Automation Update - Issue 79 by jetdigitalmedia

AUTOMATION UPDATE

WWW.AUTOMATION-UPDATE.CO.UK

Issue 79

Cable entry and cable holding systems Solutions for cable applications Cable entry and cable holding systems Solutions for cable applications See more on page 8 & 9...

Power Security & Back-Up

Instruments Ltd

DC UPS

CBI Series Input 90-305 V AC Output 12/24/48 V DC upto 20 A MODbus / CANbus Comms Remote Monitoring via ethernet Status Relay

Battery Chargers CB Series Input 90-305 V AC Output 12/24/48 V DC upto 20 A MODbus / CANbus Comms Remote Monitoring via ethernet Status Relay

Power Supplies

FLEX Series Input 90-500 V AC Output 12/24/48 V DC upto 25 A Single / Dual or 3 Phase inputs

A H

h r A

Instruments Ltd

TVR Instruments Limited 143 Butt Road, Colchester CO3 3DP Essex United Kingdom

Tel: +44 (0) 1206 575755 Email: sales@tvri.co.uk www.tvri.co.uk

Ala

AUTOMATION UPDATE Editorial Assistant Laura Sharpe 01843 580 460 laura@automation-update.co.uk Publishing Director Jodie Little 01843 580 460 jodie@jetdigitalmedia.co.uk Sales Director Tim Johnston 01843 448 443 tim@automation-update.co.uk Advertising Exec Jamie Simmons 01843 580 460 jamie@automation-update.co.uk

Automation Update is an engaging, editorially led publication & directory giving the reader news and updates on new products and services to our ever Progressing industry.

Publishing House Jet Digital Media Ltd The Forge, Spratling Court Offices, Manston, Kent CT12 5AN

www.automation-update.co.uk

Forerunner Yesterday. Today. Tomorrow. The Sensor People have been setting technological standards in industrial automation for more than 50 years. In the field of safety at work, we convince right from the start with trend-setting inventions, such as the development of the first protective sensor ever, to our latest safety innovation, “Smart Process Gating” – the space-saving solution for access guarding on conveyor lines. This is how we ensure the success of our customers in an industry that is ever evolving.

www.leuze.co.uk Automation Update - 3

What are the costs associated with an AutoCoding system? Investing in an AutoCoding system will bring huge benefits to your factory, the main benefit being peace of mind, knowing your products will always leave the factory in the right packaging with the correct label and coding information. A common question, however, is “how much will it cost to run?” That’s why we’ve taken a look at the costs associated with running an AutoCoding system to help you prepare for your potential investment.

The cost of skills

Return on Investment Implications

Some of the ways the cost of investing in an AutoCoding system are typically offset include an improvement in efficiency, reduction in packaging waste due to human error, and most significantly a reduction in downtime and changeover time. The AutoCoding system will automatically set-up and control all the devices on a packaging line from one Errors are easy to make when different central point and, whilst products are in similar packaging the cost saving would be different for every factory, if you underlying reasons for losses. By quantify the amount of downtime collecting real-time data, proactive experienced for product changeovers, measures can be taken to improve device set-ups and shift changes etc manufacturing processes, improving you’re likely to experience a significant efficiency and productivity. benefit.

Obviously one of the most important factors to consider in a business when making a major investment is the return on investment (ROI).

Furthermore, with the addition of the right value-add modules, time savings and improvements in productivity can be achieved.

Many will be under the misapprehension that AutoCoding is a sophisticated complicated piece of software that requires specialist, high-skilled staff to maintain and run it. However, this is not the case. AutoCoding does not rely on a high level of day-to-day operator intervention on the packaging line. Most of the work required is in the “back-office”, such as the Technical Department, during the initial setup. Consequently, there is no need to adjust the mix of skills in the packaging hall itself where there is quite often a high staff turnover resulting in ongoing training costs.

Errors are easy to make when different products are in similar packaging

Whilst it is categorically difficult to answer what the average ROI will be after installing an AutoCoding solution, on average we expect the ROI to be between 18 and 24 months on one line. 4 - Automation Update

For example, the AutoCoding paperless quality module automates in-line and off-line quality processes with data capture and reporting options. The application is completely configurable to individual factory requirements with all responses, images and corrective actions recorded in an audit log. Not only does this reduce the amount of time spent on carrying out paperbased checks, but by storing the results of the checks automatically in the audit log, the amount of storage space required for quality reports is significantly reduced. AutoCoding’s line performance reporting module will give you the ability to measure overall equipment effectiveness (OEE) and identify any

The cost of not having an AutoCoding system

So perhaps the question should be, “what is the cost of not having an AutoCoding system?” Product recalls can be disastrous for food and drink manufacturers, involving both direct costs, such as product scrappage and potential fines, and indirect costs, such as reputational damage. A packaging line without an AutoCoding system is much more dependent on human set-up and manual monitoring of activities, and consequently is at higher risk of human error, putting the factory at risk of the above-mentioned product recalls.

For more information, contact : janetharrison@autocodingsystems.com

Tel : 01928 790444

sales@lamonde.com

     

4 Comm ports, inc Ethernet Built-in data logging to microSD Free no-limit programming Slim stackable design Multiple i/o wiring options Starter kit available

www.lamonde.com +44 (0)20 3026 2670

Lamonde Automation Limited Quality Products: Expert Advice

Reliable lubrication without lubricating Eisele connectors supply spray dosing systems from HPM Technologie In applications as diverse as metal machining and food production, it is necessary to apply cooling lubricants, grease, oil, alcoholic solutions and many other fluids to surfaces and components. In contrast to conventional nozzle systems, the spray heads from HPM Technologie ensure precise distribution of the exact amount of the required fluid, for low consumption. The supply of compressed air and liquids to the spray heads is achieved with high-quality all metal push-in fittings from Eisele. The precise spray cone ensures economical dosing of the cooling lubricant at exactly the location where it is needed. Photo: HPM Technologie GmbH

Advantages for costs and production The essential advantage of minimal lubrication is the enormous reduction of the lubricant quantities used compared with conventional cooling lubricant systems and concepts. Processes that use minimal lubrication require only a few millilitres per hour. The minimal application of fluid also reduces the environmental impact, operating costs and system contamination. According to the Bureau of Statistics, cooling lubricant costs make up 8 to 16 % of the total costs in metal machining processes and therefore represent a relevant cost pool that can be significantly reduced by using a modern minimal lubrication system.

Advantages due to low-maintenance components To minimise maintenance and maximise user-friendliness, the spray heads at HPM Technologie are supplied with media using connection components from EISELE GmbH. The German company has more than 80 years of experience in high-quality all metal connectors for use with compressed air, gases, coolants, vacuum and liquids. Since 2013, Eisele has already been HPM’s primary supplier of 6 - Automation Update

connection components. This turns out to have been a good choice: “Eisele simply has excellent products, both visually and functionally,” says Steffen Hoffmann, member of management, in describing the cooperation with Eisele.

Guaranteed solid connections For supplying the spray heads with lubricant for minimal lubrication, HPM uses straight push-in fittings of nickelplated brass with a release sleeve from Series 14 and 14A of the Eisele BASICLINE. The push-in fittings are also equipped with a blue-coded aluminum sleeve, which unmistakably shows where to connect the blue compressed air tube. The push-in fittings with a release sleeve feature a larger gripping surface for release of the tube as compared with a simple release ring. This is especially advantageous in applications that use oils or cooling lubricants in which components near the drill or milling head – despite the high level of precision – can be covered with a spray medium.

www.eisele.eu

Leaders in temperature measurement

Hand Held Instrumentation Heading 3

A selection of hand held instruments for many applications including a large range of digital thermometers, light level meter and a range of great value handheld sensors.

IR Industrial IR Medical Infrared Thermometers Thermometers

Pressure Manometers

Digital Light Meters

Anemometers

Temperature & Wood Moisture Meter Humidity Meter

Grain Moisture Meter

www.labfacility.com Bognor Regis tel: +44 (0)1243 871280

sales@labfacility.com Shefﬁeld tel: +44 (0)1909 569446

Murrplastik is represented by Murrelektronik in the UK Tel: 0161 728 3133 Email: sales@murrelektronik.co.uk

SICK Goes Flat Out for Performance with Mini Smart Sensors SICK has launched the versatile W4F family of miniature smart sensors, developed to achieve next-generation detection performance and incorporating powerful new optical technologies, each purpose-designed to master common sensing challenges with complete reliability.

The SICK W4F family comprises eight different sensor types, split into the Optical Experts together with a range known as Optical Standards, but which deliver performance significantly above the market standard.

Optical Experts

The SICK W4F family of photoelectric smart sensors pack a choice of class-leading detection options and application-specific optics into the same, rugged, 16mm x 40mm x 12mm housing. Each features SICK’s trademark BluePilot push-turn pinpoint alignment and on-sensor status display. Impressing with their resilience to bright ambient light, the versatile W4F smart sensors multiply intelligent machine integration options for almost any application, no matter how tight the available mounting space. “The SICK W4F is really a team of tiny superstar performers and each is destined to be a future workhorse of the SICK smart sensor range,” explains David Hannaby, SICK’s UK Product Manager for Presence Detection. 10 - Automation Update

“Superstar Performers” “Whether you need to detect jet black, high-gloss, highly reflective, perforated, transparent, wire-thin or flat products, the W4F has a specialist Optical Expert that is up to the task. At the same time, the W4F’s extended smart sensor features unlock more diagnostics and monitoring, while process information including distance measurement can be output to configure smart automation tasks. “We have had excellent feedback from the first users of the SICK W4F photoelectric sensors. They have told us that they are getting the best-ever ambient light and sunlight suppression performance, as well as maximum immunity to all sources of optical interference.”

Among the W4F Optical Experts is the new SICK W4F MultiSwitch with two separate switching points, together with a distance measurement output in mm. It is therefore possible e.g. to reliably detect a pack both when it is upright or lying on its side using just one sensor, or to enable a robot arm to travel more quickly by allowing it to stop in two steps. Using distance measurement, an automated response can be designed to alert when products drift away from a pre-set detection position on a conveyor, or to measure the width of a roll of paper or fabric. Another highlight is the new foreground suppression sensor optic, capable of reliably detecting low, flat objects less than one 1mm in depth on a conveyor, even if they are highly reflective. The new SICK W4F ForegroundSuppression sensor excels when detecting flat products, even if they are extremely dark and glossy, such as chocolate bars, PCBs, batteries or smartphone components. The SICK W4F V-Optic features a new V-focused light beam, designed to achieve exceptional accuracy when detecting mirror-reflective or completely transparent products such as glass panes. Low-remission, or tiny

components such as solar wafers are detected reliably, as well as objects as thin as a single fuse wire. The SICK W4F DoubleLine upgrades SICK’s MultiLine technology adding more power and performance to detect components that have uneven surfaces, recesses, holes, perforations, grids or grooves, such as plastic totes, packs of pharmaceuticals, or printed circuitboards with cut-outs. Even when faced with dirt, vibrations or high temperature, the W4F is designed to self-monitor and will continue to deliver precise results even under tough conditions thanks to its rugged IP66/IP67 VISTAL® housing and highly-reliable optics.

Optical Standards The W4F Optical Standards sensors have already proven themselves in the field as space-saving and highperforming all-rounders. The throughbeam photoelectric sensor has a long sensing range of up to 8 metres, while the photoelectric retro-reflective sensor extends up to 5 metres. Together with two photoelectric proximity sensors with background suppression, the Optical Standards achieve exceptionally reliable object detection. The W4F Narrow-beam

sensor uses a highly-concentrated light beam and point geometry to detect jet black objects with a remission of less than one percent.

Using SICK’s intuitive BluePilot, precise alignment of the W4F sensors is easy using the push-turn mechanism guided by the on-sensor LED display. BluePilot also provides a visual indication of detection quality and enables any loss of detection capability, e.g. as a result of dirt on the lens, to be corrected before causing unplanned downtime. Useful IO-Link features include a ‘current receiver level’ read-out enabling detection to be monitored in real time. Extensive diagnostic functions ensure the system can monitor sensor status and can respond if process parameters such as temperature or degree of contamination deviate beyond pre-set limits. Extensive diagnostic data also enables rapid identification of the cause of failure, e.g. at critical temperatures, the W4F can automatically initiate maintenance, thus preventing failures. For more information, please contact Andrea Hornby on 01727 831121 or email andrea.hornby@sick.co.uk. www.sick.co.uk

Automation Update - 11

What all Engineers should know about Inverter Repairs I’m sure we can all agree Variable Speed Drives are expensive pieces of equipment that require regular maintenance to minimize premature failure and maximize the life span of your asset.

12 - Automation Update

owever, all makes of Drives do fail and one of the most common faults is IGBT (Insulatedgate bipolar transistor) failure. An insulated-gate bipolar transistor (IGBT) is a three-terminal power semiconductor device primarily used as an electronic switch in Variable Speed Drives. When a drive suffers an IGBT failure the best practice is to replace all three devices, even if only has actually failed as the fault condition more often than not weakens the remaining devices which will inevitably lead to a further premature failure and more costly downtime for the user. So far, I’m sure I’ve not told you anything you don’t already know, but the real issue with drive repairs is this…it is imperative that each repair is fully load tested

This is important because each IGBT has a free-wheeling diode which you can only accurately be tested with a full inductive load test. Most companies that offer Drive Repair do not have the required load test facilities and hence they simply carry out a resistive load test which actually does not show if the IGBT’s are fully functioning as a power device which leads to a very high percentage of IGBT drive repairs simply failing again as soon as they are fitted to the original application when load is introduced, leading to another repair cost and more costly downtime for your process. In summary all engineers should only send their valuable variable speed drive assets to drive repair facilities that have fully qualified Drive Engineers who have attended the relevant manufacturers courses. But also insist that the repairer have

load test facilities and carry out a full load test on your drive which you can attend to witness test or at the very least request a video of the final test. Insisting on these simple steps for all your drive repairs ensures 100% that your drive is repaired correctly and fully functioning before you put back into service on your plant, thus ensuring minimum repair cost and minimises expensive lost production costs. Quantum Controls have an 10,000 square foot Drive Repair Facility near Newcastle with full load testing facilities and are Official Drive Service Partners for all major Brands of Drives. When you next have a Drive failure get in touch with our expert team for repair estimate. repairs@quantum-controls.co.uk Tel :01661 835566

Automation Update - 13

Automation components from Panasonic PLCs, sensors, power supplies and much more. •

Photoelectric Sensors

Photoelectric sensors

•

DIN rail power supplies

•

PLCs

Photoelectric sensors are found in many areas of automation - although the most common applications include intelligent buildings, lighting, alarm, and HVAC systems. They are also used in devices such as ticket machines. Panasonic reflective sensors are called PaPIR, which stands for – Panasonic Passive Intrared (or pyroelectric, a type of infrared detector). The products of the Japanese manufacturer are made of environmentally friendly materials. The EKMB series stands out for its very low power consumption (1 µA or 6 µA). As their supply voltage is 2.3 V to 4 V DC, they are ideal for batterypowered devices , e.g. for occasional and automatic lighting of sites located far from the power grid and remote monitoring systems (CCTV). They have digital outputs and are immune to interference that could cause false triggering. The components are designed for through-hole technology (THT).

•

FP0R series

•

FP0H series

•

FP-X and FP-X0 controllers

Although the average consumer associates the Panasonic brand with consumer electronics, experts in industrial automation are well aware of the other face of the Japanese company. The brand formerly known as Matsushita Electric Industrial specializes in the production of devices from many fields - ensuring high specialization and product quality. That is why TME offers many Panasonic products. Most of them are available directly from our warehouses. As a result, we can reduce delivery times to customers as much as possible, which in the case of automation components means minimum downtime and improved maintenance of machines. In this article we will discuss several product groups. This is just a sample from the wide range of Panasonic products available at TME. In addition to the range described below, the on-line catalogue also includes passive components (e.g., a wide range of capacitors), microswitches, electromagnetic relays and much more. For our entire range of Panasonic products, please visit the link below. 14 - Automation Update

DIN rail power supplies FP-PS24 is a series of DIN rail mounted DC power supplies. They are designed to be powered directly from the mains anywhere in the world (85 V to 264 AC, 47 to 63 Hz). They provide a stable voltage of 24V DC that can be adjusted with a potentiometer from 23 V to 29 V. The series includes three models, with the following suffixes at the end of the model number: 023E, 060E, and 120E. Their maximum output current is 1A, 2.5A, and 5A at constant load, respectively. These values may be exceeded temporarily (e.g., during start-up) by 25% (for 7 seconds) or 50% (up to 3 seconds). The efficiency of the power supplies reaches up to 91.5%, which, combined with the use of branded capacitors with long life, guarantees ergonomic operation and durability - important features for power supplies used in automation.

PaPIRs motion sensor, 5 m detection distance.

Manufactured in accordance with EN60950 (Information Technology Equipment standard) and IEC60068 (shock testing). The power supplies are protected against output short circuit or overload. If the output voltage exceeds 35 V DC due to a PaPIRs motion sensor, 5 m detection distance.

Tel: 01296 611660 Email: rk@pmgb.co.uk www.phoenix-mecano.co.uk 26 Faraday Road, Aylesbury Buckinghamshire HP19 8RU

Media Advisory:

AD Communications appointed PR Agency for the upcoming PPMA Show Please be advised that the PPMA Group of Associations has once again appointed AD Communications as its PR agency with responsibility for the PPMA Show 2021. PPMA Show 2021 The PPMA Show 2021 will take place at the NEC, Birmingham from 28th to 30th September 2021. All PR activity for the forthcoming show is now being handled by AD Communications with immediate effect.

Show information will be issued shortly. In the meantime, if you have any queries or requests for editorial material for show preview features, please contact AD Communications.

Media contacts at AD Communications: Kirsty Jones kjones@adcomms.co.uk Tel: +44 (0) 1372 464470 Mobile: +44 (0) 7714 299520

Media Contacts at the PPMA: Ellie Martin emartin@adcomms.co.uk Tel: +44 (0) 1372 464470 Mobile: +44 (0) 7714 299520

Clare McSheaffrey Marketing Manager Clare.McSheaffrey@ppma.co.uk Tel: +44 (0) 20 8773 5522

Thin walling delivers the whole package Thin-walling has long been a practice in primary food and medical packaging to save material, showcase brand quality and maintain manufacturing standards. Nigel Flowers, UK Managing Director of Sumitomo (SHI) Demag, examines the emerging trends in this fast and evergrowing packaging segment. Global forecasts for the thin walled plastic packaging market is rising significantly. According to a report released by Smithers, the packaging market will be worth an estimated USD 1.2 trillion by 2028 expanding at a CAGR of approximately 3 percent. Food and beverage, and more widespread adoption of thin walled packaging in developing economies, will drive this growth. PE is projected to be the largest-growing segment during this forecast period. Light-weighting and consumer convenience are important factors in this expansion, with the combination of environmental pressures, improvements in recycle rates and high polymer prices placing increasing pressures on packaging manufacturers. Wider adoption of bio-based and recycled materials is also expected to boost market growth. For several decades now light-weighting and consumer convenience have given packaging manufacturers the strong commercial incentive to do more with less. No strangers to responding to demographic and lifestyle changes and balancing a wide range of variables, including cost, increased strength, recycle rates and functional requirements, lightweight formats have become the industry norm. Especially in food and medical packaging. More recently, the market has been moving more towards novelty solutions that improve performance, functionality and shelf impact.

16 - Automation Update

28 - 30 SEPT 2021 NEC, BIRMINGHAM WHERE PRODUCTIVITY MATTERS See the latest processing equipment, packaging machinery, robotics and machine vision in action Gain a competitive advantage through the latest innovations and seminars

ppmashow.co.uk

Youngs Launch UKAS Temperature Calibration Services Expanding on the enhancements added during the COVID-19 restrictions, the Young Calibration Laboratory (Lab 0604) has invested a further £200,000 in reference instrumentation for the calibration of temperature and humidity sensors.

aving successfully extended the UKAS scope of accreditation in the previous year, the company has further invested in both dry block and stirred liquid bath calibration systems, along with a range Fluke SPRT’s which will see continued improvements to the available CMC measurement uncertainty. Customers c a n ex p e c t t o s e e i m p r ove d turnaround times and extended capabilities for all temperature probes, loggers and bath calibrations in the -40 to 200°C temperature range over the coming months.

ISO 17025 Temperature Calibration within the laboratory covers the calibration of thermocouples, thermistors and platinum resistance probes using a range of leading manufacturer stirred liquid baths and SPRTs across a temperature range of -40 to 200°C with a CMC from ± 0.05°C. The reference SPRT’s provide a comparative measurement technique whilst held in stable isothermal states for optimum calibration periods offering cost effective calibrations. Dry or air probe calibrations for system temperature measurements in HVAC

probes, anemometers, IAQ sensors, data loggers, RH probes and weather stations can also be calibrated within a controlled environmental chamber across a 0 to 60°C range with a CMC from ± 0.19°C. For the user undertaking their own internal calibration work the laboratory is accredited for the calibration of dry block calibrators and stirred liquid baths using single and multipoint time dependent temperature profiling, also referred to as spatial temperature surveying or mapping with a CMC from ± 0.045°C. UKAS ISO 17025 Humidity Calibration Services Complimenting the Temperature Calibration Laboratory is another of the company’s latest investments for its’ UKAS accredited relative humidity and dew point calibration services. The UKAS (Lab 0604) schedule now covers dew point calibration from -32 to 60°C, relative humidity calibration from 5 to 95% and all across a temperature range of 0 to 60°C. Utilising both controlled environment chambers with reference SPRT’s, chilled mirrors and comparative RH probes, the facility can achieve a Relative Humidity uncertainty CMC of ± 0.2% to 1.9% across the full temperature range of 0-60°C whilst achieving a ± 0.31°C CMC for dew point measurement. Contact Details Young Calibration Ltd 5 Cecil Pashley Way, Shoreham by Sea, West Sussex, BN43 5FF United Kingdom Tel: +44 (0)1273 455572 Email: ay@youngcalibration.co.uk Web: www.youngcalibration.co.uk

18 - Automation Update

3 & 4 November 2021, NEC Birmingham The UK’s leading annual gathering of engineering supply chain professionals

SAVE THE DATE I found the event a great networking opportunity to meet industrial professionals from different backgrounds with different products. Kat Clarke, Wing Manufacturing Engineer, Airbus

10,000+ engineering professionals in attendance

500+

exhibitors showcasing their products/services

200+

hours of free-to-attend industry content

Benefit from co-location with: AERO ENGINEERING

AUTOMOTIVE ENGINEERING

PERFORMANCE METALS ENGINEERING

COMPOSITES ENGINEERING

CONNECTED MANUFACTURING

MEDICAL DEVICE ENGINEERING NEW

NEW

CONSISTENT QUALITY WITH QC, QA & ERROR-PROOFING PAPERLESS WINS Paper may be flexible and convenient, but in the context of manufacturing It loses against digital quality systems

To remain competitive, food & drink manufacturers are continually looking to make their products BETTER, FASTER, CHEAPER - that means improving quality, increasing efficiency, and reducing cost - it all starts with the approach to quality.

driven and combines inspection results with proactive prevention.

QC, QA, QI - what is what?

Paper has a range of limitations, especially in a manufacturing quality data capture context. There are three major problems associated with paper: cost, time, and risk. Next to the physical cost of paper, ink, and storage, a lot of time is wasted manually duplicating data across sheets, collating the sheets, transcribing results, and further analysis

Quality Control (QC) is focused on the end product, aiming to make sure it meets the expectations by identifying defects. This reactive approach aims to find existing defects through inspection and testing. Quality Assurance (QA) is focused on the process, ensuring that all activities will result in products meeting customer expectations. This proactive approach aims to prevent issues before they affect a product and is used to optimise processes to remove issues and avoid them happening again. Oftentimes, QC provides the QA team with feedback to guide the direction they work in to minimise defects, leading to Quality Improvement (QI). QI is more action22 - Automation Update

The importance of accurate data Key for any quality initiative is accurate data, making the right approach to data capture crucial.

Risk comes in the form of loss, damage or decay, though the primary issue is the human element, which often introduces inaccuracies like typos, poor legibility, or wrong time stamps, as well as falsification.

outlined above: Quality Control is concerned with detection of defects, Quality Assurance facilitates quality consistency, whereas Quality Improvement looks to eliminate or prevent quality issues.

The only way to ensure the availability of accurate data in manufacturing is Risk comes the form of loss, damage or decay, though using a inpaperless approach, to reduce the primary issue is the human element, which often complexity through standardisation, input introduces inaccuracies like typos, poor legibility, or verification, corrective action advice and wrong time stamps, as well as falsification. real-time reporting. Increased operational discipline asaccurate well data as The only way toand ensuretraceability the availability of instant auditsis come as additional ts. in manufacturing using a paperless approach,benefi to reduce

Which approach should I take?

complexity through standardisation, input verification, The Lean action approach corrective advice- error-proofi and real-timeng reporting. Increased operational discipline and traceability as well as Poka-yoke is aas additional Lean Manufacturing tool instant audits come benefits.

comprising numerous principles for mistakeproofi ng,approach can be -related to the different The Lean error-proofing approaches to quality management. Very Poka-yoke is a Lean Manufacturing tool comprising briefly, prevention of mistakes is achieved numerous principles for mistake-proofing, can be related through the automated setup of line to the different approaches to quality management. equipment without human involvement, Very briefly, prevention of mistakes is achieved through thus reducing the risk of human error. the automated setup of line equipment without human Employing thus techniques combining involvement, reducing and the risk of human steps error. to make work easier to perform, e.g. work the Employing techniques and combining steps to make use of paperless quality checks quality with checks stepeasier to perform, e.g. the use of paperless by-step guidance and instant feedback, with step-by-step guidance and instant feedback, is is classed as facilitation. If happens, a mistake still classed as facilitation. If a mistake still it needs to happens, needs to be identifi ed (detection) be identifiedit (detection) before further processing occurs, before further occurs, so that the so that the operatorprocessing can quickly correct the problem. operator can quickly correct the problem.

Assurance qualityon consistency, whereas Quality While QC facilitates is focused the inspection of Improvement looks to eliminate or prevent issues. finished goods using a standardisedquality process, and provides easy reporting of results Which approach should- IQA take? exceptions, in particular employs a more informed approach to improving processes While QC is focused on the inspection of fi nished goods and use process, of built-in functions to usingmakes a standardised and provides easy reporting automatically assess and improve process of results - exceptions, in particular - QA employs a more tolerances. QI, intoturn, provides visibility informed approach improving processes and makesof use of built-in functions to automatically assess and improve improvement opportunities, especially of process tolerances. QI, in attributes turn, provides visibility recurring issues, and cost and of improvement opportunities, wastage to focus efforts.especially of recurring issues, and attributes cost and wastage to focus efforts.

Any chosen solution should ideally be Any chosen solution should ideally be able to unite all able to unite all of these approaches, to of these approaches, to reap the combined benefits of reap the combined benefits of having a having a standardised, paperless approach to quality, with standardised, paperless approach to quality, continuous improvement at the heart of it, facilitated by with continuous improvement at the heart data visibility. of it, facilitated by data visibility.

The bigger picture The bigger picture The basic architecture required for such a solution lends itself very well to further automation The basic architecture required of forprocesses, such of lends line efficiency data, the a capture solution itself very wellincorporation to further of quality results into for an accuratecapture representation automation of OEE processes, of of performance, materials traceability, mass balance, yield line efficiency data, the incorporation of control, results and much more. quality into OEE for an accurate

These error-proofing concepts loosely align with the different approaches above: loosely Quality representation of performance, materials These quality error-proofi ng outlined concepts With the mass right solution, BETTER quality Control is concerned with detection of defects, Quality traceability, align with the different quality approaches balance, yield control, and is

achieved through better process control, data much more. capture and analysis are performed FASTER, WITH RIGHT SOLUTION, BETTER QUALITY and THE waste reduction leads to CHEAPER IS production ACHIEVEDcosts. THROUGH BETTER PROCESS CONTROL, DATA CAPTURE AND ANALYSIS ARE PERFORMED AND WASTE REDUCTION Learn more:FASTER, www.harfordcontrol.com LEADS TO CHEAPER PRODUCTION COSTS. LEARN MORE: WWW.HARFORDCONTROL.COM Automation Update - 23

Why handheld testers will help security installers overcome their biggest challenges

the camera has enough power to function. The compact PoE Pro tester from TREND Networks eliminates guesswork when installing, maintaining, and troubleshooting networks where PoE is deployed. Installers can easily verify Pass/Fail, even without a full understanding of the various industry testing standards, device power outputs, and cable lengths that are required for a device to operate successfully.

A new generation of handheld tools can help security installers overcome key industry challenges and benefit from significant time and cost savings, says TREND Networks. Challenge: Network “Despite the fact that the security market is changing, we see many businesses configuring, installing and troubleshooting IP security cameras using laptops, even though it’s time consuming and ineffective,” says Tim Widdershoven, Marketing Director for TREND Networks. “Many are simply unaware of the productivity benefits possible by tackling their most common challenges on the job with a new approach to test equipment.”

Challenge: Emerging Technologies Arguably the biggest trend affecting the security industry in recent years has been the switch to digital IP cameras from analogue technologies. Installers are faced with having to fit unfamiliar, fast evolving equipment and obtain new 22 - Automation Update

knowledge to keep up with customer demand. With numerous types of CCTV camera, plus many different configurations and connection methods, installation and troubleshooting can be time intensive and complicated. The handheld SecuriTEST™ IP CCTV tester supports installers through this transition, with features to help save time and boost productivity such as QuickIP, which enables novice technicians to connect and configure IP cameras quickly and easily. Even on complex installations, users may only need to use one tester, helping remove the need for in-depth and timeconsuming training. Where security installations are using Power over Ethernet (PoE), technicians also need to be able to verify that

integration “Analogue CCTV was installed with its own infrastructure, a series of hardware and cables for controlling the cameras,” explains Tim. “However, IP security cameras are usually installed to an existing network, already in place supporting computers, phones, or IoT (Internet of Things) devices. Installers now need to understand the completely new area of how network integration works in order to conduct installation correctly or troubleshoot issues.” First, it’s important to verify that the network has the bandwidth to support the cameras and prevent poor image quality, for instance. The SignalTEK 10G tester can be used to determine maximum bandwidth up to 10 Gb/s and identify areas with bottlenecks. Post installation, it can also be used to

troubleshoot Ethernet connectivity issues faster using diagnostic tools such as the 72-hour event log which helps diagnose intermittent connectivity issues faster. During commissioning and maintenance, SecuriTEST IP can also be used for a range of network troubleshooting and advanced testing requirements, including cable tracing, length, wiremap, and quality testing, removing the need for installers to carry multiple instruments.

Challenge: Changing use of cameras Cameras are increasingly being used for a wider range of purposes, not just for observing crime, such as number plate recognition, access control, and fire monitoring. Camera installations have also been used to aid compliance with Covid policies, observing that social distancing is being adhered to, for instance.

However, residential customers do not necessarily have the same understanding of how these systems work as a commercial user, making it even more important to be able to clearly document the installation has been done correctly to prove performance and prevent unpaid callbacks. SecuriTEST IP features advanced reporting to enable installers to document performance on site in detail, rather than filling in excel documents to create reports. When an issue arises, the proof of performance reports can demonstrate both camera images and network configuration, making return visits to site billable, especially in the

case that the customer has changed the network parameters. “With SecuriTEST IP, users can depend on a simple, handheld tool that can replace an Ethernet cable tester, laptop, PoE injector, PoE tester, and reporting tool. Plus, it connects first time without the need to change complex settings and deliver reliable test results,” says Tim. “And supported by a suite of our other complementary test solutions, security installers can save huge amounts of time on every job and keep their customers happy.” Buy TREND Networks handheld testers now or find more information at www.trend-networks.com.

“For outdoor cameras, installation can be especially complex where installers don’t have the correct tools to test a fixed camera,” says Tim. “Time is spent travelling up and down a ladder to check the angle on a laptop. In the case of a new network installation or where building construction is in progress, set up can only be completed at a later date, returning to site when the IT infrastructure and computer room are in place and performance can be checked.” With a handheld SecuriTEST IP tester, the whole installation can be completed, tested, and documented, removing the time-consuming need to return to site later. It is small, lightweight and does not require external power adapters and injectors, has 10-hour battery life and is operable with one hand, supporting productivity even for installers working on lifts and ladders.

Challenge: Residential security boom As demand for home security cameras and devices such as video doorbells has increased, the cost has become ever more affordable, even for those looking for more advanced solutions. The global smart home security camera market size was valued at USD 3.71 billion in 2019 and is expected to grow at a compound annual growth rate (CAGR) of 15.7% to 2027*. Automation Update - 23

TF Automation automates process for face mask manufacturer TF Automation were recently commissioned to design and manufacture a machine to automate the production of straps for face masks for a new customer - Air Filtration Solutions (AFS).

AFS

manufacture high p e r f o r m a n c e respiratory filters, face masks, respiratory masks and domestic appliance filters and filter casings. The company required a bespoke machine to automatically cut and weld the straps for face masks to accommodate on-going increases in demand. The previously manual process involved cutting the elastic to length and then hand-welding to form the loop. Our project engineers designed a machine that feeds the elastic strap material from an attached reel, drawing out at a known predetermined length. The elastic is then cut and welded using ultrasonics to form a loop. The automation provides consistent length measurement and a reliable consistent weld which was not the case whilst hand welding. Each loop had to be stretched to test its strength & then cut & rewelded in the case of a poor weld. These straps are the then used for AFS generic range of disposable face masks which are in high demand. The assembly process has been simplified with rejects and rework now being minimal, with the company seeing a 30% output increase with only occasional operator intervention to change the medial roll. Tony Hubbert, MD at TF Automation, comments, “This is one of the first machines we have designed for AFS and we are delighted with the outcome in helping them increase productivity and ensure standardisation and consistency. There are already new projects in the pipeline for further machines focussing on process automation.” www.tfautomation.co.uk 24 - Automation Update

Protecting Your Plant Before

Rotech Motion Sensor’s can be used whenever information or monitoring of shaft rotation, position, direction, speed, slip etc is required! Rotech Motion Sensor’s can be used for indication, control, interlocking, protection, sequencing, alarm initiations and many more functions! Rotech Motion Sensor’s can be used wherever materials are transported or processed By conveyors, elevators, screws, mixers, etc!

ROADSTONE

STONE

POWER STATIONS

AGGREGATE

…AND MANY MORE!

RELIABILITY Tel : +44 (0)151 356 2322 Website: www.rotechsystems.co.uk Fax: +44 (0)151 356 2437 Email: sales@rotechsystems.co.uk

Monitoring the world