34 Meet the 2015 Engineering Leaders Under 40
Sister act
Building on their father’s legacy, a new generation moves Bales Metal Surface Solutions forward 27
It’s time you get more than you paid for in a PLC.
Affordable Innovation
Introducing the NEW It’s not just the low price, but the incredible built-in features that make our new Productivity2000 a must-have controller. Why pay thousands elsewhere for features that are standard for our newest PLC, including FREE programming software? • 5 built-in communications ports right on the CPU – All the communication you need is built right in! Modbus TCP/IP, EtherNet/IP, and serial devices are supported with no additional modules required! • OLED real-time data displays – View accurate process variable data (current, voltage and temperature) as well as system diagnostics on the Productivity2000 hardware OLED displays. No meter required!
Plus – •Effortless PID loops •Flexible tag name programming •Auto-discovered I/O •Hot-swappable modules •Simple VFD configuration •Built-in data logging •Multiple wiring options •Web server functionality •Small footprint: 7-slot rack only 10-1/2” wide
And with 50MB of user memory, USB plug-and-play programming functionality and a super low cost of ownership, the new Productivity2000 is the one you need!
Order Today, Ships Today! * See our Web site for details and restrictions. © Copyright 2015 AutomationDirect, Cumming, GA USA. All rights reserved.
AutomationDirect
CPU and I/O Comparison
Allen-Bradley
Productivity2000
CompactLogix
Base (if required)
$69.00
N/A
Power Supply
$69.00 P2-01AC
$414.50 1769-PA4
CPU
$255.00 P2-550
$3,160.00 1769-L33ER
16 AC Inputs
$105.00 P2-16NA
$286.00 1769-IA16
16 24VDC Inputs
$69.00 P2-16NE3
$244.00 1769-IQ16
8 Relay Outputs
$51.00
$301.50
8 Analog Input Channels (mA)
P2-08AD-1
$199.00
$713.50
ASCII Comm Module
$0.00
$737.00
Modbus RTU Comm Module
$0.00 Built in to CPU
$701.00 1769-SM2
Total System Price with USB, Ethernet and Serial
$817.00
$6557.50
P2-04B
P2-08TRS
Built in to CPU
N/A
1769-OW8I
1769-IF8
1769-ASCII
All prices are U.S. published prices. AutomationDirect prices as of 6/5/2015. Allen-Bradley retail prices taken from www.plccenter.com 5/12/2015.
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input #1 at www.plantengineering.com/information
the #1 value in automation
kaeser.com
KAESER SUCCESS STORY
COMPRESSORS
Keep It Under Control!
Kaeser puts automotive supplier in the driver’s seat of compressed air efficiency PROBLEM: A Tier 1 automotive seating and electrical supplier was interested in taking advantage of local utility rebate incentives. For their compressed air needs, they had been relying on four compressors manufactured in the 1980’s, inherited from a sister plant. Each unit operated in modulation control and was manually switched on and off, leaving the units continually fighting each other, resulting in wasted energy, fluctuating pressure, and increased maintenance costs.
SOLUTION: Kaeser performed a complete Air Demand Analysis (ADA) to identify the plant’s current compressed air needs and to develop a plan for implementing the most energy efficient solution possible. Additionally, Kaeser recommended a Sigma Air Manager (SAM) master controller to properly control the system and ensure the most energy efficient combination of units would be selected to meet current plant demand.
RESULT: Thanks to better controls and adding an energy efficient variable frequency drive compressor, the customer was able to reduce their annual maximum power consumption by 865,440 kWh—the equivalent of removing 100 homes from the power grid for one year—all without compromising stable system pressure. With the older compressors relegated to back-up, annual maintenance costs have been reduced from $37,000 to $18,000. Less maintenance also means less downtime, for increased productivity. Specific Power of Previous System:
28.93 kW/100 cfm
Specific Power of New System:
17.66 kW/100 cfm
Annual Energy Costs of Previous System:
$252,988 per year
Annual Energy Cost Savings:
$114,720 per year
Additional Savings in Maintenance Costs:
$19,000 per year
TOTAL ANNUAL SAVINGS:
$133,720
Utility Rebate:
$71,579
TOTAL SAVINGS:
$205,299
Visit us at Pack Ex p Booth #S o in -7362
Let us help you measure and manage your compressed air costs! input #2 at www.plantengineering.com/information
Kaeser Compressors, Inc. • 866-516-6888 • us.kaeser.com/PE Built for a lifetime is a trademark of Kaeser Compressors, Inc.
©2015 Kaeser Compressors, Inc.
customer.us@kaeser.com
Get to the problem before the problem gets to you.
Condently detect problems with 4 times better resolution. Get to the heat of the problem fast with Keysight TrueIR Thermal Imagers. Avoid an unplanned shutdown with this lightweight, easy-to-use handheld device. With the in-camera ne resolution of 320 x 240 pixels you’ll spot issues quickly, clearly and as close as 10 cm away. That’s 4 times better than competitors and at no added cost. You can’t afford a factory shutdown, but you can afford the Keysight TrueIR Thermal Imager. Keysight U5850A TrueIR Series
Company A
Company B
Detector resolution
160 x 120 (19,200 pixels) 160 x 120 (19,200 pixels) 160 x 120 (19,200 pixels)
In-camera ne/super resolution
320 x 240 (76,800 pixels) N/A
(Image enhancement)
N/A
3.1 mrad
3.39 mrad
2.72 mrad
Sensitivity
0.07 °C at 30 °C
< 0.1 °C at 30 °C
< 0.07 °C at 30 °C
Accuracy
±2 °C or ±2%
±2 °C or ±2%
±2 °C or ±2%
Spatial resolution (IFOV)
(2.1 mrad with ne resolution)
Data for comparative products provided by Company A publication 4026524B D-EN-N © 2011 and publication 64501-0101_en_50.xml, ver. 1.21 © 2014 for Company B.
Limited time only: FREE 5 year warranty www.keysight.com/find/TrueIRimager USA: 800 829 4444 CAN: 877 894 4414 © Keysight Technologies, Inc. 2015
input #3 at www.plantengineering.com/information
September 2015 Volume 69, No.7
Cover image courtesy: CFE Media
27 Sister act Stacey Bales is president of Bales Metal Surfacing Solutions, tackling the strategic vision. Her sister, Sara Mortensen, is vice president and heads up the sales and marketing effort. They are leading their company, and their father’s legacy, into the future.
30 Better training leads to a stronger workforce In a world of robotic articulation, machine-to-machine communications, transfer-line technology for blank to finished workpiece flow, and even the elimination of the zone controllers, it’s obvious that controls suppliers must make a commitment to follow every development in the market.
34 Meet the 2015 Engineering Leaders Under 40 They are among the young people who have made a commitment to manufacturing and are displaying uncommon skills in moving manufacturing forward.
43 A return to apprenticeships delivers skilled workers to Pratt & Whitney Partnering with local community colleges to develop skills of future manufacturing workers is critical to the company’s success, and it has created programs near its facilities to train current and future employees. PLANT ENGINEERING (ISSN 0032-082X, Vol. 69, No. 7, GST #123397457) is published 10x per year, monthly except in January and July, by CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Jim Langhenry, Group Publisher /Co-Founder; Steve Rourke CEO/COO/Co-Founder. PLANT ENGINEERING copyright 2015 by CFE Media, LLC. All rights reserved. PLANT ENGINEERING is a registered trademark of CFE Media, LLC used under license. Periodicals postage paid at Oak Brook, IL 60523 and additional mailing offices. Circulation records are maintained at CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. E-mail: customerservice@ cfemedia.com. Postmaster: send address changes to PLANT ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Publications Mail Agreement No. 40685520. Return undeliverable Canadian addresses to: 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Email: customerservice@cfemedia.com. Rates for nonqualified subscriptions, including all issues: USA, $145/yr; Canada, $180/yr (includes 7% GST, GST#123397457); Mexico, $172/yr; International air delivery $318/yr. Except for special issues where price changes are indicated, single copies are available for $20.00 US and $25.00 foreign. Please address all subscription mail to PLANT ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Printed in the USA. CFE Media, LLC does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the material contained herein, regardless of whether such errors result from negligence, accident or any other cause whatsoever.
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PLANT ENGINEERING
September 2015 • 3
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input #4 at www.plantengineering.com/information
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In Focus PlantEngineering.com 1111 W. 22nd St. Suite 250, Oak Brook, IL 60523 Ph 630-571-4070, Fax 630-214-4504
CONTENT SPECIALISTS/EDITORIAL BOB VAVRA, Content Manager 630-571-4070 x2212, BVavra@CFEMedia.com AMANDA PELLICCIONE, Director of Research 631-320-0655, APelliccione@CFEMedia.com ERIN DUNNE, Production Coordinator 630-571-4070 x2220, EDunne@CFEMedia.com
PUBLICATION SERVICES
9 Manufacturing Day a way to reach out into the future The fourth annual Manufacturing Day on Friday, Oct. 2, is designed to show a whole new generation of young people how today’s manufacturing is all about advanced technologies, state of the art facilities and fast paced work environments.
JIM LANGHENRY, Co-Founder & Publisher 630-571-4070 x2203, JLanghenry@CFEMedia.com STEVE ROURKE, Co-Founder 630-571-4070 x2204, SRourke@CFEMedia.com TRUDY KELLY, Executive Assistant 630-571-4070 x2205, TKelly@CFEMedia.com ELENA MOELLER-YOUNGER, Marketing Manager 773-815-3795, EMYounger@CFEMedia.com KRISTEN NIMMO, Marketing Manager 630-571-4070 x2215, KNimmo@CFEMedia.com MICHAEL SMITH, Creative Director 630-779-8910, MSmith@CFEMedia.com KATIE SPAIN, Art Director 630-571-4070 x2218, KSpain@CFEMedia.com PAUL BROUCH, Director of Operations 630-571-4070 x2208, PBrouch@CFEMedia.com
14 OEE vs. MTBF: Which is the right metric? OEE (overall equipment effectiveness) and MTBF (mean time between failure) can be very informative and drive some specific behaviors when applied correctly. However, when applied incorrectly, they will likely lead to confusion and frustration. Here are some insights on how and where we might best apply these metrics to get the greatest impact.
MICHAEL ROTZ, Print Production Manager 717-766-0211, Fax: 717-506-7238 mike.rotz@frycomm.com MARIA BARTELL, Account Director, Infogroup Targeting Solutions 847-378-2275, maria.bartell@infogroup.com RICK ELLIS, Audience Management Director 303-246-1250, REllis@CFEMedia.com LETTERS TO THE EDITOR Please e-mail your opinions to BVavra@CFEMedia.com. INFORMATION For a Media Kit or Editorial Calendar, e-mail Trudy Kelly at TKelly@CFEMedia.com. REPRINTS For custom reprints or electronic usage, contact: Brett Petillo, Wright’s Media 281-419-5725, bpetillo@wrightsmedia.com
PUBLICATION SALES Tom Corcoran, West, TX, OK 1111 W. 22nd St., Suite 250, Oak Brook, IL 60523 Karen Cira, Southeast 879 Autumn Rain Ln. Charlotte, NC 28209 Maggie Hatcher, AL, FL 1111 W. 22nd St., Suite 250, Oak Brook, IL 60523
TCorcoran@CFEMedia.com Tel. 215-275-6420 Fax 484-631-0598 KCira@CFEMedia.com Tel. 704-523-5466 Fax 630-214-4504 MHatcher@CFEMedia.com Tel. 630-571-4070 x2221 Fax 630-214-4504
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Jerry Preston, West Coast 6746 E. Tyndall Circle Mesa, AZ 85215
JPreston@CFEMedia.com Tel. 602-369-3037
Stuart Smith, International SSM Global Media Ltd.
stuart.smith@ssm.co.uk Tel. +44 208 464 5577 Fax +44 208 464 5588
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Mechanical Solutions
47 Take a total system approach to compressed air reliability Understanding the total impact of running a compressed air system and identifying the necessary actions based on unique compressed air needs can reduce energy costs by as much as 20%.
52 Selecting a filler metal: Seven factors to consider Using a filler metal that provides the appropriate mechanical and chemical properties for the job—and is able to withstand the service conditions the weld encounters—is critical. It helps minimize the risk of cracking, corrosion, and/or weld defects that could lead to time-consuming and costly rework.
PLANT ENGINEERING
September 2015 • 5
SEPTEMBER
www.plantengineering.com
Trending
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VIDEO:: A bicycle built for IIoT
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Engineering eNewsletters Stay in touch with changes in the industry, including news, articles, and product updates. eNewsletters include: Hotwire, Maintenance Connection, PlantMail, Energy Management, Safety & Security, Product & Media Showcase, and Whitepaper Connection. Subscribe to one or more eNewsletters at:
In an Industrial Internet of Things (IIoT) demonstration using a mountain bike tricked out with sensors and instrumentation, ThingWorx, a PTC business, revealed how an operator might see an industrial machine’s metrics in real time by looking through a wearable human-machine interface (HMI). The presentation at the August NIWeek showed how hardware and software can widen IIoT capabilities. For more videos visit www.plantengineering.com/videos.
Your most-read stories at www.plantengineering.com
Here are the 10 most often referenced articles at www.plantengineering.com in August. Use our extensive search engine to find articles on manufacturing solutions whenever you need help with plant floor issues ranging from maintenance to personnel. 1. Five strategies to achieve world-class preventive maintenance 2. The truth about five common VFD myths 3. Understanding variable frequency drives 4. Big data drilldown part 2: Sensor and data collection technologies advance 5. How to choose the best lighting for a food facility 6. 12 tips to sustain improvement in Lean equipment maintenance programs 7. A hands-on approach for manufacturing 8. Electric motor power measurement and analysis 9. Study identifies 10 ways to improve supply chain efficiency 10. Absorption cooling makes sense
Webcasts: 1 hour to knowledge
Plant Engineering’s Webcast series offers a wide selection of on-demand knowledge— everything from the latest innovations concerning the Industrial Internet of Things (IIoT) to reports on motors, air quality and safety. All Webcasts can be completed in just an hour, and many of them offer continuing education credits. Among the current topics at www.plantengineering.com/webcasts: • Motor and Drive System Considerations to Ensure Maximum Performance, Increase Reliability and Extend Product Life • Considerations for Buying or Upgrading Dust Collection Equipment • 5 Ways to Improve Your Plant’s Training Strategy • Portable Spot Air Conditioners in Industrial Applications: Increase Revenue and Create a Safe Working Environment • 3D Laser Scanning: Revolutionizing Facility Management
6 • September 2015
PLANT ENGINEERING
www.plantengineering.com/newsletters
Read this on your tablet The tablet and digital editions of this publication are greatly enhanced and have unique content for digital subscribers. They also include interactive tools Sister act such as videos, Web links, and other items. Update your subscription, and receive the digital edition in your e-mail in-box:
34 Meet the 2015 Engineering Leaders Under 40
Building on their fathers legacy, a new generation moves Bales Metal Surface Solutions forward 27
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Upcoming webcasts Register for educational webcasts at www.plantengineering.com/webcasts: • November 3: IIoT Webcast Series Part 3: Integration considerations
Join the discussion Facebook: www.facebook.com/PlantEng Google+: http://google.com/+plantengineering LinkedIn: http://tinyurl.com/PlantEngineeringProfessionals Twitter: www.twitter.com/PlantEngMag SlideShare: www.slideshare.net/PlantEngineering www.plantengineering.com
Machining without Coolant!
Watch The Video!
www.exair.com/79/49979.htm
Replace messy mist systems & improve dry machining with clean, cold air! Extend CNC Tool Life
The Model 5315 Cold Gun cools a two flute 3/8" carbide cutter on a CNC, increasing tool life by 50%. Ideal for diamond tooling.
Milling & Drilling
Fly cutters up to 460mm in diameter have been cooled with the Cold Gun. Dissipating heat with cold air extends tool life, increases speeds and feeds, and improves finishes.
Chill Roll
Cooling a roll with 20°F (-7°C) air keeps the material on the surface from bunching up, jamming or tearing. The metal surface transfers the cold temperature to the product.
Tool Grinding
Cold air eliminates heat cracking of carbide and tool edge burning during grinding and sharpening operations. Increased tool life between regrinds is the result.
Increase tool life and machining rates! The Cold Gun increases tool life, tolerances and production rates by eliminating heat build up. It produces 20°F air from ordinary compressed air. The Cold Gun is ideal for dry machining or to replace messy mist systems. It eliminates the costly coolant purchase and disposal. • Low cost, portable, quiet • Won't freeze up during continuous use • No health problems from airborne coolant • Improves surface finish • No moving parts maintenance free
High Power Cold Gun
Twice Twice the the cooling cooling power power of of standard standard Cold Cold Guns. Guns. Manufacturing Intelligent Compressed Air® Products Since 1983 11510 Goldcoast Drive • Cincinnati, Ohio • 45249-1621 • (800) 903-9247 fax: (513) 671-3363 • E-mail: techelp@exair.com • www.exair.com
input #5 at www.plantengineering.com/information
www.exair.com/79/499.htm
@EXAIR
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• Slide fragile materials gently through smooth stainless steel tubing using low-friction polymer discs attached to galvanized, stainless or Nylon-encapsulated stainless cable • Prevent separation of blends • Short to long distances • Durable discs in 4 and 6 in. (10 and 15 cm) diameters • Available CIP accessories • Single or multiple inlets/outlets can be removed/relocated and the cable-disc circuit lengthened/shortened/re-routed • Minimal power usage • Evacuates material, minimizing waste and cleaning time
• Single-point “up-and-in” installations to crossplant systems with multiple pick-up and discharge points and automated controls • Positive pressure and vacuum dilute phase systems complete with blowers, rotary airlock valves, pick-up adapters, filter receivers, cyclones, fill/pass valves, wands and weigh batching controls • Short to long distances • Wide capacity range–feed small packaging lines to silos and railcars • Single or multiple inlet and discharge points • Total evacuation of supply vessel and the conveyor line for accurate weighments, minimal waste and easy cleaning
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USA sales@flexicon.com 1 888 FLEXICON input #6 at www.plantengineering.com/information
CHILE UK SPAIN AUSTRALIA SINGAPORE SOUTH AFRICA
+56 +44 +34 +61 +65 +27
2 2415 1286 (0)1227 374710 647 670 302 (0)7 3879 4180 6778 9225 (0)41 453 1871 DD-0931
©2015 Flexicon Corporation. Flexicon Corporation has registrations and pending applications for the trademark FLEXICON throughout the world. *See complete Guarantee for details.
IN FOCUS Manufacturing Day a way to reach out into the future By Ed Youdell Fabricators & Manufacturers Association, Intl.
In October, thousands of manufacturers, colleges and trade schools across the country will celebrate Manufacturing Day by opening their doors and inviting young people to experience modern manufacturing. The annual national event, executed at the local level, is designed to dispel the prevalent misconceptions about our industry and also address the serious skilled labor gap that now exists. It is estimated that nearly 2 million manufacturing jobs will go unfilled over the next decade due to manufacturers’ inability to find talent with the required skills. Numerous manufacturing jobs will be available for those with the desired talents. The fourth annual Manufacturing Day on Friday, Oct. 2, is designed to show a whole new generation of young people how today’s manufacturing is all about advanced technologies, state of the art facilities and fast paced work environments. It’s also an opportunity to show parents the kind of work that takes place in manufacturing plants. Students, teachers, parents, and job seekers can see for themselves that
Female students learned how metal is bent to build duct work in an HVAC program at Westmoreland County (Virginia) Community College’s Manufacturing Day event in 2014. Image courtesy: Manufacturing Day
manufacturing provides clean, safe, high-tech environments in which to pursue challenging, creative, wellpaid careers. By participating, we anticipate more young people will want to follow a manufacturing career path. Take Chris Monzyk, for example. He was a student at Ozarks Technical College in 2013 when he was part of
Since it was first launched 4 years ago, Manufacturing Day has gained attention from leaders in the manufacturing and political sectors. It also has shown remarkable growth.
a Manufacturing Day tour at Detroit Tool & Engineering(DTE) in Lebanon, Mo. Intrigued by what he saw and identified by the company as a possible potential recruit, Monzyk was offered an opportunity to join the firm. Today, he proudly works as a machinist in the 109-person company that builds tools, dies, and custom automation systems. “I like to work with my hands,” said Monzyk. “It sounds cliché, but working at DTE is fun, exciting and new every day. I get to make something from virtually nothing.”
2012 240 events, just under 10,000 attendees 2013 825 events, more than 35,000 attendees 2014 1,679 events, almost 400,000 attendees 2015 (Projected) 2,200 events and more than 500,000 attendees Source: Manufacturing Day
www.plantengineering.com
PLANT ENGINEERING
September 2015 • 9
IN FOCUS Send us your Manufacturing Day photos Manufacturing Day 2015 will feature more than 2,200 events across the country. The event has grown rapidly as manufacturing professionals are joined by educators, business and civic leaders, parents and students in celebrating modern manufacturing. Plant Engineering would like to see what Manufacturing Day events look like in your plant. Please send photos and information about how your plant celebrated Manufacturing Day, and we’ll publish them online and in the November issue of Plant Engineering. Send your photos (300 dpi, jpeg) and information to content manager Bob Vavra at bvavra@cfemedia.com. All photos submitted may be used by Plant Engineering in its print and online publications.
“ It is estimated that nearly 2 million manufacturing jobs will go unfilled over the next decade due to manufacturers’ inability to find talent with the required skills.
”
Your One-Stop for hands-on electrical safety & maintenance training courses. Offering over 52 courses including: NFPA 70E Electrical Safety Substation Maintenance Infrared Thermography Motors & Starters Circuit Breaker Maintenance Protective Relay Maintenance & More
input #7 at www.plantengineering.com/information
And then there is Micah Rider who, as a high school student in 2013, took a Manufacturing Day tour arranged through Wichita Area Technical College (WATC). By 2014, he had graduated and was enrolled at WATC and was leading one of its facility tours on Manufacturing Day. Rider is excited about his pursuit of a manufacturing career and getting other kids to follow in his path. “I ask kids, ‘What do you like to do? Do you like to play with Legos? Have you ever thought about building stuff?” he said.
Manufacturers who open their doors for Manufacturing Day 2015 are not only educating their communities about career opportunities, they also may discover a new employee or two. By reengaging local communities to showcase their manufacturing sector and demonstrate the contribution t h a t m a n u f a c t u ring makes to the local economy, we can ensure a better future and way of life for our children and grandchildren. Our future depends on our ability to strengthen and advance this vital sector of our nation’s economy. PE
To learn more about Manufacturing Day, including locations that will be offering tours, and tools and advice to plan a celebration, visit www.mfgday.com.
877-594-3156 WWW.AVOTRAINING.COM
10 • September 2015
PLANT ENGINEERING
www.plantengineering.com
input #8 at www.plantengineering.com/information
LED METAL HALIDE DIRECT REPLACEMENT “PLU G N’ PLAY ” L ED for Met al Hali de Saves $1,000s in Monthly Ener gy Cost s
IN FOCUS
Three steps to select the right fuse for control circuit protection
By Nick Offerman, Eaton Bussman
• Simply screw it in...It’s EZ! BEFORE W/ METAL HALIDE • No rewiring • No electrician • No ballast bypassing • Fast, fast payback • Rebate eligible AFTER W/ THE OEO EZ LED • 5 year warranty • 55,000+ hour life • FREE shipping this month • 30 day money-back guarantee
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Waiting Is Costly. Call Now! info@oeo.com
EIG-020 Powerinput & Consult 7/22/15 12:51 PM Page 1 #9 at www.plantengineering.com/information
Power Quality Metering & Energy Management
Nexus 1500+
®
Power Quality Metering Measure and record harmful power quality events Conduct harmonic studies Understand feeder efficiency & load balance Create automated power quality reports
Energy Management
Log energy usage at each circuit Calculate cost allocation to different processes Control loads to reduce demand Generate automated energy reports for executives
1-877-EIMETER | www.electroind.com
input #10 at www.plantengineering.com/information
Control circuit fuses have a variety of different voltage ratings, ranging from 32 to 600 V, and interrupting ratings up to 100 kA. As the physical size of these fuses does not vary with voltage or interrupting rating, the most common cause of misapplication is due to improper voltage or interrupting rating selection. When a system fault occurs and an improperly sized fuse tries to interrupt an overcurrent event, there can be adverse consequences. This mistake can lead to compromised system integrity—impacting personnel and equipment safety.
Type, voltage, interrupt rating
Find the right control circuit or supplemental fuse in three simple steps: 1. Select the fuse type. Select from time-delay fuses for inductive loads or fast-acting fuses for resistive loads. 2. Select the voltage rating required. The voltage rating must be equal to or greater than the circuit voltage for the proper application of an overcurrent protective device. The device can have a higher rating, but not a lower one; when an overcurrent protective device is applied beyond its rating, there may be potential for fire and arcing energy, posing a severe fire risk to other components in the panel. 3. Verify that the interrupting rating of the selected fuse is sufficient for the circuit application. The interrupting rating must be equal to or greater than the available short-circuit current. An overcurrent protective device must be Eaton’s Bussmann series Fuses able to safely interrupt Made Simple program helps make short-circuit currents to it easier to identify the right device which the equipment can by clearly indicating the voltage be subjected. If the fault and interrupting rating on the fuse current exceeds a level label. The voltage rating is easily beyond the capacity of identified by both the color code the protective device, and large print on the fuse label, the device may rupand the interrupting rating is printture, causing additional ed on the side of each fuse. Image damage. Therefore, it is courtesy: Eaton’s Bussmann important to use a fuse that can sustain the largest potential short-circuit currents. Failure to apply fuses with the appropriate interrupting rating can be a serious safety hazard. PE Nick Offerman is a product manager at Eaton’s Bussmann Division.
12 • September 2015
PLANT ENGINEERING
Reliable Detection For Your Application
You can’t afford not to know. See it all at thinkallied.com/sensors
1.800.433.5700 © Allied Electronics, Inc 2015. ‘Allied Electronics’ and the Allied Electronics logo are trademarks of Allied Electronics, Inc.
An Electrocomponents Company.
input #11 at www.plantengineering.com/information
IN fOCUS OEE vs. MTBF: Which is the right metric? Either can help drive specific behaviors—if correctly applied. By Mike Gehloff Allied Reliability Group
If you have had some level of classic reliability or maintenance-related training, then you may have likely at least had an exposure to some of the more commonly used metrics such as OEE (overall equipment effectiveness) and MTBF (mean time between failure). Both of these metrics can be very informative and drive some specific behaviors when applied correctly. However, when applied incorrectly, they will likely lead to confusion and frustration. While I don’t intend to make anyone an expert at these two commonly used metrics in this forum, I do want to share some insight on how and where we might best apply these metrics to get the greatest impact.
Overall equipment effectiveness (OEE)
The layman’s version of OEE is simply defined as what percentage of the time that you were capable of running good product at full capacity and with acceptable quality did you do so? Perfection at OEE is 100%. Anything more than that and you are breaking a few laws of physics, but we will save that trip down the rabbit hole for another time. The generally accepted formula for OEE is as follows: OEE (%) = Availability (%) x Performance Efficiency (%) x Quality Rate (%) With a simple definition of the components being: Availability = The percentage of the time that you actually ran and produced something. Performance efficiency = During this time that you actually produced, at what percentage of your rated capacity (speed, throughput, etc.) did you actually run.
14 • September 2015
plant engineering
Quality rate = For all of the units that you produced, what percentage of them were acceptable for sale to the customer, meeting the stated quality requirements. For example: Availability = 80% Performance Efficiency = 90% Quality Rate = 99% OEE = 80% x 90% x 99% OEE = 71.28% Both of the OEE and MTBF metrics can be very informative and drive specific behaviors when applied correctly. However, when applied incorrectly, they will likely lead to confusion and frustration. I think that OEE is a fantastic measure for a few important reasons. Nowhere in the definition do the words “maintenance” or “operations” appear. It brings us together under one common measure. It facilitates two teams who can easily work at crosspurposes to work together. For example, availability losses can be experienced as a result of both maintenance and operating practices. It forces us to focus on the loss of potential rather than what we have Assessing whether to use OEE and MTBF as a metric for your plant largely will depend on your industry and the sophistication of your current operation. Image courtesy: CFE Media
accomplished with no idea of what might be possible. It brings together three aspects that are critical to meeting our customer’s needs. For example, if we only measured availability, we might overlook the fact that we ran at 50% speed. I look at OEE as the universal measure. Mix with it some safety and cost awareness and you have a great start to a complete performance scorecard.
Mean time between failure (MTBF)
As the name implies, the Mean Time Between Failure tells us how often, on average (mean), we should expect to see an asset fail to fulfill its function. Higher MTBF is always considered to be better. A simple definition for MTBF is: MTBF = Operating Hours ÷ Number of Failures Operating Hours = The time frame (frequency of measurement). Number of Failures = The number of occurrences where the asset failed to fulfill its function. Note: MTBF is the reciprocal of the Failure Rate (1/MTBF = Failure Rate). For example: Assume we measure MTBF on a monthly basis (30 days or 720 hours), and we have experienced 10 failures in this time frame. MTBF = 720 hours ÷ 10 failures = 72 hours MTBF = 30 days ÷ 10 failures = 3 days This means that under current conditions, we should expect to experience a failure every 72 hours. MTBF is a relative measure. Measuring MTBF on a highly critical asset or group of assets can be very meaningful. Measuring MTBF across an entire department or facility provides less value. The key to leveraging MTBF is to understand where these failures come www.plantengineering.com
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www.RittalEnclosures.com (800) 477-4000 input #12 at www.plantengineering.com/information
IN fOCUS from, and to develop lasting strategies that will eliminate them. Your RCFA ability becomes very important when you are measuring MTBF.
tion and refining, and many petrochemical processes fall into this category. Unfortunately, in these types of environments, OEE might not serve our purposes for the following reasons: Availability is often so critical in process industries that we see a high level of redundant equipment (with a corresponding capital investment). If we experience a failure of one piece of equipment, we switch over to the redundant unit and continue on. For this reason, availability losses are usually greatly minimized. Performance efficiency losses can exist, but rather than run slow, we often immediately bring the backup unit online and begin a fix to the underperforming unit. It is often difficult, if not impossible, to identify quality losses in process industries. What does a bad kilowatt look like? In these situations, establishing MTBF as a meaningful measure on specific highly critical assets and trending your performance upward will likely provide much more value than OEE.
Which is right for you?
My short answer to this question is that if you can measure OEE in a meaningful way, then this is the metric for you. Sadly, OEE does not fit in all situations. Discrete Manufacturing Discrete manufacturing is the production of distinct items. Automobiles, furniture, toys, smartphones, and airplanes are examples of discrete manufacturing products. If this definition fits, then OEE is for you. You should be concerned about factors such as availability, performance efficiency, and quality rate. These factors are central to your success. Process industries Process industries are those who run a continuous batch where distinction between one unit and another is not easily identified. Power generation, oil produc-
Keeping it simple
Metrics are a funny thing. When used correctly and with the right application, they can provide a lot of value and focus to an organization. Used incorrectly, they tend to cause more harm than good. When selecting the best metrics for your team, consider the following advice: • Keep it simple. Too many measures cloud the focus. • Make sure we know what actions to take in order to improve the performance of each metric. What must we do differently in order to improve? It sounds obvious, but surprisingly it is often overlooked. • Talk about it often. A metric is only as good as the leader who draws the team together to own it. PE Mike Gehloff is principal at the Allied Reliability Group (ARG). ARG is a content partner of CFE Media. This article originally appeared on the Maintenance Phoenix blog.
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IN fOCUS PMI stumbles to 51.1% in August over global concerns By Bob Vavra, Content Manager, CFE Media
The August decline of the monthly Purchasing Managers’ Index (PMI) Index from the Institute for Supply Management (ISM) reflected the general malaise in the global markets. Even though the underlying growth
in the manufacturing sector continues, the drop of 1.6 percentage points proves there are plenty of frayed nerves. The PMI fell to 51.1% in August, down from July’s 52.7% reading and the lowest
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level for the PMI since a 50.1% reading in May 2013. The index had slipped as low as 51.5% in March and April of 2015 before rallying over the summer. All major indices that make up the PMI were lower in August, including a 4.8 percentage point drop in the New Order Index to 51.7% and a fall of 2.4 percentage points in the Production Index to 53.6%. While any figure above 50% in the PMI indicates growth in manufacturing ISM manufacturing business survey committee chairman Bradley Holcomb said the global markets were weighing on the survey committee. “Comments from the panel reflect a mix of modest to strong growth depending upon the specific industry, the positive impact of lower raw materials prices, but also a continuing concern over export growth,” said Holcomb in a press release. Among the comments from committee members: • “Falling crude oil prices are benefiting all resin based purchases as well as positively impacting fuel surcharges for inbound products.” (Food, Beverage & Tobacco Products) • “We are oversold.” (Paper Products) • “Business is still strong but has slowed slightly.” (Transportation Equipment) • “Modest growth slightly ahead of GDP. Optimistic for the remainder of the year as we have little international exposure.” (Chemical Products) • “(Foreign Exchange) continues to be a challenge, especially in Europe. Overall though, the mood is fairly upbeat regarding (the second half of 2015) as we ramp up for a new product launch.” (Computer & Electronic Products) • “Our business is good due to the increase in commercial construction.” (Fabricated Metal Products) • “Raw metals price decreases will impact our business favorably.” (Miscellaneous Manufacturing) • “Business is guarded but steady. Margins are tight. Markets are very competitive. China is lackluster.” (Wood Products) • “Automotive companies are investing heavily in upgrading their equipment.” (Machinery) PE
18 • September 2015
plant engineering
input #16 at www.plantengineering.com/information
research 2015 WORKFORCE DEVELOPMENT STUDY:
Five key findings on the unskilled workforce struggle
R
espondents to the CFE Media 2015 Workforce Development Study identified five high-level findings impacting the manufacturing industries today:
4. Actions taken: In an effort to com-
manufacturing facility today has 5% of jobs currently unfilled, down from 7% in 2014. Despite the decrease, 64% of respondents still believe that their facility’s workforce shortage will increase over the next 3 to 5 years.
bat the workforce shortage, 44% of facilities have taken to online recruitment and job postings, 40% have instituted or increased in-house training, and 35% have reached out to local technical schools for assistance. Nine in 10 respondents believe that their facilities still need to increase internal education/training programs and provide clear career paths for each new employee in order to better appeal to the younger workforce.
2. Causes: When asked about the pri-
5. Manufacturing’s image: More than
1. Workforce shortage: The average
mary causes of the workforce shortage, 56% of respondents said there aren’t enough skilled applicants to fill the roles of the growing number of retirees, and another 34% agree that their hiring rates aren’t keeping up with manufacturing’s rapid expansion.
3. Unskilled workforce: According
to respondents, the younger workforce most lacks problem solving (57%), instrumentation (55%), project management (51%), and electrical knowledge (50%); but they remain proficient in computer knowledge (60%) and other basic skills (31%).
half of respondents still don’t believe that manufacturing is portrayed as a positive career choice in the U.S. Sixtythree percent agree that offering apprenticeship programs would help to improve manufacturing’s image, and another 57% think introducing this career choice at an earlier education level—as well as improving salaries, benefits, and job security—are key action items. View more information at www.plantengineering.com/ 2015WorkforceDevelopment. Amanda Pelliccione is research director at CFE Media.
3 in 10 facilities shut down specialized automated production machinery only once a year for scheduled maintenance. Source: Plant Engineering 2015 Maintenance Study
48% of facilities conduct
regular energy audits; most audits are performed annually (62%), 16% quarterly, and 7% twice a year. Source: Plant Engineering 2015 Energy Management Study
2/3 of survey respondents
claim that the lack of available skilled workers has not kept their facilities from expanding operations. Source: Plant Engineering 2015 Workforce Development Study
MORE RESEARCH
All graphics courtesy: Plant Engineering, CFE Media
20 • September 2015
PLANT ENGINEERING
Plant Engineering surveys its audience on five topics each year: Salary survey, maintenance, energy management, safety, and workforce development. All reports are available at www.plantengineering.com/research. www.plantengineering.com
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Choosing a Compressor Solely Based on HP could Negatively Impact your Overall Operating Expenses Steve Bruno | Atlas Copco Product Marketing Manager When considering an air compressor, a primary concern should be; how can I get the most amount of compressed air for the lowest overall cost? CFM (Cubic Feet per Minute) describes the volume flow rate of compressed air. The first step in choosing the proper compressor is finding the CFM demand that your plant requires. Improperly sizing your compressor because you skipped through this step can cost you thousands of dollars in wasted electricity if you selected an oversized compressor. On the other hand, if you had more demand than you originally thought, the new compressor that you just purchased may be insufficient. As time goes on, technology improves and upgraded designs become more energy efficient. Air compressors are no different. Engineers work hard to improve the efficiency of air compressors by producing more air than previous generations. If you are replacing an existing compressor, check your CFM rating and choose a new compressor with the same CFM rating. Do not simply swap out a compressor for another one with the same horsepower rating because a newer model is likely able to produce more CFM. A compressor with a smaller HP, but equal rate of airflow can lower your energy cost without any reduction in your plant’s productivity.
A higher horsepower air compressor uses more electricity than a smaller one, so the important question is “Am I getting any more CFM for my increased electricity cost?” For compressors with the same advertised horsepower, the CFM output can vary by as much as 25% between companies and models. As an educated customer, you want the right amount of CFM at your necessary pressure, for the smallest horsepower. This will allow you to manufacture your products at the lowest cost and generate the highest profit. A group of air compressor manufacturers realized customer concerns and created a group called CAGI, or the Compressed Air and Gas Institute. Each compressed air manufacture agreed to have their compressors independently tested and verified. Once verified, certified data sheets are published publicly on each company’s website with key information that you as a customer will need in order to make your buying decision easier.
steve.bruno@us.atlascopco.com AtlasCopco.com
Download the paper at: www.atlascopco.us/usus/aboutus/sales/compressors_generators/ct_whitepapers.aspx input #18 at www.plantengineering.com/information
a
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Keeping the US Mail Moving VIBRATION ANALYSIS ON A CONVEYOR DRIVE UNIT
Mike Johnson, P.E. | Senior Analyst and Program Manager, Azima DLI To increase machine reliability and reduce overall costs, the United States Post Office’s Maintenance Technical Support Center in Oklahoma initiated a project to provide the bulk mail centers (BMC) maintenance offices with vibration analysis equipment and training to help support the maintenance process. Conveyors and other similar equipment can be found across multiple industries. They are often critical assets to production facilities where unplanned downtime can have significant financial impact beyond the parts and repair costs. Catastrophic failure usually causes collateral damage (which results in significantly more down time and repair costs) and typically happens at the worst possible time. By implementing a predictive maintenance program, an organization can increase uptime and avoid production loss. This case study shares how vibration analysis using demodulated spectra assisted the Maintenance Technical Support Center in keeping the Cincinnati Bulk Mailing Center operational during the increased holiday mail volume. Explore how predictive maintenance technologies can identify a significant problem on critical assets, evaluate the risk of continued operation and anticipate the repair and parts BEFORE failure occurs. Condition based monitoring can increase machine reliability and reduce overall costs including costly unplanned downtime. Download here: http://info.azimadli.com/vibration_analysis_conveyor_usps pe201509_whitePpr_azimaHlf.indd 1
a
input #19 at www.plantengineering.com/information
sales@AzimaDLI.com www.AzimaDLI.com
8/21/2015 11:36:37 AM
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Troubleshooting VFD Motor System Problems Despite the growing number and importance of variable-frequency drive (VFD) motor/machine systems in industrial applications, predictive maintenance professionals aren’t often aware of what is necessary to identify faults to avert unexpected, premature motor failures.The complexity of the symptoms exceeds the capabilities of common RMS handheld instrumentation, most of which is incapable of discerning symptoms or root causes. A variable-frequency drive exposes a motor to millions of impulses, which in turn requires proper installation and maintenance of both motor and drive. Protective devices such as line and load reactors, line traps and MOV surge arresters are necessary even if their return on investment is not immediately apparent. Tools available to field maintenance electricians are often limited to RMS current and voltage meters, which are inadequate when in comes to diagnostics of a given VFD’s variable operation in a motor-load system. While there are a few articles on debug and root-cause analysis of VFDs, authoritative and comprehensive technical references for analysis of VFD-related problems are not so readily available. The transient nature of VFDs, which interact dynamically with the motor and load system components, severely limits the usefulness of standard RMS and waveform types of instrumentation. This paper presents two case studies that exemplify how VFD motor load system diagnostics can be adequately performed with modern instrumentation. Register to download the paper: www.plantengineering.com/index.php?id=13860
pe201509_whitePpr_skfHlf.indd 1
input #20 at www.plantengineering.com/information
salesEMCM@skf.com www.skf.com/emcm
8/20/2015 11:52:12 AM
Turning Air Compressors into an Energy Source Werner Rauer | Product Manager for Screw Compressors, Kaeser Compressors, Inc. Michael Camber | Marketing Services Manager, Kaeser Compressors, Inc.
The rise in energy prices is an unwelcome reality in today’s manufacturing and business environment. While the rate of price increases for natural gas, heating oil, and other sources may vary from year to year, the upward trajectory is clear. Energy cost reduction strategies are vital to staying competitive. Industrial compressed air users looking for new ways to combat rising energy prices often overlook a significant resource in their plant. One important way operational efficiencies can be increased is by harnessing heat from compressed air systems, which are a major component of industrial energy consumption.
Download this whitepaper at: www.us.kaeser.com/whitepapers
The heat generated by compressed air systems can be a very good source of energy savings. In fact, 100% of the electrical energy used by an industrial air compressor is converted into heat. 96% of this heat can be recovered (the balance remains in the compressed air or radiates from the compressor into the immediate surroundings). Kaeser Compressors, Inc.’s whitepaper, “Turning Air Compressors into an Energy Source,” discusses how the heat rejected by rotary screw compressors can be harnessed for a variety of plant uses to yield sustainable energy savings. Authored by industry experts Werner Rauer and Michael Camber, it also gives key tips on when heat recovery may or may not be an efficient way to save money.
Email: customer.us@kaeser.com | Tel: 866-516-6888 www.us.kaeser.com
input #21 at www.plantengineering.com/information
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Valve Postitioners Offer Improved Control Valve Performance David Matherly | Product Manager – Controls and Instrumentation Control valve designs and the concept of controlling fluids within a system have been around since the eighteenth century. In particular, rising stem, linear modulating types have been utilized within processes to precisely control the amount of flow and pressure of those fluids. But manually setting and changing valve positions based upon downstream system demand changes quickly became impractical. Pneumatically or electrically actuating valves via a remote signal gained popularity after reliable actuator designs and automatic controllers were introduced; automatically moving a valve’s position dictated by a controller’s set-point increased system accuracy. This greatly influenced product quality and reduced waste associated with manufacturing processes. When specific sensors were added to “feed-back” information to the controller concerning the manufacturing process and the variable being controlled,
system accuracy was once again increased. The control loop was now closed between the controller, sensor, and automatic valve. Although performance was improved through the use of closed-loop control systems, control valve and actuator designs determined total system accuracy. The addition of valve positioners has radically changed the way actuated control valves respond within a process control loop. This white paper details many of the advantages of installing and applying a positioner to a basic, pneumatically actuated control valve package. Download the paper at: http://bit.ly/1VvJlks
www.spiraxsarco.com/global/us | Email: David.Matherly@us.spiraxsarco.com pe201509_whitePpr_SpiraxHLF.indd 1
input #22 at www.plantengineering.com/information
8/5/2015 3:32:51 PM
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How do you stop sensor drift? Learn how, when and why different parameters need consistent calibration to ensure long-term data accuracy. How is the relative humidity or temperature of an instrument calibrated? What parameters need regular calibration and why? What are typical calibration schedules? Regular calibration and maintenance of high performance measurement instruments are vital to ensuring most accurate measurements possible.
Download the white paper at www.vaisala.com/calibrate
This paper answers these questions and helps you understand what is involved in the calibration of these different parameters:
• • • •
Relative Humidity Temperature Dew Point Barometric Pressure
pe201509_whitePpr_Vaisala.indd 1
www.vaisala.com instruments@vaisala.com
input #23 at www.plantengineering.com/information
8/17/2015 11:46:27 AM
input #24 at www.plantengineering.com/information
Stacey Bales (left) and Sara Mortensen (right) with a picture of their father Steven, who started the family metal surfacing business in the 1980s. The sisters inherited the company after their father’s death six years ago and are reshaping it in new ways. All images courtesy: CFE Media
Sister act
Stacey Bales and Sara Mortensen chart a fresh course for the family business. By Bob Vavra Content Manager, Plant Engineering
www.plantengineering.com
S
tacey Bales is the analytical one, leading the change to improve operations and grow the family business. Sara Mortensen is the creative one, bringing her people skills to help customers solve problems. As sisters, they are two sides of the same coin; each the parts of their father Steven Bales, who began the family’s metal-finishing plant with his brother Mike in Downers Grove, Ill., in the 1980s. His daughters would tag along with him while they were still in school. “When we were younger, Dad used to bring us down here, give us masking tape, and let us do etched-glass projects,” said Bales. “I used to look forward to going to work with Dad for the day. He was a good role model.” When Mike Bales retired in 2009, Steven Bales prepared to take the business forward. Stacey had a keen interest in architecture and drafting and was working full time at the company. Sara, who had just given birth
to a daughter, was working part-time in the front office. And then Steven Bales died in November 2009 at age 53, and everything changed. “A light went out around here,” said Bales. “A big presence was lost. We were only closed a few days, and all of our employees stayed with us. Their faith in us made it easier to keep trucking.” As you tour Bales Metal Surfacing Solutions today, you hear of the plans for growth and expansion—the new lines for production, the plans to expand their laboratory and to take a strategic approach to growth. There are the subtle changes as well—a rebranding campaign, an emphasis on social media, and the brighter orange-and-blue corporate colors. Bales, 32, is president of Bales Metal Surfacing Solutions, tackling the strategic vision. Mortensen, 31, is vice president and heads up the sales and marketing effort. They are leading their company, and their father’s legacy, into the future.
PLANT ENGINEERING
September 2015 • 27
Taking the reins
The skill of employees, and their willingness to stick with the business, has been a key factor as Bales Metal Surfacing Solutions builds its business under the leadership of Steven Bales’ daughters.
28 • September 2015
When Steven Bales died, his daughters were 26 and 25 years old. There was no formal succession plan, because no one saw this coming. The sisters were forced to face critical questions about the company almost immediately. The first issue they faced was a matter of trust. Some people suggested to them the company assets should be liquidated. Mortensen and Bales weren’t interested in that solution. “The biggest difficulty was finding a good group of advisors,” said Bales. “At first, we didn’t get the guidance we needed. It was a matter of switching advisors and finding good resources.” One of those resources was Dean Tufano, the company’s technical services manager. He had been hired by Steven Bales just weeks before his passing, and Tufano admits he had doubts at first. “I thought it was going to be rough, but I was proven wrong in a few months,” Tufano said. “I was weighing if I was going to stay. They took the horse by the reins.” “Everybody stood behind us,” said Bales, who credits Tufano and technical services manager Harry Raimondi for helping them steer the ship then and now. “Most people were there to support us and help us. They have more expertise than we do, and we leveraged their experience a great deal. A lot of it was being able to admit you don’t know what you don’t know. You can’t think you have all the answers.” Today, as they guide Bales Metal Surface Solutions into the future, Bales and Mortensen face the same i s s u e s m o s t m a n u f a c t u ring businesses face—training, benefits, and employee retention. They’ve rewritten and tightened up the company handbook to focus on enforceable policies. “Our old employee handbook read like a technical manual,” said Mortensen. “We tried to put a little more fun and personality into it.” They’ve struggled with health insurance costs, and yet have retained one of their
plant engineering
“When we were younger, Dad
used to bring us down here, give us masking tape, and let us do etched-glass projects. I used to look forward to going to work with Dad for the day. He was a
”
good role model.
Stacey Bales, Bales Metal Surfacing Solutions
father’s unique benefits—a paid day off on your birthday. They’ve also worked to improve training and outreach to develop the next generation of their workforce. “We’re trying hard to reach out to the high school level, but we’re still a couple of years away,” said Bales. “For us, it’s harder; no one grows up and says they want to be a chrome plater. We train in-house, but it’s kind of a dying art form. We try to attract younger workers by having a robust benefits package.”
Unique challenges
Bales and Mortensen recognize they are an anomaly in their industry. At trade events, they are likely among a handful of women at the show. Even fewer have executive titles after their names. “If anything, I think it’s an advantage,” said Bales. “We’ll go to PMA (Precision Metalforming Association) events, and we’ll be a couple of the only women in a room. People tend to remember you if you’re one of only a few women in a sea of men. If anything, it’s helped the networking.” “I’ve had experiences at trade shows where I’ve almost made a game out of it,” said Mortensen. “When I’m there with Dean, half the time I’m answering someone’s question, but they’re looking at Dean.” Bales also has joined Women in Manufacturing (WIM), a spinoff organization of PMA that provides a forum for professionals Continued on page 32 www.plantengineering.com
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seweurodrive.com / 864-439-7537 input #25 at www.plantengineering.com/information
Better training leads to a stronger workforce
‘A
By Randy Pearson Siemens Industry Inc.
“The metalworking
industry as a whole benefits from the ongoing cooperation of controls suppliers, the machine builder community, and educational institutions, whether high school shop classes, vocation schools, or university engineering departments.
”
30 • September 2015
rising tide lifts all boats.” That quote typically is ascribed to John F. Kennedy back in the 1960s, when my metalworking involvement consisted of playing on the jungle gym at the school playground. Actually, his speechwriter borrowed the quote from a local chamber of commerce, who had the same idea I present to you here. The metalworking industry as a whole benefits from the ongoing cooperation of controls suppliers, the machine builder community, and educational institutions, whether high school shop classes, vocation schools, or university engineering departments. It also benefits from everyone in the end-user world, from the fiveman job shop to the production department of a major original equipment manufacturer (OEM). This is not pie-in-the-sky or Pollyannaish behavior; it is serious business. For example, my company has formed an alliance with the Tooling and Manufacturing Association (TMA), formerly the Tool and Die Institute, located near Chicago. This association changed its name when it broadened its scope to include more companies, larger companies, and more affiliate members among the industry supply base. This was done to expand the input, thinking, and direction of the group—something from which we can all benefit. The members are still related to metalworking, but they include stampers, weld shops, chipcutters of all sorts, and even the machine builders and dealers who supply the industry. They find that they have much more in common when running their businesses, and those perspectives are useful to all the members. We’re helping to sponsor competitions among the members and the students at local schools, with an eye on raising the bar—or water level in this analogy—to improve the skill sets of current workforce as well as the next generation of machine operators, programmers, machine designers, and maintenance engineers. Meanwhile, the feedback we get from these various groups helps us design controls that are more flexible, more responsive to user
plant engineering
needs, more adaptive to the rapidly changing landscape in machine shop operations today, and, maybe most importantly, look ahead to the future of manufacturing in America. I think of the speed with which we transitioned from manual machines to numerical control tape drives to computerized numerical control (CNC) machines. Now we have robotic articulation, machine-to-machine communications, transfer-line technology for blank to finished workpiece flow, and even the elimination of the zone controllers on fully automated production/assembly lines. After all this change, it’s obvious that controls suppliers must make a commitment to follow every development in the market. This is not done to make us richer, as our involvement in most training enterprises is offered gratis. Rather, it’s done to make us a better supplier, to make our customers build better machines, and to make the industry more viable and more competitive worldwide. In the end, everyone wins. Several machine build customers are now sending their students and customer workforces our way for specific training on CNC technology. In the field, too, better training means a better operator workforce that’s capable of running multiple and very different types of machines. The days when an operator of Brand X lathe wouldn’t even consider working on a Brand Y lathe are gone—and thank goodness they ARE gone, because U.S. shops wouldn’t survive with that mindset anymore. Through the cooperation of controls suppliers, machine builders, educational institutions, and the end-user community, the boats will indeed all rise and prosper. PE Randy Pearson, a long-time veteran of the machine tool industry, is the Siemens sales support manager for U.S. dealers and OEMs. His special interest is the many levels of training on CNC machine tools. He conducts various seminars, workshops, and classes the company conducts at Siemens training facilities around the country. His e-mail is randy.pearson@siemens.com. www.plantengineering.com
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www.miltoncat.com Milford, MA 866-385-8538
www.ransome.com Bensalem, PA 877-RANSOME
input #26 at www.plantengineering.com/information
© 2015 Caterpillar All rights reserved. CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow,” the “Power Edge” trade dress as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission. www.cat.com www.caterpillar.com
Continued from page 28 in the manufacturing sector. They now have 500 members and will hold their annual convention in Minneapolis on Sept. 23-25. “I just started to participate. It kind of makes you feel not so all alone,” she said. “There are a lot of women in ownership positions. I’m hoping to build a solid network of people I can call on and collaborate with.”
The family approach
Stacey Bales and Sara Mortensen have brought a lighter touch to the business, including a new color scheme and a new motto for employees to wear.
32 • September 2015
The work each day is to create engineered plating and coating solutions of all kinds of metal surfaces. Bales’ customers are in the automotive, medical, packaging, lighting, and electrical industries, and the company includes a satellite facility in Harlingen, Texas. But as owners of a family business, Bales and Mortensen are acutely aware of tempering the organization in the same way their workers temper metal. They have families of their own: Bales is a single mother of 15-year-old Sarina; Mortensen and her husband, Dave, and their 8-year-old daughter, Laney, all have earned their black belts in karate. They are now looking into succession planning for the company, something that wasn’t in place when their father passed away, so that the future for Bales Metal Surfacing Solutions are secure. The sisters understand the need for a workplace that is both firm and flexible, as needed.“We listen to a lot of employees. We listen to their issues at home,” said Bales. “We worry about the family. We really rely on our employees as much as possible.” “There are a lot of advantages to having a female boss,” said Tufano. “In an all-
plant engineering
“ We’re trying to offer more
services without overgrowing ourselves. We want to be calculated and strategic about our moves. We want to take care of our customer base first.
”
Stacey Bales, Bales Metal Surfacing Solutions
male organization, a lot of guys are unapproachable about issues.” They’ve brought their own personalities to the job as well. Mortensen has led the effort to put a fresh face on the company’s external message. They’ve hired a public relations firm, rebranded the company, and provided a lighter touch in many areas. For example, workers have T-shirts that read “We finish what others start.” “I’m more than thrilled to be on the marketing side, going to trade shows, helping our customers through the problems, and helping them through the solutions,” said Mortensen. That leaves Bales to manage the business strategy. “We’ve expanded our capacities and linked up with more strategic customers,” she said. “We’re trying to be more creative and work as Lean as possible. We were able to create a second shift and get parts out to customers faster, without raising overhead costs. We’re trying to offer more services without overgrowing ourselves. We want to be calculated and strategic about our moves. We want to take care of our customer base first.” Bales likes the board game Monopoly; Mortensen prefers Scrabble. The sisters are still sisters; you can see the interplay between them during a photo session. They share an office at the plant (“The first time we’ve shared a room since we were 2,” Mortensen), and their combined efforts are taking Bales Metal Surface Solutions into the next generation. It is not the path they imagined, of course, but their father’s memory and his best individual characteristics are evenly divided among his daughters, and that’s helped them. “We’ve got a lot of his good traits between the two of us,” said Bales. “We can make this work.” PE www.plantengineering.com
CFE Mediaâ&#x20AC;&#x2122;s
Global System Integrator Database
CFE Mediaâ&#x20AC;&#x2122;s Global System Integrator Database is an interactive community of global end-users and system integrators hosted by Control Engineering, Plant Engineering, and our global partners in Asia and Europe. Through this database you will be able to connect with System Integrators by searching their corporate profiles which highlight: industries served, engineering specialties, product experience, geography, and other pertinent data. Find and connect with the most suitable service provider for your unique application.
Start searching the Global System Integrator Database now!
www.plantengineering.com/global-si-database
Daniel Ackmann .........35
Amanda Pelliccione, Project Manager and Director of Research
Chad Albert .................35 Corey Arrick ................35 Joseph Bastone .........35 James Couto ..............36 Dave Denison .............36 Stephen Dora ..............36 Jesse Dorn ..................36 Alfredo Flores .............37 Michael Gagne ........... 37 Cassy Gardner ...........37 Miguel Gutierrez .........37 Bryant Jackson ..........38 Robert Jardel ..............38 Jayesh Jariwala .........38 Scott Lawless .............38 Hunter Longshore ..... 39 Sean Mascarenhas ....39 Abid Munawar ............39 Justin Nielsen .............39 Jayson Pestow ...........40 Jeff Poirier ...................40 Justin Robinson .........40 Carl-Johan Roos ........40 Kori Shane ..................41 Lee Smith ....................41 Bret Van Wyk ..............41 Chris Vitale ..................41 Nathan Wingate ..........42 David Ziskind ..............42
34 • September 2015
W
The 2015 Engineering Leaders Under 40 are a dedicated group of engineers that give hope to the future of manufacturing.
With the future
of manufacturing heavily relying on the younger workforce, Control Engineering and Plant Engineering are honored to present the 2015 Engineering Leaders Under 40. These 30 individuals are involved in a variety of industries and responsibilities that force them to sharpen their multi-tasking and management skills daily. The majority—70%—serve the engineering and system integration (SI) sectors, while instrumentation and measurement (57%), consulting (50%), and food, beverage, and tobacco (50%) round out the top four segments in which they are involved. Here is a quick look at this year’s Leaders: • Education: 90% of the Leaders have earned their bachelor’s degrees, 20% master’s degrees, and 7% associate’s degrees. • Job function: 23% are primarily involved in SI roles, 17% control engineering, 10% general/corporate management, 10% consulting, 7% product design, 7% manufacturing engineering, and 6% plant management/engineering.
PLANT ENGINEERING
• SI or engineering services: 79% provide SI or engineering services to manufacturing organizations. • Products or systems: The top five products or systems purchased or specified by this year’s Leaders are industrial control equipment or systems (57%), software (53%), I/O products or systems (53%), instrumentation (53%), and programmable logic controllers (53%). • Machines for resale: 37% design, build, or install machines for resale to other companies; 47% design, build, or install machines for use within their companies. The 2015 Engineering Leaders Under 40 are featured in the following section and with more information online at www.plantengineering.com, and will be honored at the 2016 Engineering Awards in Manufacturing dinner hosted by Control Engineering and Plant Engineering on Monday, March 21, 2016, in downtown Chicago. For information on how to nominate for 2016, visit www.plantengineering.com/EngineeringLeaders.
www.plantengineering.com
Daniel Ackmann, CEM, LEED AP BD+C, 28
Chad Albert, 30
Project Manager; Energy Engineer; Enviro-Management & Research Inc.; Springfield, Va.
Engineering Manager; Bluff Manufacturing; Fort Worth, Texas
BS Civil Engineering, Purdue University
BS Civil Engineering, Western Michigan University
A
ckmann enjoys the nonroutine nature of working with multiple federal agencies, of helping find out-of-the-box solutions to save energy and money, and of having a considerable indirect impact on so many people. He has consulted for federal agencies looking to optimize performance—including the U.S. Dept. of Defense, where he assisted in achieving federally mandated energy and greenhouse gas (GHG) reduction goals, developed and maintained GHG inventories, analyzed utility bills and rate structures for opportunities to lower costs, and identified energy conservation capital investments and lower cost opportunities. In response to the American Energy Manufacturing Technical Corrections Act of 2012, Ackmann was the lead writer and researcher in identifying advanced meter best practices in federal facilities, buildings, and equipment for the U.S. Dept. of Energy. Ackmann manages the development and operation of the Architect of the Capitol’s utility metering enterprise system and bill verification system to ensure that all U.S. Capitol facilities effectively manage energy use and retain data to establish near- and long-term utility budget goals. Ackmann has authored federal guidance for procuring public utility and energy management services through area wide and utility energy service contracts for the General Services Administration. Recently, he and his wife vacationed in Iceland to enjoy the people, geology, and beauty of the country.
lbert brings his advanced skills in creating automation systems for the engineering team at Bluff Manufacturing. As an innovator, Albert drives new product development and redesigns existing products for greater manufacturing efficiency. He consistently leads his team to deliver solutions and value to their customers, increasing revenue for his company. Albert has transformed the way Bluff’s products are created with his process development framework designed for the engineering department. He also has created automated tools to streamline the customer ordering process and systematize products, resulting in decreased ordering cycles. In the engineering industry, Albert has been the Bluff member representative of the Loading Dock Equipment Manufacturers group of the Material Handling Institute, which reviews, discusses, and revises the standards for the design, performance, and proper operation of loading dock equipment. Outside of work, Albert enjoys spending time with his 2- and 4-year-old sons. He is involved with community service, including mission trips to Central America and helping with Hurricane Katrina cleanup in Alabama. Albert volunteers for his church through community cleanup projects and assisting the homeless in Fort Worth.
Corey Arrick, 38
Joseph Bastone, 37
Engineering Manager, BAE Companies, Philadelphia
Marketing Manager; Honeywell; Fort Washington, Pa.
BS Agricultural & Biological Engineering, Purdue University
BS Chemical Engineering, Rensselaer Polytechnic Institute
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rrick has broad experience as a process engineer and project manager working in the food, pharmaceutical, and health/personal care industries. He has worked as a design and construction engineer for various clients, ranging from Godiva Chocolatier to GlaxoSmithKline. He also has worked in plant operations and as a quality specialist in the meat industry. Recently, Arrick managed the operations team and acted as the start-up engineer at a meat import and processing facility. He manages the quality department for the company’s products, achieving U.S. Dept. of Agriculture import and domestic status and leading the facility to Safe Quality Food certification. In 2001, Arrick received an Operational Achievement Award at Godiva Chocolatier for the installation and start-up of a caramel-cooking process, and in 2012 he received a PRIDE Award—Professionals Recognizing Individuals who Demonstrate Excellence—at Barry-Wehmiller Design Group. Arrick has five U.S. patents and two European patents for hot-beverage products. Arrick is a motorcycle enthusiast and enjoys experimenting with foods and drink by brewing his own beer, wine, and ciders and making his own yogurt and cheese.
www.plantengineering.com
A
astone uses his strong analytical capabilities to consistently prioritize tasks for effective commercialization of prominent developments at Honeywell in Fort Washington, Pa. He manages the Experion PKS Control and I/O portfolio, which includes five product manager direct reports who represent more than 100 years of experience. Starting as an application engineer, Bastone spent his first 8 years with Honeywell in the field with key customers. He later joined the product marketing team as the product manager for Experion controllers and was selected to launch derivatives of Experion PKS, for which he received a Corporate Marketing award in 2012. Bastone is now the marketing manager for this product, and he recently launched the Universal I/O for Experion. He is also a key contributor for the LEAP initiative at Honeywell Process Solutions, challenging how automation projects are implemented and deployed. For this, he also won a Corporate Marketing award in 2015. Bastone always has been drawn to technology and the path it offers: exposure to new, high technologies while managing a business. At home, he does time-lapse photography with his two children, along with a student robotics platform.
PLANT ENGINEERING
September 2015 • 35
James Couto, 32
Dave Denison, 39
Project Manager; Autopro Automation Consultants Ltd.; Calgary, Alberta
Director, DeltaV Product Marketing; Emerson Process Management; Round Rock, Texas
BS Electrical Engineering, Lakehead University; MBA, University of Calgary
C
outo is currently the youngest project manager contracted at Autopro Automation Consultants. Couto also manages his own company, Couto Consulting, and a separate software-as-a-service business. He is recognized at Autopro as a strong leader and an effective team builder, and he is always looking for ways to improve processes and drive efficiency in projects. Couto’s broad range of skills and experience, including an excellent balance of people and technical skills, contributes to his tremendous ability to mentor others, even staff members more senior than he is. In the past year, Couto successfully completed his MBA at the University of Calgary, an achievement that consumed all of his spare time. The desire to broaden his experience and move away from a pure technical focus to one that includes the business perspective prompted him to pursue the degree independent of financial support from the company. Off the clock, Couto volunteers with Engineers Without Borders and works on the corporate engagement team to establish awareness of the organization. He participated in the 2012 Enbridge Ride to Conquer Cancer and raised more than $5,000 for the Alberta Cancer Foundation.
BS Computer Engineering, Iowa State University; MBA, St. Edward’s University
O
ver the past 16 years at Emerson Process Management, Denison collaborates cross-functionally to create a compelling product and technology vision based on customer needs and new innovations. He contributed to the DeltaV distributed control system (DCS) as a software engineer, software development manager, and director of software applications and is a DeltaV product marketing director. Denison wrote real-time software responsible for running control logic and interfacing to multiple I/O technologies within the DeltaV controller. Denison led the effort to design and certify the DeltaV SIS with the Electronic Marshalling product. Denison is a recognized innovator and has been awarded seven patents associated with DeltaV. Denison planned and directed multiple programs within the product areas of operations environment, engineering clients and servers, virtualization, and remote monitoring. Denison’s move into product marketing has increased his responsibilities and ownership of the DeltaV product lifecycle. During free time, Denison plays softball, basketball, and golf, and coaches his daughter’s youth basketball team.
Stephen Dora, 33
Jesse Dorn, 32
Engineering Specialist, Plant Planning; Toyota Motor Engineering & Manufacturing North America Inc. (TEMA); Erlanger, Ky.
Project/Maintenance Manager, Manufacturing; Victaulic; Easton, Pa.
BS Electrical Engineering, Rose-Hulman Institute of Technology
AAS Tool Making Technology & BS Manufacturing Engineering, Pennsylvania College of Technology
D
D
ora demonstrates leadership in his role as project leader for the TEMA Plant Planning Section for specification, design, construction, and handover as the owner for Toyota manufacturing plants in North America. At Toyota Motor Manufacturing Kentucky he exhibited continued growth in leadership roles for plant expansion to bring the Lexus brand to the U.S. Dora has advanced from his background of electrical engineering through building components and systems, including civil/structural, mechanical and piping, and electrical power and distribution. He has brought and led innovative cost-effective design and construction improvements while Toyota budgets and schedules have compressed. He participates in seminars and conventions to continue professional development. Dora is a leader for Toyota projects primary commitment to construction safety by obtaining his Occupational Safety and Health Administration 30-hour credentials as well as participating in all Toyota electrical safety and lockout training. He has authored several Toyota training courses on power distribution and electrical systems. Dora married in July 2015, and he and his wife enjoy running 5 and 10k races, traveling, and yard saling.
36 • September 2015
PLANT ENGINEERING
orn’s intelligence, self-motivation, and professionalism has allowed him to be successful in multiple roles within Victaulic, including his present position as the project/maintenance manager in manufacturing. Dorn began his career at Victaulic in 2007 in the rotational engineering program and has rapidly advanced while undertaking various leadership roles. He has served as a cost reduction team leader and municipal operations facility manager to his current position. With a strong understanding of U.S. operations, Dorn has been instrumental in implementing effective process improvements that have enabled Victaulic to achieve major savings while boosting productivity, improving manufacturing output, and enhancing on-time product delivery for customers. Dorn is skilled in process improvement, including finding ways to secure local efficiency gains and manufacture products close to customers. He has a strong passion for locomotives, specifically fixing and performing maintenance on steam trains. He volunteers at several tourist railroads. When not working on trains, Dorn likes spending time with his wife, two children and other family, out on the river in his kayak, or riding dirt bikes and four wheelers with friends.
www.plantengineering.com
Alfredo Flores, 31
Michael Gagne, 28
Senior Controls Engineer; RedViking; Plymouth, Mich.
Senior Software Engineer; Kepware Technologies; Portland, Maine
BS Mechatronic Engineering, Monterrey Institute of Technology and Higher Education, Querétaro (ITESM)
G
BS Electrical & Computer Engineering, University of Maine
lores is a detail-oriented leader in implementing standards that unify RedViking’s processes across diverse business units. From his origins in mechanical design, Flores has shown aptitude for quickly acquiring new skills and leads in electrical engineering, controls engineering, and project management for the manufacturing execution systems (MES) and manufacturing and assembly solutions teams. At age 25, Flores took over a factory information systems launch project with great success. At 27, he managed a staff of eight engineers to successfully implement a complete tracking and error proofing system (EPS) in a new plant, before conveyors were installed. Flores’ EPS worked flawlessly upon launch without time for the normal debugging process. He recently designed a unique controls architecture for RedViking’s battery-free inductively powered automated guided vehicle system, Wingspan. Flores is the new knowledge leader and has designed a new approach to make the AGVs “controls-agnostic.” In his free time, Flores is studying for his Master’s degree in engineering management and enjoys playing outdoor sports with his two young children.
agne’s extremely versatile skill set allows him to lead projects in all of Kepware’s major markets. He is well respected among his peers, serving as a mentor to new hires and contributing to key decisions behind Kepware’s major product releases. In 2009, Gagne was one of the first recipients of Kepware’s Scholarship for Excellence in Engineering. This recognition led to an internship with the company followed by his graduation in 2010. From there, he quickly advanced his career, moving from software engineer to senior software engineer. Gagne played a major role in the design and development of the Scheduler, a data optimization tool integrated within the company’s flagship product, KEPServerEX. As lead engineer of the project, he ensured the technology maintained its core purpose and functionality from inception to release. His ability to contribute across many areas of the business makes him an invaluable asset to the company and enables him to lead future initiatives. Currently, Gagne is spearheading the development of Kepware’s OPC Unified Architecture implementation. Gagne also promotes science, technology, engineering, and mathematics (STEM) education by volunteering in local career fairs, encouraging students with his own story to pursue careers in technical industries.When he’s not overseeing engineering projects, Gagne spends free time homebrewing his own craft beers, having recently joined the American Homebrewers Association.
Cassy Gardner, 24
Miguel Gutierrez, 35
Engineer; Banks Integration Group; Vacaville, Calif.
Project Manager; Maverick Technologies; Santa Ana, Calif.
BS Biological Systems Engineering, University of California, Davis
BS History, California State University, Fullerton
T
G
F
hough Gardner is in an entrylevel position at Banks Integration Group, she has significantly impacted her company and continues to help reshape its direction and culture. Gardner is actively involved in creating a positive environment at Banks; she has taken the lead role in Bright Ideas, one of Banks’ management’s initiatives aimed at improving employee engagement. In this role, Gardner has engaged and collaborated with employees of all levels within her company. Gardner has developed the infrastructure to help employees make a positive impact and influence the direction of the company through this iniative. In addition to her contributions at Banks, Gardner enjoys working with children to foster interest in the science, technology, engineering, and mathematics fields. She recently participated as a mentor in the Women in Science and Engineering program at UC Davis and helped execute and coordinate an outreach presentation at the local Boys & Girls Club of America. She actively participates in the local International Society for Pharmaceutical Engineering (ISPE) chapter planning and organizing events and also has spoken at the local student chapter of ISPE about controls engineering.
www.plantengineering.com
utierrez combines many first-rate skills to make him an effective engineering leader at Maverick Technologies. He quickly learned the necessary technical skills early in his career and still demonstrates an ongoing personal drive to always know more. He engages with customers to understand their needs and with coworkers to encourage, help, and train them. Gutierrez knows what it takes to execute a project right the first time with the highest quality, keeping the team focused so that the customer is delighted and Maverick is the preferred choice for customers and employees. A liberal arts background forms the foundation of Gutierrez’s experiences. However, as he worked through school he acquired database programming experience that quickly transitioned him into the automation industry where he found an aptitude for human-machine interface and programmable logic controller development. He has consistently gained skills and executed increasingly complex projects through his career, pushing himself to excel in each task. He is a regular contributor to company blog posts that promote excellent work skills. When he’s not working, Gutierrez can be found at the paintball park with friends or preparing for his next Zombie Run or dragon boat race.
PLANT ENGINEERING
September 2015 • 37
Bryant Jackson, 28
Robert Jardel, 30
Systems Engineer/Task Manager; Leidos Engineering; Walled Lake, Mich.
Controls Engineer; Airline Hydraulics; Bensalem, Pa.
BS Electrical Engineering Technology, Michigan Technological University
AAS Mechanical Engineering, Camden County College
J
J
Jayesh Jariwala, PE, 39
Scott Lawless, 35
Project Manager; Applied Control Engineering Inc. (ACE); Owings Mills, Md.
Project Manager; Leidos Engineering; Walled Lake, Mich.
BS Chemical Engineering, University of Delaware
BS Electrical Engineering & Computer Engineering, Kettering University
J
L
ackson is an eager, capable young professional who has quickly risen at Leidos because of his outstanding talent and aptitude. His ambition is apparent to all that work with him. Jackson enjoys a challenge and volunteers for new and difficult responsibilities, resulting in him quickly becoming a leader within Leidos as a systems engineer and project manager. He is willing to tackle any task, running straight toward a problem to find the solution. Jackson was hired at Leidos immediately following his graduation from college in 2010. He took on additional responsibilities, even outside the expectations of his managers. He is most proud of his work at a casting facility in Toluca, Mexico—a very difficult project that he encountered in his career. He started as the lead project engineer, responsible for the design, implementation, and commissioning of a new utility control system to be tied into an energy management system. He is currently the main point of contact for the majority of this customer’s projects.Jackson spends his time away from work with his wife and their 5-month-old daughter. He also volunteers for philanthropic walks and is active in other similar events.
ariwala possesses expertise in classic control systems including human-machine interfaces and programmable logic controllers. Jariwala differentiates himself with a breadth of knowledge on plant historians, database schemas, reporting applications, and custom programming applications. Strengths include designing systems to capture critical process data and developing dynamic Web-based reports for a variety of users. He has also worked with customers to bring plant floor data into manufacturing execution systems and enterprise systems. Since graduating from the University of Delaware, Jariwala has enjoyed a career as a process control engineer at ACE. He began his career in ACE’s Newark, Del., office and then transitioned to be a senior technical resource for ACE’s Chesapeake Region office in 2010. Throughout his career at ACE, he has been a highly sought-after resource internally and to ACE’s customers. Jariwala is also the FIRST chair of the Baltimore/Washington D.C. section of the International Society of Automation (ISA). For the past 5 years, he has volunteered as a mentor for the FIRST Robotics Competition. Jariwala mentors an all-girls robotics team from Western High School in Baltimore, providing programming training and troubleshooting support.
38 • September 2015
PLANT ENGINEERING
ardel is the type of person who can pick up a book or manual, read it, and retain all the knowledge inside. He is self-motivated, hardworking, and is always willing to go above and beyond to help and teach others in his spare time. Jardel quickly expanded his skill set when he started with Cryovation LLC in 2013, which resulted in company growth. He was quick to put his acquired skills to use, helping to develop new processes for the company; this led to the release of two new products that Jardel designed. Jardel also took leadership roles in a number of startups, interfacing with multiple engineering disciplines, salesmen, as well as the customer. Currently, Jardel is employed with Airline Hydraulics where he hopes to once again develop and implement innovative solutions for a growing industry. At home, Jardel has set up a programmable logic controller (PLC) test station with human-machine interfaces, PLCs, and other automation controls in order to develop his skills and discover new techniques for his profession. Even though his work finds its way home every night he never misses an opportunity to spend quality time with his fiancée, Katie, and daughter, Caylen.
awless is a project manager and engineer who consistently performs and completes projects successfully, gaining him the trust, confidence, and respect of his clients. Lawless has developed profitable programs for major customers at Leidos Engineering and is a leader in his part of the company. Lawless’ strengths lie with implementing system integration program solutions and teaching young engineers within Leidos. His team is currently working on a fan array air handling system program that is developing a standard control system design to meet the requirements of his clients, Ford Motor Co. and General Motors. His team is in the process of designing a modular chilled-water control system that can be assembled and tested before shipment to the client’s site. Lawless is a certified energy manager through the Association of Energy Engineers and a project management professional through the Project Management Institute. Within the company he is a go-to person for system controls/integration questions and assistance. Lawless is close with his family and friends, well connected, and respected in the community. He has been involved with multiple kickball tournament fundraisers and local charities and has a great camaraderie with his coworkers.
www.plantengineering.com
Hunter Longshore, 33
Sean Mascarenhas, 33
R&D Professional—Control Systems Engineer; Sandvik Mining; Alachua, Fla.
Senior Engineer; Autopro Automation Consultants Ltd.; Calgary, Alberta
BS Electrical Engineering, University of Florida
B.Eng. Electrical Engineering, McMaster University
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Abid Munawar, 33
Justin Nielsen, 37
Central Engineering Lead; Intech Process Automation; Houston
Manager—Control Systems & Instrumentation; Excel Engineering; St. Paul, Minn.
ongshore is a talented, detailoriented, and hands-on control systems engineer at Sandvik Mining. Having taken a system lead role at the Sandvik Automation Modules (SAM) product line, he has responsibility for upgrades, rollouts, investigating issues, providing hot fixes, and other primary tasks related to SAM. Additionally, he has undertaken mine visits where he engages the end user to suggest new features and capabilities as well as conducting troubleshooting and training sessions. Longshore has led several training classes within the Sandvik factory in Florida to educate shop floor personnel whenever new features are released and on testing. While studying at the University of Florida, Longshore found a genuine interest in mechatronics and dedicated one of his senior projects to developing closed-loop control motor driver boards for a threeaxis computerized numerical control machine. Additionally, during his college career, he spent a couple of summers in South Africa working at a robotics lab where he was introduced to machine controls. Aside from work, Longshore is also an avid cyclist and runner, often training with his co-workers for off-road cycling events and half marathons.
BS Mechatronics Engineering, National University of Sciences and Technology; MBA, Virtual University of Pakistan
M
unawar has demonstrated leadership skills required at a management level to achieve his career goals and to contribute in achieving company targets. He is continually striving to enhance his professional skills so that his team can improve as a whole. Munawar’s main contribution has been in establishing a central engineering lead function and managing a large pool of project resources. He has developed and successfully run batches of trainee engineers to harvest resources for meeting Intech’s future needs. Munawar has established an effective performance management mechanism to not only evaluate performance periodically but to chalk out a career road map and provide mentorship to younger engineers so they can achieve their objectives. For this, he formulated a new competency framework for his business unit by using his analytical skills and mapped the existing competencies of the resources of his department on the new framework for gap analysis. Munawar has led a volunteer group that planted and cared for more than 3,000 trees in Lahore, Pakistan. He recently relocated to Australia and is looking forward to contributing to its automation and control society.
www.plantengineering.com
ascarenhas has progressed very quickly since graduating from McMaster University. He was responsible for major projects very early in his career—within his first 5 years he led a large distributed control system upgrade project, including a successful shutdown and turnaround. When Autopro opened its location in Pune, India, Mascarenhas was one of the first people sent to train and mentor new technical staff, working long hours to orientate them and get them ready to work on Autopro’s projects. More recently, he was electrical lead on a large greenfield project for a major petrochemical producer, the largest project in Autopro’s 25-year history. This involved managing a team of more than 20 technical staff, in addition to interfacing with the client and subcontractors, and ensuring that quality standards were met on all electrical deliverables. There was a great deal of complexity in the number of engaged vendors, number of Autopro branches that provided project staff, and new technologies that were deployed on the project. For the past 6 years, Mascarenhas has volunteered as a high school football coach. He loves football and sharing his passion for the game to develop leadership skills with youth.
BS Chemical Engineering, Clarkson University
N
ielsen has provided a fresh perspective to broaden the services provided by Excel’s Control Systems group, as well as the client base that Excel Engineering serves. He is able to understand what the client needs, ensure that the individuals performing the work are performing optimally, and provide quality services to Excel’s clients. He has a vested interest in sharing his knowledge with the engineers who work with him and helping them succeed in their careers. Nielsen has been involved in controls and automation engineering since 1999 and has a strong background in the pharmaceutical, chemical, and power generation industries. Nielsen has been the lead for control system engineering on several multi-million dollar controls system upgrade projects for key clients. Nielsen’s functions include developing new business relationships, mentoring junior level engineers, and continuing to broaden the services that engineers can provide. Nielsen is an International Society of Automation (ISA) member and an ISA-certified automation professional. Nielsen is a dedicated father of two boys, who are 7 and 9 years of age. He enjoys coaching their baseball and basketball teams and participating in activities that capture his sons’ interests.
PLANT ENGINEERING
September 2015 • 39
Jayson Pestow, 31
Jeff Poirier, 39
Senior Controls Engineer, Functional Safety Engineer (TÜV Rheinland); Frakes Engineering; Indianapolis
Senior Controls Engineer; RedViking; Plymouth, Mich.
BS Automation & Control Engineering, Indiana State University
P
estow is very passionate about machine safety and works hard to help customers achieve a safer facility. While in high school, Pestow participated in a 2-year technical program for machine tool technology and was inducted into the National VocationalTechnical Honor Society. After graduating college, Pestow maintained his commitment to the constant learning curve in engineering and technology. As a young engineer, he earned his Six Sigma Green Belt and used those tools to lead Lean initiatives for several years. Working as an engineer comes with inherent risk, and being a witness to two nonfatal industrial accidents propelled him into the concentration of machine safety. Frakes Engineering shares his commitment to safety and presented him the opportunity to pursue a certification as a functional safety engineer through TÜV Rheinland, a certification that fewer than 100 engineers nationwide receive each year. Pestow has been a competitive runner and triathlete for 6 years. In 2012, he proposed to his now-wife, Tara, at the finish line of his first marathon. This past May he was a top-500 finisher in the Indy 500 Mini-Marathon, a large U.S. half-marathon.
Justin Robinson, PE, CAP, 30 Performance Excellence Specialist; Maverick Technologies; Columbia, Ill. BS Chemical Engineering, Auburn University
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obinson has experience working in an array of industrial manufacturing industries, on various distributed control system (DCS) platforms, and in multiple roles on Maverick project teams. Robinson has led significant DCS and human-machine interface migration projects. He also supports coaching and mentoring of team members, and he is the subject-matter expert of high-performance graphics within Maverick, supporting the technical leadership of projects. Robinson started his career with Maverick as a process control engineer. He has since been promoted from engineer I, engineer II, and senior engineer to a principal engineer within 7 years due to his technical expertise, leadership, and customer support dedication. Robinson was most recently promoted to a new role as a performance excellence specialist. Robinson says that learning new things is the most fulfilling aspect of this career. Professionally, he enjoys learning coding, languages, processes, controls platforms, or work processes. When he is not working, Robinson enjoys playing guitar with his church’s worship band as well as expanding his cooking and “handyman” skill sets.
40 • September 2015
PLANT ENGINEERING
BS Electrical Engineering, University of Michigan
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oirier designed first-of-its-kind helicopter transmission flexible testing software at RedViking that enables motors to switch roles during and between tests to accommodate highly complex test profiles on one test stand. The challenge of configuring four 3,000-hp motors to change roles was unprecedented. In an example of a typical helicopter test stand, Motor A might always control speed with Motor B slaved or geared to follow it with balanced torque. Motor C creates load, and Motor D absorbs load and syncs to the first two motors. And all of these have to be synced and balanced. Poirier has built software to allow the test operator to change the system at the push of a button, so that the speed is now controlled by Motor C and torque is controlled by Motors A and D. In the same test or in the next test speed can be controlled by Motor B and torque by Motors A and D. Poirier’s software creates previously impossible flexibility in helicopter powertrain testing and provides outstanding cost savings. Poirier is an avid mountain biker; while on his honeymoon in Hawaii, he and his wife rented road bikes and used them to climb to the top of the Haleakalā volcano, an 83-mi ride with 10,700 ft of climb.
Carl-Johan Roos, 34 Functional Safety Officer; Emerson Process Management, Rosemount Division; Shakopee, Minn. M.Sc. Electrical & Computer Engineering, Chalmers University of Technology; MS Electrical & Electronics Engineering, Georgia Institute of Technology; MBA, University of Gothenburg
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oos was one of the driving forces behind a new standard for overfill prevention that has been a major safety contribution to the oil industry. Roos has built-up a global overfill prevention business with unique competency based on thousands of installations. This know-how is now used in a customer-centric approach where Emerson provides the global process industry with the equipment, solutions, and lifecycle services compliant with functional safety standard IEC 61511 to minimize the overfill risk. Roos has led the extension of modern level measurement technologies into safety-critical applications. He has contributed significantly to product achievements at his company, including taking safety to the next level by introducing the world’s first SIL 3 radar level gauge, reducing installation costs considerably through a patented two-in-one radar level gauge, and introducing new proof-testing technologies, such as verification reflectors. Outside of work, Roos is a fanatic floorball player, which can be described as hockey but without the ice and the skates. He and his wife have two sons, ages 9 months and 3 years old.
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Kori Shane, 38
Lee Smith, 30
Safety and Environmental Manager; Schneider Electric; Cedar Rapids, Iowa
Lead Software Engineer; Mettler Toledo Safeline Ltd.; Manchester, England
BS Environmental Health, Illinois State University
MS Software Engineering, The University of Manchester (UMIST)
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Bret Van Wyk, 32
Chris Vitale, 38
Program Manager; Interstates Control Systems Inc.; Sioux Center, Iowa
Director of Marketing; Turck; Plymouth, Minn.
BS Computer Science & Systems Administration, Dordt College
BS Electrical Engineering, Minnesota State University—Mankato; MBA, University of Phoenix
hane is an integral part of the management team in the Schneider Electric Cedar Rapids facility, providing leadership in the location’s direction beyond her primary function of leading safety and environmental activities. She is the leader of the plant safety committee at her facility and a member of the plant emergency response team. Shane has led the campaign for safety-improvement ideas as well as developed and implemented the plant’s behavioral safety audits. She was responsible for implementing the use of active release technique in her facility; a technique that proactively treats injuries to prevent them from becoming serious. She is also leading the development of the facility’s business continuity plan—an action plan that actively anticipates the impact that a crisis or disaster could have on a plant. Shane is the North American representative to the GlobES Phase II Steering Committee, which integrates the global processes for safe chemical management. Beyond the plant walls, Shane drives to take safety and environmental aspects into her home. She has a passion and dedication to her children and works to raise them in a safe and healthy environment.
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an Wyk is a key resource in working with Interstates’ customers to find solutions for supervisory control and data acquisition (SCADA) computer systems, industrial networks, and hosted virtualization platforms. Van Wyk is a leader in the company’s manufacturing information technology (MIT) services group, and his primary responsibility is in the quality of project delivery. Van Wyk began his career with Interstates as an MIT systems analyst and has assumed additional responsibilities over the past several years. He has been heavily involved in developing an industrial patching solution for a Fortune 500 company that services all plant floor PCs. This process includes analyzing the software on the system and offering approved Microsoft patches accordingly. Van Wyk is now an Interstates program manager. In this position, he is responsible for all projects within MIT, as well as developing internal work processes for his team. Van Wyk is driven to find ways to continually improve his work. Because of Van Wyk’s push, the MIT team has made progress in documentation, efficiency, and work accuracy. Outside of work, Van Wyk enjoys learning how to use his new meat smoker. He enjoys spending time with family and playing with his kids.
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mith is a lead software engineer for Mettler Toledo’s metal-detection business. Based in Manchester, England, he has strategic and technical ownership of the connectivity and machine-integration capabilities for all metal-detection products. In addition, he has responsibility at a divisional level to define a harmonized approach to connectivity and machine integration across all of Mettler Toledo’s product-inspection systems. Smith is one of Mettler Toledo’s Organization for Machine Automation and Control (OMAC) representatives and is also a member of the PackML Technical Advisory Board. He holds a master’s degree in software engineering from UMIST and is an elected Chartered Engineer on the UK Engineering Council. Smith recently presented at the OMAC PackML workshop in Chicago where he provided a case study of Mettler Toledo’s PackML implementation as well as examples of how to use PackML in combination with various industry standard protocols to offer customers a true end-to-end integration solution. Smith and his wife spend free time with their three young sons, including a recent visit to the Chill Factore indoor snow park—a new experience since the U.K. doesn’t get much snow.
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uring his 15 years with Turck, Vitale has demonstrated a deep understanding of how their products work and make a difference in the field. He has a passion for educating others about Turck technology and how it can be applied. He is constantly searching for ways to evolve this skill, most recently transitioning from a role as product manager of Turck’s network and interface division to serve as director of marketing. Vitale is skilled at connecting and creating conversations between end users and engineers, and he continues this tradition in his current position. Vitale has helped guide many products from concept to installation in customer applications, including Turck’s Multiprotocol Ethernet technology platform. After 6 years in the division, Vitale transitioned to lead the marketing department as its director in December 2014. He saw this as an opportunity to apply his product knowledge and engineering mindset to the creative design and marketing skills of the team. Outside of work, Vitale spends as much time as possible being outdoors and with his family. His hobbies include hunting and fishing, working out, family bike rides, and playing sports like Wallyball and basketball.
PLANT ENGINEERING
September 2015 • 41
Nathan Wingate, 26
David Ziskind, PE, 33
Utilitiesand Technology Manager; Cooper River Partners; Goose Creek, S.C.
Automation Engineer; The Dennis Group LLC; Duluth, Ga.
BS Mechanical Engineering, University of North Carolina—Charlotte
BS Electrical Engineering, Georgia Institute of Technology
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ingate exhibits the technical and analytical skills of a competent engineer and positive character and moral foundation apparent to all who work with him. He has a logical sense of what is required of engineered systems, the analytical engineering knowledge to test his intuition, the curiosity to delve into working details, and the engineer’s fulfillment of accomplishment when his involvement has resulted in a more efficient and safer plant operation. Wingate began his career as a maintenance engineer and advanced to utilities and technology manager, which includes management of all operational utilities, process control systems, and information technology. Wingate’s diligence have contributed to an overall utility uptime of 99.97% for three successive years in a facility that operates round the clock. Wingate applies analysis skills to guide problem solving and drive corrective action through the maintenance department and capital projects. Wingate understands that his professional and family responsibilities are intertwined. He is a leader in his community and church with a deep interest in promoting missions to help underprivileged people.
eyond his direct automation and electrical engineering responsibilities, Ziskind leads recruiting efforts for The Dennis Group’s Atlanta office, which has seen personnel growth of more than 60% over the past 2 years. Part of this strategy includes building relationships with more than eight colleges, universities, and trade schools. Additionally, Ziskind has built a co-operative program from the ground up, a program which now has more than 10 co-op participants performing engineering work for the company. Ziskind started in the industry as a co-op at Polytron in 2001. Six years later, he managed the company’s design group, including rolling out Autodesk’s AutoCAD Electrical throughout the organization and leading the effort to outsource modular design work. Ziskind led the electrical and startup effort for a major revamp of a cold-fill beverage line for a Fortune 500 company, successfully leading to the product’s market debut. Ziskind enjoys traveling, having visited South America and hiking the Inca Trail with friends in 2009. Ziskind and his wife, Miriam, reside in Atlanta with their two sons.
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Johnny Campbell, a machine cell operator in welding, is one of the Pratt & Whitney employees who have benefitted from the company’s onboarding program. All images courtesy: Pratt & Whitney
A return to apprenticeships delivers skilled workers to Pratt & Whitney Community college partnership a key to growth in Maine. By John Mayo Pratt & Whitney
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s aircraft-engine maker Pratt & Whitney looks to ramp-up engine production to a level that the company hasn’t seen in decades, it has committed significant resources to modernizing its manufacturing processes and expanding its assembly and supply chain operations. Partnering with local community colleges to develop skills of future manufacturing workers is critical to the company’s success, and it has created programs near its facilities to train current and future employees. One example, which will benefit from the coming growth, is the company’s Pratt & Whitney—North Berwick (PWNB), Maine, facility. The plant is the largest manufacturing facility under one roof in the state, and manufactures and repairs commercial and military aircraft parts.
“Our challenge is to add a significant number of skilled manufacturing employees to meet the demand,” said Leo Dionne, manager of strategic sourcing/transitions at Pratt & Whitney. “We got together as a team to talk about our employment strategy and develop a plan. It’s been a tremendous challenge to find skilled tradespeople not just in Maine, but across the country.” To that end, Pratt & Whitney has community college partnerships near its facilities in several other states, including Connecticut, Georgia, and Florida. Dionne is uniquely qualified to lead a “transition” effort, as he’s seen a lot of it over his 31-year career at North Berwick. “I can understand what these new employees are going through as I started my career here as a machinist in a 4-year apprentice program,” he said. Over the years, Dionne has held managerial positions in engineering, shop supervision, PLANT ENGINEERING
September 2015 • 43
onboarding training program, is structured to give new employees all the basic skills to become a machine operator, including an introduction toquality to quality and environment and health and safety concepts, which are critical building blocks to a successful career at Pratt & Whitney. The program includes classroom learning, as well as exposure to manufacturing techniques both at the PWNB facility and YCCC’s modern machine shop at its Sanford, Maine, facility. Over the past two years, approximately 30 employees have graduated, with all of them being placed in manufacturing positions at PWNB.
Expanding apprenticeships
Lauren Johnson works on a coordinate measuring machine and inspects a blade outer air seal at the Pratt & Whitney plant in Maine.
business unit management, and quality. In his transition role, he’s helping to manage the transformation of the company. In the beginning, PWNB was able to recruit from local businesses, but soon found it was running out of candidates with necessary skill sets. That’s when a unique public-private partnership was formed with Pratt & Whitney, the state of Maine, and York County Community College (YCCC) in Wells, Maine. The North Berwick facility is benefiting from two programs being run in conjunction with the local school. The first, a 6-week
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The second, more ambitious course is an 8,000-hr apprenticeship program in which Pratt & Whitney employees take part in a trades technology curriculum that results in an Associate of Applied Science degree. While the program gives participants exposure to the latest in manufacturing technology, it also incorporates an academics portion and rotational assignments throughout the North Berwick facility. Participants spend their 8-hr day learning and working in both the facility and the classroom. Fifteen students are set to graduate in the first wave early next year and will be placed in assignments that use their manufacturing, business, and leadership skills. “Given the growth path we’re on over the next several years, our partnership with the state of Maine and the community college system is a crucial part of our employment strategy,” said PWNB General Manager Mike Papp. “YCCC’s ability to accommodate and tailor its curriculum to support our onboarding and apprenticeship programs is proving to be very effective in helping our facility train new employees for technical positions with a minimal negative impact to the facility. “With the apprenticeship program, we’ve been able to work with the school to create a degree program which complements our technical apprenticeship program and also to create a curriculum comprised of both Pratt &Whitney-specific and YCCCspecific content. The jointly developed curriculum is intended to give new employees critical foundational skills as they begin their assigned tasks,” he added. “Both programs are critical in helping us prepare employees to serve our requirements at all levels of our hourly workforce, while also preparing them www.plantengineering.com
for possible entry into our salaried workforce down the road.”
From massage to manufacturing
Apprentice Lauren Johnson had been a Pratt & Whitney employee for about 1½ years when she saw a posting about the program. She took an entrance test, passed it, and is now part of the first apprenticeship class. “This is my first time going through a formal college program,” Johnson said. “Not only will I come out with an associate’s degree, but also the education I’m receiving in machine skills, academics, business processes, and people and management skills is preparing me for my career.” Johnson said she’s come a long way already. “Prior to working at Pratt & Whitney I was a massage therapist, and I decided it was time for a career change. When I first joined the company, I was overwhelmed with the size, the noise, and the number of people. But my dad was a mechanic and I’m a very hands-on person and enjoy the manufacturing side very much.” Johnson can’t stress enough how valuable her training in people skills has been. “You need to make a good reputation for yourself,” she added. “Understanding the business and the technology is crucial. But it’s just as important to be able to relate and communicate and establish relationships with all the people with their different personalities that you encounter. You can’t be productive if you don’t connect with those around you.” While the onboarding program addresses the lion’s share of manufacturing employment needs at the facility, the apprenticeship program’s success is crucial to replacing high-level hourly leaders, many of whom are beginning to retire after long careers with the company. And the right curriculum is the key. “When we began working with YCCC, we formed a cross-functional team at Pratt made
up of shop operators, supervisors, working leaders, business unit leaders, and others who had come up through the ranks, to help build the right curriculum,” Dionne said.“We answered the basic question: ‘In which attributes and skill sets do we need to train new employees?’ Then we got together with the school and asked, ‘Can you develop a curriculum to support this?’ YCCC has been very responsive to our needs and we’ve been very pleased with the results.”
A career opportunity
Johnny Campbell, a machine cell operator in welding, joined the company in January 2015 and immediately joined the onboarding program. “I had been welding at another company and came to Pratt & Whitney looking for more welding experience,” Campbell said. “The program has taught me so much more—from how to operate different machinery, to manufacturing terminology, to blueprint reading, to measuring product tolerances. It definitely gave me a broader picture of the manufacturing opportunities across the company.” “These programs are offering not just a job opportunity, but a career opportunity,” Dionne said. “Given the advanced state of manufacturing technology, we need highly skilled, business-oriented people. We’re starting at the beginning, investing in adaptable, hard-working individuals who want to have careers with us.” Dionne said the company is now reaching out at the high school level, meeting with high school counselors within a 30- to 40-mile radius of the facility. “For years, high schools have been driving students toward 4-year colleges and away from the trades, believing that industry was dead. We’re a testament to the fact that it’s alive and well and offering highly skilled, meaningful career opportunities. Partnerships like the one we have with YCCC prove that it can work.” PE
“While the onboarding program addresses
the lion’s share of manufacturing employment needs at the facility, the apprenticeship program’s success is crucial to replacing high-level hourly leaders, many of whom are beginning to retire after long careers with the company. www.plantengineering.com
”
plant engineering
September 2015 • 45
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MECHANICALSOLUTIONS A facility can spend between 10% and 30% of their total electric costs to generate compressed air, and as much as 10% of the initial system cost on annual maintenance, and still may waste up to 50% of the air they create. Yet, the focus on equipment costs often trumps the issues of maintenance and reliability. All images courtesy: Ingersoll Rand
Take a total system approach to compressed air reliability Understanding how systems work together can lead to savings. By Chad Larrabee Ingersoll Rand
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irtually every modern manufacturing facility uses compressed air in their production processes. It’s clean, easy to store, and can be used for a vast number of applications, from operating power tools to conveying or lifting materials to controlling robotics. The plant manager is responsible for maintaining reliable compressed air power while upholding process requirements and keeping costs in check. By taking a total systems approach, plant operations can increase performance and reduce inefficiencies for significant bottom-line benefits. Understanding the total impact of running a compressed air system and identifying the necessary actions based on unique compressed air needs can reduce energy costs by as much as 20%.
A one-sided view can prove costly
Many companies have a limited view of compressed air system performance, often focusing on routine compressor maintenance and power consumption. While compressor technology is important, focusing on supplywww.plantengineering.com
side components alone won’t guarantee cost savings or performance improvements. Factors such as undersized downstream equipment, wasted air, and leaks can reduce potential savings and performance along the way. Most plant managers are familiar with the equipment in their compressor room and how to remedy isolated issues that arise in this environment. While knowing how to manage the compressor room is essential, additional factors such as air pressure and flow, heat recovery, air quality issues at point-of-use, and wasted air must also be assessed to effectively impact system performance, energy use, and cost savings. Even in cases where a system appears to be running well, it’s likely that somewhere along the line costly compressed air is being wasted. Taking a total systems approach, including a complete analysis of both the supply and demand sides of your system, is the only way to ensure constant and steady system pressure, uninterrupted workflow, and minimal downtime. A total systems approach PLANT ENGINEERING
September 2015 • 47
MECHANICALSOLUTIONS K EY WORDS: At www.plantengineering.com, KEYWORD: COMPRESSED AIR, you’ll find more articles on this topic:
PREVENTING COMPRESSED AIR LEAKS: TAKING A PROACTIVE APPROACH • Much has been written about leak management programs, best practices and the like, but little has been offered in terms of a proactive approach. That is, when installing a new system or expanding or rerouting an existing one, what can be done to prevent leaks? The pipe-joining method is an important decision that will impact maintenance programs down the road. Press-to-connect pipe-joining systems can be a means to prevent air loss in compressed air systems. COMPRESSED AIR EFFICIENCY AT A DISTANCE • Until recently, compressed air system maintenance was reactive—an unforeseen event required immediate intervention from a service technician. In this scenario, the facility is in the dark about maintenance needs, suffers from inefficiencies, and is at increased risk of breakdown. Remote monitoring of compressed air equipment is one of the most effective strategies to help facilities avoid downtime. Whatever the facility’s production schedule, 24/7 remote monitoring is constantly compiling compressed air data in real time—data that can be analyzed for key performance indicators to predict potential problems. THE BUSINESS CASE FOR COMPRESSED AIR SYSTEMS • Do you operate a compressed air system as a business, understanding the financial consequences of your actions or as a misunderstood necessity? Do you carefully consider additions and changes as you would with electricity or water? If the answers to these questions are no, it may be difficult to understand why management seems to place this critical asset so low on their priority list. also is central to understanding your total cost of ownership. Constituents of supply • Excessive pressure drop–filters, dryers, inadequately-sized piping. • Air loss–timed condensate drains, cracked valves, leaks at connections or instrumentation. • Inefficient control scheme–modulating valves or load/unload with short cycling. Constituents of demand • Air events where specific applications create large swings in demand. • Leaks in transmission and point-of-use. • Inappropriate uses of air-venturi vacuums or open blowing for cooling or drying. • Inefficient consumption equipment analysis, especially multiple regulation devices. • Flow restrictions or undersized hose at point-of-use. • Rate of change in a facility’s overall demand profile.
The real cost of air
A compressed air system is a significant investment for any operation and requires
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“ When facility owners invest
in compressed air, they want a good return on that investment—they’re looking for something that’s going to last. We’re here to make that happen because, in the end, there’s no substitute for reliability.
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disciplined maintenance to ensure maximum performance, payback, and system longevity. For example, the initial cost of a 100-hp compressor with air treatment can cost up to $100,000 with installation. Following the initial investment, a facility can expect to spend between 10% and 30% of their total electric costs to generate compressed air, and as much as 10% of the initial system cost on annual maintenance. Compressed air systems are also notorious for inefficiencies and leaks that, on average, waste from 30% to 50% of compressed air. Yet in the majority of cases, the idea of “total cost of ownership” is trumped by the initial equipment and installation investment cost on paper. According to the Compressed Air Industry Sourcebook, “Many facilities have no idea how much their compressed air systems cost on an annual basis or how much money they could save by improving the performance of these systems.” In fact, an overwhelming majority of compressed air users rate consistent and reliable air supply over efficiency and energy savings. With priority needs that include immediate reliability and uptime, plant managers often consider the cost of new or replacement equipment rather than the complete and ongoing efficiency of the system—leaving near- and long-term dollars on the table. You can’t accurately determine savings without looking at the entire system, part by part, and how each element works together. This includes supply-side components such as compressor controls, air-treatment equipment, dryers, and filters as well as demandside equipment that includes heat-recovery and point-of-use systems. How air-system components work together to produce air and www.plantengineering.com
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mechanicalSOLUTIONS Developing a compressed air system today requires not just proper piping, but also sensors throughout the system to look for leaks and inefficiencies.
delivery and storage infrastructure. Companies that take control with a total systems approach not only reduce their total cost of ownership, but also significantly boost their operational performance. When equipment providers and end users come together with a shared focus on maximizing the total cost of ownership, it’s possible to turn the liabilities of an inefficient system into a performance advantage. Implementing total systems programs help companies improve the energy efficiency and performance of compressed air systems. PE
exactly what’s happening throughout that process to configure, calibrate, and maintain optimal performance is what a total systems approach is all about. Advances in compressor technology are making total system expertise not just desirable, but increasingly essential as many companies look to their equipment provider for specialized know-how and component expertise. In addition, advanced analytics are now available to help determine the right equipment configurations throughout the system to optimize performance.
Know your options
Working with a compressor provider who understands the demand and supply sides of your compressed air system can help you identify your requirements and maintain a reliable supply of air while reducing your overall energy and maintenance costs. You will also want to protect your investment. Consider how an all-inclusive agreement, with access to experienced compressed air experts, can help manage your air demand and supply system and related assets with an eye to reducing operational costs. With a wide range of known inefficiencies and an obvious lack of controls, many problems can arise within compressed air
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Chad Larrabee is director of services marketing in North America for Ingersoll Rand’s Compressed Air & Gas business unit. Larrabee has 23 years of experience in the compressed air industry and currently serves as education committee chairman for the Compressed Air and Gas Institute.
The BoTTom line: • Taking a total systems approach to compressed air, including a complete analysis of both the supply and demand sides of your system, is the only way to ensure constant and steady system pressure, uninterrupted workflow and minimal downtime. A total systems approach also is central to understanding your total cost of ownership. • You can’t accurately determine savings without looking at the entire system, part by part, and how each element works together. This includes supply-side components such as compressor controls, air-treatment equipment, dryers and filters as well as demand-side equipment which includes heat recovery and pointof-use systems. • Working with a compressor provider who understands the demand and supply sides of your compressed air system can help you identify your requirements and maintain a reliable supply of air while reducing your overall energy and maintenance. www.plantengineering.com
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mechanicalSOLUTIONS Selecting a filler metal: Seven factors to consider From matching the base material to picking the right equipment, consider the process before starting to weld.
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By Bruce Morrett Hobart Brothers Co.
Using a filler metal that provides the appropriate mechanical and chemical properties for the job—and is able to withstand the service conditions the weld encounters—is critical. Image courtesy: Hobart Brothers Co.
sing a filler metal that provides the appropriate mechanical and chemical properties for the job—and is able to withstand the service conditions the weld encounters—is critical. It helps minimize the risk of cracking, corrosion, and/or weld defects that could lead to time-consuming and costly rework. There are seven key factors to consider when selecting a filler metal the base material to be welded, the welding position, regulatory specifications and codes, design requirements, shielding gas, post-weld heat treatment, and welding equipment. Below is a detailed look at each of these factors and how they dictate which filler metal to use.
Factor No. 1: the base material to be welded
Joining together two materials is, for the most part, a matter of chemistry: Which filler metal best matches the base material? If the chemistry of the materials matches, the mechanical properties (such as the tensile and yield strength) will also match. Welding operators can rest assured that their weld deposit will have the same strength and properties as the base material. When materials being joined are not the same strength, there are other considerations. As a rule of thumb, welding operators should match the strength of the filler metal to the lower strength of the two base materials. During the welding process, dilution from the higher-strength base material is sufficient to strengthen the weld metal deposit. Most base metals can easily be identified through tests based on appearance and reactions to magnets, fracture, chisel, and flames or sparks; and a welding operator typically knows what base material he or she is working with. In some cases—usually during repair or rework welding—it may be necessary to take a sample to a lab that can conduct a chemical analysis.
Factor No. 2: the welding position
Whenever possible, welding opera-
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tors should rotate the part so it can be welded in a flat position. Welding in a flat position is always the most economical method, followed by horizontal or vertical and, lastly, an overhead position. If a welding operator must work with a large weldment that can’t be manipulated, however, it forces the need to weld in multiple welding positions. Out-of-position welding can be especially challenging if there is only one wire size available. For example, a vertical weld-up using a 3/32-in.-diameter wire may be extremely difficult or even impossible. A better choice would be a wire ranging from .045 to 1/16 in. in diameter, but it would require setting up an additional wire feeder or another power source for the job. It would also require a change in feed rolls and, potentially, the welding gun. Companies should keep in mind that changing welding positions can slow the process and compromise efficiency, and select a filler metal type and size that will allow for the most versatility.
Factor No. 3: regulatory specifications and codes
Job specifications often dictate what class of wire to use. If not, welding operators should carefully consider the service requirements the welds may encounter. For example, if a welding operator uses a mild steel filler metal for applications exposed to harsh elements, it is likely that the welds will rust, deteriorate, and corrode at a faster rate than the base material. This action could lead to weld failures, especially if the end product is of critical importance, such as a pressure vessel used in high-temperature environments or a bridge that will be exposed to the elements. In the end, whatever filler metal a welding operator uses must also meet the service condition of the final product so that the weld deposit lasts as long as the base material. It’s equally important when welding to code that the filler metal should meet the qualifications or certification of that code.
Factor No. 4: Design requirements
In addition to following codes (when required), it is important to select a filler metal that meets www.plantengineering.com
K EY WORDS: At www.plantengineering.com, KEYWORD: WELDING, you’ll find
more articles on this topic:
BALANCE SAFETY, PRODUCTIVITY AND COMFORT WHEN CHOOSING A WELDING HELMET • There are several factors to consider when choosing the proper welding helmet—some critical, some more related to personal style—but the primary objective is to ensure that the eyes and skin are protected from the hazardous by-products of the welding process. WELDING CELLS ADAPTING TO MANUFACTURING CHANGES • Creating an adaptable weld cell goes beyond just improving the physical space, but that is also a very important component. WHY WELDING REMAINS VITAL FOR TODAY’S MANUFACTURERS • One of the primary benefits of welding is its flexibility. Industrial plants can weld materials in one location, ship them to the facility for installation, and position them in various configurations. or exceeds the needs of a joint design, as specified by the engineer’s welding configuration. For instance,when welding on thin material, it is important that the arc characteristics are appropriate—a wire that provides deep penetration may cause the welding operator to burn through. On the other hand, if the part to be welded is thick and features a single “V” joint, a filler metal with better penetration characteristics allows for better tie-in at the root and sides.
input #28 at www.plantengineering.com/information
FACTOR NO. 5: Shielding gas
It’s important to ensure the filler metal and shielding gas used for an application are compatible. Different shielding gases have different effectson filler metal. For example, the addition of argon to carbon dioxide (CO2) allows the welding operator to transfer more of the filler metal’s chemistry into the weld deposit. This mixture provides consistent weld quality, offers good weldpool control, and generates lower levels of spatter. Conversely, using CO2 (an oxidizing gas) burns off some of the filler metal elements. One hundred percent CO2 offers the advantage of deep-weld penetration, which is desirable when welding thicker materials. It does tend to have larger ball transfer and can create more spatter than shielding gas mixtures that are a combination of argon and CO2. There are wires capable of operating with both straight CO2 and an argon/CO2 mixture. Companies should consider their available gas supply and desired weld characteristics provided by each when choosing a filler metal, and make sure that the selected filler metal is compatible with the shielding gas chosen.
FACTOR NO. 6: Post-weld heat treatment
There are certain steels and material thicknesses that must be preheated to a certain temperature before welding commences. Preheating allows the part to cool down at a slow rate to avoid weld-shrinking issues and cracking. Similarly, post-weld heat treatment (PWHT) is used to reduce the stresses and slowly PLANT ENGINEERING
September 2015 • 53
input #29 at www.plantengineering.com/information
mechanicalSOLUTIONS lower the residual heat introduced during welding, allowing the weld joint and base materials to return to the desired properties. On materials that require PWHT, it is important to select a filler metal capable of producing welds that respond appropriately to the application of heat.
Factor No. 7: Welding equipment
The type and size of equipment being used impacts what filler metal is best for the job. Specifically, the power source needs to provide enough amperage for the diameter of wire being used for the job. In the event that there is not enough amperage it will be necessary to either change wire diameters, which could result in slower production to complete the weld, or change to a highercapacity machine. It’s also important for the power source to offer the proper welding current for the filler metal chosen. Welding in the wrong current can lead to spatter and poor weld quality. Determining the desired weld characteristics is equally important. Filler metals
that operate on reverse polarity (electrode positive, or EP) provide great penetration, while straight-polarity (electrode negative, or EN) filler metals produce a more shallow joint penetration. Although the effect of various elements in filler metals can be rather complex and inter-related, a review of their general properties can also help welding operators determine which filler metal is ideal for the job. Carbon, for example, generally increases hardness, tensile strength, and wear resistance but decreases ductility, impact, and machinability. Nickel, on the other hand, increases hardness, tensile strength, impact, and ductility but decreases the part’s ability to be machined. Similarly, there are various alloying elements that have different properties to deoxidize, refine grain structures,or improve ductility. It is important for welding operators to consider the properties needed in a completed weld when making the filler metal selection. PE Bruce Morrett is a product manager for Hobart Brothers Co.
The BoTTom line: • Whenever possible, welding operators should rotate the part so it can be welded in a flat position. Welding in a flat position is always the most economical, followed by horizontal or vertical and, lastly, an overhead position. • Whatever filler metal a welding operator uses must also meet the service condition of the final product so that the weld deposit lasts as long as the base material. It’s equally important when welding to code that the filler metal should meet the qualifications or certification of that code. • The type and size of equipment being used impacts what filler metal is best for the job. Specifically, the power source needs to provide enough amperage for the diameter of wire being used for the job.
2015
Workforce Development
Turning research into insights makes for better business decisions The 2015 Workforce Development study asked key questions on the causes and effects of the lack of a skilled workforce in the U.S., what manufacturing plants are doing to combat this issue, and how facilities are establishing a positive relationship with their communities. According to the study the lack of available skilled workers has kept 35% facilities from expanding operations. In an effort to combat the shortage, 44% of plants have taken to online recruitment and 40% offer in-house training for less experienced applicants. Access the full Plant Engineering 2015 Workforce Development report with additional findings and insights.
www.plantengineering.com/2015WorkforceDevelopment
GLOBAL SYSTEM INTEGRATOR 2016 REPORT INTEGRATE YOUR MESSAGE TO 146,000 ENGINEERS In December, CFE Media will publish an enhanced Global System Integrator Report. The December Report to the 146,000 readers of Control Engineering and Plant Engineering will now feature a Corporate Close-Up, allowing system integrators to describe their companyâ&#x20AC;&#x2122;s unique experience and success as an engineering service provider. Below is an example of a half-page Corporate Close-Up:
Cimation
OPERATIONS TECHNOLOGY SOLUTIONS TO SUIT YOUR AUTOMATION, INDUSTRIAL IT, AND CYBER SECURITY NEEDS Van Wilson, Chief Operating Officer Houston, Texas Telephone: (713) 452-3350 info@cimation.com www.cimation.com
Primary Industries Chemicals, Petrochemicals Oil & Gas Extraction (onshore, offshore) Oil & Gas Refining Pipelines Information and communication systems
Other office locations Denver, CO Pittsburgh, PA New Orleans, LA
Lafayette, LA Calgary, AB London, UK
Cimation is an operations consulting company delivering secure technology solutions to the global energy industry. With experience in process automation, industrial IT, enterprise data, and ICS cyber security solutions and more than 200 employees in 7 global offices, we are ready to execute efficient strategies that converge IT and operations technology. Armed with diverse project experience, process knowledge, and technical expertise, we improve energy operations by engineering and integrating industrial technology. In our years, Cimation has executed thousands of reliable systems integration and engineering projects for oil and gas, refining, chemical, power, utilities, and storage businesses. We understand the processes and objectives that drive industrial operations and help companies improve safety and efficiency through holistic solutions customized to meet their business needs. Since opening our doors in 2009, we have grown by developing trusted partnerships with both clients and vendors. More than 300 customers in North America, South America, Europe, and Africa including independent companies, mid-size operators, and global super majors trust their operations technology infrastructure to Cimation. By tailoring our services to the unique needs and requirements, we help realize process efficiency and longterm cost-savings in spite of market volatility. Speak to one of our leading industry experts today to learn more!
Visit our Corporate Profile at www.cfemedia.com/global-si-database/Cimation
To start searching the Global System Integrator Database, or to create your own System Integrator Corporate Profile visit www.cfemedia.com/global-si-database
To discuss advertising in the Global System Integrator 2016 Report, contact Brian Gross BGross@CFEMedia.com 630-571-4070 x2217
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Compressed Air System Installation Guide
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Layout Considerations for a Reliable, Energy Efficient, and Safe Compressed Air System
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Written by Kaeser’s team of engineers and compressed air experts, this e-book provides essential tips for planning and installing a compressed air system. It includes installation diagrams, information on piping, ventilation, air treatment, and energy management strategies. » Now available for complimentary download, visit www.kaeser.com/CASIG Input #110 at plantengineering.hotims.com
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meltric.com 800.433.7642 Input #111 at plantengineering.hotims.com
PLANT ENGINEERING
September 2015 • 57
IN NOVATIONS Rotary screw compressor The UP6S Series 15- to 30-hp fixed-speed rotary screw compressor adds several standard features to the standard unit, such as progressive adaptive control (PAC) protection, O-ring face seals to reduce leak points, and a totally enclosed fan-cooled (TEFC) motor. The unitâ&#x20AC;&#x2122;s TEFC design reduces the risk of particulates entering the motor while also keeping it cool, so the compressor can be used in harsh environments. Its NEMA Type 4 rating allows it to be used indoors or outdoors, and the new Tri-Voltage motor enables it to adapt to a variety of applications. Ingersoll Rand www.ingersollrand.com Input #200 at www.plantengineering.com/information
Ground-shaft monitor The Smart Ground Monitor is an innovative condition-monitoring system that provides users with instant feedback on the performance of the current diverter ring (CDR) in diverting shaft currents away from the bearings to ground. The monitor provides a leading indicator of CDR performance. A simple interface alerts users in real time if there is not optimal contact between grounding brushes and the shaft, preventing bearing failure. If contact has been interrupted, routine maintenance can be performed to return shaft grounding to peak performance. The Smart Ground Monitor has external ports for safe and convenient oscilloscope readings and can be set up in standalone or auto mode for performance indication. Inpro/Seal www.inpro-seal.com/smartcdr Input #201 at www.plantengineering.com/information
Keyless lock The Keyless Keypad Lock for drawer cabinets serves as an alternative to the SL10 keyed locking option. The keyless lock offers such benefits as the ability to program up to 25 different user codes for unique user access and eliminating the need to order and manage multiple locks and keys for different cabinets within a facility. The mechanism includes a zinc-alloy lock housing with a motorized lock mechanism and retaining clip, and a lock toggle and lock rod (based on cabinet depth). Vidmar www.stanleyvidmar.com Input #202 at www.plantengineering.com/information
58 â&#x20AC;˘ September 2015
PLANT ENGINEERING
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Send new product releases to: peproducts@cfemedia.com
Casters
Current transducer The RCTrms-3-ph current transducer delivers a convenient, safe, and accurate solution for measuring current in three phases. It features a thin, cliparound, flexible sensor coil and provides accurate true RMS measurement with 4- 20 mA or 0- 5 V output, enabling simple installation with PLCs, SCADA systems, or automation equipment. With 18 current ratings options from 100 to 50,000 A, and a choice of 300-, 500-, and 700-mm or custom coil lengths, the RCTrms-3ph can be used in many applications and connected to a wide variety of SCADA systems, PLCs, data loggers, protection equipment, or motor controllers. The clip-around coil design allows fast and easy positioning, and provides accurate results without needing to be centralized around the conductor. An isolated BNC-BNC cable-split option is available to ease installation, such as when threading through existing conduit.
Spinfinity is a line of heavy-duty, maintenance-free casters. Incorporated into the kingpinless construction is special CNC machining to host a large internal seal that is made from nitrile butadiene rubber (NBR) and is completely enclosed inside the swivel assembly. With no outside exposure, the swivel assembly is able to keep grease in and contaminants out. The top plate and inner raceway are one forged steel piece to provide strength in shock conditions. Hamilton Caster www.hamiltoncaster.com/spinfinity Input #204 at www.plantengineering.com/information
Power Electronic Measurements Ltd www.pemuk.com Input #203 at www.plantengineering.com/information
Dust-collection diagnostics The GoldLink system provides round-the-clock access to dust-collection operations by monitoring four preset analog inputs and 16 preset digital inputs. Designed for facilities that do not have building management systems, it is especially useful for companies with many remote dust collectors, 24/7 operating schedules, sensitive applications, and/or the need to generate reports for OSHA, the EPA, or other regulatory bodies. The GoldLink unit ships preprogrammed and is installed and connected to the Internet; data is packaged in a usable format that allows customers and other authorized personnel to monitor the health of their filtration systems via website. Camfil www.camfilaypc.com Input #205 at www.plantengineering.com/information
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September 2015 â&#x20AC;˘ 59
IN NOVATIONS
Send new product releases to: peproducts@cfemedia.com
HMI panel The TP3000 series human machine interface (HMI) employs a rugged, allmetal housing with a fanless design that consumes less energy and produces less heat. The free VISU+ EXPRESS programming software provides easy programming and features trending, alarming, logging, and recipe handling.Screen sizes range from 5.7 to 15 in., with certain panels available in a 16:9 aspect-ratio widescreen. The software supports many communication protocols, including Ethernet/IP, Modbus TCP, and OPC DA. This makes it compatible with PLCs from a variety of manufacturers. Phoenix Contact www.phoenixcontact.com Input #206 at www.plantengineering.com/information
Hydraulic hose The E-Z Bend Hose has half the bend radius of standard hoses for easier routing and more space savings. It is ideal for highpressure hydraulic oil lines in mobile hydraulic applications. E-Z Bend Hose has four spiral layers of high-tensile steel-wire braid to handle the most robust and demanding applications. The tube material is oil-resistant synthetic rubber with reinforcement of four spiral layers of high-tensile steel-wire braid. The working temperature range for E-Z Bend Hose is -40 to 212 F and meets flame-resistant MSHA designation. Kurt Hydraulics www.kurthydraulics.com Input #207 at www.plantengineering.com/information
Turning machine The VL 2 vertical turning machine is designed for the quality and costconscious manufacturer and subcontractor. A universal production tool that impresses with its small footprint and an advantageous price-performance ratio, it also includes automatic loading and unloading of the workpieces. The workpieces are transported using O-automation, with the pick-up principle being used to load and unload the VL 2. Workpieces are loaded directly into the carrier prisms or, where necessary, into workpiece holders inserted into the prisms. A measuring probe located outside the machining area adds an automatic, in-process quality assurance operation to the cycle, with the measurements taken between finish-machining point and workpiece removal. EMAG LLC www.emag.com Input #208 at www.plantengineering.com/information
60 â&#x20AC;˘ September 2015
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For more information on how to advertise in Plant EnginEEring’s Internet Connection, call Jim Langhenry at 630-571-4070 x2203 alliedelec.com
flexicon.com
seweurodrive.com
Allied Electronics is a small order, high service level distributor of electronic components and electromechanical products with over 50 sales offices across the United States and Canada. Allied Electronics
Flexicon designs and manufactures bulk handling equipment and custom-engineered and integrated plant-wide systems. Flexicon Corp.
One of the largest global suppliers of drive technology, SEW-EURODRIVE specializes in gear reducers, motors and electronic motor controls. SEW-EURODRIVE USA
atlascopco.us
flir.com
sullair.com
FLIR Systems designed, develops, manufactures, markets, and distributes thermal imaging infrared cameras. FLIR Systems Inc.
Sullair is a designer and manufacturer of stationary and portable rotary screw air compressors, air treatment equipment, and pneumatic tools. Sullair Corp.
Atlas Copco produces and markets compressed air equipment and generators, construction and mining equipment, industrial tools, assembly systems, services and rentals. Atlas Copco
automationdirect.com AutomationDirect offers 6,500+ industrial automation products through their free catalog and online store, including PLCs, operator interfaces, sensors, and more. AutomationDirect
avotraining.com For almost 50 years, AVO has been helping organizations create safe and reliable electrical systems. AVO Training Institute
baldor.com Baldor Electric designs, manufacturers, and markets a broad line of industrial energy-efficient electric motors, mechanical power transmission products, and more. Baldor Electric Co.
camfilapc.com Camfil Air Pollution Control (APC) is a leading global manufacturer of industrial dust, fume and mist collection equipment and is part of Camfil, the world’s largest air filtration company. Camfil APC
cat.com Caterpillar is a manufacturer of construction and mining equipment, diesel and natural gas engines, industrial turbines and diesel-electric locomotives. Caterpillar
electroind.com Electro Industries specializes in power meters and smart grid solutions that excel at revenue grade energy measurement, power quality and advanced telemetry. Electro Industries/Gauge Tech
erectastep.com Modular work platforms and aluminum stairs pre-engineered for unlimited configurations. Platforms and metal steps bolts together with no fabrication required and are easily repurposeable. ErectaStep
exair.com Exair’s product line includes Vortex Tubes and products utilizing Vortex Tubes, Air Amplifiers, Air Knives, air-operated vacuums and ionizing products for static elimination. Exair Corp.
62 • September 2015
plant engineering
us.kaeser.com Manufacturer of air system products, including rotary screw compressors, portable compressors, rotary lobe blowers, vacuum packages, refrigerated and desiccant dryers, filters, and condensate management systems. Kaeser Compressors Inc.
klsummit.com Industry leader in synthetic lubricant technology with a line of over 200 products that can service almost any industrial application. Summit Industrial Products
keysight.com
unitedrentals.com
Keysight Technologies is an electronic measurement company that offers wireless, modular, and software solutions. Keysight Technologies Inc.
United Rentals is the largest equipment rental company in the world with locations in 49 states and 10 Canadian provinces. United Rentals Inc.
lubriplate.com Lubriplate manufactures more than 200 high quality lubricants, including high performance synthetic lubricants and NSF-H1 lubricants for food processing and beverage. Lubriplate Lubricants Co.
oeo.com
yaskawa.com Yaskawa is the world’s largest manufacturer of ac inverter drives, servo and motion control, and robotics automation systems. Yaskawa America Inc.
OEO’s mission is to deliver cost effective energy solutions to businesses and institutions. OEO Energy Solutions
orival.com Orival is a leading manufacturer of self-cleaning water filters, automatic water filters and strainers, for use as industrial water filters, irrigation filters, cooling tower filters, and more. Orival Inc.
procoproducts.com Proco Products Inc. is a global leader in the design and supply of piping/ducting system expansion joints and rubber check valves. Proco Products Inc.
rittal-corp.com Rittal manufactures the world’s leading industrial and IT enclosures, racks and accessories, including high-efficiency, high-density climate control and power management systems. Rittal Corp.
rogers-machinery.com Manufacturer of rotary screw and reciprocating air compressors, fixed and variable speed drives, rotary and centrifugal compressors, blowers, and vacuum systems. Rogers Machinery
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Rittal Corporation 800-477-4000
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Kaeser Compressors, Inc 866-516-6888
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September 2015 • 63
INCONCLUSION
The workforce economics of supply and demand
I Bob Vavra Content Manager
“ You need to
sell your job opportunities with the same enthusiasm— and with the same incentives— as you do with your sales force.
”
64 • September 2015
slept through a good deal of Economics 101 in college. In my defense, it was a large, warm lecture hall, and it was early in the morning. I was a college student and, after all, it was Economics 101. I did manage to make it through enough of the course to earn a “C” and a passing knowledge of supply and demand. You don’t need to be an economist, or even awake, to grasp the basics of supply and demand. Prices fall when supply is high and demand is low, and prices rise when demand is high and supply is low. The goal is to find a way to consistently balance supply and demand, which helps you maximize profits and optimize production. The supply and demand concept works well with commodities, but people aren’t commodities, no matter what political candidates might think. When you need more people to work in your plant to help you grow your business, the rules of supply and demand go out the window. You have to focus on more than just money to bring workers into your organization. The continuing workforce shortage in manufacturing is reaching a critical point. With a manufacturing economy in full recovery, companies are looking to expand. After their retirement plans were left in tatters seven years ago, older plant workers now see a more stable present and can look toward retirement with more optimism and with less dependence on their current jobs. The combination of economic growth and worker retirement will stretch our thin resources further, and automation and robotics will only be able to do so much to stem this tide. We need more people on our team. Plant Engineering has touted for years the importance of outreach by plant management to attract, train, and retain this next generation of workers. We need to assess the specific needs of our plants—what kind of worker do we need to fill the roles? We then must marshal resources to bring our manufacturing opportunities to the potential workforce, and to show people how these manufacturing opportunities create not just a job for today, but a future for tomorrow. In our articles this month that focus on training and workforce development in manufacturing, there were two compelling quotes that sum up the issues that manufac-
PLANT ENGINEERING
turers and potential workers must consider. One was from Stacey Bales, the president of Bales Metal Surfacing Solutions, who said, “We’re trying hard to reach out to the high school level, but we’re still a couple of years away. For us, it’s harder; no one grows up and says they want to be a chrome plater. We train in-house, but it’s kind of a dying art form. We try to attract younger workers by having a robust benefits package.” And then there was Leo Dionne, manager of strategic sourcing/transitions at Pratt & Whitney: “These programs are offering not just a job opportunity, but a career opportunity. Given the advanced state of manufacturing technology, we need highly skilled, businessoriented people. We’re starting at the beginning, investing in adaptable, hard-working individuals who want to have careers with us.” Some frustrated manufacturers might hear all these platitudes and ask, “Where do I find these people?” The obvious response is, “Well, where are you looking?” If you’re just staring at your front door waiting for the workforce to break it down, you’re going to be waiting a long while. If you’re setting up shop at job fairs, that’s a better effort, but not close to enough. You need to sell your job opportunities with the same enthusiasm— and with the same incentives—as you do with your sales force. Your current employees should be your best ambassadors for your company. Do you offer a bounty for every new recruit they bring through the door? Do you have an active program to train workers at the local community college? If you invest in the school by providing them your equipment for training, will that investment pay off in workers ready to step in and produce on day one? The numbers surrounding workforce development are obvious to all, but they’ve stayed roughly the same over the past decade. We’ve continued to grow manufacturing in that time, but we’ve been living on mostly borrowed time. We understand the problem, but at some point that understanding has to translate into action. We lack the needed supply of workers. We have to create a demand to work in our plants. To do that, we need a supply of funds and initiatives from our plant leadership. And we have to demand it. PE www.plantengineering.com
CELEBRATING 100 YEARS Thank you to our customers, associates and partners for 10 decades of success. SEE IT ALL COME TOGETHER
Booth# C-4243
PACK EXPO International September 28-30, 2015 Las Vegas, NV
Celebrating 100 years of proven performance, Yaskawa is the world’s largest manufacturer of ac drives, motion control, and robotics.
YA S K A W A A M E R I C A , I N C . DRIVES & MOTION DIVISION 1 - 8 0 0 - YA S K A W A | YA S K A W A . C O M input #30 at www.plantengineering.com/information
For more info: http://Ez.com/yai813
©2015 Yaskawa America Inc.
Poultry Proven.
Baldor•Dodge® Quantis Ultra Kleen® and Tigear-2® Ultra Kleen stainless steel gear reducers are the ultimate choice for poultry and meat processing applications. Completely sealed and made of premium stainless steel, each gear reducer features long-life gear construction, maintenance-free operation and IP69K rated protection against high pressure and high temperature washdown environments. You can count on Quantis Ultra Kleen and Tigear-2 Ultra Kleen stainless steel gear reducers for the superior reliability it takes to survive harsh washdown applications…day after day after day.
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• Premium Stainless Steel
• Maintenance-free
• Rounded Surfaces Prevent Water Pooling
• IP69K Rated Protection
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• 24-Hour Shipments Available
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