HMI CHECKLIST: Top factors and features to consider when shopping for an HMI solution. p.22
MOTORS AND DRIVES: An overview of the most popular rotary motion technologies. p.24
COST CONTROL: How a stronger employeecustomer connection will improve productivity. p.26
AutomationMag.com
Your resource for Canada’s industrial automation news
ENJOYING THE BENEFITS
OF RAMPED-UP AUTOMATION Automating specialized armored vehicles has paid big dividends for Inkas. p.18
MAY 2016
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May 2016 Vol. 31, No. 3
DEPARtmENtS
The latest industry news, deal makers, and movers and shakers
pHoto: JoHn pACkmAn
4 From the editor 5 Automation upfront
18
16 Centre stage Stefan Fickenscher, Trumpf Canada managing director
COLumNS 10 Machine safety Learning about automation safety over a non-safe industrial network
12 Lean insights
ContEntS
Lean proves to be “one of the right tools” for Tree Island Steel
COvER StORy
18 Ramped-up automation
14 Industry watch A take on how we can bust manufacturing job myths and get to the next generation
30 Backstory Reshoring in Canada
NEW PRODuCtS Process Control Wire & Cable Machine safety Motion Control Power Supplies Communications & Networking 29 Data Acquisition 29 Wireless Technology & Security
Automating specialized armored vehicles has paid big dividends for Inkas By Treena Hein
16
22 HMI checklist Top factors and features to consider when shopping for an HMI By Mary Del Ciancio
24 Systematic selection
27 27 28 28 28 29
MANUFACTURING AUTOMATION · May 2016 MA_Murrelektronik_May.indd 1
An overview of the most popular rotary motion technologies By David R. Bickert
26 Finding value
22
How a stronger employee-customer connection will improve productivity By Shawn Casemore
AutomationMag.com
3
2016-04-21 10:11 AM
from tHE EDitor By ALySSA DALtON
NOtABLE tWEEtS
Your resource for Canada’s industrial automation news
@JeremySCook The birth of the PLC in the late 60s - Inspiring how company came to be: bit.ly/1xOqd7W @duffaroola Good news from my old home in Alberta... I wouldn’t have expected anything less RT @AutomationMag Bilton Welding and Manufacturing opens Vancouver location DICK MORLEY: A glimpse into the many facets of the esteemed “Father of the PLC.” p.18
SPOT THE DIFFERENCE: How to choose the right lighting for machine vision applications. p.26
TRAINING: How you can attract millennials and simultaneously boost your business. p.17
AutomationMag.com
Your resource for Canada’s industrial automation news
PC-BASED CONTROL
IN THE DRIVER’S SEAT Sodecia uses PC control, EtherCAT and programmable safety to accelerate robot cell performance for automotive assembly. p.22
MARCH / APRIL 2016
PM 40065710
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@Brian_Papke This year’s #MC2Conf will be an excellent opportunity to see how digital connectivity is impacting the industry @dave196413 Too bad it is not in Canada RT @automationmag Ford investing US$1.6B in new small car factory in Mexico: shar.es/1jaJdo @MikeQuindazzi IoT Vertical Services: 42% of #IoT developers are currently wiring #software that uses #sensors
4
EDItOR
The people behind the machines
I
consider the manufacturing industry to be a very human business. That may sound strange at a time when big data analytics, the Cloud, and other abstract concepts are all the rage. However if you strip away the technologies, products, buzzwords, silos and sectors, the general purpose of the global manufacturing workforce can be reduced into one simple statement: a company makes and/or provides a solution to satisfy the needs of a dedicated population. Every machine builder, component manufacturer, contractor, consultant, system integrator and end-user, regardless of sector, is seeking to create or assemble a product that will “give the people what they want.” Humans are the backbone of this business, and Clement D’Souza is just one of our many, many key personnel. Last month, D’Souza was featured in the What Makes a Honda is Who Makes a Honda video series, which spotlights the careers and individuals within Honda. A mechanical engineer and 26-year company veteran, D’Souza led the creation of the new Performance Manufacturing Center in Ohio, the exclusive global production facility for the 2017 Acura NSX supercar. Over the course of the four-minute video, we learn about D’Souza’s progression at Honda, as well as his childhood in India and aspirations of becoming an aerospace engineer. We find out he is a skilled field hockey player who recently competed on the U.S. team in the 2016 FIH Masters World Cup, and also coaches The Ohio State University’s club field hockey team. Honda is certainly not the first manufacturer to profile its employees CONNECt @AutomationMag
Alyssa Dalton adalton@annexweb.com PuBLISHER
in this manner — some businesses do this regularly — but it’s crucial we don’t forget the value of doing so. It’s these faces and stories that remind us of humble beginnings, motivate us to think beyond what’s possible, and inspire next generations to venture into this field. Without these individuals, we wouldn’t have this industry altogether, and we cannot afford to hide these successes. But as the development of robotics and artificial intelligence in automation grows, so does the fear of robots wiping out millions of jobs. This, however, shouldn’t diminish the power of humans in manufacturing. A Power Automation Systems blog post provides this rationale: “It’s true that robots provide a level of accuracy, consistency and endurance unmatched by humans but ... machines can’t think or act like humans, and they’re far from being able to do so. The human mind is the most complex piece of machinery there is, capable of making split-second decisions. That leaves greater opportunities for workers to stretch their creative and problem-solving muscles ... The onus is on people to develop critical thinking skills now that will ensure them a place alongside burgeoning technology.” Technology may be the way of the future, but human passion is still the core of manufacturing. This will not go away anytime soon, unless we let it. | mA
adalton@annexweb.com
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David R. Bickert, Shawn Casemore, Mary Del Ciancio, Treena Hein, Paul Hogendoorn, Gabriel Khon, Paul Siniak, Nigel Southway Manufacturing Automation is published seven times a year by: Annex Business Media 222 Edward Street, Aurora, Ontario L4G 1W6 Tel 905-727-0077 Fax 905-727-0017 Printed in Canada ISSN 1480-2996 Publication Mail Agreement #40065710
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EDItORIAL ADvISORy BOARD AL DIGGINS, President and General Manager, Excellence in Manufacturing Consortium, and Chairman and CEO, Canadian Manufacturing Network DAVID GREEN, Technology and Business-to-Business Consultant DON MCCRUDDEN, Vice-President, Business Development, Festo DAVID MCPHAIL, President and CEO, Memex Automation NIGEL SOUTHWAY, Business Productivity Consultant and Author on Lean Thinking BILL VALEDIS, Vice-President, Precision Training, Products and Services Inc.
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Occasionally, Manufacturing Automation will mail information on behalf of industry related groups whose products and services we believe may be of interest to you. If you prefer not to receive this information, please contact our circulation department in any of the four ways listed above. The contents of Manufacturing Automation are copyright © 2016 by Annex Publishing & Printing Inc. and may not be reproduced in whole or part without written consent. Annex Publishing & Printing Inc. disclaims any warranty as to the accuracy, completeness or currency of the contents of this publication and disclaims all liability in respect of the results of any action taken or not taken in reliance upon information in this publication. We acknowledge the [financial] support of the Government of Canada.
Automation upfront
NEWS Investment
PHOTO: BRIDGESTONE CANADA
Bridgestone pumps up to $300 million into Joliette plant expansion Bridgestone Canada has announced that it is expanding its Canadian passenger and light truck tire manufacturing facility in Joliette, Que., as part of a fiveyear investment that could total upwards of $300 million. The multi-phase expansion of the facility is expected to break ground this year, and will help the plant produce larger diameter tires that fit today’s pickup trucks and SUVs, as well as “increase productivity and enhance the plant’s global competitive position,” it says. According to Bridgestone, the overall project will help increase plant capacity by 3,000 tires per day, bringing the daily production to 20,000 tires per day by 2023. “Our investment in updated equipment and improved manufacturing processes reflects our ongoing commitment to identifying new, cost-effective and innovative ways to serve consumers, dealers and original equipment manufacturers,” said Robert Verreault, Joliette plant manager. “Canada continues to represent an important market for our company, and this investment represents a tremendous opportunity for Bridgestone, Joliette, the Lanaudiere region and the North American markets by enhancing the long-term viability of this facility.” One of the group’s most environmentally sustainable plants, the Joliette facility produced its 150 millionth tire in 2014. This significant investment comes as the facility celebrates its 50th anniversary this year. The plant team has achieved a number of awards, including the Productivity Improvement Award and Business of the Year Award by the Federation
of the Chamber of Commerce of Quebec, Grande Mention at the Grand Prix Quebecois de la Qualite from the Government of Quebec, Silver Award for Quality at the Canada Awards for Excellence, and Recyc-Quebec Certification – Gold Level 3 certification given by the Government of Quebec to companies that recycle more than 90 per cent of their waste.
MANUFACTURING AUTOMATION · May 2016
Plant overhaul: The project will boost production by 3,000 tires a day.
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Automation upfront
RELOCATION
Valeant moves Jublia production from Asia to Quebec Valeant Canada says its Laval, Que.-based plant will become the North American production site for the prescription medication Jublia, a topical solution that treats toenail fungus. The United States production represents nearly 80 per cent of the total volume of Jublia, which was previously manufactured in Tokyo, Japan, and packaged in the U.S. So far, this relocation has generated a total investment of more than $1 million for the Laval plant. This investment has helped fund the changes to the medication’s packaging, the construction of specialized rooms used to manipulate ethanol, and improved flammable safety storage units. According to company
representatives, the Laval plant now meets global standards and can safely handle a “significant increase” in production volumes. “Laval is a strategic choice for Valeant. This facility’s lean, state-of-the-art, high-tech manufacturing and efficient production processes have made us competitive on the global stage and helped set our performance apart,” said Jacques Dessureault, president and general manager of Valeant Canada. “As we take on the role of global production centre for prescription dermatology products, this now world-class facility allows us to become a major player in our industry at home and abroad.” This transfer of production to Laval also guarantees the maintenance of many specialized manufacturing jobs in Quebec, says the company, as well as the “continued growth” of Valeant Canada’s operations.
The NEW encoder module that gets the job done. Need a highly-configurable encoder with resilience, accuracy, and endurance? With its compact size and flexible installation options, EPC’s new Model 30M Magnetic Incremental Encoder Module can fit in tight spaces.
Safety
Pilz Canada offers PHSR service Pilz Automation Safety Canada is now offering customers the PreStart Health and Safety Review (PHSR) service, which it says will compliment the “whole host of services offered by Pilz that are designed to help customers implement the relevant standards and directives and develop an optimum safety strategy for entire plants.” In accordance with Section 7 of the Ontario regulation 851 for industrial establishments, prior to any worker being permitted to operate any machinery, equipment, or a process in a hazardous environment, the employer is responsible for ensuring that a thorough report is prepared that indicates that the equipment is safe. The PHSR report is required to review all of the relevant regulations pertaining to that particular type of equipment. The provided PHSR document includes: • Identification of applicable standards, regulations and industry best practices; • Statement of machine limits; • Examination of all hazards; • Risk estimation; • Recommended approach for bringing the machinery, equipment, or process into
compliance; • Details any additional testing necessary prior to operation; and • Pilz professional engineer’s seal affixed to the report. Innovation
Save your spot for Wago’s mobile tour Save the date to attend Wago’s 2016 Innovation in Automation Tour in a city near you. “With increasingly hectic work schedules, it’s sometimes a challenge to find time to attend industry trade shows. So let our 2016 Innovation in Automation Tour (IIAT) instead bring the trade show to you,” say company representatives. Two IIAT vehicles are currently crisscrossing North America to bring the company’s latest developments to existing and potential customers. “Whether you seek to minimize cabinet space, want to spec the latest Internet of Thingsready PLCs, or just want to find out what’s new, our IIAT vehicles are filled with new products, software demos, interactive pick-andplay displays and Wago-trained professionals ready to guide your experience,” say Wago officials. New for 2016: • e!COCKPIT software development environment for
Its bearing-less design allows the 30M to work at high speeds – yet it’s tolerant of shaft misalignment, thanks to an air gap up to twice the size of other encoders in its class. The magnetic sensor and optional IP69K seal mean it can go into your dirtiest, dustiest, wettest applications and keep going strong.
1.800.366.5412 www.encoder.com
6
Wago wheels: Two tour vehicles are now travelling across North America. May 2016 · MANUFACTURING AUTOMATION
@AutomationMag
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PHOTO: wago
Call EPC today and discover how the Model 30M can tackle your toughest applications.
automation tasks; • XTR extreme environment I/O with built-in protection for climatic influences, vibration, impacts and surge voltages; • Epsitron power supplies for a range of functions and applications; and more. Visit www.wago.us for a list of tour dates and stops. DIStRIButION
Oil and fuel filtration systems added to the Wajax portfolio Wajax, a Canadian industrial products distributor and service provider, has added Oil Filtration Systems to its filtration portfolio. Oil Filtration Systems manufactures a line of oil purification equipment that is designed to remove contamination (water, particulate, varnish, etc.) from a variety of fluids, including lube
oil, hydraulic oil, transformer oil and diesel fuel. Oil Filtration Systems, like Wajax, serves a range of markets, including power generation, mining, oil and gas, pulp and paper, and other industries. “Across all major industries, the need to keep lubrication and hydraulic oils absolutely clean and dry has never been greater,” says Clive King, business development manager for filtration at Wajax. “Removing contaminants from oil is a ‘best practice’ for the proper maintenance and reliability of rotating equipment, extending the life of critical components, minimizing downtime, and reducing overall maintenance costs. Oil Filtration Systems is in a unique position to provide a wide range of oil purification equipment and services to end users throughout Canada.” “Wajax was selected as the marketing partner for Oil
the new Ford Ranger that was launched last year. According to the automaker, the investment will create 1,200 new jobs at Ford South Africa and within the South African supplier network. “Our customers love the capability and utility offered by the allnew Ford Everest,” says Jim Farley, Ford executive vice president and president of Europe, Middle East and Africa. “By producing the Everest in South Africa, we will be able to make it more readily available, and in a greater variety of models, for customers throughout Sub-Saharan Africa. “The investment reaffirms the importance of these markets as part of our growth strategy across the Middle East and Africa,” Farley adds. “It further reinforces South Africa’s position as a strategic export base for Ford Motor Company.” The Silverton facility joins
Filtration Systems based on multiple factors: Wajax offers technical sales coverage for the entire country of Canada in the selected marketplaces that Oil Filtration Systems desired to participate, it has excellent service experience, and it has a long relationship with Oil Filtration Systems’ parent company, Clark-Reliance,” adds Doyle Gould, vice-president of sales, Clark-Reliance. INtERNAtIONAL SOutH AfRICA
ford’s Everest Suv operations to get uS$170 million upgrade Ford Motor Company is investing about US$170 million to expand operations at its Silverton Assembly Plant in Pretoria, South Africa, to produce the new Ford Everest, along with
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MANUFACTURING AUTOMATION · May 2016 MA_Omega_May.indd 1
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Automation upfront
The Silverton Assembly Plant boasting “state-of-the-art automation” will be equipped to produce 10,000 Everests annually.
“Digitalization will turn the world of today upside down. Processes, business model and entire sectors will either change or perish.”
Mexico DEAL MAKERS
Building capacity: The investment will create 1,200 new jobs at Ford South Africa and within the South African supplier network.
AutoAlliance Thailand in Rayong; Ford’s Chennai plant in India (where it is sold as the Endeavor) and the JMC Xiaolan Plant in Nanchang, China, as production hubs for the Everest. Initial production at Silverton of the Everest will commence in the third quarter of 2016. South African-produced models will be sold
locally and exported to markets across Sub-Saharan Africa. Part of this investment has been directed towards the production of the new Ranger, which is already running at maximum capacity at the Silverton Assembly Plant, with domestic sales and export demand at an “all-time high,” says the company.
PROGRAMMABLE INCREMENTAL ENCODERS
Harting has announced plans to start production in Silao, Mexico, where it will be manufacturing overmoulded cables and cable harnesses. “Harting can be found wherever our customers are,” says Dr. Frank Brode, senior vice-president New Technologies, Harting Technology, referring to the large production plants operated by the VW Group and the suppliers who have products manufactured in Mexico. “For all of Central and North America, we are focussing on the target markets: automation; energy; transportation; radio, stage and event technology; machine construction; medical technology; and infrastructure.” North America, in particular the U.S., is “very clearly” a future market for the Harting Technology Group, says company officials. “Driven by IT and software, the highly dynamic U.S. economy offers huge opportunities for Harting, as classic suppliers of solutions for machine and plant construction and integrated industry experts,” says Brode.
Norcan Fluid Power is Rexroth’s authorized distributor in Western Canada Norcan Fluid Power has been appointed Bosch Rexroth Canada’s authorized distributor for industrial and mobile hydraulics in Western Canada, including British Columbia, Alberta, Saskatchewan and Manitoba. The agreement aims to provide customers with greater access and choice for Bosch Rexroth’s hydraulic products and solutions to achieve specific application requirements, along with service, technical support, application expertise and local inventory, says the company. According to Bosch Rexroth, customers and industries will benefit from Norcan Fluid Power’s multi-branch footprint and “extensive industry experience and Western Canada presence.” Tom Light, president of Bosch Rexroth Canada, and Bill Dix, president and CEO for Norcan, say they are “very excited” about the opportunities for the two companies.
Find the Sensors that are Exactly Right for Your Application POSITAL’s outstanding range of mechanical configurations and programmable performance make it easy to get exactly what you need.
www.posital.com A done deal: The agreement aims to offer customers greater access and choice for Bosch Rexroth’s hydraulic products and solutions. 8
May 2016 · MANUFACTURING AUTOMATION
@AutomationMag
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PHOTOs:FORD MOTOR COMPANY. BOSCH REXROTH CANADA
Harting plant in Mexico to serve North America
MOVERS & SHAKERS Steve Prahalis has been appointed the director of Canadian operations for SME, an organization serving the manufacturing industry. Prahalis will assume responsibility for the growth, strategic direction and financial performance of SME’s Canadian business and develop new Canadian opportunities for all SME business units. In addition, he will assume leadership of SME Studios, a new program producing “one-ofa-kind customer initiatives and special projects.” Prahalis joined SME in 2003 and has been responsible for the introduction of several initiatives, including the creation and launch of imX - the Interactive Manufacturing Experience. Big Kaiser Precision Tooling is welcoming Pierre Bruyere to its rep network where he will manage distributor relationships and sales efforts with customers in Quebec, Newfoundland and Labrador, New Brunswick, Nova Scotia and Prince Edward Island. According to Big Kaiser, this position was strategically created to increase market exposure and support sales growth initiatives in Quebec and other areas of Eastern Canada outside of Ontario. Big Kaiser says Bruyere will be able to “better provide factory support to local customers at a moment’s notice,” especially those who prefer to communicate in their native French language. His career in the industry spans 25-plus years. His first 15 years were spent as a machinist, then he rose to foreman, and eventually became a buyer. For the last 10 years, he worked as a sales representative for a tooling distributor.
Vulcan Spring and Manufacturing Co., a designer and manufacturer of flat steel springs and related assemblies for diverse global markets, has hired Chuck Hallquist as a regional sales manager. In this role, Hallquist is responsible for sales in Western U.S., Canada, and select international regions for both its industrial and point of purchase markets. “His background, combined with his drive to assist our clients, will help Vulcan Spring continue our growth in the region,” said Don Jarvie, vice-president of sales and marketing.
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Wesco International has appointed Nelson Squires to serve as group vice president and general manager of its Canadian operations. Squires joins Wesco from Air Products and Chemicals in Allentown, Pa., where he served as vice president and general manager, North American Gases, and president of Air Products Canada. “Nelson brings a successful track record of building strong management teams in a diverse range of functions and in delivering sales and profitable growth,” said John Engel, Wesco chairman, president and CEO. “We are very excited to have him join Wesco to help us make the most of the substantial opportunities we believe are emerging in the Canadian market.” Aaron Cochran has been named product training manager at Wago, bringing with him a “wealth of experience in engineering and automation,” says the company. He says he sees a “lot of potential for Wago’s products in the marketplace.” He will be based in Germantown, Wisc. | MA
MANUFACTURING AUTOMATION · May 2016
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2015-12-10 12:54 PM
inDuStrY wAtCH
Paul Hogendoorn (paulh@getfreepoint.com) is co-founder of FreePoint Technologies, “Measure. Analyze. Share.” (Don’t forget to share!) Visit www.getfreepoint.com for more information.
By PAuL HOgENDOORN
Getting to the next generation
M
anufacturing in North America has fallen behind, and now many are paying for it. Yes, we’ve invested in innovation and yes, we’ve invested in training and yes, we pay better than average wages but still we are struggling to fill our vacant jobs and we struggle even more to attract and retain younger workers. We’ve let our on-floor factory jobs become stagnant, unexciting, unengaging and unattractive. This hasn’t just happened all of a sudden. It started a generation or two ago when we started teaching our kids that they wanted something other than a blue-collar job. We told them to stay in school to get a good career, like a teacher, a doctor, a lawyer, or anything in the information technology sector. That’s what was going on outside our plants that made new workers choose to stay away and what’s going on inside our plants that is making the problem worse — or perhaps it is more accurate to say it’s what is not going on inside our plants that is making new workers stay away. Our factory workplaces fail to recognize that times have indeed changed as far as the new working generation is concerned. Young people today aren’t motivated simply by money; lifestyle and interaction with others are very important to them, as is feedback and the belief their input matters. They don’t have the same delineation of life that previous generations may have had (i.e. “working life,” “family life,” and “social life”). And, they are not as content to do something seemingly meaningless all day long just because it is their job. They have an insatiable need for feedback. They grew up playing games where measurement was constant and feedback was immediate. They are not content to wait until the end of the month, or even the week, to be told if they’ve done a good job or enough work. In most workplaces, it’s just assumed that a sufficient standard was met — that was sufficient for other generations, but it isn’t for emerging generations. The other part of the problem is what is happening (or not happening) 10
@AutomationMag
There’s a lot more pizazz and wonder happening on our plant floors that we need to share with the younger people.
outside of our factories. I’m not suggesting that all the jobs we offer on the plant floor are meaningless and mundane, we have, however, certainly allowed that perception to perpetuate and we continue to do so. This was the topic of a recent London Region Manufacturing Council (LRMC) meeting, of which I am a member. It’s been a topic many times before. Over the last few years, the LRMC, in conjunction with the local EMC chapter, has arranged plant tour days for select high schools but this isn’t enough. It’s hard to get the high-school-aged kids interested. Here again, the perception works against us. To break that perception, we need to start even earlier — perhaps grade 7 or 8 — or maybe even earlier than that. A couple great ideas emerged from our conversations. One member’s company has sponsored local children’s sports teams for years with only one stipulation — the players, along with their parents, must take an organized tour through the company to learn what the company does. Another idea was “borrowed” from the
local home improvement big box outlet that I took my grandson to. Every month, it hosts an event for children between ages 5 and 10 to hammer a few nails into some pre-cut pieces of wood. The kids leave with not only a neat thing they built for themselves, they leave with a sense of satisfaction that comes with working with hand tools to build something — a simple thing almost entirely lost in recent generations. We can do the same thing as that retailing giant. Rather than shuffle high school kids through our factories, overwhelming them with our big machines and complicated processes, we should make simpler, more satisfying opportunities available, such as sticking two pieces of metal together (welding), stamp something out (to create a keepsake), bend something, or push a button and watch something small get machined before their eyes. There’s a lot more pizazz and wonder happening on our plant floors that we need to share with the younger people — and I mean the really younger people. By the time they get to high school, it could be too late to change the perception. | mA May 2016 · MANUFACTURING AUTOMATION
pHoto: CrEDit tk HErE
MANUFACTURING AUTOMATION · May 2016
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LEAN INSIGHTS BY Paul Siniak
Paul Siniak is the lean manager at Tree Island Steel. He holds a Black Belt in Lean and a Green Belt in Six Sigma. He received his training from David Koichi Chao of Lean Sensei International, and has travelled to Japan as part of the extensive training that Lean Sensei provides.
Bringing Lean to Tree Island Steel
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few years back, a new CEO took the helm at Tree Island Steel, a wire mill located in Richmond, B.C., with 360plus team members. He was rebuilding a company that had struggled through a recession and he had a vision — a vision to reposition Tree Island as the industry leader it was capable of becoming and to assemble a team to lead the company into the future. Dale MacLean refocused his finance, sales, procurement and scheduling departments to move in one direction and he has not changed course since. He and his executives have quarterly meetings with all staff and operations personnel to inform them of the state of the business while opening up the floor to comments and observations on what and where we need to improve. Lean is just one more tool in our company’s war chest that was embraced during the early stages of our turnaround strategy and is visibly supported by our CEO and senior management team. Tree Island has been in operation for more than 50 years and everyone knows you don’t achieve such a significant milestone without doing something right and operational excellence is the key. We still have a lot of same generation equipment and a lot of the same people — with a very proud culture. Lean has proven to be one of the right tools because it educates and reinforces the same message every day: reduce waste, standardize, create a “no blame environment,” and look at problems as opportunities! Lean education is a key which turns a lock that makes people think. As part of our employee induction program, I spend 45 minutes with every new employee on Lean 101 and we talk about our nine waste program:
I also train front line supervisors and other managers on Toyota’s 14 management principles. We do this weekly and I strongly suggest to anyone leading this type of training that you keep it light and as entertaining as possible but still communicate the message. Sometimes I provide examples using other types of products other than what we produce, like a bakery. If I hired five bakers to bake bread, I could get five different results unless I provided them all with a Standard Operating Procedure (SOP) that details the ingredients, measurements T - Transportation and temperatures. This illustration I - Inventory shows standardization and will give M - Motion and movement you the same results every time. No W - Waiting defects! O - Over-production Making your factory a visual workO - Over-processing place is very important. Don’t bury D - Defect your production numbers or downN - Not using your time in computers or on papers. Do employees’ input ing this results in situations like this, E - Energy (How big was your “Hey Bob, what happened yesterday? electric or water bill?) This is I notice your production was pretty a waste worth going after! low and had 20 per cent rejects?”
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Lean is just one more tool in our company’s war chest that was embraced during the early stages of our turnaround strategy and is visibly.
45
The number of minutes Siniak spends with a new employee on Lean 101 as part of the company’s employee induction program
Well, Bob had some problems and never saw a supervisor all shift so he just struggled through and the results came to light the next day. Our supervisors actively walk the shop floor and check production boards halfway through the shift giving them time to react to situations. We are not perfect and don’t have boards everywhere, but we are introducing more. It’s a journey, it’s not something that can be done overnight; support from above is essential. If I could offer advice on how to apply Lean, it would go something like this... don’t try to do too much all at once, go slow, be patient, but continually reinforce the same messages. Your team will slowly start to pick it up and run a little — reward them when you see it. Support them. Try to make small improvements every day. Celebrate your small successes, even if you just talk about it. Get out from behind your desk and practice Genchi Genbutsu, which is Japanese for Go and see for yourself. | MA May 2016 · MANUFACTURING AUTOMATION
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technology from the control cabinet directly into your machines. That saves space, sharply reduces the wiring costs up to 90% and optimizes your energy balance. Thanks to the integrated motion logic, complex motion sequences can be achieved right at the drive level. The IndraDrive Mi is a fully-equipped automation system, with a wide variety of certified safety functions and multi-protocol interface. Put the intelligence of this system to use in your modular machine concepts as you start your journey into Industry 4.0.
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AutomationMag.com 13
MACHINE SAFETY
Gabriel Khon is the product manager - I/O & Network at Phoenix Contact in Milton, Ont. Born in 1980 in Buenos Aires, Argentina, he earned a degree in electrical engineering from Michigan State University and a master’s degree in marketing from Universidad de San Andrés. He has worked with Phoenix Contact for 10 years.
By Gabriel Khon
Automation safety over a non-safe industrial network
M
achine and plant engineers must observe functional safety standards, such as ANSI B11.19, EN ISO 13849 and IEC 61508, when they are constructing their equipment. Safety in today’s market has come a long way from the simple, single-function safety relays of the past. Now engineers are left to question what is best for the efficient implementation of the prevailing safety requirements in their process: programmable, network-enabled safety controllers or spatially limited, configurable safety relays?
Configurable safety relays
Configurable safety relays are similar to hardwired safety relays, but contain the logical processing power required to configure multiple safety sensors using a single device. The logic configuration is typically done using a screwdriver on a selector dial, a simple onboard configuration screen or basic software configuration. Technological developments also allow these devices to report status back to a master PLC via an RJ45 or fieldbus module connection. Easy configuration and communication with logical controllers have greatly contributed to the growth of configurable safety relays in hazardous applications. Customers can now have a customizable safety solution that requires less wiring time and 14
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can be integrated without special training or advanced classes in programming languages. This can reduce logistics costs, because one part number can be stocked to handle all safety applications for all machines or processes. Even the safety program can be saved and transferred to replacement devices for easy repair. But even with all these advantages, configurable safety relays still fall short of safety PLCs in distributed safety applications because they cannot communicate over a safe network. In a distributed safety application, safety inputs and outputs are needed throughout the machine. To accommodate systems like this, there are two options: 1. The installer can run safe I/O wiring across long distances through the machine back to the configurable safety relay, or 2. Each remote safety application can use separate configurable safety relays. This will lead to increased wiring and setup times, as well as inefficient use of configurable safety relay I/Os. Because of these shortfalls, the only efficient way to connect a distributed safety system is to use a safe PLC and its associated safety protocol. Programmable safe PLCs
While configurable safety relays replace
simple relay solutions at moderate safety I/O counts, the programmable fail-safe PLC replaces the configurable safety relay at higher safe I/O counts. A programmable fail-safe PLC also has significantly more processing power and safety functionality. These specialized PLCs offer better integration, programming resources and a larger amount of usable safety signals for functions like safe motion and robot control. The fail-safe PLC uses a standardized safety network to communicate to safe I/Os on the network. This allows direct control and monitoring of hazards. Programmable fail-safe PLCs offer increased computing power and functionality, but they also require certain preconditions that can present challenges in designing and certifying a system. The first and most important precondition is that the PLC being used has a “fail-safe” version. Though safety technology has grown significantly over the past decade, some PLCs do not have a fail-safe version or add-on processor widely available yet. Machine builders also need to consider that specific customer control requirements may vary region to region, and different PLCs may be specified altogether. Designing systems for multiple PLCs can be time-consuming and expensive, especially considering change control within each May 2016 · MANUFACTURING AUTOMATION
system. If a change is made to the overall design, then each individual safety design must also reflect that change. This could lead to multiple versions of multiple controls systems being in the field at the same time. If you are considering different solutions for different regions, then it is also worthwhile to consider the safety network and communication protocol each solution requires. A system that uses both PROFIBUS and EtherNet/IP will require communication bus couplers, cabling and safety I/O for each of those protocols. This increases the need for logistical control and stocking for these parts. BRIDgINg SAfELy: tHE DIStRIButED CONfIguRABLE SAfEty RELAy
Today, however, a different approach to distributed safety in an automated industrial network is available. New technology makes it possible to eliminate the strong dependencies between the fail-safe PLC and the safety protocol by achieving two conditions: • The safe logic must not be an integrated part of central PLC, but rather decentralized and separated from the standard PLC as in
distributed sensors and write safety outputs to actuators. To reach these conditions, a special logic module can act as a standard network device. This logic module is distributed in the network and handles all safety logic processing on-site. Processing this safety data is done via internally redundant processors, much like a configurable safety relay can process its own safety program. Unlike a configurable safety relay, the distributed logic module can communicate to its associated safe input and safe output signals via a special protocol on the standard network. This safety protocol does not contain any network or PLC-specific dependencies, but operates on the “black channel” principle, like that of a PROFIsafe system. The entire network, including the standard PLC and all infrastructure components located in the data path of the safety signals, is part of the black channel. Safety failure detection is only implemented at the end points of communication, which can detect failures within the case of a configurable safety relay. • The safe logic must communicate via special the black channel with a residual failure protocol over an already installed standard probability for the highest safety levels (PL network to read safety input signals from e, Cat 4, SIL 3). | mA
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2016-03-15 11:37 AM
CENTRE STAGE
MA: How would you describe your experience as the managing director of Trumpf Canada? SF: Besides the fact that it’s hard to believe it has already been a year, the last 12 months were really challenging at times but were mainly full of new opportunities. We, as a company, continuously try to improve and give our customers the best possible customer service experience, and within the past year, we started different initiatives, like in our spare parts area or service department. By using feedback from our customers, we have introduced new processes or technologies that we hope will make their life easier. It [has been] really exciting and satisfying. Trumpf Canada is a relatively small subsidiary with a little more than 30 employees. As a comparison when I worked in the U.S., we had about 700 and at the German headquarters when I started with Trumpf, we already had more than 2,000 people working there at that time. This results in everybody [here] having to wear several different hats and being true ‘all rounders.’ MA: Your appointment was announced at the grand opening of the relocated Mississauga, Ont., office last April. What response has the new facility gotten so far? SF: We’re really happy that we can permanently demonstrate our equipment with our new showroom, this is something we couldn’t do before. It has been a big success, especially for customers within a two- to three-hour driving distance. It’s much easier for customers to come in for a one-day trip to [check out] and test 16
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our machines, instead of flying to [our showrooms in] Connecticut or Germany. It brings our customers much closer to us and us closer to them. A lot of our customers, I would say around 80 per cent, are small job shop companies and a lot of times when they invest in equipment, it is the biggest investment they’ve ever made in their life. There’s a big trust factor involved and the relationship between the customer and the supplier is very important. Having the possibility to just quickly come in and spend time [face to face] strengthens this relationship. MA: Before taking on this position, you worked in Germany and the United States. What differences have you noticed between the various manufacturing industries? SF: From my experience, it’s always very helpful to see different organizations or countries as it gives you the opportunity to benchmark and improve your own organization. The trend towards automated systems started early in Germany before starting here in Canada
or North America. When you look at German manufacturing plants, you see shops that are using load-unload systems and have machines completely attached to storage systems that run 24/7 unmanned and it seems like a lot of smaller [operations] here are slowly [incorporating] automation and that has been quite interesting to see. Something I really like about Germany — and I think this is a part of its success — are the apprenticeship programs where students get trained for three or four years; they work in factories but about 50 per cent of their time is spent in schools. They are getting prepared to become experts in their particular field. With these programs, the students can immediately work in the factories [after completion] and are quite efficient, and as a result, the supply of skilled workers on the production floor is guaranteed. This is something that we see all over the place back in Germany and here in Canada, some of the bigger companies are now starting systems like that. It’s an approach that I think is very successful.
MA: How would you rank Canada’s strength in manufacturing on a global level? SF: We know that the Canadian manufacturing sector has quite an impact on Canada’s overall prosperity but it really does not play a significant role on the global stage. Canada needs to follow the global trends we see at the moment. We [need] to raise the bar by investing in technology and productive capital equipment to increase [our] efficiency and productivity — this is a critical factor for longterm economic success. The big topic for the next few years is the division and execution of the smart factory, and Industry 4.0 is a big part of that. We require self-regulating and self-learning systems for all processes in which high productive and high-quality machines produce parts automatically. With the Internet of Things, systems will communicate and cooperate with each other in real time and will even make decisions by themselves, and machines will be able to predict component failures in advance and can ask for maintenance without any kind of human interference. These are global trends that will bring new opportunities to Canadian manufacturing and will allow us to gain greater significance on an international scale. I think our biggest challenge is staying competitive globally, but I’ve been to many presentations and events here on [the smart factory] and based on discussions with our customers here, there is a lot of interest in this topic, so I’m positive [Canada] will not fall behind in this respect. | MA Watch our video from the 2015 grand opening of Trumpf Canada’s relocated office: bit.ly/1qWhT4A.
May 2016 · MANUFACTURING AUTOMATION
PHOTO: A. DALTON
It has been one year since Stefan Fickenscher took on the role as Trumpf Canada managing director — Manufacturing AUTOMATION sat down with him to find out how the past year has gone.
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Cover story
Enjoying the benefits of ramped-up automation Automating specialized armored vehicles has paid big dividends for Inkas By Treena Hein
“The synergies of having metal fabrication in-house are priceless, resulting in a much happier and more integrated workforce.” Its markets span from Africa and South America to the Middle East and Eastern Europe. Most sales are made to government agencies or law enforcement; the U.S. military is a big customer. Other customers include private security firms, banks or celebrities — and a few wealthy folks who just want a really cool and secure vehicle to drive around in. It was back in 2012 that Inkas made the 18
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decision to do its own metal fabrication, creating a new company division called Metaline. With this in place, metal cutting, bending and all precision machining for the other divisions are finished in-house (Inkas also makes safes). Metaline has also increased overall production capacity by more than 30 per cent and enabled the company to accept custom outside jobs, says COO David Fraser, adding that Inkas offers the only high-end precision machining in the area and busy ongoing orders have meant a second shift has been added, with plans to add a third shift this year (24-hour manufacturing). We spoke to Fraser about how the aspects of the division have automated and streamlined the company’s manufacturing processes. “Because of efficiencies and economies with the automation, we are much faster,” says Fraser. “Development time and production time have been reduced significantly and we are able to do last-minute jobs right away. The synergies of having metal fabrication in-house are priceless, resulting in a much happier and more integrated workforce. The production crews can talk to those bending and the benders can see where it’s going. The engineers can talk to the manufacturing end and see how their designs are implemented, improving the overall process.” Communication, notes Fraser, is also much faster. “The dialogue between the engineers and the programmer in charge of the work order is ongoing now,” he says. “The engineers can see the product being cut or bent, and can have that conversation with the bending or laser operator right on the floor.
L to R: Olexiy Miroshnychenko, an automotive painter; David Fraser, chief operating officer; and Dmitrii Rozenberg, welder, armoring division.
That happens everyday and it’s made us so much stronger.” Fraser says he can’t see Inkas without this increased capability. “We would not be able to produce 35 vehicles a month or create new models. It would be very, very expensive and much, much more time-consuming to the point of not being feasible. We have to have new models every year.” Before they made the decision, Fraser and other executives looked carefully at capital costs. He says that from the perspective of being able to access outside jobs, going ahead with bringing fabrication in-house made sense. “We knew there was a great market out there with very lucrative work,” he says. “There were and are lots of small May 2016 · MANUFACTURING AUTOMATION
PHOTO: John Packman
T
oronto, Ont.-based Inkas Armored Vehicle Manufacturing is now reaping the benefits of automating and streamlining its manufacturing process with the creation of an inhouse metal fabrication division. Inkas produces specialized armored vehicles from luxury sedans, trucks, SUVs, special purpose military vehicles, cash-in-transit vehicles and even four-wheel-drive tractor trailer platforms. “Stretching” limousines and SUVs into longer versions while adding executive interiors and luxury options is also a big part of the business, with hearse manufacturing a small division in itself. Established in 1996, the company is now the global designer and producer of specialized armored vehicles, with sales offices in several countries.
fabricators out there but we have the high-end equipment and a workforce that can provide quick, high-quality turnaround. There were no surprises with the demand. We had done our homework and we were well-prepared for the orders.” Metaline takes up about a third of Inkas’s 170,000 ft2 plant footage. As a result, the manufacturing space has been squeezed a bit, he says, adding that no one minds as “quality and efficiency is so much better.” ROI was achieved in 2015 (within three years) and became faster after the second shift was added. A few MANUFACTURING AUTOMATION · May 2016
pieces of equipment, such as a bigger metal-bender, were also added over time.
From start to finish The production process can be broken down into three main stages: preparatory, armoring and finalization. The production process starts with engineering and design, where the engineering team designs all materials required for armoring using 3D software. After that, the design project is submitted for precision laser and cutting. Then, the vehicle is stripped down to its frame so the re-building
50
The average number of armored vehicles Inkas produces each month
can begin. Armoring and other modifications add 20 to 25 per cent to the original vehicle weight, so upgrades to suspension and braking are a must. Door hinges are also reinforced and ballistic glass is added. Options include run-flat tires, protection for fuel systems and electronics, escape hatches, sirens, bomb-jamming devices, water cannons, pop-up gun turrets, sniper platforms, gun ports, spotlights and more. Customers can also get “night mode,” where no vehicle light is visible. All Inkas products are GPSequipped and certain functions, such as door-locking and engine turn-off, AutomationMag.com 19
Cover story
can be done remotely. The firm has also developed the Inkas Overlap System, which is built into vehicle doorframes to protect passengers from bullets. When fully armored, the vehicle is upholstered
“Having things done externally was very slow. Lead times in general have been cut from nine days to two or three days. Our fiber laser cuts parts in seconds, not minutes — about 650 inches per minute.” with the customer’s finishing requirements. And in case you were wondering, a finished Inkas vehicle is usually double 20
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the sticker price of the original. Prototypes are built if the client has the budget or if the design is likely to be used again. The latter applies to the Inkas Huron, a 16-passenger tactical attack and defence police/military personnel carrier. The team settled on a four-wheel-drive tractor trailer as the basic platform, adding extreme heat and noise insulation as well as floor-blast protection verified through third-party testing to defend against the equivalent of a light anti-personnel mine. The Huron’s design process took about three months (prototyped around the same time Metaline was being started up), and Metaline manager Denis Kraus estimates that today, the timeline would be six weeks or less. “It’s the control over all the processes that speeds things up so much,” he
3
The number of years it took Inkas to achieve ROI with Metaline, its own metal fabrication divison
notes. “Having things done externally was very slow. Lead times in general have been cut from nine days to two or three days. Our fiber laser cuts parts in seconds, not minutes — about 650 inches per minute. And the programmable break presses are also a significant time-saver, with less waste, less operator error.” Over the years, the company has received some unusual requests, such as an armored convertible, a rocket-launching turret and the ability to shoot flames from the back of a car, but Philip Daskal, vice-president of sales, says they can usually convince clients to consider other options. With regards to the future, he thinks more smart vehicle functions, such as remote operation, are coming. “The depth and breadth of sensors is also increasing,” he says, “and we’ll likely be building the capacity to launch unmanned aerial vehicles from the trunk in the near future.” With the streamlined efficiency of Metaline, anything is possible, he notes. | MA Treena Hein (treenahein.wordpress.com) is an award-winning Ontario freelance science and tech writer. May 2016 · MANUFACTURING AUTOMATION
PHOTOs: JOHN PACKMAN
Members of the Inkas team are hard at work in the various stages of the armoring process: door armoring (above) and upholstery (left).
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HMI & Operator interface
HMI checklist Top factors and features to consider when shopping for an HMI solution By Mary Del Ciancio
I
n today’s manufacturing landscape, many companies are challenged to do more with less, while meeting the growing demands of their customers and facing increased global competition. It’s this need for greater productivity and efficiencies that is fuelling the demand for industrial automation, and with that, the demand for human machine interface (HMI) solutions — a combination of hardware and software that allows users to connect, monitor and control increasingly complex industrial automation equipment, and visualize the data coming from these machines.
HMI solutions are no longer just push-button replacers — they can be a troubleshooting tool, a data logger, a device to remotely control and access the machine, and a communications interface between multiple devices. HMI solutions have evolved in recent years, and offer more capabilities than ever before. They’re no longer just push-button replacers. Today’s HMIs can be so much more — a troubleshooting tool, a data logger, a device to remotely control and access the machine, and a communications interface between multiple devices. As more options and features become available, the selection process becomes increasingly challenging. And whether the customer is an original equipment manufacturer designing and selling machinery, or an end-user working with the machine, there are certain factors to consider to help determine the appropriate solution that will best meet your needs, or the needs of your customers, now and in the future. With that in mind, Manufacturing AUTOMATION asked HMI experts from Idec Corporation, Unitronics, B&R Industrial Automation and Red Lion Controls about the major factors to consider when selecting an HMI solution, and which features are most 22
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important for manufacturers today. Based on their input, we developed this checklist.
Key considerations The environment: Consider the environment that the HMI will be operating in — whether it’s outside in below freezing temperatures, in a refrigerated environment indoors, or situated next to a boiler. Depending on the environment, rugged packaging that can withstand vibration, extreme temperatures and more may be essential. Most HMI providers have a wide selection of both indoor- and outdoor-rated devices available with broad temperature ranges. Communication needs: An HMI panel is essentially a communication centre that acts as a gateway to your control system. As such, it must provide connectivity and support a range of protocols to bridge the communication between the control application and enterprise resource planning (ERP), explains Benny Magrafta, R&D manager, PLC + HMI development (Software) with Unitronics. Paul Bunnell, director of automation products with Red Lion Controls, says it’s important to consider which communication networks the HMI needs to talk to. Some manufacturers may have “disparate-type
products” on their plant floor that mix old and new technology. He says users may want to consider an HMI solution that can talk several protocols or that offers protocol conversion for added versatility. Screen size: Depending on the complexity of the machine or process that is being controlled, screen size can be a big factor, says Bunnell. These days, HMIs are offered with a variety of screen sizes. A larger size can show more information and more complex data, but it comes at a higher price point. Non-complex applications may only need a small screen. HMI provider and support: When it comes to selecting an HMI provider, Magrafta recommends choosing one “with a proven track record — one who can provide you with triedand-true technology, while staying current with worthwhile technological trends.” And, says Bunnell, make sure the HMI manufacturer supports its older products. “If I’m upgrading to a newer technology, is it a form function fit? Will the same software be able to be reused or converted? Things like that are very important,” he explains. Derrick Stacey, a solutions engineer with B&R Industrial Automation, recommends selecting a provider with products that are May 2016 · MANUFACTURING AUTOMATION
“backwards compatible.” “Make sure things are very backwards compatible, so that when they come out eventually with HTML6, 7, 8, anything done in HTML5 will still be supported,” he says. “The more open it is, the more established architecture that you use, then you won’t have to worry about a ‘phasing out’ situation.” Britt Davis, automation and safety sales manager with Idec Corporation, says endusers should ask HMI providers what kind of support they offer. Ask if free technical support is available, as well as free local support — not just via an 800 number or a website.
Must-have features Web server capability and remote access: An HMI with a built-in web server is a must, says Bunnell, because it gives users a remote view of what the HMI is looking at. “I can be anywhere in the world and remotely connect and then see what’s going on in an application,” he says. Remote access allows users to monitor and troubleshoot wherever they are. And it’s a crucial capability in today’s mobile world — one that will help minimize, and ideally avoid, system downtime. It also allows users to remotely modify or update the HMI application. Web-based tools also offer more design options. With the right software, you can design web pages without knowing any HTML or Java, and access them via any Internet browser. Many of today’s HMI panels support HTML5 and .css, and this is a must, Magrafta says. Data management: For many companies, Bunnell says, it’s important to have the capability to capture data, as well as date and time stamp it for archive purposes, so that they can go back and look at what went on at a particular point in time. HMIs should have data management tools that enable runtime data to be logged, manipulated and sent as reports via email and ftp, says Magrafta. Display backlight: Davis says to pay close attention to the type of display backlight being used, as well as the backlight life rating and the brightness of the overall display. “An HMI that uses an LED backlight with a high backlight life rating and a bright display will look better, for a longer period of time, than one that doesn’t,” he notes. Multimedia support: There is a trend to include video and audio in HMI applications. This feature is very effective in guiding machine operators through troubleshooting, setup and more, says Magrafta. PDF support
is also key, as it enables an operator to access complete operating manuals and read them on the HMI screen, he adds. User access control: Not all users are meant to have access to every detail on an HMI about a machine or process. User access control, and features like multiple password protection, offer the ability to protect the application from unauthorized entry. Alarms: An HMI with the ability to notify managers of developing situations—via alarms, emails or text messages before they turn critical —is a huge benefit because it can help operators avoid downtime by informing them of potential problems and provide them with instructions on how to prevent issues, says Magrafta. Embedded diagnostic apps are also important because they can easily run updates, diagnose issues and capture data, he adds. Ease of use: A well-designed HMI solution makes it easier for the user to interact with the machine. And, since many advancements in HMI technology have been driven by consumer products, more and more solutions are beginning to behave like consumer devices. “What we’ve seen in talking with customers is the faster they can get an operator to understand and get comfortable with the screens of their HMI, then it requires less training, there’s less user fatigue,” says Stacey. Ease of use extends to application programming. Easy, fast HMI application programming is at the top of the list for Magrafta. Expandability: Bunnell thinks that every HMI should have multiple connections to it, such as Ethernet and serial ports. He encourages end-users to consider the future when selecting an HMI and look for something that offers expandability.
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Making a list, checking it twice Indeed, there are many factors and features to consider when selecting an HMI solution, but the most important point to remember during the process is what the end goal is — maximum productivity. “It’s critical to have machinery operating at maximum efficiency,” explains Bunnell. “And getting information out of that is the best way for companies to manage their assets.” HMI solutions — and their increasingly impressive capabilities — are a critical tool to help manufacturers achieve their productivity goals. | MA Mary Del Ciancio is a Stouffville, Ont.-based business writer, and a former editor of Manufacturing AUTOMATION.
MANUFACTURING AUTOMATION · May 2016
AutomationMag.com 23 MA_Eplan_May.indd 1
2016-04-12 1:51 PM
mOtORS AND DRIvES
SYSTEMATIC SELECTION An overview of the most popular rotary motion technologies By DAvID R. BICKERt
w
The compact ring drive (CRD) system comes complete with a precision grade bearing and drive mechanism in a sealed housing.
Belt drives Belt-driven rotary tables generally offer the advantages of high speed and low cost in rotary positioning applications. Belts are typically made of fiber-reinforced elastomer and contain teeth that interface with rotor pulleys to efficiently transfer torque and prevent slipping. Typical belt-driven tables offer speeds up to 1,000 rpm, continuous torque to 6.6 N-m and resolution down to 0.16 arc-second using ring encoders. Additional advantages of belt-driven systems include the fact that they generate relatively little noise and require relatively little maintenance. Due to the potential for elongation of the belt, positioning 24
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300 rpms - the speed that a precision ring drive is capable of achieving up to
accuracy of belt drives is often inferior to other alternatives, such as planetary gearheads or precision ring drives. In summary, belt drives are a good choice for applications that require high speed and low cost, however, offer relatively poor life and limited load capacity, accuracy and rigidity.
Cam indexers Cam indexers have been used in rotary positioning applications for many years and are frequently used in dial machines, conveyors and linkages. There are two types of cam indexers. The most common is the fixed index cam indexer, which does not use a servo motor. With fixed index cam indexing, a mathematical motion curve is machined into the cam to provide accurate positioning to a discrete number of defined positions. During rotation of the cam indexer, maximum displacement velocity usually occurs around the midpoint of the index cycle. Any fluctuation in cam speed tends to generate increased output torque at the high displacement portion of the cycle. These torque fluctuations sometimes generate irregular rotary motion during indexing, as well as audible noises when the indexer approaches a station. These problems can be avoided by maintaining shaft speed within a very narrow range. Fixed index cam
indexers provide high-precision positioning at a reasonable cost for applications that will always index to the same angle and do not require high acceleration. Fully programmable cam indexers combine a servo motor with a cam-driven index drive. This type of cam indexer is advantageous when a flexible motion pattern is required, such as when two different products that require different indexing patterns are run on the same machine. A fully programmable cam indexer is also beneficial for applications where extremely fast positioning is required, followed by a long dwell period.
Planetary gearheads Planetary gearheads are frequently used on motion control applications that require a high torque to volume ratio. Planetary gearheads utilize an arrangement in which one or several planet gears rotate around a pinion or sun gear. The planet gears rotate within an internal gear that is most often cut into the internal diameter of the gearhead. The planetary gear decreases the reflected load inertia at the motor shaft by the inverse of the square of the gearhead ratio, which increases the control system responsiveness and generally provides more consistent and accurate motion response. The planetary gearhead offers the advantage of a wide range of May 2016 ¡ MANUFACTURING AUTOMATION
pHotoS: nEXEn Group
hen the ability to provide accurate rotary motion is critical in a wide range of applications in the automation equipment, medical device, machine tool, energy, welding, robotics, automotive, aerospace, semiconductor and heavy equipment industries along with many others. Some of the key rotary motion technologies available to address these applications include belt drives, cam indexers, planetary gearheads, direct drives and precision ring drives. It’s important to look carefully at the pluses and minuses of each of these technologies in order to ensure that you select the approach that provides the right mix of accuracy, economy, durability, speed, noise, etc., for each specific application. A systematic selection and application process can help ensure that the rotary motion technology that is selected meets all requirements of the application while maximizing the performance and minimizing the cost of this critical component.
Selecting the right technology can improve performance, ensure long life and reduce the overall cost of the assembly. gear ratios which, in many applications, will make it possible to operate both the motor and the application at their ideal speed. Single-stage planetary gearheads typically provide ratios from 3:1 to 10:1. Helical gearing improves the performance of a planetary gearhead over spur gears by increasing the contact load line. The potential drawbacks of planetary gearheads include their relatively high cost and the fact that they contain backlash and can be damaged by shock loads.
Direct drive A direct drive rotary motor is typically a large diameter permanent magnet servo motor. The unique characteristic of direct drive rotary positioning systems is that the motor is connected directly to the load eliminating all mechanical transmission components. Rotary positioning systems built around direct drive rotary motors are wide used in the factory automation, medical equipment and energy industries. Direct drive systems generate energy savings by operating at high levels of efficiency because the elimination of the power transmission system provides a substantial reduction in friction. Direct drive systems also have fewer components, which often reduces maintenance requirements and provides quieter operation because there
are few parts that can vibrate. The elimination of the gear train also reduces backlash and compliance. Sometimes a direct drive system is combined with an encoder mounted on the rotary table to provide precision positional feedback and a high stiffness bearing to improve positional accuracy and repeatability, however, this approach is quite expensive relative to other technologies discussed here. While direct drive motors provide high levels of performance and efficiency, they are limited by low load capacity, high cost and relatively low accuracy without costly ring encoders.
Roller pinion systems The precision ring drive is a somewhat new type of rotary positioning system featuring a unique roller pinion/toothed rack combination that delivers high accuracy positioning with zero backlash and virtually eliminates cumulative error. Precision ring drives at first glance look similar to ring and pinion sets but, instead of spur gear teeth, bearings supported rollers engage the ring teeth. The rollers engage a tooth profile designed to match the pinion’s path, providing friction-free meshing that allows the pinion to be pre-loaded into the ring, eliminating mechanical clearance. The rollers approach the tooth face on a tangent path An application illustration of headstock welding.
An application illustration of a CRD rotator robotic arm.
and then smoothly roll down the face. Each tooth is precisely measured relative to the first, eradicating cumulative error and maintaining high positional accuracy. The resulting smooth rolling friction provides 99-percent efficient rotary motion. Due to the smooth way the rollers engage the rack teeth, the new approach generates very low noise and vibration. The system is whisper quiet at low speeds and produces less than 75 db noise at full speed. Drives are offered with ratios ranging from 64:1 to 220:1. Peak torque goes from 563 to 1,936 Nm. Accuracy ranges from ±11 to ±35 arc-sec, with repeatability of ±4.2 to ±1.2 arc sec. Unlike traditional cam-drive systems, the precision ring drive can start and stop at any incremental position. Users can change the motion profile simply by loading a new servo drive program. The roller pinion system driving the precision ring drive also allows the application of maximum acceleration or deceleration at any point without risking damage. The precision ring drive is capable of speeds up to 300 rpm and can handle peak torque inputs at any time, resulting in index speeds up to two times faster than other types of positioning systems. A given size product in a premium model can support a maximum dynamic load
(N) of 1,000. The drive mounts on a table supported by cross-roller bearings rated for 1,575-kN loads. The roller pinion system requires little maintenance. The pinion consists of 10 or 12 needle-bearing supported rollers that are sealed and lubricated for life. The ring is lubricated with a high performance light grease at installation and then every six months or 2 million pinion revolutions; no messy oil baths are required. Pinion life is rated at 60 million revolutions and the pinion gear can usually be replaced numerous times before the ring gear needs replacement. The ring drive has a large open centre that allows users to easily mount equipment and cabling in the centre of the rotating plate.
Conclusion Rotary motion technologies, such as belt drives, cam indexers, planetary gearheads, direct drive systems and roller pinion systems each offer their own unique mix of advantages and disadvantages. In order to apply the correct type of rotary motion technology in a particular application, the design engineer should carefully consider the specific capabilities of each alternative. Selecting the right technology can improve performance, ensure long life and reduce the overall cost of the assembly. | mA
David R. Bickert, regional sales manager for Nexen Group, has more than 24 years of work experience in automation and motion control. He has a bachelor of science (B.Sc.) degree in mechanical engineering technology from Penn State University and an M.B.A. from Fontbonne University. Bickert has worked at Nexen Group for more than 13 years. MANUFACTURING AUTOMATION · May 2016
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Cost control
Finding value How a stronger employee-customer connection will improve productivity By Shawn Casemore
I
n today’s fast-paced, technology-centric workplace, CEOs, executives and managers struggle to find ways to increase and sustain high levels of productivity within their teams. It would seem that despite all of the ways in which technology supports increasing individual and team productivity (big data, real-time information gathering, human error reduction), trends demonstrate productivity is actually declining, not increasing. Sound familiar? I could, for the sake of argument, suggest that the drivers behind productivity are not as simple as they seem. We can’t blame a lack of work ethic in millennials (although that’s what some executives I meet during talks across North America seem to think), nor can we make a blanket statement that technology has reduced our ability to think creatively (although there have been studies tied to this). The problem is unfortunately more complex and so, a simple straightforward answer would not do our discussion any justice. Instead, we need to see past the media hype and evangelists shouting their message from the rooftop, and revert back to some well-known, yet often, forgotten facts. People are individuals, and it should therefore go without saying that to capture their attention, interest, and commitment — which are the fundamentals on which individual and team productivity are built — we need to create a strong connection between our employees and the value their work brings. This is what I call the Employee-Customer connection. Let me give you an example of how this works, and more importantly, how you can apply this concept in your team or across your entire organization. Consider for a moment your finance department — a very vital role to a business of any size, yet what kind of metrics are used to motivate and manage the finance department? My guess is that your finance department today is expected to manage and reduce costs in some way, shape or form. Considering this, would you say that reducing or managing costs is always in the best interest of the customer? If you ask 26
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anyone in sales, the answer would be a resounding No! — yet finance works, often tirelessly, to find ways to keep costs in check that can in turn hamper customer value. Turn the tables for a moment. What if
More value to the customer is the desired outcome of higher productivity. finance connected their work — specifically their actions, response times, oversight activities and the like — with adding value to the customer? Would this drive a more positive and productive approach to their job? The answer is yes. Anytime you can take someone and connect their activities with responding to and supporting a specific customer, their interest, attention and commitment will increase. I’ve studied this employee-customer connection for more than a decade myself, and have found time and time again a direct correlation between productivity and the extent to which an employee connects their activities with a customer’s needs. You see, productivity is not a measure of output (how many invoices processed in an hour or how many parts produced in a day), but a measure of value (the quality of products produced, the accuracy and timeliness of invoices sent to customers). Value is measured by the customer, so if we desire higher levels of productivity from our employees, we need to give them a reason to produce more value, and the only way to do this is to let them see, connect with, and understand who
they serve. More value to the customer is the desired outcome of higher productivity. So what can you do? To be honest, there are literally dozens of ideas I could share, but here are five that I think are the most crucial. 1. Help employees connect their activities and responsibilities with end-customer needs. How do they contribute and what value does this bring to the customer? 2. Remove silos and allow internal departments to work together, dare I say collaborate, on projects that impacts the customer. 3. Prompt, listen for, and quickly act on barriers that employees identify as impacting their ability to service the customer. 4. Have executives connect directly with front line employees to understand what might add more value to the customer — don’t rely on managers to escalate issues that may not be a priority to them. 5. Make it a priority to break down barriers; treat employee suggestions and concerns as a priority. It’s time we stop attempting to place blame for diminishing employee productivity, and start looking for ways to add more value to our customers through our employees. If you take this approach, I think you’ll find employee interest, commitment and attention will increase and lead to higher productivity and morale, and stronger customer relationship. | MA Shawn Casemore is the president and founder of Casemore and Co Inc., a management consultancy helping business owners and executives improve the performance and profitability of their business through their people. May 2016 · MANUFACTURING AUTOMATION
NEW PRODUCTS WIRE & CABLE
Sensor cables AutomationDirect now offers IP69K-rated M8 sensor cables available in lengths ranging from 2 to 10 meters. Available with axial and right-angle M8 quick disconnects with open leads and 316L stainless steel coupling nuts, the IP69K rating makes these cables suitable for food and beverage-rated sensors, says AutomationDirect. The cables are fitted with a “rugged premium grade” PVC outer jacket, it says, to withstand high pressure and high temperature washdown applications. Meanwhile, patch cables with quick-disconnect plugs on each end are also available in lengths ranging from 0.6 to 5 meters. The sensor cables are UL and CSA approved and REACH compliant. www.automationdirect.com
PROCESS CONTROL contacts are modular and assembled together to provide crimp-, screw- and springclamp termination technology. The hoods and housings are mainly made of die-casted aluminium or thermoplastic, “robustly structured to provide mechanical and environmental protection for the connector,” it says. www.te.com
Rectangular heavy duty connectors TE Connectivity (TE) has launched a range of rectangular heavy duty connectors (HDC), suitable for a range of applications in harsh environments within machinery, robotics, railway, wind energy and conventional energy generation and distribution. The
HDC product range utilizes a modular design, which it says enables customers to realize a structured approach to install equipment “conveniently and efficiently.” The products consist of three key elements: inserts, contacts and hoods and housings. The inserts and MANUFACTURING AUTOMATION · May 2016
Process controller for distributed oil, gas assets
Honeywell Process Solutions (HPS) says its RTU2020 process controller will help operating
companies in oil and gas, mining and other process industries manage remote automation and control applications without the need to send personnel to the field to troubleshoot. The unit offers visibility into the utilization of distributed assets, promising to cut equipment monitoring and diagnostic time from hours to minutes. www.honeywellnow.com
Building a high-precision actuator is easy!
Simply couple any servomotor to one of our precision Quick Connect™ gearheads! • • • • • • •
Complete line of gearheads now available Harmonic Drive® or Harmonic Planetary® gearheads Zero backlash and low backlash versions Ratios: 3:1 - 160:1 Peak Torque: 3.9 N•m - 3940 N•m Sizes: 40mm - 230mm Output Configurations: Hollow Shaft, Flange, Keyed Shaft
TM
Harmonic Drive LLC 247 Lynnfield Street Peabody, MA 01960 800-921-3332 www.HarmonicDrive.net
Electromate Industrial 6221 Highway 7, Unit #15 Vaughan, Ontario, Canada L4H 0K8 (877) SERVO98 (737-8698) www.electromate.com
Harmonic Drive® and Harmonic Planetary® are registered trademarks and Quick Connect is a trademark of Harmonic Drive LLC.
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NEW PRODUCTS power supplies
machine safety 1500W power supply
S8VK-T power supplies Omron Automation and Safety says its 3-phase S8VK-T switching power supply offers “robust design and construction that withstands harsh environments and provides stable operation over a wide-operating temperature range.” According to the company, the design takes up less panel space than other 3-phase power supplies and delivers 90 per cent energy efficiency, reducing heat build-up and the need for cooling fans. The S8VK-T series are available in 120W (5A), 240W (10A), 480W (20A) and 960W (40A) with 24 VDC output. The series boasts a temperature range of -40 C to 70 C. A double set of DC output terminals (three for the negative) promises “easy wiring of multiple circuits,” says Omron, adding that series and parallel wiring is possible. The series boasts UL 508, ANSI 12.12.01, UL 60950-1, CSA No. 60950-1, and more. www.omron247.com
Sager Power Systems has announced the LCM1500 series of 1500W power supplies from Artesyn, describing it as an enclosed power supply consisting of five primary single output models of 12, 15, 24, 36 and 48 VDC. All models boast 89-percent high-efficiency operation;
performance through 10,000 mating cycles or more.” The Han HMC is best suited for applications in laboratories and engineering testing facilities where devices and machines are often disconnected and reconnected several times a day. It also suits modular machine construction and automatic tooling systems, where there is a need for electrical interfaces that can be plugged in and disconnected, over and over again. www.harting.ca
Rite-Hite Machine Guarding Defender Cell promises to restrict access and provide point-of-operation guarding around potentially dangerous automated and automatic processes including stretch-wrap machine operations. It boasts perimeter safety products — Rite-Hite’s RoboGuard steel-wire fencing and point-of-operation guarding with a high-speed, automated barrier door, the Defender — in a four-sided safety cell. The fencing can be customizable to accommodate various applications and designs. The Defender’s automated door separates machine operators and manufacturing processes at the point-of–operation, while also allowing access to the process cell once it has powered down.
DC-DC converters an operating temperature range of -40 C to 70 C; remote margining; and variable speed controlled fans. All models are safety approved to UL/cUL/EN 60950-1, UL/cUL/EN 60601-1 and BSMI with CB Reports and bear the CE Mark (LVD). power.sager.com
Connector boasts 10,000 mating cycles
Harting’s Han HMC claims to be the first rectangular connector designed to deliver “robust, consistently reliable
Defender cell helps guard around dangerous processes
Absopulse Electronics has released the HVI-50-F2 series of 50W, high input voltage DC-DC converters. The converters are suitable for operation in rugged industrial environments, says the company, adding that they can also be modified for solar and railway applications. The series accepts a nominal input voltage of 900Vdc, with a 600Vdc to 1200Vdc input range; standard outputs include 12Vdc, 24Vdc and 48Vdc. Cooling by conduction and natural convection enables operation over a 0 C to 50 C temperature range without derating, says the company; higher temperatures can be accommodated on request. www.absopulse.com
-826-6342
m/pages/
OMEGA introduces our Customizable Smart Graphics Displays
“Zero-backlash” CSF2UP gear unit
CATION)
er
MOTION CONTROL
The OMEGA® OM-SGD Series of panel meters with bright color TFT smart graphics displays are available in 3 screen sizes. They offer a wide operating power supply voltage range of 4 to 30 Vdc and two alarm outputs. Waterproof NEMA 6 (IP67) versions are also available. Using the provided Simple Wizard based configuration software, select from over 40 standard display configurations to program in seconds to your exact requirements. Customize colors, text labels, input scaling and units before uploading the selected display configuration to the meter via USB interface to the PC. The OM-SGD is ideal for process monitoring in a wide range of industrial or laboratory applications. CA Price Starts at $110
Email: info@omega.ca http://www.omega.ca/om-sgd-series 28
Harmonic Drive has introduced the “ultra-flat, zero-backlash” CSF-2UP gear unit, which it says features a large cross-roller bearing with high-moment stiffness. The CSF-2UP gearheads are ideally suited for robots or manipulators requiring
process, and C language control into one platform, adding that it is designed for applications requiring integrated motion and safety control, tight syn-
Control platform boasts integrated machine and plant control
chronization between various processes and high production throughput.The system can have up to four CPUs per rack for various combinations of motion, sequence or process control. us.mitsubishielectric.com/fa/en
Mitsubishi Electric Automation says its iQ-R series incorporates sequence, motion, safety,
May 2016 · MANUFACTURING AUTOMATION
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an ultra-compact solution, says the company. Complete with a housing and precision output bearing, Harmonic Drive gear units are “lightweight and extremely compact.” Gear ratios of 30:1, 50:1, and 100:1 are available in each size, offering the machine designer a selection of speed and torque specifications. www.harmonicdrive.net
2016-04-15 11:02 AM
DATA ACQUISITION According to the company, the roll-up design leaves a small physical footprint and is suitable for use around robotic processes. www.ritehite.com
Enhanced data loggers
Safety controller Rockwell Automation says that with the Allen-Bradley Compact GuardLogix 5370 controller, users no longer need separate networks and controllers for safety and motion in applications with up to 16 axes, “making it easier to design safety” into standard and custom machines. The unit includes dual Ethernet ports to support both linear and device-level-ring (DLR) network topologies. Built-in energy storage removes the need for batteries, and a removable 1-GB Secure Digital card claims to improve data integrity. www.rockwellautomation.com
Explosion proof horn sounders
The D2x family from E2S Warning Signals is based on a high output 116 dB(A) SPL 64-tone 4-stage horn sounder, which can be combined with a 5 or 10 Joule Xenon strobe in a 130-mm wide, 125-mm deep die-cast marine grade aluminum housing. Designed for use in Zone 2, 22 and Division 2 hazardous locations, the D2x claims to be a “truly global product range,” with approvals permitting use in regions covered by IECEx, ATEX, NEC and CEC regulations. With four remotely triggered alarm stages, the D2x can signal multiple safety warnings or process events. In the combined units, the Xenon strobe beacon and the alarm horn sounder can be activated individually via separate terminations or linked for simultaneous operation from a common power supply, says the company. www.e2s.com
Omega says its OM-CP-TEMP1000IS-A and OM-CP-RHTEMP1000IS-A data loggers offer “compact design and portability” which allows for placement in hard-to-reach locations. Features include a 316 stainless steel enclosure, fast response
times, and faster downloads, it says. A docking station for full communications promises no more removal of end-caps to download data. Both data loggers are certified for Class I, Division 1, Groups A, B, C, and D and non-incendive for Class I, Division 2 Groups A, B, C, D environments, making the devices suitable for monitoring temperature and humidity in sterilization processes, environmental studies, chemical/petrochemical testing or R&D labs. www.omega.com
Data logger for multichannel applications Delphin Technology says it has extended its Expert Logger range with the new Expert Logger 300
which promises to handle “any multi-channel requirement” and is equipped with 46 universal channels. According to Delphin, all inputs are differential and have galvanic isolation to protect them against interference from sensor circuits and earth loops. The analog inputs offer 24-bit resolution and sampling rates of up to 50 measurements per second. The logger is suitable for a range of applications, including: temperature measurement and monitoring; industrial plant and machinery optimization; acquisition of measurement data; and condition and remote monitoring of plant and machinery. CAS DataLoggers is Delphin’s master distributor in North America. www.dataloggerinc.com
Wireless technology & security New kit connects industrial sensors and devices to Cloudconnected databases Moxa says it is now offering system integrators and OEM machine builders a solution to connect sensors and devices to a management platform or database over 4G LTE wireless networks. The 4G LTE Jump Start Kit strives to address two key pain points when connecting operations to the Industrial Internet of Things
includes an I/O module, Modbus gateway, and 4G LTE module. www.moxa.com
ADVERTISER INDEX (IIoT): collecting data from industrial devices, and transmitting that data to a Cloud-connected platform. The core of the kit is a programmable Modbus data logger that runs Debian Linux and is powered by a 1 GHz ARM7 processor. As well, the kit
COMMUNICATIONS & NETWORKING Fieldbus gateway Wago says its PFC200 750-82xx is now ANSI/ISA12.12.01 certified for operation in Class 1, Division 2 hazardous locations. Besides multiple network and Fieldbus interfaces, the controller claims to support all digital, analogue and specialty modules found within the 750/753 Series. The unit features a 600 MHz ARM Cortex A8 processor, multiple fieldbus ports, and 256 MB on-board memory. Acting as a fieldbus gateway, the PFC200 can communicate between
MANUFACTURING AUTOMATION · May 2016
MODBUS TCP/UDP/RTU, CAN, Profibus, smart grid and RS-232/ RS-485. www.wago.us
Advantech Industrial Automation Group 15 Allied Electronics Inc. 1 Allied Electronics Inc. 7 AutomationDirect 2 Beckhoff Canada 5 Bosch Rexroth Canada 13 Eaton Canada 11 Encoder Products Company 6 EPLAN Software & Services LLC 23 Fraba Inc. 8 Harmonic Drive LLC 27 Hiwin Corporation 9 Murrelektronik Canada 3 Omega Engineering 7 Omega Engineering 28 SCHUNK Intec Corp. 31 Siemens Canada Ltd. 32 TURCK Chartwell Canada Inc. 21 TO ADVERTISE Contact Klaus B. Pirker kpirker@annexweb.com AutomationMag.com 29
BACKSTORY WHAt WE PuBLISHED IN... 1998 “Dispelling myth of cheaper business southside” 2009 “Spread the word: Canada is a great place for business”
2014 “Canadian manufacturer ‘takes back manufacturing,’ moves to larger facility”
2011 “Right at home: Instead of bending to pressure to move overseas, one manufacturer found a cost-effective way to boost productivity and improve safety, while still keeping jobs in Canada”
The future of reshoring in Canada
R
eshoring has been a discussion point over the last decade and was a reaction to the heavy globalization of manufacturing that moved production capacity out from western economies to emerging markets offshore. “Take back manufacturing” advocates have now convinced most corporations that globalizing manufacturing just for low cost labour, while grossly over extending supply chains, has significant hidden total costs; many are now accepting that much more sustainable and environmentally-friendly short supply chains can be the better solution. Many products are now reshoring back to local manufacturing supply chains to support the consumer base within NAFTA, but in some situations, active reshoring may be a very slow process that requires the rebuilding of local supply chains that declined in the last 30
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decade of globalizing manufacturing. Although an increase in political will for reshoring now firmly exists in North America, future national economic and industrial policies will continue to shape business decisions as to “if, how” and “where” reshoring happens. Recent trends point to Mexico and the Southern U.S. right-to-work states being the more obvious and favourable option for reshoring, and while some exceptions and success stories do exist, many experts do not consider Canada a logical and typical reshoring destination within NAFTA. The reasons for “why not Canada?” are many. We are a relatively high-cost destination with a questionable political will to set a consistent, national industrial policy in hopes of convincing business leaders to invest, but often times, Canada presents a comparatively small consumer base with flat growth,
2015 “Home sweet home: how to focus our reshoring efforts to Canadian soil”
2012 “Business, after all, is a competition, just like a golf tournament. The players are all competitors.” 2013 “China, India and other Southeast Asian countries... are really upping their game when it comes to best practices and improved processes. And that may translate into more competition, as opposed to reshoring.”
an unpredictable resource-driven exchange rate, high overall energy costs, non-competitive transportation and border transactions, as well as high labour expenses and punitive safety and environmental legislations. Our advantage of a lower corporate tax rate and a strong — yet fast eroding — skilled workforce does not offset this longer list of disadvantages. Our governments, manufacturing sectors and our educational support organizations must respond to these challenges, and work more cohesively to reverse this outlook, or we will continue to see further decline in many of our manufacturing sectors. | mA Commentary by Nigel Southway, who is a Lean business consultant, author of Cycle Time Management, and a founding partner and Engineering VP at Additive Metal Manufacturing. He is also a current member of Manufacturing AUTOMATION’s editorial advisory board. May 2016 · MANUFACTURING AUTOMATION
© 2015 SCHUNK GmbH & Co. KG
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The new SCHUNK Grippers PGN-plus-P und PGN-plus-E of the
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Generation Permanent With lubrication pockets in the multi-tooth guidance.
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New! Innovative SINAMICS G120 drives
Higher power, less space – discover the new generation of drives! Whether pumping, ventilating, compressing, moving or processing, the SINAMICS G120 drive series fulfills the widest range of requirements for industrial applications such as general machinery construction, conveying, automotive and packaging. SINAMICS G120 advantages at a glance • Works with wide range of communication protocols • Innovative push-through cooling design and side-by-side mounting saves cabinet space • Integrated, comprehensive safety concept up to PLe/SIL3 takes away the need for external safety components
The second generation of SINAMICS G120 drives features higher power density in the same enclosure size. Depending on the application, the power module can be combined with the matching Control Unit and optional components such as an operator panel. Additionally, the functionality of the Control Unit has been expanded to offer precise vector control as well as basic positioning. For more information, call 1-888-303-3353.
siemens.com/sinamics-g120 32
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May 2016 · MANUFACTURING AUTOMATION
PHOTO: CREDIT TK HERE
• Available in three voltage versions: 200–240, 380–480 and 500–690 V