries Partnering with Pavilion helps us continue reducing our operating costs while further ing our commitment to continu ously provide our customers with top quality products The Pavilion Dairy Industry Solution is based on the Pavilion8 modular software platform to pro vide modeling prediction control and optimization capabilities in one system Bongards will leverage the Pavilion solution in its dryer application to help manage product quality consistently closer to prod uct specifications reduce variability of product quality and maximize throughput subject to equipment and process constraints Pavilion Technologies A Rockwell Automation Company www pavtech com dairysolutions HEBEI PROVINCIAL GOVERNMENT ENTERS PARTNERSHIP Rockwell Automation has signed a strategic partnership agreement gt gt Encompass Partner Briefs nership with the Hebei provincial government will lead to cleaner more modern and energy efficient manufacturing
16. Figure 1 The preview pane shows the top protocols and their percentage of total packets on the network Tap the Details button to see a list of all the discovered C S E ise biAS Prema teen PiE Meisi H O Fi o LLES a Dg f mj wim ij ae S a al a LN z 7TH iT ints Tiri ijas eh tH Thea Timi tat aa F ies u E e TL E TT l eps a i LIF Frai e ii pea Figure 2 Using the Details button reveals a list of all the discovered network protocols network protocols on the local network segment see Figure 2 Select a device in the summary view to see Device Details for that device see Figure 3 Using Protocol Statistics will help ensure that the only traffic on your network is the type you want and know about _ Rockwell Automation Encompass Partner Fluke Networks Everett Wash supplies test tools for cabling infrastructure and network diagnostics Fluke Networks www rockwellautomation com go p fluke Rockwell Automation Encompass Product Partner Program www rockwellautomation com go tiencompass m a EI hi MHE ee a BU AHIR iiia main kai sre THER fr miman binhe be et ninh Hann kimi p PSE Vile LAE ee ee a Ws i ra a a boat E mm Narr Bi Figure 3 Select a device and get detailed information about it WWW ROCKWELLAUTOMATION COM THEJOURNAL APRIL 2009 THE JOURNAL 47 TECH TIPS WHAT IS TARE VALUE Learn how tare value is use
17. client side software on every PC in the company Whichever data source owns the data remains its owner no new master database is created EMI soft ware can recognize what information is located in which data source and interacts with it whenever users need Presentation and Information Analysis Made Simple EMI software now can provide users with access to intel ligent reports that offer alert detection through live data connections It can automatically drive user attention toward exception conditions missed targets and plan deviations All of this information arrives as dashboards reports and charts via standard browsers such as Internet Ex gt gt Business Intelligence That Makes Sense FactoryTalk VantagePoint from Rockwell Automa tion seamlessly links the enterprise business systems with production information The solution relies on a Unified Production Model that provides users with a logical view of their operations The model allows us ers to build representations of their businesses using real world terminology instead of talking about tag names protocols and SQL statements Users can cre ate portable content that they can look at visualize and report on independently of the underlying data infrastructure The software allows users to interact with existing model definitions of plants production lines and equip ment that are contained in an enterprise database They use data mapping to manifest that informat
18. com Communication Modules IAS Grace Engineered Products www grace eng com GradePort R Series 3 Hardy Instruments Inc www hardyinstruments com Process Control Technology 45 Helm Instrument Company Inc www helminstrument com Process Control Systems Force Transducers Software 46 item North America www itemamerica com Structures 39 Longwatch www longwatch com Video Surveillance 45 Matrikon Inc www matrikon com Software Remote Alarm Notification A8 Online Development Inc www oldi com Enterprise Transaction Modules Is Phoenix Digital Corp www phoenixdigital com Optical Communications Modules 51 ProSoft Technology Inc www prosoft technology com Communication Modules 60 Rockwell Automation www rockwellautomation com go Sitj Solution Providers 17 Rockwell Automation www RSTechEd com RSTechED 2009 7 Roxtec Inc www roxtec com Cable Entry Seals 55 SchenckAccuRate www accuratefeeders com Weighing Instruments 31 46 Spectrum Controls www spectrumcontrols com I O HART Modules 6 SyTech Inc www sytech com XLReporter 46 TCL ULC www transcoil com AC DC Driver Peripherals A6 Wittenstein wwwwilttenstein com Gearheads 2 46 58 THE JOURNAL APRIL 2009 WWW ROCKWELLAUTOMATION COM THEJOURNAL Invest in You Premium Education in Manufacturing and Production More than 110 technical sessions hands on labs and user presentations promise to sharpen your skills and help you navigate the most challenging business climate in decades The week l
19. diligent approach to operational improvement using metrics such as OEE A Targeted Approach Achieving leading class OEE scores has been shown to help improve bottom line results in a range of industries For Clos du Bois installing OEE software to evaluate the performance of its critical production assets helped the winery improve ef ficiency by 20 see page 46 October 2008 issue of The Journal From Vine to Bottle The win ery was able to leverage advanced performance management techniques and real time informa tion from its own processes to improve efficiency and optimize production Located in the Sonoma County wine region in Northern California the winery wanted to cut costs and boost production A key area of focus was the high speed bottling line because it had the greatest influence on overall production and yield The line was experiencing unplanned bottle necks and stoppages and running at a mere 65 efficiency However without a clear picture of what was actually hap pening it was difficult to identify the areas that needed improve ment To make any improvement Clos du Bois first needed to under stand where the problems were and what was causing them The winery partnered with Rock well Automation for a sophisticated data acquisition system that could deliver accurate real time informa tion to help management identify the cause of problems and drive continuous improvement Operators now use Fa
20. implementing dashboards and portal technology to improve interactions with suppliers and customers They re doing this by establishing a customer Web portal for all order entry and tracking a portal that exchanges information directly with the factory floor Inte gration benefits extend into customer service as well with the ability to connect manufacturing to customer relation ship management CRM systems accessed by sales people and supplier networks Real time knowledge sharing in a way that helps both manufacturer and supplier means higher sales while offer ing customers expanded choices and improved responsive ness to market demands Advanced performance management technologies are helping manufacturers across all industry sectors achieve de monstrable value from baselining visualizing and comparing plant performance to historic measures Those companies that capitalize on these technologies will be the ones best positioned to reap continuous performance improvements and gain a substantial competitive advantage now and into the future Rockwell Automation Information Solutions www rockwellautomation com go performance WWW ROCKWELLAUTOMATION COM THEJOURNAL APRIL 2009 THEJOURNAL 25 gt Many people are confused about the differ enterprise manufacturing intelligence EMI systems ences between business intelligence BI and Although both terms refer to gathering and analyzing inf
21. resource planning ERP level and extend down to the plant floor usually by deploying production management or other similar and more comprehensive types of applications In a typical plant information is collected by PACs and HMIs These communicate this information to and from manufacturing execution system level MES platforms and ERP systems Examples of MES platforms include Computerized Maintenance Management Systems CMMS Laboratory Information Management Systems LIMS data historians production scheduling systems and many others Popular ERP systems include SAP Oracle and other smaller brands The skill sets needed to handle and make sense out of information collected by automation systems vary All program members have been thoroughly vetted by Rockwell Automation greatly from traditional plant floor automation experience To imple ment systems at the enterprise solu tion level the potential partner must understand IT systems plant floor automation systems and the business drivers for manufacturing plants and enterprises Much of the implemen tation is integrating a larger system into an existing ERP system Information Solutions Partnering Because two ways exist to solve these applications Rockwell Auto mation has improved and extended its traditional Systems Integrator Program to assist you in finding the right partner We do this by approv ing potential partners to establish t
22. served as manager of the Columbus Ohio electrical department project manager and lead engineer for numerous projects both domestically and internation ally His background in electrical systems design includes process instrumentation and control power distribution control of large induc tion and synchronous machines and control system software integration In his new role Krupp will be responsible for development of multi discipline design and equipment supply projects River Consulting www rockwellautomation com go p riverconsulting ODVA ISSUES 50 DECLARATIONS OF CONFORMITY ODVA and the Center Verteilte Systeme at the Institute of Ergo nomics CVS IAF Manufacturing Systems and Automation of Otto von Guericke Universitate Magde CVS IAF Oy Buericke Universit burg have issued 50 Declarations of Conformity for EtherNet IP single products and product families that successfully passed the ODVA conformance test for EtherNet IP conducted at CVS IAF This number of Declarations of Conformity from European based EtherNet IP vendors reflects vendor confidence in the EtherNet IP tech nology the open network standards of ODVA and its conformance test ing process and CVS IAF as one of ODVA s test service providers The goal of the ODVA confor mance testing process is to help to ensure to the greatest extent prac ticable that products implementing ODVA technologies and standards comply w
23. the next phase Improvement Phase Il Supply Side e Select a compressor s configuration that can fulfill the needs of optimized requirements of the demand side e Check storage and compressor sizing and control to provide proper pressure and flow supply e Lower supply side generated pressure where possible Ongoing Data Collection and Monitoring e Continue to collect data with activated alarm thresholds that notify you if compressed air consumption electric energy consumption or pressure fluctuations exceed certain limits 38 THEJOURNAL APRIL 2009 WWW ROCKWELLAUTOMATION COM THEJOURNAL The energy monitoring package quantifies air con sumption pressure and flow values of different machine operation modes to evaluate the pneumatic system s health status find a machine s optimal point of operation identify inefficiencies schedule preventive maintenance and to per form central or decentralized air consumption monitoring Once commissioned the energy monitoring package continuously monitors the machine s air consumption to provide constant updates about system performance An increase in system air consumption or pressure fluctuations are quickly indicated This helps to reduce downtime and keeps equipment operating It also helps provide a cost effective production schedule and deliver a quality product The user can configure the energy monitoring package for up to 16 different processes These can be configur
24. to 1600x1200 resolution with either monochrome or color output The flexible GigE camera ports allow mixing of camera resolutions and expansion to support multiccamera applications It is available with two software options iNspect and Sherlock to ad dress application needs of machine vision users DALSA www rockwellautomation com go p dalsa gt gt Linear Displacement Transducer The Synchronous Serial Interface SSI Linear Displacement Transducer LDT trom Ametek Automation amp Process Technologies a participat ing Encompass Product Partner in the Rockwell Automation Partner Network is designed to offer absolute continuous linear position feedback with 1 micro resolution under the most extreme conditions The unit is IP 68 rated and lab tested to 1 000 Gs of shock and 30 Gs of vibration The Gemco 953S VMax is suited for applications that involve No more cutting servo cables and connectors Allows pre terminated cables to be used for better connectivity no EMI or signal loss UL NEMA 4 4X 12 and 13 Roxtec Cable Entry Seals E Allow preterminated cables and reduce costly repairs of machines due to improper cable terminations Roxtec 10127 E Admiral Place Tulsa OK 74116 ae PHONE 800 520 4769 918 254 9872 E Longterm operational reliability FAx 918 254 2544 E Easy to add cables any time EMAIL oem us roxtec com E Fits enclosures and cabinets www roxtec com oem
25. used for the safe operation of nuclear reactors Ultra has concentrated its nuclear systems activities both military and civil in its Information amp Power Systems division Weed will be a bolt on to that division and will report through the group s Advanced Tactical Sys tems business in Austin Texas Weed is a privately owned com pany that designs and manufactures high integrity instrumentation for the civil nuclear and other indus tries mostly for the North American market It specializes in temperature and pressure sensors and fiber optic converters and switches for nuclear aerospace and military applications Based in Round Rock near Austin Weed employs about 100 people Weed Instrument Co Inc www rockwellautomation com go p weedinst COOPER OPENS TECHNOLOGY CENTER Cooper Bussmann a division of Cooper Industries and a participating Encompass Product Partner in the Rockwell Automation PartnerNet work recently celebrated the grand opening of the Cooper Technol ogy Center near Cooper Industries headquarters in Houston as part of its 175th anniversary celebration The 35 000 square foot facility features an auditorium conference room and multiple training rooms designed for education and hands on demonstra tions of the Cooper Industries line of industrial products and solutions The products of all eight Coo per divisions are represented in the Technology Center with dedicated displays
26. with the Logix Control Platform and the FactoryTalk integrated production and performance suite The solution included an Allen Bradley ControlLogix programmable automation controller PAC with Kinetix Integrated Motion and Factorylalk View human machine interface HMI software The seamless integration capabil ity of these three technologies control motion and visu alization helped Remmele meet the client s performance and throughput demands Remmele Engineering can now offer its clients an entirely new level of control system capabilities for throughput efficiency and reliability Kinetix Motion Control leverages the Logix Control Plat form to reduce programming time and improve information flow between components Other solutions require a dedicated controller for discrete and I O control and another for motion control each with its own software package hardwiring communications and synchronization logic The Logix Con trol Platform provides a single integrated system The single programming environment in Rockwell Soft ware RSLogix 5000 a common tag based programming structure eliminates programming and synchronizing two separate controllers for every machine function One ad dress makes programs easier to read and access Tag names can be shared between controller programs HMI and other applications by defining each tag only once The Perfect Blend Effective blending of design and te
27. 24 THEJOURNAL APRIL 2009 fine tune processes and note the effects of any variations introduced as the tool hones in on various phases of batch production processes This is useful because the company standardizes the processes behind each product once it has arrived at the optimal recipe and performance level For example in its ready to drink beverage operations engineers developed a new formulation of flavored milk Then they established an end to end series of operations for factories that would produce the product Those standards include the formula for the drink and exact procedures for equipment operation and specific data points that must be monitored for quality control and compliance The stan dards even address how the data should be displayed on the Web Now when the company expands to another factory it can replicate the exact process Rockwell Automation FactoryTalk VantagePoint www rockwellautomation com go tiftvantagepoint LEAN POCKETS gt o fa E rrii WWW ROCKWELLAUTOMATION COM THEJOURNAL EER Te 2 applications It makes data in these systems visible and ac tionable by presenting a coherent picture of the production operation through an Internet browser and PC interfaces The dashboard provides the foundation for a range of manufacturing analytics including real time executive dashboards automated production reports KPI monitor ing and alerts downtime analysis and reports and process v
28. AL In fact 79 of the costs for compressed air are from the cost of electrical energy while 15 and 6 are the costs for capital investment and maintenance respectively Surprisingly this isn t a well known or accepted fact among manufacturers The potential remains unrealized to optimize com pressed air systems to save electrical energy for compressed air Manufacturers can save up to 33 on electrical energy costs by improving the dimensioning of compressors and air distribution nets optimizing drives reducing leaks and avoiding inappropriate use of compressed air Figure 1 shows the results of a European Union EU study in which the components of saving potentials are documented With these statistics it s clear why Mike Cybulski president of Festo Corp Hauppauge N Y confirms that customers are more frequently asking how much compressed air and pressure is needed at the point of consumption and how much com pressed air and pressure their compressor rooms should supply during shifts weekends and peak flow events Many customers using energy management solutions like Rockwell Software RSEnergyMetrix for the electrical side are already achieving impressive energy and cost reduc tions says Sean Schmelzer product manager of RSEner gyMetrix for Rockwell Automation However now they want to expand their system and incorporate the pneumatic side into their existing energy management solution to achieve cost saving
29. API often in The finished pharmaceutical prod Solvents have several uses includ powder form ready for Fill Finish uct is commonly required to contain ing preparation extraction and pu and solvent waste streams As the only trace amounts of solvent if rification in the API process These bulk API moves on for further pro any Therefore the masses of sol range from familiar substances such cessing the solvent waste streams vent put into the process must be WW W ROCKWELLAUTOMATION COM THEJOURNAL APRIL 2009 THE JOURNAL 49 i SUSTAINABILITY CORNER removed consumption should equal discharge A widespread practice has been to incinerate this solvent waste stream rather then recover or reuse it because the production process uses only fresh or virgin solvent An off site con tracted waste removal company usually incinerates the solvent and this can be a major manufacturing expenditure with unwanted environmental impact Reuse of the recovered solvent was previously precluded by drug filing regulations If a drug is approved for use when manufactured with virgin solvent a new regulatory filing would have been required to use the recov ered product instead Solvent Handling in Sustainable Production New business drivers are changing this mindset Companies now are mo tivated to implement solvent recovery rather than incinerating their waste These drivers include drug patent gt
30. APRIL 2009 JOURN From Rockwell Automation and Our Partners Life Sciences Update Cut Pneumatic Energy Costs Increase Plant Power Reliability Use information now Cuts costs increase efficiency maintain quality Aer ere li Auf at hon Encompass Product Partner WITTENSTEIN being one with the future y Al P gt www wittenstein us com WITTENSTEIN OSHA s Goming Don t HHI Gaughi iih Your Pants aii BURNIE and LES iatiliini a a i i s sg i nell Se Hop a Long but that TempCover is for the pa Nice shorts Hop a di Increase Safety While NEW Maai olyant Ai aJe Vsi Enhancing Productivity 3 Long Life LED s safet 5 40 750 VAC 30 1000VDC No Fuses e Meets OSHA Applicable Standards 29 CFR 1910 General Industries CHE ee VOLTAGE 29 CFR 1926 Construction Koef R ails e Rated up to 600 Volts Max 1000VAC gt VOLTAGE PRE TEST PONTS e e Puncture Tear Resistant Installs in a 1 4 Hole m e Non Conductive Magnets i i j Quick Pay Back with 2 3 jobs Touch Safe Voltage Portal gt CA Q US aj a EN Gy GS RAGE Automation sit EN GIN EER ED Encompass PRODUCTS INC Product Partner 800 280 9517 www graceport com CONUN a z 4 N gt 2 ho N E P T N N N y 4 N S g D f N E j 4 vv 1 N 1 N y N L Sa S 4 y C
31. Also Bryan Krupp has and has been with River for more president and CEO of Longwatch a been appointed director of project than a decade He has designed participating Encompass Product development hundreds of concrete silos and stor Partner in the Rockwell Automation PartnerNetwork A video process monitoring system continuously archives live video from multiple cameras around a plant When an event occurs the system can provide video from be fore and during the event and put it on the HMI screen for the operator to view as many times as desired Video clips also can be stored in an historian logged with time gt fF stamps and event information and used to confirm that process steps were performed properly help diagnose intermittent problems and train operators The white paper describes the hardware and software elements of a video process monitoring system how it uses the plant s industrial network to transmit video to the control system and how the video images appear on HMI screens Plant Floor to Computer Data canaries aie Exchange that Manufacturing IT and www longwatch com solutions a eat the CFO Can Agree On Longwa tch Inc eATM data appliances minimize the costs and time for setting up controller to computer data transactions They let you easily select configure and move data between plant floor controllers and back office computers all without having to buy a PC s
32. Based Reporting To meet its needs the company implemented a compre hensive plant wide reporting solution Data coming from 150 different operations 200 work cells and 180 plant level controllers is now managed using FactoryTalk Metrics With its Web based reporting function and flexible report ing design the dashboard software provides a standard tool set for generating reports and integrating with Martinrea s operating system which allows people to view plant floor information from multiple offices Martinrea management uses the data to improve production processes and now can quickly respond to the demands of its automotive manufacturing customers with the ability to gather and report production data to them on short notice In effect we ve established a common template for plant performance reporting that maximizes our productivity and efficiency Allison says We have less downtime and we re extremely pleased with the products and support we ve received Each new application we add to the solution is seamlessly integrated with our existing infrastructure and that is exactly what we need to continue to succeed in the automotive marketplace In effect we ve established a common template for plant performance reporting that maximizes our productivity and efficiency Darren Allison Manager of Information Technology Martinrea International s Hopkinsville Plant Gaining an Edge Some companies are
33. DM doesn t improve energy efficiency by itself It does lead to better informed decisions about technical measures that can help achieve the best overall system performance to help to cut costs Those measures can have a positive effect on nearly every aspect of compressed air system and include Modified production schedules to avoid high demand and peak flow events e Altered compressor types compressor room technology and compressor locations e Modified control systems e Changed overall system design including multi pres sure systems or subsystems e Identified localized and reduced air leaks e Identified localized and reduced pressure losses in the compressor room the air distribution system and on the demand side e Optimized pneumatic components air preparation units valves drives sensors pipes connectors storage blowing and vacuum applications etc in the air distribution system and on the demand side The first step to improve energy efficiency is to mea sure and track the compressed air system performance This helps users make decisions about changes in main tenance practice equipment replacement or extensions in systems based on reasonable documented facts and consequently help achieve the highest possible cost savings Also tracking performance over time is vital to detect performance degradation or changes in charac teristics or air use especially as compressed air systems gro
34. OURNAL 27 toh are a 1 0 st to en a A STO OA SD EH Hi EHE Sere eee eee phere BSB ess i ER DU RER E E R E BA EEO ia E ie rat oy M A A mataa TEFFEPFEREEERE By Jim Ricigliano Director of Process Excellence Wyeth Pharmacuticals and Bob Honor Vice President Information Solutions ai i A a er gt gt Life sciences companies seeking to achieve world class performance can view the pharma ceutical industry s adoption of information technology IT at the production operations level although still in the early stages as a highly relevant precursor of changes to come In our industry the original impetus took the form of regulatory pressure Mandated compliance with govern ment quality expectations helped drive the adoption of systems that eased the pain and simultaneously increased the accuracy reliability and speed of retrieving product genealogy for batch or assembly operations EBR DHR as well as validating process rigor CFR21 part 11 Ironically the same impetus for improvement in our industry may hinder additional advancements due to vali dation costs associated with changes in production related processes 28 THE JOURNAL APRIL 2009 Digitizing manual and paper based processes introduces new levels of consistency visibility and reliability to opera tions It institutionalizes business rules and tribal knowl edge This transforms the art of production into a science that can be measur
35. a S part without consent of the copyright owner including digital reproduction SUBSCRIPTIONS Qualified reader sub scriptions are accepted from Operating Management in the Industrial Automation industry at no charge To subscribe or unsubscribe e mail Theresa Houck at thouck putman net Putman Media Inc which also publishes Chemical Processing Control Control Design Industrial Networking Pharmaceutical Manufacturing Plant Services Food Processing and Wellness Foods assumes no responsibility for validity of claims in items reported Putman Media Inc is not affiliated with Rockwell Automation Inc The Journal from Rockwell Automation and Our Partners is a trademark of Rockwell Automation Inc and its use in the title and masthead of this publication is by license granted by Rockwell Automation Inc to Putman Media Inc Some photographs ZZ 7 gt iN ir T N a E gt _ a Ay and other illustrations printed in this publication may be used with safety equipment eis lt i removed or altered for illustrative purposes However in actual operation it is recom a sien lt lt peer Odi War WN mended that all correct safety procedures and equipment always be utilized PAA TON EL Le i Allen Bradley Rockwell Software Automation WWW ROCKWELLAUTOMATION COM THEJOURNAL APRIL 2009 THE JOURNAL
36. actuation A dedicated reset signal is the only way to reset the valve into the run mode eliminating accidental resets It also features a feedback switch for controls system integration for troubleshooting assistance Ross Controls www rockwellautomation com go p rosscontrols gt gt Backlash Free Servo Couplings The ROTEX GS elastomeric jaw coupling from Rockwell Automation Encompass Product Partner KTR Corp uses a pre loaded spider element for backlash free perfor mance and vibration dampening Urethane and Hytrel spiders are available in three standard durometers allowing a simple way to fine tune the system Cross clamped hubs are standard Keyless clamping ring hubs also are available KTR Corp www rockwellautomation com go p ktr WWW ROCKWELLAUTOMATION COM THEJOURNAL APRIL 2009 THE JOURNAL 57 PRODUCT FOCUS PI REGY ail gt gt Protocol Converter pa RECY Rockwell Automation Encompass Product Partner Miille Applied Research Co Inc offers the MARC Model P 266 POO Omnii Comm microprocessorbased communication module with an Ethernet option that expands a ERROR the number and type of applications for this module It transfers data between the serial ports and the Ether fate net port to integrate a serial port protocol into a modern communication network MARC It is available in AC and DC powered versions with one Ethernet port and two to four serial communica N PE tion ports Each serial p
37. acturers have access to tools that au tomatically find correlate and distribute information critical for smart business decision making even for users who have a variety of systems This was precisely the situation facing Nestl one of the world s largest producers of food beverage and phar maceutical products As the company expanded the number of process operations at one site manage ment determined it needed a more powerful deci sion support and visibility system that could provide employees with a single point of access to data from multiple devices across the facility The system also would need to organize the information so employees from different departments of the company could read and understand it And the system had to provide advanced analyses and Web reporting capabilities Nestl chose to implement FactoryTalk Vantage Point EMI an enterprise manufacturing intelligence EMI application that leverages technology Rockwell Automation acquired from Incuity Software The ap plication helps correlate data from different sources so decision makers across the enterprise can see diverse views and new relationships within a Web browser The reports key performance indicators KPI and operational metrics then can be assembled quickly into dashboards to help management mea sure performance across the facility Additionally Nestl leverages the FactoryTalk VantagePoint EMI trending tool to compare batch runs
38. al technologies will be required to meet the rigorous demands Many manufacturing facilities already have more computers in the factory than in the front office IT departments wouldn t think of operating their servers without power protection shouldn t factory automation get the same level of protection SoftSwitching Technologies Middleton Wis is a partici pating Encompass Product Partner in the Rockwell Automa tion PartnerNetwork The company offers the Grid Alert power grid sensing notification and corroboration utility and the Dynamic Sag Corrector DySC voltage sag mitigation and power quality solution SoftSwitching Technologies www rockwellautomation com go p softswitching Rockwell Automation Encompass Product Partner Program www rockwellautomation com go tjencompass 44 THE JOURNAL APRIL 2009 WWW ROCKWELLAUTOMATION COM THEJOURNAL Rockwell Automation Encompass Product Partner ENCOMPASS SHOWCASE Proportional Pressure Regulator VPPM with CPX MPA VPPM allows for proportional pneumatics with directional or stand alone valves to be integrated with Rockwell Automation leading network technology EtherNet IP and Devi tors A unique dual pressure technology for ceNet The complete system supports a combination of regulators valves and I O with a maximum of 16 regulo precise regulation enables VPPM to provide optimized performance via one of th
39. ale The implications are many Our goal is simple Provide our customers with best in class dry solids metering systems by combining our and deploying plant level information systems that some manufacturing man agement teams hold award winning feeders and DISOCONT au fockwen Just as no world class company controllers with the latest Allen Bradley E F i ncompass would consider deploying a home PLCs HMI devices and DeviceNet or i grown ERP application today the sys EtherNet IP communications products Americas and expertise Let us help you by calling 800 606 9252 tems that manage your manufacturing process should be governed deployed and maintained with similar IT rigor Evaluate your software partners wisely SC h enc k Acc U R ate for that elusive combination of domain expertise market commitment and www accuratefeeders com resource depth Wyeth s partner of we make processes work choice for plant wide information soft 2008 Schenck AccuRate ware and automation control systems is Rockwell Automation a choice based WW W ROCKWELLAUTOMATION COM THEJOURNAL APRIL 2009 THE JOURNAL 31 Despite a wealth of experience designing and building systems for a range of industries leaders at Remmele Engineering New Brighton Minn be lieved the company could differentiate itself in the life sci ence market This could be accomplished by using a better mechanism for addressing potent
40. and product in the build ing design itself A replica of an industrial plant helps to complete the learning environment with more than 250 of Cooper s industrial offerings installed as they would ap pear in a refinery Based on the current schedule and bookings to date several thou itt tar kr 4t The most complete line of Planetary Gearheads i p tee Sy ARR Co SE X Fress SHIP IN 24 HOURS Rockwell Automation Encompass Product Partner Americas WWW ROCKWELLAUTOMATION COM THEJOURNAL APRIL 2009 THE JOURNAL 9 sand people are expected to use the facility each year Cooper Industries CEO Kirk Hachigian explains Our vision for the Cooper Technology Center came from the industry s thirst to keep current with the latest tech nology and products that facilitate increased productivity enhanced energy efficiency and maximum safety for both workers and facili ties Now professionals who design and build industrial facilities can see Cooper s entire line of industrial offerings under one roof from the newest lighting technologies and electrical fuses to transformers and energy automation solutions to mass notification systems Cooper Bussmann www rockwellautomation com go p cooper SCHREIBER JOINS BACHELOR CONTROLS Philip Schreiber recently joined Bachelor Controls Inc BCI a Rockwell Automation Solution Provider Sch
41. ations for batch operations with different air consumption profiles and can be totally independent from each other If batches have many variations a new teach in is unnecessary Previously generated data is available in the memory and is automatically uploaded This allows different operating batches at different clock hours in a 24 7 operation Documenting ac tual value comparisons permits a full analysis of the machine allowing potential problems to be immediately discovered Rockwell Software RSEnergyMetrix energy manage Tracking performance over time is vital to detect performance degradation or changes in the amount of air use ment software captures analyzes stores and shares energy data across the entire enterprise Using a Web browser users can get energy information from a company s LAN or WAN to help optimize energy consumption RSEnergyMetrix and GFDM can easily be combined as part of a plant wide and long range plan to account for energy consumption and to match compressed air demand in the field with the compressed air production in the compressor room While GFDM measures and monitors the pneumatic side in the field RSEnergyMetrix provides plant wide load profiling energy usage logging cost alloca tion and billing analysis tools It also views and trends historical data dynamically or within custom reports and charts creates energy budgets and forecasts or compares alternative rate schedules to analyze pote
42. ccomplishing this usually is driven from one of two directions Which approach is right for your company depends upon the business issue s you re addressing The first approach typically is focused on delivering functionality that s more finite in scope and origi nates from the plant floor and can PartnerNetwork Business Enterprise Strategic Alliances Enterprise Solution Partners Consultants amp Specifiers Sales amp Solutions Distributors a Solution Providers Product Reference Technology Licensing Machine Builders Rockwell Automation has expanded its automation centric program by extending it into the informa tion level The Enterprise Solutions Partners adds a new partnering level that recognizes professional services firms that have demonstrated MIS competency Products amp Technologies extend up to the enterprise applica tion layer The second approach typi cally is more comprehensive in scope It originates from the enterprise layer and extends down to the plant floor The goal is to turn data into information turn information into strategy and turn strategy into execution The scope of the business issue s you want to solve will dictate the class of manufacturing information solution and the types of partners you ultimately choose to help you Because of this Rockwell Automa tion has established a two pronged partnering solution as part of the Rockwell A
43. ced environmental impact of incineration e Custom design for your specific process needs e Highest purity solvent for reuse ProsCon Ltd a Rockwell Automation company has extensive experience in ACN separation and has a long track record in supplying solvent recovery systems to the life sciences market globally If you can provide us with the purity of ACN required and details on the spent solvent waste stream we can supply a system to meet those needs For more information contact Charles R McBride at crmcbride ra rockwell com phone 714 938 9019 expirations and resultant increased competition from generic manufac turers the rising cost of raw materials environmental regulations and con sumer and community imperatives As a result the trend to recover and reuse solvent is gaining widespread acceptance Solvent Recovery Solvent recovery is the process of tak ing a waste stream and separating the components The goal is to produce a solvent product stream to the specified purity required for reuse in production such as 96 ethanol 4 water Various types of solvent recovery technologies encompass all variations of solvent waste streams generated during manufacturing Systems can be designed to handle one specific solvent waste stream or multiple dif ferent solvent waste streams Benefits of Solvent Recovery Solvent recovery helps manufacturers to be more competitive because they can e Reduce the amount o
44. chnology is another way Remmele mitigates risk reduces cost and produces better equipment for its clients HMI technology plays a critical role Through the Proof of Principle PoP process Remmele helps clients incorporate advanced technologies while minimizing project risk in the efficient flow of work and data through the system and can have a profound impact on machine operation Remmele s contextual process achieves much of the HMI design before a design engineer ever puts fingers to keyboard Remmele engineers interview machine opera tors to determine the how and why of every interaction the operator makes with the machine What controls does the operator need to access When do they need to access them How does each human machine interaction fit into the overall flow of the operator s procedure Rockwell Automation used Remmele s contextual infor mation to create compliant secure ergonomic and highly specialized multi disciplined functionality with the Logix Control Platform Additionally using the FactoryTalk Transaction Manager FactoryTalk Historian Factorylalk Metrics and FactoryTalk Scheduler Rockwell Automation worked with Remmele to bridge the gap between the HMI and machine control system through the manufacturing execution system MES and into the enterprise business system This helped to create smooth accurate data flow from the plant floor to anywhere in the world The Rockwell Automati
45. ckly evolving New Web based human machine interface HMI capabili ties are shattering previous notions about how and where HMI can be used Manufacturing staff from the shop floor to the top office now can benefit from the freedom that on demand access to plant operations data offers Advanced Web based HMI software gives you and other managers the ability to remotely access critical visualization displays and alarms of any part of the plant in real time Managers can monitor production and equipment status from anywhere The ability to view and use real time data and make criti cal production decisions without the need to be physically present at the plant helps improve speed and efficiency For production managers providing coworkers access to critical information from any location saves significant time com pared to manual collection and routing Users will quickly discover that while gathering information is valuable the ability to share it quicker and easier is even more powerful With Web based HMI you re accessing visualization screens from a home PC or hand held device so you prob ably expect your display to be one dimensional right Not One driver for using automated OEE technology is mea suring and comparing the performance of different plants and the assets operating within them For example many software packages use an OEE model to measure or compare performance of plants lines machines and even production teams wi
46. clude a qualified air system supplier before starting the next phase Improvement Phase The Demand Side and Air Distribution System e Start with the prioritized potentials for improvement on the demand side and air distribution identitied leakages pressure losses substitution of components with high air consumption etc At the end of this phase the demand side and the air distribution system should be optimized Data Collection Phase Il e Collect data for a time covering normal production peak production events weekends events of problems in the air system etc if necessary over several weeks Data Evaluation of Phase ll e Share monthly air consumption and compressed air cost statements of defined plant areas or at the point of con sumption with colleagues and upper level management e Reevaluate the data after Improvement Phase and compare the actions taken with the success achieved e Categorize where and when compressed air use is high e Determine when and where peak flow events occur e Check how much air demand and pressure is required at the point of consumption and compare the demand side with the supply side e Check the plausibility of compressor activities accord ing to compressed air requirements e Plan the actions that need to be taken in order of priority to help reduce energy consumption For cases in which the data evaluation is too complex include a qualified specialist before starting
47. ct Partner Global DIN Rail STANDALONE MODULES FAULT TOLERANT SELF HEALING FIBER OPTIC NETWORKS RING BUS STAR NO RESTRICTIONS Optical Communication For ALL CONTROL NETWORKS ControlNet Ethernet Ethernet IP Modbus TCP IP Data Highway Plus Remote I O DH 485 DF1 Modbus Modbus Plus RS 232 485 and other Communication Networks PANELMOUNT STANDALONE MODULES 1756 PLUG IN MODULES ControLogix UL and UL C Class I Div 2 CE Mark 1746 PLUG IN MODULES SLC Real Time Diagnostics Phoenix Digital 7650 East Evans Rd Bldg A Scottsdale AZ 85260 Phone 1 480 483 7393 Fax 1 480 483 7391 e mail phxdigital aol com WWW ROCKWELLAUTOMATION COM THEJOURNAL APRIL 2009 THE JOURNAL 51 PRODUCT gt gt Process Weighing System Vishay BLH a participating Encompass Product Partner in the Rock well Automation PartnerNetwork offers the G4 process control instru ment designed for process weighing force measurement web tension and high speed batching blending It features synchronized sampling up to 800 updates per second and integrated flexible digital I O All units support high update rate and high sample rate up to 20 kHz with synchronized measurement channels and integrated digital O The modular structure allows it to be customized to the application It is available in DIN rail panel desktop and harsh environment enclo sures The G4 is c
48. ctory Talk Metrics to evaluate the performance of critical production assets while Facto ryTalk Historian is used to collect analyze and report production data through Web based reporting via the company s intranet Customized reports are displayed on PCs off the shop floor Management can view general OEE calculations by work cell downtime for each machine quality data changeover times and specific events that cause line stoppages such as a jammed bottle or spilled product Visibility is Key In their quest to drive revenue and cut costs companies have invested heavily in data collection technologies Therefore in many cases it s not more automation that s needed but better visibility and insight into manufacturing so operators can re act faster and more intelligently to the data they re receiving As a real time measurement system OEE provides a window to analyze out of the ordinary ISSUES However empowering decision makers with timely clear and context rich in formation presents a number of technical challenges First the information often is fragmented residing in multiple systems scat tered across the enterprise At the same time different proprietary user interfaces present only part of the picture and make it extremely difficult to correlate and interpret data This is where collaborative dashboards are augmenting performance improvement efforts by offe
49. d and trusted partners scope of functionality Rockwell Automation Life Information is the Next Bringing your production opera Sciences Industry Solutions Industrial Revolution tions into the digital age isn t easy but www rockwellautomation com go stj Like many other industries pharma ceutical manufacturers are experienc ing the impact of macro trends that are significantly changing the manufactur ing landscape A recent flurry of con Sch enck Accu R ate pa sumer product contamination issues illustrates the need for better visibility D ry 0 i d Fe d e rs An d across supply chain networks Expectations are changing Our Ee Weight Based Control Systems customers partners suppliers and even the government expect more when it comes to the velocity ease and accuracy of our business process es Technology is changing so rapidly that companies that apply it wisely in their business processes can realize a true competitive edge Pharmaceutical manufacturing op erations are being managed as a strate gic business asset with all that bestows including investment in appropriate Schenck AccuRate with its modular DISOCONT Loss In Weight controller is proud to be a part of the Rockwell including rejecting the traditionally Automation Encompass Program insular view associated with developing technologies to create a closed loop information architecture on an enter prise sc
50. d in weighing systems By the Hardy Instruments Technical Support Team gt gt In your weighing system the tare value is the numerical difference between gross weight and net weight This article illustrates how tare values are used The examples are described using modules from Hardy Instru ments a participating Encompass Product Partner in the Rockwell Automation PartnerNetwork When the tare function is activated on the HI 1746WS HI 1756WS HI 1769WS HI 1771WS HI 200DNWM HI 2110WI HI 2151 30WC HI 3010 HI 3030 and HI 4050 the current gross weight is placed in the Tare Value register You also can input this data from the front keypad MatrikonOPC Learn from Those Who Do Become the Expert in DCS Connectivity and PLC Connectivity Floriri Alar tenia hi pail Encompass Product Partner Diii www OPCTraining com or across communications The process of doing a tare or updating the Tare Register varies slightly from model to model Consult the model type user manual for procedures The following examples explain how tare value is used Example No 1 Filling e The operator places an empty container weighing 30 pounds on a scale e He pushes the tare button e A value of 30 is automatically entered into the Tare Register e The gross weight is 30 pounds the tare value is 30 pounds and the net weight is 0 pounds gross weight tare value net weight e As the container is filled t
51. d to sags and prevent downtime Solving PQ problems requires equipment purposely built for the task Cost effectively deploying power quality equipment requires careful planning A battery free energy efficient voltage sag corrector like this one is built specifically to mitigate industrial power quality problems The Dynamic Sag Corrector DySC from Rockwell Automation Encompass Product Partner SoftSwitching Technol ogies is a battery free solution optimized for industrial PQ problems It s fast scaleable energy efficient and nearly maintenance free Cost effectively deploying PQ equip ment in the factory requires careful planning some operations don t require PQ protection In a typical automated facility less than 50 of the total power is used for equip ment that is both critical and sensitive to voltage sags The nature of the business also is a consideration Manufactur ers that need PQ protection include e Those who are production constrained e Plants suffering from expensive scrap e Factories constrained by just in time JIT contracts and needing to minimize finished goods inventories and punitive back charges Voltage sags impact capital equipment utilization scrap expense rework expense missed deliveries idled direct ex pense and factory overhead So the true cost of downtime is much higher than you might think As factories and plants commit to tighter process con trols high speed digit
52. dCommunications SST PLC communication modules that provide the interface required for a Rockwell Automation PLC controller to connect to specific industrial tieldbuses The SST Modbus and Profibus modules for Controllogix provide users with increased performance and quicker startups by eliminating the ladder logic programming trom most applications The modules also now support Add On Profiles for easy integration into the Controllogix system using RSLogix 5000 software trom Rockwell Automation and Remote Link Library functionality that allows remote configuration and diagnostics using the Rockwell Automation Integrated Architecture Users benefit from faster configuration better diagnos tics and enhanced module data display Molex Inc www rockwellautomation com go p molex WWW ROCKWELLAUTOMATION COM THEJOURNAL APRIL 2009 THE JOURNAL 53 PRODUCT FOCUS gt gt AC Line Regeneration Modules Rockwell Automation Encompass Product Partner Bonitron Inc s M3345 Line Regen AC line regeneration modules are designed for sustainability Regenerated energy usually is dissipated as heat through resistive loads The M3345 Line Regen returns power to the line at 95 efficiency at near unity It is ideal for use where frequent regenerated energy occurs to minimize environmental impact optimize energy efficiency and reduce operational costs Bonitron Inc www rockwellautomation com go p bonitron gt gt Pr
53. dlogix L63S PAC also is available with this release Guardlogix controllers are designed to help perform safety and standard functions so the amount of time required for programming validation and testing is reduced The Rockwell Automation Stratix family features a Rockwell Auto mation and Cisco co branded line of modular managed switches with attributes that will add value for both IT and automation control professionals Other product lines in the portfolio include Embedded Technology and lines of fixed managed and unmanaged switches and physical media The entire portfolio uses standard unmoditied Ethernet and is optimized for use in EtherNet IP applications and the Integrated Architecture system The Cisco operating system user environment and feature set is exclusive to the Stratix 8000 line For machine builders the new Allen Bradley Compactlogix L23 PACs leverage the Rockwell Automation Integrated Architecture system in a compact package Offering three I O and communica tion contigurations the new controllers can be expanded using Allen Bradley 1769 Compact I O Multilingual project documentation with language switching also is available Rockwell Automation Integrated Architecture www rockwellautomation com go tj1 Oia 56 THEJOURNAL APRIL 2009 WWW ROCKWELLAUTOMATION COM THEJOURNAL gt gt Coding Systems RSI Systems a participating Encompass Product Partner in the Rockwell Automation PartnerNetwo
54. e Tunnel ovens e Pudding lines e Bottling lines Our customers who track the process impact of voltage sags have concluded that sags account for as much as 70 of their total annual unscheduled downtime The correlation between voltage sag events and unscheduled downtime is high but the time down can vary widely A 0 1 second voltage sag can shut down an aseptic packaging line for nine hours for cleaning can break a CNC machine tool bit that can take hours to replace and can idle thou sands of factory workers for hours in an automotive assembly plant Shielding your production lines from voltage sags can cost effectively increase your annual productivity by as much as 2 How Do You Get Started First look in the right places While being the primary cause of unsched uled downtime isolating PQ prob lems can be tricky Simply monitoring the power isn t enough It helps to choose a PQ monitoring system that can identify the source of voltage WWW ROCKWELLAUTOMATION COM THEJOURNAL APRIL 2009 THE JOURNAL 43 disturbances by distinguishing between a local PQ event and a grid event The power monitor must be properly set up in your plant have fast response time and have the ability to capture the event data for future reference Each time any operation in your plant goes down you ll want to check the power monitor If the monitor reports a sag you know what caused the downtime However you still don t kn
55. e different levels of access depending on use and they should be able to easily enable and disable security Mobility is increasingly important and Web enabled access to plant floor systems is an important tool to help meet the requirements of today s remote users Cutting edge visualization solutions make it easier than ever for managers OEMs and system integrators to view and manage their pro duction operations using nothing more than a Web browser Rockwell Automation Web Enabled HMI http discover rockwellautomation com go webhmi specific operator running a machine or a particular equipment setup procedure This information as opposed to a simple timer to monitor downtime provides actionable intelligence to enable proactive adjustments rather than merely serving as an alarm to report a stoppage In other words the software adds the why to the what when and how often Delivering OEE calculations and metrics to plant person nel doesn t automatically guarantee uptime performance to improve or scrap rates to reduce The notification of poor performance must be first be noted and then acted upon by taking the proper corrective action A systematic approach to continuous improvement and a management culture supportive of adaptive change permits the highest levels 22 THEJOURNAL APRIL 2009 WWW ROCKWELLAUTOMATION COM THEJOURNAL of improvement Best in class results only can be realized through a
56. e of a successful approach to dividing up systems turf e ERP Materials resource planning MRP processes bill of material final usage decision inven tory control order genealogy and production order generation e MES manufacturing process control master batch record log books and process data retention e Laboratory Information Management Systems LIMS lab results stability studies retains mate rial potency batch disposition and recommendation based on lab results At Wyeth we found that it was easier to define these roles and responsibilities for our strategic en terprise systems once we appointed system owners or champions and moved away from a management by committee format This created a place for the buck to stop for each strategic enterprise system It doesn t discourage debate however it ensures that a clear line of author ity exists for making a decision on the direction and vision for a given strategic enterprise system We recognize that changing busi ness needs may dictate a review of 30 THE JOURNAL APRIL 2009 WWW ROCKWELLAUTOMATION COM THEJOURNAL these lines of demarcation so these on its alignment with Wyeth s com the journey is exciting and rewarding system owners or champions meet on a mercial off the shelf COTS software Don t take on the task without the periodic basis to challenge status quo philosophy global support needs and help of qualifie
57. e time to research new manufac turing techniques or technologies via seminars and conferences This is where working closely with IT has added significant value at Wyeth The IT team helped manufacturing management un is being backed up and how often Are you conducting stress testing or disaster recovery planning How long will it take to recover These are just a few of the technol ogy gotchas that manufacturing teams need to understand to create effective and scalable support for an T intensive production system Our IT brethren must under stand what high availability means to manufacturing What are the critical manufacturing parameters and how must that data be man aged collected and protected How is this data being used Where in the process is data being entered stored and retrieved Convergence creates value by heightening each organization s understanding of the other s area By establishing common ground we enable more productive discussion of manufacturing technology issues opportunities and benefits Drawing the Turf Lines Master data management MDM is a complex topic that needs to reflect the assigned roles and responsibili ties of both the people and systems involved in your production process MDM is an essential element in your manufacturing IT strategy that ageregate and extract key production data for planning and reporting Our experience at Wyeth provides one exampl
58. ectly match In a following step the pressure delivered by the compressor can be reduced On the demand side the energy monitoring package measures and monitors the pneumatic energy consumption spent by machines or applications Data transfer between the energy monitoring package and RSEnergyMetrix is based on OPC communication Which plant managers should consider complementing their energy management system for compressed air Specific compressed air users who can benefit include those who e Don t want to add more compressor capacity e Don t want to spend additional money for leaking compressed air e Want to replace inefficient leak detection programs e Want to allocate compressed air costs to certain pro duction areas e Want to synchronize the demand side with the supply side e Have energy intensive production processes suffering over proportionately rising energy costs e Have to add more compressor capacity and wonder what size of air compressor what type of control sys tem and where to locate the additional compressor e Want to understand the locations and reasons for undesired pressure losses or fluctuations e Want to avoid unscheduled downtime related to their pneumatic machines Benefits of Improving Performance Manufacturers can spend hundreds of thousands of dollars each year on energy that powers compressed air systems However complementing an energy accounting system such as RSEnergyMetrix with GF
59. ed evaluated and consistently improved However when you transition a workforce from paper batch to electronic records training and change manage ment play critical roles Typically everyone on the shop floor has varying degrees of computer skills Initially con ducting a basic computer skills assessment goes a long way in determining the readiness of your workforce so you can follow up with proper computer remediation training Payoff Tactical or Strategic Demonstrating consistent process control has long been a challenge issued by regulatory organizations to pharma WWW ROCKWELLAUTOMATION COM THEJOURNAL Rockwell a ms ia i i m CERET be iooi ool oM aoo ceutical manufacturing sites The ability to view system strategic asset that impacts the businesses ability to respond generated control charts that show processes working quickly and efficiently to change to support corporate comfortably within prescribed operating limits adds initiatives and to execute innovation another level of consistency This means bringing an enterprise perspective to your Process consistency also has a direct impact on game and gaining a better understanding of strategic production cycle time Paper based processes often are implications that a more connected enterprise infers riddled with batch record errors causing manufacturing For some pharmaceutical manufacturers this has created teams to regularly grapple with manu
60. energy management system upgrade In the compressor room Allen Bradley Powermoni tors from Rockwell Automation measure the compressors power consumption while pressure and flow sensors deliver the pressure flow and air volume information of the com pressed air leaving the compressor room In the air distribution system compressed air travels from the compressor room to the point of use demand side If flow and pressure sensors are integrated cross points of the air distribution system plant areas can be monitored for purposes such as cost accounting Pressure sensors at the outlet of the compressor room and at the points of consumption deliver information about pressure drops of the air distribution system WWW ROCKWELLAUTOMATION COM THEJOURNAL APRIL 2009 THE JOURNAL 39 Figure 4 RSEnergyMetrix delivers load profiles in certain time frames with a mouse click power consumptions of compressors together with pressure and air supply of the compressor room Plant managers can com pare this information with pressure and consumption figures of individual machines on the demand side ps Ma MM dt BAA et dd L ili Figure 5 This graph shows pressure monitoring at an aluminum saw red compared to the pressure at the outlet of the compressor room green After removal of pressure losses caused by clogged filters and by the air distribution system both pressure signals perf
61. ercise more control over high profile operations such as energy efficiency or global supply chain execution The FactoryTalk VantagePoint application will be offered in The FactoryTalk VantagePoint LE application also features multiple versions The first version FactoryTalk VantagePoint Line third party connectors that address native and OPC DA realtime Edition LE combines data produced by the Rockwell Automation devices OPC HDA historians Wonderware IndustrialSQL Server Integrated Architecture with other third party production systems in Historian GE Proticy Historian and OSI PI Historian an easily configured and installed out of the box solution Rockwell Automation soon will release FactoryTalk VantagePoint It includes standard pre configured reports for managing de Enterprise Edition a more comprehensive version designed to ag vices equipment alarms events and control loops as well as batch gregate and analyze data from multiple enterprise systems produc or production run and shift reports The application also includes tion lines or facilities trending and dashboard capabilities to support powerful analysis Rockwell Automation FactoryTalk VantagePoint and uses Microsoft Excel for easier report generation www rockwellautomation com go tiftvantagepoint gt gt PLC Communication Modules Molex Inc a participating Encompass Product Partner in the Rockwell Automation Partner Network recently added new features to its Bra
62. erification and optimization The ability of dashboards to display metrics in graphic representations contributes to quicker actions by helping users better understand how to respond to the data Likewise calculations representing operational efficiency metrics are easily applied for comparison to historic mea sures hese comparisons allow identification of deviations for further analysis and can be complemented by alerting based on thresholds This in depth insight provides unprec edented operational visibility and many companies claim millions of dollars of value from it For example Martinrea International a tier one au tomotive supplier wanted to implement a more efficient data collection and reporting system that would help it to respond more effectively to changing market de mands At its facility in Hopkinsville Ky the company produces a variety of automotive components including chassis modules frame assemblies and steel stampings With an output volume averaging 10 000 to 13 000 parts per day Martinrea must anticipate volume increase demands from top automotive manufacturers such as Ford General Motors and Chrysler We had manual paperwork sheets for everything which required double and triple entry of data across the company increasing costs and significantly reducing productivity says Darren Allison manager of information technology for Martinrea s Hopkinsville plant Seamless Integration and Web
63. f solvent purchased e Mitigate the risk of solvent shortages currently the problem for solvents that are the by product of other manufacturing industries that are slowing such as acetonitrile e Minimize the volume of dis charged waste and therefore decrease disposal costs e Meet environmental regulations while maintaining the required manufacturing quality Recovering solvent also benefits the community and environment Reduced raw material consumption reduces the stress on the earth s resources In addi tion by using solvent recovery instead of incineration carbon emissions can be significantly reduced Solvent recovery can be applied to 50 THE JOURNAL APRIL 2009 WWW ROCKWELLAUTOMATION COM THEJOURNAL an array of manufacturing solvent waste streams and it s especially ap plicable for the life sciences industry Each application is unique The capi tal investment can range from several hundred thousand dollars to several million dollars but payback periods often are realized in two years or less With strategies such as modular build project life cycles can be less than 18 months and require minimal footprints and minimal site disruption Operational costs are quite low compared to tradi tional distillation technologies and heat integration and complete automation systems further minimize energy usage The Shift On site solvent recovery is becoming an imperative to remain compe
64. facturing devia the impetus for organizational process and policy conver tions As a result production is slowed or halted In our gence of corporate IT and manufacturing departments It s pre digitized world we planned for this inefficiency vital for both perspectives to have input into technology scheduling 80 batches to make 90 In the post digitized investments architectures and policies that meet mission world our confidence interval for producing golden critical requirements and still scale on a global basis batches is closer to 1 It s also critical to involve senior management at the Production productivity consistency and reliability highest levels Investing in enterprise wide production and typical are success measures when justifying an investment performance management applications such as manufac in plant wide IT Manufacturing IT finally is viewed as a turing execution systems MES is widely viewed as mis WWW ROCKWELLAUTOMATION COM THEJOURNAL APRIL 2009 THE JOURNAL 29 sion critical but these systems introduce radical process change Executive sponsorship and change management are common threads within successful manufacturing IT strategies Control concepts at the heart of such systems such as adjusting for product potency process verification derstand how IT infrastructure can support mission critical production systems and worked with us to answer an array of questions What s a segmented
65. gether then ultrasonically welded cut stacked and positioned into a cartridge Each completed cartridge contains a set of 50 in vitro diagnostic test slides with a specific chemical signature Multiple cartridges with different testing properties are loaded into the machine and slides are individually dispensed according to the specific set of tests re quired This creates automated easily customized results from a single patient sample The cartridges require accurate labeling and tracking for compliance to medical industry standards and the 32 THE JOURNAL APRIL 2009 WWW ROCKWELLAUTOMATION COM THEJOURNAL machine needed to be designed for fast easy change out of empty cartridges or alternative chemical signatures explains Terry Johnson vice president and general manager of Remmele s Automation Division Because our client was asking for a dramatic increase in the speed of the equipment we proposed a PoP process that would proactively address a number of potential risks while accommodating the increased speed requirements he says Remmele personnel had some doubt about whether the speeds the client wanted to achieve could be met with a PoP Remmele developed a PoP design leveraging the Rockwell Au tomation Integrated Architecture a fully integrated scalable solution for a full range of control and information disciplines The Integrated Architecture encompasses both automation and information segments
66. gh ourselves We visit the dentist to check for cavities We monitor our car s oil usage and tire pressure We check the inside moisture level of a cake to see if it s done that s what I ve heard anyway I m not much of a cook Even though I m not a good cook I know that every day I practice perfor mance management I assess progress toward achieving my goals of good health and avoiding a breakdown on the highway We all do that in some way In manufacturing real time performance management strategies have decreased inventory manufacturing cycle times and machine downtime These strategies have helped companies to achieve more complete and on time ship ments of better quality products It s really just a matter of making sure that technical resources in the infrastructure perform as you expect and provide the best value for your investment Thats why metrics such as overall equipment effectiveness and other key per formance indicators are so important to you Performance management provides a way to collect organize and analyze the data you need to identify areas for improvement Then you can make those improvements Cooking using a curling iron swimming the butterfly stroke playing the oboe I don t know how to do any of these things But I know performance management And so do you And so does Rockwell Automation Check out the comprehensive discussion of manufacturing performance management starting
67. go tjsubscribe IS RELIABILITY NOUGH Poor power quality causes more downtime than you think learn how to detect the causes of voltage problems and help end power quality related downtime AIN N D A y T N a X A K ASLAN aN T NC N N J N i GF YON D a N LS y A A NV By Dr Bill Brumsickle Vice President of Engineering SoftSwitching Technologies Y 4 A La T he eS Y gt gt Is 99 999 reliability keeping your processes running That s what most U S electric utilities are provid ing five nines of reliability When compared to power reliability around the world five nines is good translating into roughly five minutes without power each year or maybe a single hour with no power every 10 years In most industries one hour without power every 10 years is a manageable problem Surely companies don t need to spend a lot to insulate them from this unless the safety of their employees is threatened So why do firms spend millions on premium utility ser vice generators transfer switch gear and uninterruptible power supplies UPS Those are viable solu tions to power reliability problems But power reliability is only one of the power problems Y A Lot
68. he difference between gross weight and net weight will remain a constant 30 pounds Example No 2 Discharging e A vessel is permanently installed on load cells and calibrated e The vessel is filled with 1 000 pounds of material e An operator pushes the tare button e A value of 1 000 is automatically entered in the tare register e The gross weight is 1 000 pounds the tare value is 1 000 pounds and the net weight is 0 pounds e When 100 pounds is discharged from the vessel the net weight will read 100 pounds and the gross weight will read 900 pounds e A tare is performed before each discharge Example No 3 Intermediate Bulk Containers e Full containers arrive with the empty container weight listed e An operator enters the empty container weight into the tare register via the front panel or downloads it from a PC or programmable logic controller PLC e The net weight is now the weight of the material in the container e The gross weight is the total of the material and container e The tare value is the weight of the container You can use your weighing systems more effectively by understanding how tare values are used Rockwell Automation Encompass Product Partner Hardy Instruments San Diego designs and manufactures process weighing instrumentation Hardy Instruments www rockwellautomation com go p hardy 48 THEJOURNAL APRIL 2009 WWW ROCKWELLAUTOMATION COM THEJOURNAL
69. heir competency To become a recognized participant in either tier of the program a professional ser vices firm must comply with certain criteria First the firm must have the re quired number of certified employ ees Employees can build compe tency through training and work experience and then demonstrate this competency by passing certifi cation exams in the required areas of experience Second the firm must have suc cessfully implemented projects for manufacturers in their claimed areas of experience product and industry Rockwell Automation interviews manufacturing firms after projects are completed to make sure they re satis fied with the firm s competency and professional services The result is that all program members have been carefully vetted by Rockwell Automation This saves you time and money in your selec tion process It also lowers your risk because you know that members of the program have had prior suc cess in the specific technical areas encompassed by your project PartnerNetwork Hard at Work for You Rockwell Automation has taken all of the things you have come to expect about our automation centric program and added further value by improving the original program to extend into the information level The addition of the Enterprise Solu tions Partners adds a new partnering level that recognizes professional services firms that have demon strated manufacturing information syste
70. ial design and operational issues to mitigate the risk of machine failure and regula tory noncompliance They also recognized the increasing demand for data integrity and security To meet these demands Remmele which offers preci sion machining and manufacturing engineering services began to use a Proof of Principle PoP process to address potential design and operation issues mitigating risk and buffering development costs for its clients The company also partnered with Rockwell Automation to supply tech nology and technical support The Rockwell Automation OEM team of technical consultants engineers and project managers helps Remmele with successful implementation of automation technology to decrease the total cost of engi neering and build a competitive edge An OEM used the Proof of Principle process and Rockwell Automation Integrated Architecture to help its life sciences client to boost equipment speed and reliability This partnership and process recently was put to the test when a life sciences manufacturer asked Remmele to boost the speed and reliability of its ultrasonic welding equip ment Using solutions based on the Rockwell Automation Integrated Architecture Remmele helped the client incor porate advanced technologies and boost equipment speed and reliability while minimizing project risk Adding a Little PoP The ultrasonic welding system involved three webs that needed to be precisely registered to
71. igh quality sys tems integrator to help you achieve your goals To learn more call your local Autho rized Allen Bradley distributor or visit www rockwellautomation com partners gt gt Only High Standards Will Do To earn designation as a Rockwell Automation Solution Provider systems inte grators are evaluated based on many of the same criteria the Control Systems Integrator Association CSIA uses for its certification process The CSIA is an organization of systems integrators that work together to help other systems integrators improve their business practices for the purpose of reducing risk for current and potential customers of their services The CSIA was organized in 1994 and continues to grow in membership every year explains Ed Diehl executive director of CSIA The organization has demonstrated value to our members through our Systems Integrator Best Practices and Certification Furthermore members have gained incredible insight into improving their own businesses by collaborating with their peers it s one of the only places where system integrators can come together share ideas and work to improve the industry and their own operations The CSIA is continuously raising the bar our long term goal is for CSIA Certification to be recognized as the de facto standard for professionalism and performance in the systems integration business Diehl adds CSIA www controlsys org
72. ight be used as context for a manufacturing report to Management 26 THEJOURNAL APRIL 2009 WWW ROCKWELLAUTOMATION COM THEJOURNAL True Business Intelligence Effective EMI systems now can link the transactional database environment of enterprise business systems re lational data from maintenance and quality systems and the object oriented time series world of automation and control systems in a single coherent environment This provides context for plant floor data so that people at any level in a company from plant floor to executive offices can make better business decisions So when the BI system reports that a revenue goal wasnt met an EMI report gives line personnel and man agement the tools they need to drill down and determine the cause of the problem In addition the EMI system using the business data as context could have provided an early warning that a set of goals might not be at tained under current operating conditions EMI software users can leverage actionable infor mation to help personnel recognize opportunities and EMI software users can leverage actionable information to help personnel recognize opportunities and problems earlier problems earlier react swiftly and easily communicate the issues This helps guide decision making to improve bottom line profitability Staff is empowered to create content from known valid data and IT departments don t have to worry about deploying
73. ion in the Incuity model In addition the solution provides multi level support for dashboards including preconfigured dashboards featuring common tools with which people already are familiar gauges sliders switches and other elements and a dashboard editor that helps people easily build complex interactive dashboards Extensive security features which are mandatory for a system that can connect to so many different data sources allow users to impose security on any item in the model and specify exactly who is allowed to read write access or change any of the data coming in from those different data sources For more information visit http discover rockwell automation com go emi plorer People will find information quickly and under stand the production issues in the context in which they need to use the information Because the software s rich database views and data transformations are usable with existing data warehouse and data mining software products people can con tinually evaluate real time production information to monitor key performance indicators KPI This will help them better understand events surrounding issues such as product quality or machine downtime Now that s a true business intelligence system for the manufacturing industries Rockwell Automation Information Solutions www rockwellautomation com go performance WWW ROCKWELLAUTOMATION COM THEJOURNAL APRIL 2009 THE J
74. ith the specifications and interoperate in multi vendor sys tems A cornerstone of this process is the passing of the ODVA confor mance test at an ODVA authorized test service provider TSP ODVA TSPs must meet certain standards including vendor independence neutrality and technical competency in networks and testing practices CVS IAF has been an autho rized ODVA TSP for EtherNet IP since 2004 Since its authoriza tion as an ODVA TSP CVS IAF has not only conducted confor mance tests on behalf of ODVA for EtherNet IP products but also has contributed to the continuous improvement of the ODVA con formance test process through its experience gained in conducting ODVA conformance tests TSPs perform conformance tests that are designed developed and managed by ODVA and conduct the tests in accordance with ODVA test requirements and procedures The ODVA conformance test for EtherNet IP products is a composite test comprised of three parts e An automated computer test for compliance with The EtherNet IP Specification which includes the Common Industrial Proto col CIP and the EtherNet IP adaptation of CIP e A visual inspection of the product for compliance with the physical layer of The EtherNet IP Specification e An interoperability test that exercises the product using pre scribed test scenarios designed to demonstrate the successful interoperability of the product in multi vendor systems The ve
75. jor market with critical expertise Terry Gebert Vice President and General Manager Rockwell Automation Systems amp Solutions industries and oil and gas market enhances our Canadian oil sands op portunities and establishes a robust delivery capability in a major market with critical expertise said Terry Gebert vice president and general manager Rockwell Automation Sys tems amp Solutions Rutter Hinz customers will continue to receive the high level of service they currently enjoy said Ryan Hinz Rutter Inc president and CEO This acquisition continues to strengthen our global project man agement and engineering solutions delivery capability as we have done with ProsCon and ICS Triplex acquisitions in Europe CIE in Latin America and Xi An Hengsheng in China Gebert added Customers will now benefit from the expanded portfolio of application solutions expertise and delivery capacity that Rutter Hinz offers particularly to the oil and gas market Rockwell Automation Industry Solutions www rockwellautomation com go tiindustries WEED INSTRUMENT ACQUIRED BY ULTRA Weed Instrument Co Inc a participating Encompass Product Partner in the Rockwell Automa tion PartnerNetwork has been acquired by Ultra for 31 6 million 8 THEJOURNAL APRIL 2009 WWW ROCKWELLAUTOMATION COM THEJOURNAL Ultra specialized in sensors and control systems
76. k putman net Managing Editor Ken Schnepf kschnepf putman net Art Director Jason Vargas jivargas putman net Art Director Jennifer Dakas jdakas putman net Advertising Sales Manager Scott Walters swalters putman net Production Manager Anetta Gauthier agauthier putman net Putman Publishing Team President and CEO John M Cappelletti Vice President Julie Cappelletti Lange Vice President Content Keith Larson Vice President Circulation Jerry Clark Group Art Director Stephen C Herner The Journal from Rockwell Automation and Our Partners is published six times a year by Putman Media Inc The Journal from Rockwell Automation and Our Pane is a trademark of Rockwell Automation and its use in the title and masthead of this publication is by license granted by Rockwell Automation to Putman Media Inc Other trademarks are property of their respective owners To subscribe or unsubscribe e mail Theresa Houck at thouck putman net The Journal from Rockwell Automation and Our Partners 2009 All rights reserved gt PutmanMedia M NOT A GOOD COOK BUT KNOW PERFORMANCE MANAGEMENT gt gt Performance management is the process of assessing progress toward achieving goals That sounds pretty fancy but it s really just a straightforward method we use every day We get or give performance appraisals at work We measure and monitor our calorie and carbohydrate intake We wei
77. le in multiple ratios 4 5 7 and 10 1 and also includes many double stage reductions including the odd ratios of 21 31 61 and 91 1 It s available in seven sizes ranging trom the exclusive 47 mm through the larger 255 mm that will plug and play for comparable designs on the market today save up to 30 The precision helical design has an efficiency of 97 and is available in three precision classes as low as 1 arc minute with a five year warranty and 100 on time delivery Call 631 244 9040 or visit www apexdyna com APEX DYNAMICS USA Video Historian _ The Longwatch Video Histo rian enables users to acquire and store video clips linked with process and manufactur ing variables such as time of day camera number batch step machine ID and other control system tags Much like a process historian that stores information about processes the Video Historian archives video that documents pro cedures in batch applications provides visual proof of regulatory compli ance monitors machinery observes operator actions and helps improve quality reduce downtime and avoid costly losses For more information call 877 LONGWATCH or visit www longwatch com LONGWATCH 46 THEJOURNAL APRIL 2009 WWW ROCKWELLAUTOMATION COM THEJOURNAL FIND NETWORK TRAFFIC THAT DOESN T BELONG Spot and remove unwanted protocols to improve network performance Eric Anderson Product Marketing Manager Fluke Network
78. m MIS competency This delineation cuts your selection time and costs and it helps to reduce your risks during the critical stage of project execution Contact your local Rockwell Automa tion representative if you need help in selecting the best partner for your next project Rockwell Automation PartnerNetwork www rockwellautomation com partners WWW ROCKWELLAUTOMATION COM THEJOURNAL APRIL 2009 THEJOURNAL 19 j By Darren Riley Market Development Manager Software and Applications Rockwell Automation 20 THEJOURNAL APRIL 2009 WWW ROCKWELLAUTOMATION COM THEJOURNAL Vex Shine Accurate performance management helps you use plant floor data to create a productivity phenomenon that boosts your bottom line gt Manufacturers across all industry sectors are embracing real time perfor mance management as a way to improve flexibility and profitability while coping with the reduction of labor and the burden of monitoring assets This is intensify ing the need for companies to make key performance indicators KPI visible across all levels of the operation to help provide that processes are operating correctly and assets are being effectively utilized While many companies have enormous potential for improving plant performance they re challenged with collecting organizing and analyzing the data needed to identify areas for improvement By applying performance management solutions co
79. med Codian Under PWR Pack the delta robot ics activity has grown rapidly so this area has been separated to the Codian company to maintain a focus on qual ity and continuous improvement that is separate from the turnkey solutions PWR Pack builds for the packaging industry Codian will be focused on the OEM market for high speed pick and place robotics Codian USA will be building and selling robots out of its Waukesha Wis office to better serve the North ern American market and provide Fluke Offers Online Training Fluke Corp a participating Encompass fast response to customer needs Product Partner in the Rockwell Automation PartnerNetwork has unveiled PW R Pack will continue its business www leachMefFluke com The site offers training that includes calibration and and further specialize in the field of metrology electrical measurement safety power quality and thermal imaging robotic picking lines with the use of Codian delta robots PWR Pack Americas www rockwellautomation com go and free classroom materials for qualified instructors and company trainers On line seminars hands on seminars application notes videos virtual demonstra tions online tools and links to additional resources also are available Fluke Corp www rockwellautomation com go p fluke p pwrpack 10 THE JOURNAL APRIL 2009 WWW ROCKWELLAUTOMATION COM THEJOURNAL CREAMERY CHOOSES PAVILION TECHNOLOGIES Bonga
80. mpanies can simplify the information gathering process Combining advanced visualization analysis and reporting tools with engineering experience these solutions are designed to help companies shift from a repair focused asset management strategy to a plan that s reliability focused This helps reduce overall main tenance costs while transforming production data into actionable information that drives continuous improvement Accurate Insight One performance management metric that delivers powerful results is overall equipment effectiveness OEE OEE measures the most common and costly sources of manufacturing productivity loss from availability performance and quality It provides a composite view of anomalous activity and issues to permit staff a prioritizing framework for reducing inefh ciencies and driving improvements WWW ROCKWELLAUTOMATION COM THEJOURNAL APRIL 2009 THE JOURNAL 21 gt gt Web based HMI It s Everywhere You Want To Go By Mark Hobbs Product Manager Rockwell Automation The world s workforce is more mobile than ever The number of mobile workers is expected to continue climbing sharply reaching 1 billion by 2011 according to predictions from market intelligence firm IDC The flexibility of today s technol ogy means workers in all industries can access e mail and the Internet from almost anywhere Why should access to plant floor data be any different Rich Internet application technology is qui
81. ndor of the product may at its option observe the test at the TSP Upon the product s success ful completion of the test the TSP submits the test results to ODVA for review and final approval Con tingent upon passing results from the conformance tests and other requirements of ODVA ODVA issues a Declaration of Conformity for the product Declarations of Conformity are posted on ODVA s Web site ODVA www odva org 14 THE JOURNAL APRIL 2009 WWW ROCKWELLAUTOMATION COM THEJOURNAL SPNEWS FEELING THE PINCH NO PROBLEM Rockwell Automation Solution Providers are held to high technical and ethical standards so they deliver dependable systems integration services to help you through the tough times By Mark Moriarty Manager Systems Integrator Solution Provider Program Rockwell Automation gt gt If you find yourself in the clutches of the unyielding beast of tough economic times you re not alone Manufacturers throughout North America and the world are trying to figure out how to maintain long term stability by improving ef ficiency with minimal resources So as you review your operations to make improvements where do you start looking for someone with the technical capabilities and industry knowledge that can help you meet your goals How do you know who to trust How do you accomplish this with minimal risk The good news is that we can put you in touch with dependable compa nies
82. network and why is it important What are the pros and cons of wired versus wireless access points What s a SAN What data helps guide how plant and enterprise systems should interact This becomes increasingly im portant as business or supply chain systems such as enterprise resource planning ERP are interfaced into execution quality or other plant level production management systems to Bringing your production operations into the digital age isn t easy and certainly not a task to take on without the help of qualified and trusted partners or digital signatures also represent strategic risk management opportuni ties that warrant senior management visibility and support Convergence Creates Synergies Improving information flow in your manufacturing enterprise is like the impact of a healthy circulatory system on human performance Production operations are the heart of a manufac turing enterprise but it s your ability to reliably accurately and efficiently circulate that information among business and production systems that helps you react faster and enjoy stron ger control over desired outcomes One of the most immediate benefits of blending IT and manu facturing perspectives is developing a shared vision for what s possible when creating a modern manufac turing IT architecture Consider that most manufacturing teams are so focused on getting product out the door that they typically don t hav
83. ntial cost savings Figures 4 and 5 show how historical data of compressed air demand and supply can be evaluated to help make decisions about compressed air capacity Figure 3 The GFDM configurable energy monitoring package mea sures and monitors compressed air on the demand side using sensors and a diagnostic module Energy Management for Compressed Air Systems In hundreds of air audits conducted by Festo Corp on the demand side between 35 and 65 savings in compressed air consumption could be achieved Those are already impressive numbers However if compressed air and pressure values could be continuously audited and tracked from the supply side compressor room to the demand side point of consump tion this not only could help reduce the amount of com pressed air spent on the demand side but could also help optimize the whole plant air system The result is long term generation of sufficient data to help detect and eliminate inefficiencies in the entire air system With the right technical measures compressed air demand and supply can be synchronized I am convinced that the combination of RSEnergyMe trix with GFDM will help improve compressed air system s efficiency If GFDM and a powerful energy management system like RSEnergyMetrix are combined the plant wide true costs of compressed air demand and supply and locations of inefficiencies and waste are revealed deliver ing a quicker payback on the
84. oduct Spotlight Conveyor Scale Controller The IND560dyn and IND9D56 weighing controllers trom Mettler Toledo a participating Encompass Product Partner in the Rockwell Automation PartnerNetwork can be used with a variety of Mettler Toledo scale conveyor systems or other suitable scale conveyor systems using analog load cells The IND56O0dyn EXPRESSWEIGH scale terminal weighs random weight packages as they pass over the Mettler Toledo 9477 or other suitable scale conveyor The configurable output can include averaged weight consecutive number time and date package ID and package dimensions The IND9D56 EXPRESSWEIGH scale controller offers connec tions for photo eyes and other I O devices to create a complete solution lt also can accept startand stop weighing commands trom an external master interface The scale terminal and scale controller provide three zone check weighing for up to 25 target IDs Configurable tolerances and reject timers are easily entered and the easy to read operator display shows a clear graphical comparison between each package s weight and the target value gt gt Electrical System Schematic Software Bentley Systems Inc a participating Encompass Product Partner in the Rockwell Automation PartnerNetwork recently introduced promis e V8i software for automatically generating electrical system schematics and supporting documentation The intelligent easy to use software which can be u
85. oftware and endure p longwatch the added costs of programming and maintenance www rockwellautomation com go Just snap the appliance in an Allen Bradly controller and connect to a computer by Ethernet In no time at all you can be using this versatile appliance to simplify tasks such tracking and tracing batch recipe or bill of material downloads machine and robot RIVE R configuration and more all without programming It all adds up to a low cost easy way to exchange data See for yourself visit our web site for peony meetin APPOINTS TWO DIRECTORS River Consulting a Rockwell Bridging the Gap DEVELOPMENT INC 2009 Online Development Inc All Rights Reserved All trademarks are the property of their respective owners ON 0626 TJ Automation Solution Provider has WWW ROCKWELLAUTOMATION COM THEJOURNAL APRIL 2009 THEJOURNAL 13 E NEWS amp NOTEWORTHY age projects throughout his career He recently led the engineering for the 100 000 ton capacity Houston Cement silos which stand 186 feet tall and move 1 5 million mtpy In his new role Harvey will lead the silo design practice as well as provide knowledge and guidance to the structural engineering staff on material handling and storage projects Krupp has more than 18 years of experience in electrical design auto mation and project management for industrial projects Krupp s project experience spans numerous indus tries and he has
86. omation will use its industrial automation technology control and information solutions to help develop greater manufacturing efficiencies in Hebei s key industries including met als oil and gas power cement and water treatment Additionally Rockwell Automa tion will explore opportunities to cooperate with Hebei area universi ties enterprises and research and design institutes to perform technical research projects and technical train ing to research develop and apply automation information and energy efficiency products The first area the partnership will address is energy efficiency With Hebei s energy consumption ranked second in China and a GDP reaching nearly 200 billion many opportunities exist for positive results to help the province achieve its sustainability goals and make it a model for other Chinese cities Rockwell Automation www rockwellautomation com VIDEO MONITORING WHITE PAPER AVAILABLE The new Video Process Monitor ing white paper discusses the new est trend in HMI SCADA embed ding video into an HMI screen so operators can actually see what is 12 THEJOURNAL APRIL 2009 WWW ROCKWELLAUTOMATION COM THEJOURNAL happening in a process plant along appointed Tim Harvey as director Harvey has more than 30 years of an assembly line or in remote areas of material storage and handling cement and bulk material experience The paper is written by Steve Rubin systems
87. ompatible with communication interfaces including Remote O DeviceNet Ethernet USB RS485 and RS232 Software upgrades can be downloaded from the Web or can be transterred via USB port connection Vishay BLH www rockwellautomation com go p vishay gt gt Product Spotlight O Wiring Conversion System CADEA tery ed ta ere Rockwell Automation offers an I O wiring conversion system to help users migrate existing control platforms to the Allen Bradley Control logix PAC based I O platform It s part of the Rockwell Automation migration solutions program and is designed to reduce costs risks and complexities involved with PLC migration projects aug BH So o oon LT SO pe The conversion system helps manufacturers cost effectively replace PLC systems that are no longer supported by their original manufacturers with the Rockwell Automation Integrated Architecture The system also helos manutacturers that are looking to up grade to the platform By preserving existing tield wiring the conversion system helps users reduce downtime wiring time and labor costs by lessening the number of connections needed to complete the system migration Users now can quickly replace Modicon 800 Series I O racks with the Controllogix I O system without disturbing field wiring The swing arm conversion system takes the existing Modicon 800 I O swing arm and converts the field terminations to match a compat ible Controllogi
88. on information architecture is 21 CFR Part 11 compliance ready This is a regulatory speci fication that calls for electronic data records and signatures through every stage of manufacturing New Level of Control Because of the strong partnership with Rockwell Automa tion and a rigorous PoP process Remmele Engineering now can offer its clients a new level of control system capabilities for throughput efficiency and reliability For example the Rockwell Automation Integrated Architecture helped Rem mele to boost throughput on one welding system from 200 ppm to 900 ppm an increase of more than 300 Also standardizing on a common visualization platform through FactoryTalk View Remmele provides customers WWW ROCKWELLAUTOMATION COM THEJOURNAL APRIL 2009 THE JOURNAL 33 Our customers have very unique needs that constantly push the boundaries of control and information technology and we need a partner that can deliver the goods and has a clear understanding of the end result says Johnson An integral part of our success is based on relationships with our key suppliers such as Rockwell Automation Internally Remmele Engineering has realized an 8 to 12 cost reduction using the Rockwell Automation Integrated Architecture These reductions are largely the result of superior interoperability and scalability of the Logix Control Platform which helps minimize design and engineering time Additional cost
89. ong event provides a highly interactive classroom style environment set up for people working in manufacturing process and OEM industries Hear from subject matter specialists as they share their experiences and discuss current and emerging technologies Join us Learn how Allen Bradley Rockwell Software Automation Copyright 2009 Rockwell Automation Inc All Rights Reserved AD FTALK ADO10 EN P Need to transfer data between multiple systems Put ProSoft Technology in the middle The Message Manager has arrived simple Easy to use high quality products e Transfer data between Rockwell Automation Schneider Electric and Siemens Controllers Smart Easy setup and installation get your application running with unlimited Technical Support that e Supports Rockwell Automation networks as well as keeps it running Siemens Industrial Ethernet and Modbus TCP IP e No PLC programming a Seamless e User friendly embedded web configuration tool Cost effective solutions that allow connectivity between diverse networks and controllers ete amp 7 O00 Product Partner pei TECHNOLOGY Where Automation Connects 1 661 716 5100 www prosoft technology com TheJournalApr09 ASIA PACIFIC AFRICA EUROPE MIDDLE EAST LATIN AMERICA NORTH AMERICA
90. ormation from multiple applications their deploy ments are quite different BI usually is involved with transaction oriented business applications such as enterprise resource planning ERP supply chain management SCM finance and enterprise asset management EAM BI solutions are critical for help ing management to better run a company but they can t deal with time series data from the plant floor As a result BI solutions don t provide all the intel ligence needed to manage manufacturing operations Be smart With Jour 1 aq Learn the difference between business intelligence and enterprise manufacturing intelligence and discover why they re critical for managing manufacturing operations By Doug Lawson Vice President Incuity Software a Rockwell Automation Company Generally they report against results obtained over a reporting cycle last month last quarter etc EMI applications also aggregate information from multiple applications and maintain key relationships between different data elements within them However unlike BI solutions that are targeted toward enterprise applications traditional EMI systems focus on plant floor production data EMI applications can connect to virtually any data source in manufacturing and at the enterprise level They allow information to be generated from data derived across all of these systems For example batch or shift data from an enterprise system m
91. ort can be independently configured to work with more than 60 communication OMNI protocols in both master and slave configurations Miille Applied Research Co Inc www rockwellautomation com go p marc gt gt Directional Control Valves Parker Hannifin Pneumatic Division a participating Encompass Product Partner in the Rockwell Automation PartnerNetwork recently introduced an extension of the ISYSnet fieldbus system for directional valve control in process applications ISYSnet is a modular fieldbus system connecting to Isys using ControlNet DeviceNet and EtherNet P The ISYS Micro Valve Series connects to the standard ISYSnet Communications Modules and offers an extender cables expanding the input and output capability of the ISYSnet System ISYSnet con nects to a compact hightlow valve with a backto back valve design Isysnet handles 264 inputs and outputs O modules are digital or analog and use Me M12 or M23 connectors Parker Pneumatic Division www rockwellautomation com go p parker ADVERTISERS INDEX Company Web Address Product Page Apex Dynamics www apexdynamicsusa com Gear Boxes 9 46 Burkert Fluid Control Systems www burkett com Flow Controllers A5 EPLAN Software amp Services LLC www eplan us Electrical Design CAD Software A5 Festo Corporation www testo com Pneumatic Valve Manifolds A5 FieldServer Technologies www tieldserver
92. ow what caused the sag it could have been something in your facility but more likely it was a grid event that occurred outside your fence Companies spend hours looking for the causes of downtime and often never find it Plant engineers are in a real bind if they must tell the plant manager that they don t know what caused the line to drop So based on speculation or in the interest of job security they blame the equipment such as the programmable logic controller PLC variable frequency drive VFD a sensor or a failed soft starter In many cases they actually extend the duration of the process downtime while replacing innocent equipment Isn t it ironic that as much as 70 of all automation equip quip About 98970 of all power disturbances are voltage sags lasting less than two seconds ment returned to the equipment supplier for repair while under warranty is diagnosed as no problem found We recently were informed of one automotive assembly plant that returned 15 PLCs to the manufacturer after all 15 shut down at the same time How long did it take the plant to replace the 15 PLCs How much did it cost in downtime These are all costly actions that affect the plant s productivity Use Equipment Designed for Industrial Environments Because voltage sags are so short in duration power reli ability technologies such as generators automatic transfer switches and standby UPS aren t fast enough to respon
93. per ceptible In a three phase industrial environment a voltage sag on phase B won t be recognized if the lights are wired on phase A Highly automated factories have hundreds or thousands of ice cube relays scattered throughout produc tion lines often part of emergency off EMO or EPO circuits It only takes one tripped relay to bring down the line A one cycle 16 ms sag with 75 voltage remaining will trip most ice cube relays but will barely cause the lights to flicker Unfortunately the resulting down time isn t as fleeting as the voltage sag In many cases a sub second voltage sag can cause hours of lost production What Happens to Automated Production Lines After a Voltage Sag In the semiconductor industry voltage sags often shut down the fol lowing e Etch tool e Photolithography tool e Metrology e Surface preparation and cleaning tools e CVD e Jon implant tool e Diffusion furnace e Gas cabinet e CMP e Water handling system e Scrubber e Inspection e Packaging In the automotive industry voltage sags often shut down the following e Weld shop e Paint shop e Robotics e CNC tools e Compressors e Transfer lines e Machining centers e Heat treat ovens e Flexible assembly e Engine test cells e Transfer systems e Draw panels In the food and beverage industry voltage sags often shut down the fol lowing e Dry extruders e Aseptic packaging lines
94. ransferred into 100 pneumatic energy Machine 1 2 Machine 2 9 Machine 3 9 Machine XY 2 Figure 2 Where is your compressed air going An internal survey by Festo revealed that 70 of compressed air users are not aware of how much compressed air and pressure is generated and where and how much compressed air is actually used in their plants WWW ROCKWELLAUTOMATION COM THEJOURNAL APRIL 2009 THEJOURNAL 37 gt gt Checklist for Maximizing Savings Plant managers can use this checklist to help turn the ac quired data from the energy management system into cost savings It helps to chart a path toward applying energy management solutions to pneumatics The steps can be more detailed and depend on the situation on site Preparation Phase e Assign a plant wide compressed air champion e Make a drawing of your air system and divide your plant into areas pneumatic machines or applications of interest e Select power pressure and flow sensors for the com pressor room e Select GFDM energy management system configurations for compressed air requirements of the demand side e Include the IT department to set up a server running RSEnergyMetrix Installation Phase e Install sensors kilowatt pressure and flow sensors in the compressor room and if required in the air distribu tion system Sensors before and after filters determine the degree of information detail At least a pressure and a flow sensor
95. rds Creameries Bongards Minn a creamery cooperative has selected the Pavilion Technologies Dairy Industry Solution from Rock well Automation for advanced process control of its deproteinized whey DPW and stork spray dryers at its Perham Minn plant The Bongards DPW and stork spray dryers are essential for remov ing moisture to produce high quality powdered whey products The Pavilion Technologies Dairy Industry Solution controls the final product s average moisture to a de sired target while reducing overall moisture variability and operating just below the glass transition point to achieve optimal performance Bongards Creameries uses Pavilion Technolo gies Dairy Industry Solution for advanced process control of its deproteinized whey DPW and stork spray dryers at its Perham Minn plant Improving control of its dryers will help Bongards increase capacity reduce energy consumption and increase yield Bongards Creameries teamed up with Pavilion Technologies to help meet our customer demand as well as to optimize our DPW and stork dryer operation said Brent Jewett operations manager Bon ControlLogix Communications Interface Module SlotServer Fire Panels HVAC Boilers VAV Chillers VFD Building Controls Building Automation World s Largest Protocol Library Connect to hundreds of devices LonMark Certified BACnet Listed Metasys
96. ree response functions fast universal and precise For more information visit www testo com us vpom rqj FESTO CORP SlotServer ControlLogix Interface to Fire Alarm Control Panels Process systems offen need to interface the plant s building automation systems and fire alarm control panels FACP via the Control Logix platform Fire alarm panels tend to uti lize proprietary protocols FieldServer has the complete library of fire alarm panel protocols enabling Controllogix interface to fire alarm panel systems For more information call 408 262 2299 or 888 509 1970 e mail sales fieldserver com or visit www fieldserver com rockwell FIELDSERVER TECHNOLOGIES Burkert Mass Flow Controllers for Gases Burkert s comprehensive line of Mass Flow Controllers MFC for gases includes the Type 8712 employing CMOSens technology for responses four times faster than conventional MFCs with an optional low flow rate as low as 0 04 cm3N min Other Burkert MFCs include the Type 8626 with a low flow rate ranging trom 25 1500 N min This permits a constant gas flow or flow following a pre defined set point profile compatible with ammonia gas For more information call 949 223 3100 or visit www burkertusa com BURKERT FLUID CONTROL SYSTEMS Gear Motor Systems Solutions Wittenstein s TPM is the succes sor to the gear motor by Rockwell Automation With more ratios improved dynamic pe
97. reiber will spearhead the company s expanded efforts in gt gt Encompass Partner Briefs i NEWS amp NOTEWORTHY Philip Schreiber oversees Bachelor Controls manufacturing information management solutions providing manufacturing informa tion management solutions using analytical and intelligence software tools Schreiber comes to BCI from Northwest Analytical a provider of software for manufacturing analytics Before that he worked at Rockwell Automation within both the Process Engineering and Infor mation Solutions business units He has worked with the World Batch Forum since its inception and has co authored articles and designed training courses on the application of the ISA 88 and ISA 95 standards Our clients rely on us to play a lead role in helping them address their needs in the manufacturing information space said Ray Bach elor president of Bachelor Controls and Phil s technical and business development experience will make him well suited to lead that effort concentrating particularly in the food and life science industries Bachelor Controls Inc www rockwellautomation com go p bachelor PWR PACK FORMS CODIAN FOR ROBOTICS To be able to offer a better solution to the delta robotics market Rockwell Automation Encompass Americas Europe partner PWR Pack of the Netherlands has split off its robot activities and formed it into a new company na
98. rformance and factory programmed with Kinetix motion control data files this product is a mechanical drop in replacement for the Rockwell Automation MPG Compact and powertul this product packs a real punch Call 888 534 1222 or visit www wittenstein us com WITTENSTEIN INC Bulk Solids Metering Controls The Schenck AccuRate DISO CONT dynamic weightbased bulk solids metering control is designed specifically for loss in weight gain in weight and loss oFweight feeding applications It is utilized when dry bulk materi als need to be measured fed or batched with the use of a Schenck AccuRate feeder weighfeeder or solids flow meter Compatibility with DeviceNet and EtherNet IP fieldbus communications are achievable with the control For more information visit www accuratefeeders com or call 800 606 9252 SCHENCK ACCURATE Weigh Scale Modules Hardy Instruments single scale HI 1769 WS and dual scale HI 1769 2WS weigh modules read weight and diagnostic data supplied by load cells trom one or two independent scales They then communicate this data over an integrated backplane to Allen Brad ley Micrologix 1500 and Compactlogix controllers Both modules reduce installation time and system costs as the system needs no external stand alone scale instrument with a wired communications link to the PLC For more information visit www hardyinstruments com 1769 or call 800 821
99. ring a simple and more graphical way to make KPIs visible throughout the enterprise Dashboards provide a window into the process by incorporating performance metrics as well as the situational display of manufacturing information at the machine line plant and enterprise level These measurements can focus on many different facets of manufacturing operations in cluding how effectively the company manages production equipment use material use waste and output and OEE The role based reporting engine integrates with existing control systems and business WWW ROCKWELLAUTOMATION COM THEJOURAQRUE APRIL 2009 THEJOURNAL 23 gt gt How Nestl Reaped the Data Harvest By Keith McPherson Director of Market Development Rockwell Software The swift rise of information technology has brought many blessings to manufacturers However the proliferation also has created barriers that block communication between different operational groups As manufacturers add to their arsenal of information gathering technologies they risk creating an environment of patchwork systems each stor ing its own specific data That information typically is only accessed by the particular user or user group monitoring a piece of equipment Also functions such as alarms or real time process values are duplicated in each silo creating challenges for users who need to access or consolidate information from multiple areas Fortunately manuf
100. rk offers the Caselet MVP Plus and Caselet MVP Procase coding systems based on HP thermal inkjet printing tech nology It features builtin serial ports and TCP IP and OPC interfaces for easy integration into Factorylalk applications The two systems in clude a single butter mode to ensure that the correct message is printed on each case Both case coding systems include a 15 inch color touch screen tour levels of security RSI s ProPrint software a multicSKU database that stores hundreds of print jobs for fast retrieval and a controller that allows rapid changeover of print message and helps to ensure ac curate message printing The MVP Pro also comes with an advanced I O module for easy communication with PLCs and other machines RSI Systems LLC www rockwellautomation com go p rsisystems gt gt Safety Exhaust Valve Encompass Product Partner Ross Controls recently introduced the size 2 DM2 Category 4 safety exhaust valve available in 1 4 inch and 3 8 inch port sizes Used in safety systems for machine safeguarding applications the DM2 Double Valves with Total Dynamic Monitoring and Memory combine the dirttolerant wear compensating characteristics of poppet technology with new double valve features Memory cross monitoring and airflow control functions are integrated into two identical valve elements DM2 valves lock and inhibit further operation upon sensing an asynchronous movement of valve elements during actuation or de
101. s TECH TIPS gt gt networks and the services they provide evolve and serv ers or user machines are replaced and upgraded the likelihood of passing un wanted often obsolete protocols within the network increases Potentially more challenging is the existence of protocols that may degrade network performance Each situation is unique but knowing how to find these protocols and having a tool that shows which devices are using a particular protocol as well as where these devices are connected to the network is critical The Fluke Networks EtherScope Series II Network Assistant can iden tify unwanted protocols and discover networked devices Fluke Networks isan Encompass Product Partner in the Rockwell Automation PartnerNet te r iri ST T E i a4 E EE wee T Sh et fi ae k tee m Fal a ae 1 F Fh i way af imei gt Pt ee pt a re Lp orp Caps Tig a hE Bsr oer rE E aea Tei wi 2 gt Figure 1 Selecting Protocol Statistics from the home page identifies unwanted protocols work When connected to a span port the EtherScope analyzer monitors net work traffic and automatically provides protocol statistics for an extensive list of protocol types The analyzer monitors network traffic and automatically provides protocol statistics To identify these unwanted protocols using the EtherScope analyzer select Protocol Statistics from the home page see
102. s for the pneumatic side as well The new energy monitoring package for pneumatic sys tems GFDM generates cost savings says Cybulski But what multiplies the cost savings is if pressure values and compressed air figures are seamlessly measured and tracked from the supply side to the point of consumption See Figure 2 Energy Management for Pneumatic Systems To measure and monitor compressed air generation distri bution and consumption different hardware and software products have to work together The GFDM energy monitoring package from Festo Corp a Rockwell Automation Encompass Product Partner is a product for measuring and monitoring compressed air on the demand side see Figure 3 Sensors inserted into the main air line of existing or new pneumatic applications are combined with a diagnostic module The diagnostic module can be installed in the pneumatic machine s cabinet All available machining modes are monitored stand by off running part A part B etc Pressure and consump tion figures for each mode are determined and sent to a front end display FED SCADA system or plant wide energy Management system 26 42 All Other Reducing Measures Air Leaks 10 Adjustable Speed 12 Drives 10 Overall Recovering System Design Waste Heat Figure 1 These are potential areas for major energy savings Source EU study 2001 In the compressor room electric energy is t
103. savings are achieved through reductions in time required to program and configure operator inter Integration of standard components provides Remmele s clients with cost faces and integrate the machine s motion control elements effective flexible solutions The company increased throughput on one The technical support and engineering expertise Rockwell welding system by more than 300 Automation provided also helps reduce training and docu mentation requirements needed to support a system with the contextual design concepts customers need One Rockwell Automation Life Sciences Industry Solutions client called Remmele s innovative HMI design approach www rockwellautomation com go stj astounding reporting a 96 reduction in causes of hu Rockwell Automation Integrated Architecture man error on its assembly machine www rockwellautomation com go tj1 Oia ATTENTION ROCKWELL AUTOMATION ENCOMPASS PRODUCT PARTNERS THE Rockwell Automation Encompass Product Partner You enjoy exclusive advertising opportunities in The Journal to promote your products Take advantage of this opportunity to showcase your products that complement Rockwell Automation solutions Encompass Product Partner Showcase ads are cost effective 6 page four color ads produced for you at no additional charge For more information contact Scott Walters 440 835 2545 swalters putman net Skype s_m_wallters
104. sed on MicroStation Micro Station PowerDraft or AutoCAD platforms reduces electrical design time by more than 30 In addition it makes the electrical design process more accurate with more than 2 million up to date parts in its extensive content repository It can be used as a stand alone product or to support MicroSta tion V8i as an add on It also can exchange data with other Bentley Plant products via the common project database shared by Bentley s plant design applications AutoPLANT and PlantSpace Bentley Systems Inc www rockwellautomation com go p bentley The powder coated mild steel construction and IP54 ingress protection are standard features of both the IND560dyn and IND9DS6 Both units carry NTEP compliance to 3000d Mettler Toledo Inc www rockwellautomation com go p mettlertoledo 54 THE JOURNAL APRIL 2009 WWW ROCKWELLAUTOMATION COM THEJOURNAL gt gt Digital Vision Appliance Rockwell Automation Encompass Product Partner DALSA offers the IPD VA61 DALSA s first Gigabit Ethernet ready GigE Vision Appli ance It has two expandable GigE camera ports industrial O and a high performance processor It is suited to applications involving multiple monochrome or color GigE cameras The company s Vision Appliances are embedded machine vision solutions that are quickto deploy for automated quality inspection applications The VA61 supports DALSA s compact Genie cameras from 640x480
105. should be implemented at the main air distribution pipe e Implement GFDM in front of the selected machines or applications Air consumption during nonproduction in dicates leakage Make those machines or applications leak free It only makes sense to create reference values and to start monitoring if pneumatic machines consume a minimum of compressed air e Teach GFDM From that moment on GFDM monitors air consumption and machine pressure and informs you if tolerance thresholds are exceeded such as by new leaks e Connect all sensors and GFDMs to the intranet e Commission Rockwell Software RSEnergyMetrix Data Collection Phase e Collect data for a period of time covering normal production times peak production events weekends events of problems in the air system etc if neces sary over the course of several weeks Data Evaluation of Phase e Share monthly air consumption and compressed air cost statements of defined areas of the plant or at the point of consumption with colleagues and upper level management e Categorize where and when compressed air use is high e Check where air is consumed during nonproduction times to determine the location of leakages e Determine when and where peak flow events occur e Find unnecessary pressure reductions and pressure losses e Plan the actions that need to be taken in order of prior ity to reduce energy consumption For cases in which the data evaluation is too complex in
106. ste and costs while helping the environment by using on site solvent recovery 4 THE JOURNAL APRIL 2009 WWW ROCKWELLAUTOMATION COM THEJOURNAL From Rockwell Automation and Our Partners Find Network Traffic That Doesn t Belong 47 Spot and remove unwanted protocols to improve network performance What Is Tare Value A8 Learn how tare value is used in weighing systems DEPARTMENTS Editor s Viewpoint 7 News and Noteworthy 8 SPNews 15 PartnerNetwork News 18 Encompass Showcase AS Sustainability Corner 49 Product Focus 52 L S Z 7 RY Ke Ad Index 58 te Ltt OKA eX The Journal from Rockwell Automation and Our Partners CPC Int l Pub Mail 40028661 Express Messenger International PO Box 25058 London BRC Ontario Canada N6C6A8 Volume 16 Number 2 is published six times a year by PUTMAN MEDIA INC 555 W Pierce Rd Suite 301 Itasca IL 60143 Phone 630 467 1300 Fax 630 467 0157 Address all correspondence to Editorial and Executive Offices same address Printed in the United States The Journal from Rockwell Automation and Our Partners 2009 All trademarks company names and product names referred to throughout this publication are used for identification purposes only and are the properties A N s PY of their respective companies All rights reserved The contents of this publication may not be reproduced in whole or KN A
107. t s used in nearly every plant energy management and accounting systems haven t com pletely covered compressed air systems in the past pri marily because of the lack of appropriate devices to monitor compressed air consumption of plant areas and pneumatic machines or applications However with new field devices to monitor pneumatic systems users can easily measure track and add to existing energy and accounting monitoring solutions the genera tion distribution and consumption of compressed air This provides comprehensive analysis cost control diagnostic control and consumption control Cutting Costs of Pneumatic Drive Use Pneumatic drives are the preferred drive technology for many applications because of their numerous advantages compared to electrical and hydraulic counterparts Pneu matic drive technology offers overload resistance speed long service life ease of assembly reliability and safety The advantages of pneumatic drive technology suggest that monitoring functions are unnecessary Unfortunately compressed air is one of the most expensive sources of energy on the plant floor The U S Department of Energy estimates the cost at 18 cents to 30 cents per 1 000 cubic feet of compressed air With the rising costs of electricity in mind a 100 hp compressor system can cost about US 75 000 annually for energy depending on its operating hours 36 THEJOURNAL APRIL 2009 WWW ROCKWELLAUTOMATION COM THEJOURN
108. tabases and much more For more information call us at 508 520 9957 or download your tree evaluation copy from our Web site at www TheReportCompany com SYTECH Electrical CAD CAE Software Design and document your controls hardware systems efficiently and accurately with EPLAN Electric P8 Automatic tunctions such as online cross reterencing device tagging wire numbering and project reports that match schematics 1 1 signiticantly reduce design time and eliminate errors associated with manual tasks Advanced capabilities such as EPLAN macros with variants project options and automatic JIC IEC standards conversion provide further productivity gains For more intormation and to try EPLAN free for 30 days visit www eplanusa com EPLAN SOFTWARE amp SERVICES Harmonic Mitigation Filters Your goal is to have an efficient ap plication that you don t have to worry about every day TCI offers the products that will help you achieve your goal The HGZ HarmonicGuard Series Filter limits current distortion to less than 7 percent TDD and improves true power factor This helps ensure an efficient system and a happy customer To learn more visit www transcoil com TCI LLC Helical Planetary Gearbox The in line and rightangle Apex Compact AD ADR series product provides the ultimate solution where positioning under load is necessary and space is tight The Ultra Stiff patented design is availab
109. that can help you escape the grasp of economic challenges As part of its PartnerNetwork Rockwell Automation has more than 35 systems integrator partners we des ignate as Solution Providers located throughout North America Outside of North America more than 40 are in South America and we re begin ning to identify partners in Europe and the Asia Pacific What is a Rockwell Automation Solution Provider Solution Providers are best in class system integrators who provide industry and applications knowledge They re established organizations with extensive experience in manufactur ing solutions design implementation project management and mainte nance and have delivered innovative results to keep manufacturing facili ties like yours efficiently running It s all about mitigating your risk Solution Providers have strong reputations for delivering technology integrated with our solutions They ve been selected into the program because they have a strategic fit that complements the Rockwell Auto mation delivery strategy Rockwell Automation delivers solutions to its customers and Solution Providers complement those solutions To help identify the best in class we go through an evaluation process that includes assessing their financial stability and technical professional and ethical practices This evaluation is based on some of the same criteria the Control Systems Integrator As sociation CSIA
110. thin a manufacturing enterprise The OEE model yields a single performance rating to help plant personnel determine how a particular manufacturing activity or asset is performing while also providing detailed unit and machine event history to document performance The most effective OEE systems intelligently report the status of individual production line components such as the correlation of a downtime event with the time of the day the true The latest Web based HMI software uses advanced visualization technology which means you ll get crisp sharp images and a rich user experience Unlike many older Web based HMI software solutions the FactoryTalk ViewPoint Web based HMI software from Rock well Automation for example leverages familiar features of the most popular browsers such as Internet Explorer This includes hyperlinks navigational functionality and favorites And a thin client configuration means there s no client soft ware to install or maintain Also this new Web based HMI doesn t depend on termi nal services the server is a smaller piece of software that uses less bandwidth and fewer system resources Maintain ing this small footprint allows users to run on desktop comput ers and on HMI displays Security is a major concern with any Web based applica tion HMI software is no exception Software should provide secure access to Web applications and site administration Administrators should be able to provid
111. tion System Rockwell Automation recently expanded its Integrated Architecture production control and information system with more than 30 new capabilities for end users and machine builders Featuring the Rock well Automation Stratix family advanced process control APC and satety functionality and three new Logix PACs for mid range machine builders and end users this expansion is designed to help improve inte gration and performance within the manufacturing and IT infrastructure New APC features include run time partial import export func tionality APC function blocks and controller online change logging Runtime partial import functionality helps reduce downtime risks and improve productivity during deployment and maintenance operations New APC function blocks provide simpler multivariable control with automatic tuning built in The controller online change logging feature allows users to be notified when application changes are made New safety tools for use with Allen Bradley Guardlogix PACs offer a suite of 10 specific metalforming instructions certified by German based Berutsgenossenschatten BG as compliant with leading safety standards These instructions associated with clutch brake control and satety valve control and cam and crankshaft monitoring improve ease of use simplity diagnostics and streamline maintenance to canning ap plications and other metalforming press control and safety applications The new Guar
112. titive to conform to increasingly stringent environmental regulations and to remain sustainable The benefits are clear solvent re covery reduces production costs raw materials hauling and treatment re duces waste volumes mitigates supply risk meets regulatory requirements and satisfies green initiatives all while maintaining the quality required for manufacturing Solvent recovery benefits manufac turers as well as the world with reduced solvent consumption and reduced emis sions Manufacturers who don t have such capability owe it to themselves to explore this opportunity 1 David J C Constable Conchita Jimenez Gonzalez and Richard K Henderson Perspective on Solvent Use in the Pharmaceutical Industry 2007 American Chemical Society ProsCon Ltd a Rockwell Automa tion company is an engineering firm offering technically unique design solu tions to the process industry Headquartered in Cork Ireland with an office in Dublin ProsCon primarily serves the pharmaceutical and biotechnology industries and offers expertise in process technology control systems and information technology ProsCon Ltd A Rockwell Automation Company www proscon com Rockwell Automation Sustainable Production Solutions www rockwellautomation com go tisustain Redundancy 1771 PLUG IN MODULES PLC 5 Over 60 Miles 96 km Apart Rockwell Automation Encompass Produ
113. utomation PartnerNet work see page 15 Feeling the Pinch No Problem to help guide you through this maze Automation amp Information Solutions Automation amp Information solu tions are the collection exchange 18 THEJOURNAL APRIL 2009 WWW ROCKWELLAUTOMATION COM THEJOURNAL and analysis of information measured by control systems In Rockwell Automation parlance Automation amp Information starts at instrumentation and sensors and moves up through programmable automation controllers PAC to the human machine interface HMI level It s bounded at the point in which a definite purpose informa tion solution is deployed to extend and improve the automation system The first skill set needed to oper ate in this area is a detailed knowl edge of the hardware and software products typically used to control and monitor manufacturing facili ties This knowledge allows prac titioners to select the right tool in each plant line or work cell A second critical skill is a deep understanding of the specific manu facturing processes and operations that need to be controlled and moni tored It s impossible to efficiently control a manufacturing facility by just becoming an automation product specialist systems integrators also must understand production facilities industry applications and processes Enterprise Solutions Enterprise solutions typically are ap proached from the enterprise
114. w change and develop Festo Corp based in Hauppauge N Y participates as an Encompass Product Partner in the Rockwell Automation PartnerNetwork The company is a global manufacturer of pneumatic and electromechanical systems components and controls for industrial automation Festo Corp www rockwellautomation com go festo Rockwell Automation Power amp Energy Management Solutions www rockwellautomation com go tipems Rockwell Automation Encompass Product Partner Program www rockwellautomation com go tjencompass 40 THEJOURNAL APRIL 2009 WWW ROCKWELLAUTOMATION COM THEJOURNAL POC COOH HEE E HEHE EOE TOOHE EEO HSOT EE EEHHOEESOSOOOE OO OEHEO TEES OOTSE OO ESOT EE ESHOE EES OSEOE OS EOHOOT ES HOHETTOSETO TSO ES OSH SES OSEEE SE SOOSO TES HOOESS OSHS OS TOES OSHS EO OSEH EOE ESOHO EES HOOEESOSEHOT TS ET OHS ES OSEOTO SESH HOEESOSOSESOSEHOOESOTOOHEE TOSSES OE EEHSEEES ESOS O SEES e AN ELECTRONIC SUBSCRIPTION TO JOURNAL IS 1 CLICK AWAY THE From Rockwell Automation and Our Partners Life Sciences Update Cut Pneumatic Energy Costs Increase PI li Power Re It s that easy to get The Journal We keep you up to date on industry trends and help you increase productivity and profitability by getting the most from the technology and services offered by Rockwell Automation and its Encompass Partners and Solution Providers Get your e subscription today Visit www ROCKWELLAUTOMATION COM
115. x I O module Also the Controllogix I O system takes no more panel room than the existing platform allowing users to keep the same footprint The conversion system includes a mounting ground faceplate Modicon 800 series swing arm conversion modules cover plate and Controllogix O system with interface cables Rockwell Automation Migration Solutions www rockwellautomation com go tjmg 52 THE JOURNAL APRIL 2009 WWW ROCKWELLAUTOMATION COM THEJOURNAL gt gt Product Spotlight Web Based Reporting of PlantFloor Data Rockwell Automation has launched Rockwell Software FactoryTalk VantagePoint an addition to its Factorylalk Integrated Production and Performance Suite Factorylalk VantagePoint allows users to seltcontigure Web based dashboards trends and reports without time consuming sup port resources The software leverages the Factorylalk service oriented architecture and technology acquired through the company s purchase of Incuity Software It delivers automatic access to production information trom both Rockwell Automation and third party systems Through an Internet browser Microsoft Office user interfaces and predefined connectors to third party systems Factorylalk Van tagePoint users can install and configure their systems in as little as a few hours with minimal technical support This allows employees at every level of a production facility to better monitor and manage productivity and ex

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