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Vol. 65 Number 5

MAY 2018

16-25

CAREER UPDATE COVER STORIES: See career-related coverage in this issue on pages 16-25, with an introduction on page 14. COVER IMAGE: Training is critical to improving how engineering is done, and is offered by universities, system integrators, consultants, associations, and automation vendors, like this session, taught by Doug Bell, at AutomationDirect, near Atlanta. Bell also teaches CFE Media’s CFE Edu “Introduction to PLCs” course. Image courtesy: AutomationDirect

INSIGHTS 5 | Achieving profitable efficiency through process control 6 | Power systems engineers help facility managers NEWS

26 | Understanding convergence of IT and OT 30 | Secure circuit protection 32 | Global robotics standards update 34 | Create safe, efficient barriers for human-machine interaction INSIDE PROCESS

P1 | Open Process Automation status P7 | Ten reasons to build a process model for a manufacturing plant

INNOVATIONS NEW PRODUCTS FOR ENGINEERS

44 | Oscilloscope probe, wireless sensors, safety-based communications, precision limit switches, multi-volt timer BACK TO BASICS

48 | Six tips for designing and building a small controls project

CONTROL ENGINEERING (ISSN 0010-8049, Vol. 65, No. 5, GST #123397457) is published 12x per year, Monthly by CFE Media, LLC, 3010 Highland Parkway, Suite #325 Downers Grove, IL 60515. Jim Langhenry, Group Publisher/Co-Founder; Steve Rourke CEO/COO/Co-Founder. CONTROL ENGINEERING copyright 2018 by CFE Media, LLC. All rights reserved. CONTROL ENGINEERING is a registered trademark of CFE Media, LLC used under license. Periodicals postage paid at Downers Grove, IL 60515 and additional mailing offices. Circulation records are maintained at 3010 Highland Parkway, Suite #325 Downers Grove, IL 60515. Telephone: 630/571-4070. E-mail: customerservice@cfemedia.com. Postmaster: send address changes to CONTROL ENGINEERING, 3010 Highland Parkway, Suite #325 Downers Grove, IL 60515. Publications Mail Agreement No. 40685520. Return undeliverable Canadian addresses to: 3010 Highland Parkway, Suite #325 Downers Grove, IL 60515. Email: customerservice@cfemedia.com. Rates for nonqualified subscriptions, including all issues: USA, $ 150/yr; Canada/Mexico, $180/yr (includes 7% GST, GST#123397457); International air delivery $325/yr. Except for special issues where price changes are indicated, single copies are available for $30 US and $35 foreign. Please address all subscription mail to CONTROL ENGINEERING, 3010 Highland Parkway, Suite #325 Downers Grove, IL 60515. Printed in the USA. CFE Media, LLC does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the material contained herein, regardless of whether such errors result from negligence, accident or any other cause whatsoever.

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INSIGHTS INTERNATIONAL Peter Martin, Schneider Electric

Achieving profitable efficiency Providing real-time feedback to process control operators allows them to determine the financial impact of their actions and results in real-time profit control.

rofitability control cascades to process control to maximize operational profitability in real time. While this is a new execution method, its concept is already ingrained in the DNA of process control. The primary objective of process and logic control is to improve the efficiency of an operation. This has traditionally been measured by determining whether or not throughput has increased while energy and material consumption have decreased. To improve efficiency, a feedback control loop measures the variables that need to be controlled, determines the variation from the desired set point, and adjusts the variables to move toward the set point. Since the 1960s process control has advanced beyond single-loop feedback control. Multi-loop cascade control, feed forward control, and coordinated multiple variable control use dynamic process models to enable sophisticated control strategies. Real-time control involves making and acting on decisions in a period of time defined by the process being controlled. Human schedule decisions are referred to as management decisions; decisions on process schedules are referred to as control decisions.

Types of control

Traditional control strategies include four basic types: manual and automatic control strategies, and feedback and predictive strategies, which can use automatic or human control. When humans are provided the information they need to make effective real-time control decisions, as well as the tools they require to act on this information and to realize a positive result, they are empowered. An empowered workforce relies on operators being given the tools necessary to effectively serve as controllers. It was once understood that improvements in efficiency could be translated into improvements in operational profitability. This is no longer the case. Since the early 2000s, the speed of industrial business has increased steadily, triggered by the deregulation of electrical power. As electrical power was deregulated, the supply-to-demand ratio on the grids started to fluctuate. Energy suppliers and grid managers tried to deal with these fluctuations by increasing the price of energy when the demand was high and supply was low and reducing the price of energy when the demand was low and supply was high. The result was while plants might increase energy

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consumption, their energy bill could increase. The frequent fluctuations in electricity prices caused a domino effect across other energy sources and raw materials. To deal with unstable costs, industrial companies started changing the price of their products more frequently. This effect is seen in energy markets, but it also affects consumer production. In an increasingly speedy industrial market, plant managers must decide how much to produce, and operators must determine the best time to produce, which can sometimes diminish the importance of operational efficiency. That is, it might be more profitable to run the plant less efficiently, according to the traditional efficiency measures, to more costeffectively meet market demand and opportunity.

New approaches for process control

Process control for improved operational efficiency no longer had a direct impact on improved operational profitability; new approaches were required for the ever-increasing real-time dynamics of industrial business variables. The first response was to turn to information technology (IT) departments and enterprise resource planning (ERP) suppliers for solutions. Few, if any, realized the desired results, primarily because the IT teams and ERP software were experienced in solving traditional management problems, not real-time control problems. The solution involved understanding that, as operational profitability fluctuated more rapidly, management decisions had become control decisions. Real-time control was required. The field of real-time control is expanding from traditional process and logic control for operational efficiency improvements to other real-time domains, such as operational profitability. As new control strategies are applied to new domains, the performance of industrial operations will improve significantly, to levels never before expected. Profitable efficiency, by ceding profitability control to process control, represents one new approach and allows the user to keep the process and profits in control. ce

Peter Martin is vice president, Innovation and Marketing Process Automation at Schneider Electric. This article originally appeared April 2 on the Control Engineering Europe website. Edited by Chris Vavra, production editor, Control Engineering, CFE Media, cvavra@cfemedia.com. CONTROL ENGINEERING

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KEYWORDS: efficiency,

process control Profitable efficiency is a relatively new concept, but it is already quite common in process control applications. Implementing profitable efficiency throughout an industrial operation tends to drive new and improved levels of operational profitability. Profitable efficiency allows the user to keep both the process and profits in control.

ONLINE Read this article online at www.controleng.com for more on real-time control.

CONSIDER THIS What other benefits could profitable efficiency provide manufacturers?

May 2018

â&#x20AC;˘

INSIGHTS

TECHNOLOGY UPDATE Eddie Jones, PE, Schneider Electric

Power systems engineers help facility managers Power systems engineers (PSEs) can identify faults and optimize electrical systems in facilities.

rom installation to maintenance, all the way to modernization, electrical equipment needs care and attention to ensure its longevity. Throughout a facility’s lifecycle, electrical distribution infrastructure should be consistently maintained to ensure equipment performs reliably and reaches its full life expectancy (thus lowering overall total cost of ownership). While facility managers have the know-how to identify and fix issues within electrical systems, power systems engineers (PSEs) are the go-to specialists with the expertise to modernize, ensure proper operation, and increase efficiency of electrical systems. PSEs are often only brought in when there is a problem in the facility. PSEs can offer more to facility managers than just fixing problems and their knowledge can prove useful throughout any state of an electrical system’s life. PSEs can offer counsel n the early planning stages to influence efficent electrical system design. After installation, PSEs can be engaged with to handle a variety of tasks including commissioning, conducting engineering analysis, modernization, and addressing safety compliance issues.

Performing an engineering analysis

PSEs are very proficient in performing engineering analyses. Part of an engineering analysis is defining the current state of an electrical system and tasking the PSE with finding a way to improve it. PSEs are highly skilled in being able to look at the electrical system to identify any faults, or simply find areas of improvement. Through KEYWORDS: power their analyses, they can pinpoint specific areas systems; power system of the system that may not be performing as engineers (PSEs) well as they should, and offer realistic soluPSEs can add value to facility managers. tions that a facility manager who works with How a PSE can offer the system daily may not recognize. PSEs have strategies for risk mitigation. specialized knowledge bases surrounding difCONSIDER THIS: ferent parts of electrical systems, giving them a How can your facility breadth of knowledge on very specific details. managers work with PSEs PSEs may specialize in one area but also can to optimize your facility’s realize how their specialty can affect the peroperations? formance of the system. Thus, PSEs can effecONLINE tively guide facility managers on when to See related articles on address electrical system concerns and offer power systems on counsel on the most efficient way to do so. www.controleng.com.

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Risk mitigation

When facility managers implement a new project, a variety of risks and complications may arise, including financial, safety and operational issues. PSEs can help mitigate these risks by offering their knowledge throughout planning and implementation. PSEs can impose strategies to reduce risks such as: • Financial risk: Facility managers are interested in having an operational electrical system that can be an asset to their business. However, due to budget constraints for facility management, they often run into budget issues for projects. PSEs can help to ensure the electrical project can be implemented as cost effectively as possible. • Operational risk: Having a cost-efficient electrical system is only part of the battle; facility managers need the entire power system to be fully operational and functioning. They can rely on the expertise of PSEs to ensure maximum operation and reliability. • Safety risk: In addition to their knowledge of operational efficiency, PSEs also are highly knowledgeable with the most current safety compliance procedures, allowing them to ensure the project’s output operates safely.

PSEs are valuable partners to facility managers at any stage of a project. Bringing them in early allows them to offer their counsel from the planning and development stage and provide the knowledge around how to maintain and modernize the electrical system. Their skills in identifying ways to improve electrical systems makes them reliable resources for addressing safety concerns as well as reducing the financial burden a project may place on a facility. By using PSEs’ expertise in engineering analysis, facility managers can have a better understanding on how to increase operational efficiencies for their electrical systems. ce Eddie Jones is an engineering manager at Schneider Electric. Edited by Emily Guenther, associate content manager, Control Engineering, CFE Media, eguenther@cfemedia.com. www.controleng.com

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INSIGHTS

NEWS

Hannover Messe 2018: highlights, IIoT The Hannover Messe 2018 technology trade fair in Hannover, Germany, included many developments influencing industrial automation, such as trade, award-winning process-sensing technology, and Industrial Internet of Things (IIoT) advancements. In welcoming Mexican president Enrique Peña Nieto to Hannover to lead the delegation for Mexico’s role as Partner Country at Hannover Messe 2018, German chancellor Angela Merkel celebrated the trade deal and laid out her expectations for future agreements—with the European Union (EU), and for trade deals as a whole. The deal with Mexico and the EU, which is similar to ones signed with Japan and Canada, is reported to virtually eliminate tariffs on products exported between the two trading partners.

Mexico cuts a deal with EU

“The technical work should take place quickly now but it’s really good news for Europe, for Germany and for Mexico,” said Merkel. “We believe multilateral cooperation can add value for everyone and that’s why we’re advocating global trade that is as free as possible and which is based on common rules.” Two years ago, when Merkel welcomed Barack Obama as head of the United States Partner Country delegation at Hannover, relations on trade and business were warm between the two nations and negotiations were underway on the Transatlantic Trade and Investment Partnership (TTIP). Merkel

Two years ago, robots were offering handshakes at Hannover Messe. In 2018, the greeting has been updated to a fist bump. Image Courtesy: Hannover Messe

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CONTROL ENGINEERING

traveled to Washington, D.C., April 27 to meet with President Donald J. Trump, who has criticized the EU in general and Germany in particular over trade issues, and also has been critical of past regional trade deals. One of those pacts is the North American Free Trade Agreement (NAFTA), which is being renegotiated. Peña Nieto sounded an optimistic note over the future of NAFTA in his opening ceremony remarks. “We have optimism as well that we’re going to be concluding the renegotiation, modernization of the North American Free Trade Agreement with North America, as I have said, ensuring benefits for all partners,” Peña Nieto said. Besides all the trade talk, Mexico took center stage to present its cultural entertainment for more than 3,000 dignitaries and members of the global trade press that attended the opening ceremonies. The presentation was a bow to both Mexico’s Aztec heritage and its campaign to position itself as a major player on the manufacturing and technology stage. The annual Hermes Award for innovation bypassed two augmented reality (AR) platforms and was presented to Endress+Hauser for its hygienic compact thermometer featuring a self-calibrating sensor for process temperature measurements.

IIoT potential has big names seeking new solutions

In the manufacturing renaissance that is the IIoT, it’s clear that no one supplier can be all things to all plants. It’s also clear more companies are trying to provide more options than before. SAP is an enterprise software company that has introduced a digital manufacturing cloud. “When you think about digital coming to the shop floor, you look at vertical integration,” said Georg Kube, the SAP global vice president for industrial machinery and components. “That information has to be processed in the logistics system. We’re the people who have done all the logistics, so it was a natural point for us to expand into actually producing the product.

“Manufacturing changed; it’s become more focused on the individual order, the individual workpiece,” said Kube. “Now that become we’ve become faster, more individual needs need to be catered to. We want and need more products in small batches. That was not humanly doable before, and that is why digital came onto the shop floor.”

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Cybersecurity scope expands

Inherent in the digital age is cybersecurity. Microsoft has expanded into cloud computing and is working with the OPC Foundation to securely connect its Azure cloud service through OPC UA servers. The goal is to allow automatic security in cloud computing. “The big thing we’ve added is the automatic discovery of assets in the factory. We make them available to the cloud by registering them automatically,” said Erich Barnstedt, principal software engineering lead for Microsoft. “The key word is ‘automatic’. You just want to be able to tell the user that their machines are secure.” Barnstedt said many manufacturers aren’t far enough along on the IIoT journey to be concerned about security. Right now, they’re still struggling with whether or not their plant is big enough to extract value from IIoT technologies. “It’s a big problem. What we tell them is that, you can generate value at just the first step by centralizing data and creating dashboards,” he said. “That already is revolutionary to a lot of folks. The trick is to start collecting data.” Bob Vavra is content manager, Plant Engineering, CFE Media, bvavra@cfemedia.com.

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NEWS

Ten best practices for system integration companies and projects Automation and control system integrators and those doing system integration project should consider 10 attributes, according to the Best Practices and Benchmarks Manual, version

5.0, from the Control System Integrators Association (CSIA). Critical considerations in each of the 10 areas follow below, including what should be included in project management, system

development lifecycle, quality management, and cybersecurity: • General management: strategic management, organizational structure, facilities and equipment, computer systems management, and corporate risk management • Human resources managment: administration, recruitment and selection, performance management, training and development, compensation and benefits, and employee communication • Marketing, business development, and sales management: marketing plan and sales strategy best practices • Financial management: measures of performance, financial planning, billing procedures, and tax policy • Project management: aspects of project management include contracts, procurement, planning, risk, resources, communications, scope, scheduling, budgets, change, quality, and closure • System development lifecycle: internal kickoff, requirements, design, development, unit/module and integration testing, factory acceptance testing (FAT) and site acceptance testing (SAT), system shipping, installation, and commissioning • Supporting activities: process development and maintenance, standards and templates, project methodologies, procurement management, risk management, configuration management, and reuse management • Quality management: continuous measurable improvement, client satisfaction measurement, client service, and project quality assurance • Service and support: strategic management, organizational structure, methodology, and service management • Information systems management and cybersecurity: facilities and equipment protection from an information systems management and cybersecurity standpoint. - Edited from a CSIA press release by CFE Media.

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Digital edition? Click on headlines for more details. See news daily at www.controleng.com/news

Vibration, industrial process control companies merge

ottinger Baldwin Messtechnik GmbH (HBM) and Brüel & Kjær Sound and Vibration A/S (BKSV), both owned by U.K.-based Spectris plc, will merge their businesses. The merger will become effective on Jan. 1, 2019. Preparation activities will take place through the remainder of 2018. The merger will build on each company’s respective capabilities and also will be reflected in the name of the new company: Hottinger, Brüel & Kjær (HBK).

Both BKSV and HBM are global market leaders in their respective disciplines. BKSV´s strength is in sound, noise, and vibration; HBM focuses on propulsion efficiency, electrical properties, industrial process control, and

weighing. The merger is intended to strengthen their ability to drive digital transformation for their respective customers around the world. - Edited from an HBM press release by CFE Media.

Headlines online Top 5 Control Engineering articles April 16-22 Most viewed articles included ladder logic, Triton cybersecurity advice, AI and robotics, digital plant-floor technologies, and wellsite valve manifolds. University opens engineering facility Louisiana State Univerity College of Engineering celebrated the opening of the Patrick F. Taylor Hall, which at more than 400,000 sq ft is the largest academic building in Louisiana and one of the largest freestanding U.S. engineering academic buildings. Embedded vision systems’ potential for imaging, vision technology Embedded vision systems have the potential to transform imaging and vision technology and will push the boundaries of what’s possible with machine vision technology. Robotics’ impact on construction Robots are being used more for certain applications to improve overall worker safety and handle some repetitive tasks in an industry known for a lack of automation. Industrial Ethernet market projected to show strong growth The industrial Ethernet market is set to grow from its current market value to over $72 billion by 2024: Global Market Insights. Survey: Senior executives not confident in cyber protection Few organizations are highly confident in the ability to manage the risk of a cyber attack even though it is a major priority, according to a survey by Marsh and Microsoft.

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INSIGHTS

Digital edition? Click on headlines for more details. See news daily at www.controleng.com/news

NEWS

Fog computing conference to cover IoT, 5G, future The second edition of the Fog World Congress, scheduled Oct. 1-3 at the San Francisco Airport Hyatt, will bring together industry leaders, technologists, and researchers from around the world to discuss, explore, and share fog computing

insights, research, applications, and projections. A full day of tutorials and research tracks are scheduled for Oct. 1, followed by keynotes, panel sessions, and exhibitions on Oct. 2 and 3. The Fog World Congress, “Through

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tutorials, case studies and futuristic research, it provides a comprehensive lens into how fog is changing the game in Internet of Things (IoT), 5G, and artificial intelligence (AI),” said Helder Antunes, chairman of the OpenFog Consortium and senior director, Cisco. “Whether you are new to fog or are immersed in it, this conference is the place to come to network with others and to learn about who and what is driving the coming era in fog.” Last year’s inaugural event attracted hundreds of attendees, 80 speakers, 30 exhibitors, and representatives from companies across the globe. Event organizers predict the attendance numbers to increase as fog computing continues to advance and the technologies become more mainstream. “Last year conversations were focused on ‘what is fog and why do we need it.’ Fast forward one year, and much of that conversation has shifted to ‘fog is now moving innovation from the lab to the real world,’” said Lynne Canavan, cochair of the Fog World Congress and vice president of marketing, OpenFog Consortium. “From package-delivering drones to factory-floor robots, and from privacy in connected cities to robotic surgery, we’re hearing the mantra ‘this is fog’ growing louder.”

Headlines online Internet and manufacturing event announced The 2nd Annual Internet of Manufacturing Midwest conference in Chicago, June 6-7, 2018, is designed to bring business and technical executives from leading manufacturers to share best practices and case studies, and to inspire new revenue opportunities. Manufacturing remains red hot, but labor issues abound The Institute for Supply Management’s (ISM’s) purchasing manufacturers’ index (PMI) dipped slightly in March to 59.3%, but skilled worker shortage remains a concern.

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2018

Career & Salary Research SPONSORED BY:

Turning Research into Insights Makes for Better Business Decisions Control Engineering career and salary research shows that engineers are getting paid more and a greater percentage expect to get increases in 2018 while technical challenge and feeling of accomplishment continue to rank higher than financial compensation for job satisfaction. With the average respondent being in their 50’s, the average base salary earned by 50- to 59-year-olds was $104,482, and the average bonus received in 2017 was $11,102 – for a total take-away of $115,585. The top three factors that impact end users’ satisfaction towards their jobs are the level of technical challenge, feelings of accomplishment, and financial compensation. Access the full Control Engineering 2018 Career & Salary Research with additional findings and insights. www.controleng.com/2018SalaryReport

INSIGHTS THINK AGAIN

3010 Highland Parkway, Suite 325, Downers Grove, IL 60515. 630-571-4070, Fax 630-214-4504

Learning from mistakes Minimize risk and maximize rewards of control system integration projects with this advice.

nderstanding pain others have Clearly document IP Intellectual property (IP) rights, as felt in control system integration projects can help avoid part of many system integration projects, similar experiences. System should be carefully spelled out in the conintegrators learn from each other using tract, and any changes documented as the “Best Practices and Benchmarks the project progresses, said Miller, echoManual,” version 5.0, from the Control ing advice offered by Mark A. Voigtmann, System Integrators Association (CSIA; see partner, Faegre Baker Daniels LLP, in a related news story), in peer groups, and session the day prior. Project management tips in the “Lessons from Touching from Miller included the fola Hot Stove,” a conference seslowing. Trust and rely on your sion at the 2018 CSIA Executeam. Don’t agree to a bad deal: tive Conference in April. “No,” is the most powerful word Nigel James, chief strateyou have. Avoid one client being gic officer at Burrow Global; a majority of your business. Kenneth Miller, president at If litigation is involved, don’t Erdo Miller; and Titus Crabb, panic. Consult with experts, president at Vertech, explained Mark T. Hoske, notify insurance and legal teams what they learned, citing CSIA Content Manager immediately, talk to clients and best practices. employees honestly and transSize, scope, optimism bias parently, explore every avenue of defense, James warned against optimism bias, and try to work it out and settle at the explaining the lure of a large contract may right time. Continue to work toward a setcause system integrators to overlook key tlement. End ongoing relations with the warning signs. Scope creep, where a projplaintiff. Finish projects and put boxes on ect gets larger in what seems like insigthe client’s doorstep. Bring a lawsuit to an nificant increments, can cause challenges end as quickly as practical (it takes time) later if not addressed early. Communicate without ignoring family and yourself. appropriately upfront when a problem Trust and verify arises, discussing the right information, Crabb warned against taking on a projright impact, at the right time, with the ect that would represent a majority of revcorrect tone, without delay. enue for a year. Other advice included to “Don’t be afraid to tell the client what ensure the needed experts are available can go wrong” when changes are proprior to bidding for a project, check proposed, James said, and be sure to ask the grammers’ code often, and ensure random right questions of project managers. drug tests are in place for everyone. For Poor: “How’s it going?” which will financials, use tools to manage cash flow. likely return, “Fine.” Better: “What is different?” which may For project execution, set internal milestones and reviews. Develop project methreturn critical details, such as: “The cusodologies and note they may differ by tomer gave us 15 new process and instrumentation diagram (P&ID) changes today, industry and project type. When jumping at a system integrawhich could set us back 2 weeks.” tion project and thinking, “We got this,” James advocated continuous learning. think again. All lessons learned here have best practices written all over them, Crabb said. Learning from others, including reviewing questions in the CSIA’s “Best More advice follows on the following pages Practices and Benchmarks Manual,” can and at www.controleng.com/CE-research. help avoid taking lumps yourself. ce

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May 2018

CONTROL ENGINEERING

Content Specialists/Editorial Mark T. Hoske, Content Manager 630-571-4070, x2227, MHoske@CFEMedia.com Jack Smith, Content Manager 630-571-4070, x2230, JSmith@CFEMedia.com Kevin Parker, Senior Contributing Editor, IIoT, OGE 630-571-4070, x2228, KParker@CFEMedia.com Emily Guenther, Associate Content Manager 630-571-4070, x2229, eguenther@CFEMedia.com Amanda Pelliccione, Director of Research 978-302-3463, APelliccione@CFEMedia.com Chris Vavra, Production Editor CVavra@CFEMedia.com

Contributing Content Specialists

Suzanne Gill, Control Engineering Europe suzanne.gill@imlgroup.co.uk Ekaterina Kosareva, Control Engineering Russia ekaterina.kosareva@fsmedia.ru Seweryn Scibior, Control Engineering Poland seweryn.scibior@trademedia.us Lukáš Smelík, Control Engineering Czech Republic lukas.smelik@trademedia.us Aileen Jin, Control Engineering China aileenjin@cechina.cn

Editorial Advisory Board

www.controleng.com/EAB Doug Bell, president, InterConnecting Automation, www.interconnectingautomation.com David Bishop, president and a founder Matrix Technologies, www.matrixti.com Daniel E. Capano, president, Diversified Technical Services Inc. of Stamford, CT, www.linkedin.com/in/daniel-capano-7b886bb0

Frank Lamb, founder and owner Automation Consulting LLC, www.automationllc.com Joe Martin, president and founder Martin Control Systems, www.martincsi.com Rick Pierro, president and co-founder Superior Controls, www.superiorcontrols.com Mark Voigtmann, partner, automation practice lead Faegre Baker Daniels, www.FaegreBD.com

CFE Media Contributor Guidelines Overview Content For Engineers. That’s what CFE Media stands for, and what CFE Media is all about – engineers sharing with their peers. We welcome content submissions for all interested parties in engineering. We will use those materials online, on our website, in print and in newsletters to keep engineers informed about the products, solutions and industry trends. www.controleng.com/contribute explains how to submit press releases, products, images and graphics, bylined feature articles, case studies, white papers, and other media. * Content should focus on helping engineers solve problems. Articles that are commercial or are critical of other products or organizations will be rejected. (Technology discussions and comparative tables may be accepted if non-promotional and if contributor corroborates information with sources cited.) * If the content meets criteria noted in guidelines, expect to see it first on our Websites. Content for our e-newsletters comes from content already available on our Websites. All content for print also will be online. All content that appears in our print magazines will appear as space permits, and we will indicate in print if more content from that article is available online. * Deadlines for feature articles intended for the print magazines are at least two months in advance of the publication date. Again, it is best to discuss all feature articles with the appropriate content manager prior to submission. Learn more at: www.controleng.com/contribute

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2018 CAREERUPDATE

Control Engineering

Career and Salary Survey Engineers are getting paid more, and more expect to get increases in 2018; technical challenge and a feeling of accomplishment remain the highest factors for job satisfaction.

ngineers are getting paid more in 2018 ($100,339 compared to $96,045 for 2017 survey respondents), and 75% expect to get a salary increase in 2018, according to respondents to the Control Engineering Career and Salary Survey for 2018. That’s up from 69% who expected an increase in 2017. Additionally, technical challenge and feeling of accomplishment both rank higher than compensation for job satisfaction criteria. As Figure 1 shows, almost 20% expect 4% or more for a salary increase in 2018 (up from 13% in 2017); 7% expect an increase more than 6% (up from 4% in 2017); 23% expect the same (29% did in 2017); and just 2% expect a salary decrease (equal to 2017). Upward salary pressures correspond with strong U.S. manufacturing results, more than 19 months of growth as of March, according to the Institute for Supply Management (ISM) monthly purchasing manufacturers’ index (PMI).

Expected change to 2018 base annual salary Decrease 2%

Increase more than 6%

Stay the same

23%

Survey methods

Survey respondents for the Control Engineering Career and Salary Report for 2018 were invited to anonymously provide their annual compensation information and opinions on the current state of their facilities and industries. The 2018 Control Engineering Career and Salary Report reflects data gathered from 331 automation professionals; margin of error is +/- 5.4% at a 95% confidence level. For non-salary compensation (Figure 2), 21% expect an increase (down from 27% in 2017); 15% expect an increase of 4% or more (10% in 2017); 9% expect more than a 6% increase (6% in 2017); 58% expect about the same (62% in 2017); and 11% expect less (same as 2017). For base salary compensation, the minimum was $25,000 (same as 2017) and the maximum was $342,000 ($216,513 in 2017), for 299 survey respondents providing this information. For non-salary compensation, the 2018 average received among 299 respondents was $10,091 (up

from $9,594 in 2017); among the 68% receiving a bonus (203 respondents) was about the same as 2017, and the average was $14,863 (up from $14,216 in 2017). The highest bonus reported, as Figure 3 shows, was $344,000.

Bonus criteria

Two leading criteria for bonus compensation were company profits, 73%, and personal performance, 62% (Figure 4), which is a significant shift from 59% and 43%, respectively, in 2017. Other significant criteria from 35% to 25% include product profitability, safety metrics, new business, sales increase, quality metrics, and plant or line productivity. Graphic shows five other double-digit criteria, including energy efficiency at 11%.

Technical challenge

Rank order of job satisfaction factors (Figure 5) year over year remained the same for the top four: technical challenge, feeling of accomplishment,

Compensation summary 2018

Expected change to 2018 non-salary compensation Increase more than 6%

Decrease

Increase 4% to 6%

11%

12%

6% 16%

Minimum

$25,000

Maximum

$342,000

Non-salary compensation

Increase 4% to 6%

Figure 1: 75% expect a salary increase in 2018. All graphics courtesy: Control Engineering 2018 Career and Salary Survey

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May 2018

CONTROL ENGINEERING

Stay the same

$10,091

Percentage receiving bonus Average among 203

Increase 1% to 3%

$100,339

Average among 299

58%

56%

Salary

Increase 1% to 3%

Figure 2: 31% expect an increase in 2018 non-salary compensation and about half of those expect more than a 6% increase.

68% $14,863

Minimum

Maximum

$344,000

Figure 3: In 2018, average salary of respondents topped $100,000, with average non-salary compensation adding more than $10,000. www.controleng.com

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financial compensation, and relationship with colleagues. Location moved into the fifth spot, up from eighth in 2017. Other criteria above 15% are benefits, flexible work hours, job security, and feeling of recognition. Flexible work hours was added to the survey list of possible answers in 2018 and made a strong debut in the ranking among respondents.

Mark T. Hoske is content manager, Control Engineering, CFE Media, mhoske@cfemedia.com. Amanda Pelliccione, CFE Media research director, provided data, apelliccione@cfemedia.com.

Company profitability Product profitability Safety metrics New business, sales increase Quality metrics Plant or line productivity Company stock performance Reducing plant costs Uptime/downtime Customer feedback Energy efficiencies Other

10%

20%

30%

40%

50%

60%

70%

Figure 5: Top job satisfaction factors are technical challenge and feeling of accomplishment, followed by financial compensation and relationship with colleagues.

Areas of operations

Technical challenge Feeling of accomplishment Financial compensation Relationship with colleagues Location Benefits Flexible work hours Job security Feeling of recognition Relationship with boss Ability to work from home Advancement opportunities Workload Company's financial health Leading a team Company size Travel Relationship with subordinates Managing people Work environment Other

Budget, profits, financials Automation and controls Operations Customers, sales Safety Product development Energy Maintenance Manufacturing IT Systems

Highest emphasis Should have highest emphasis

Training, education Other Equipment upgrades Instrumentation Human Resources

10%

20%

30%

40%

Figure 4: Leading criteria for non-salary compensation by a significant margin are company profitability and personal performance with product profitability and safety metrics next in line. www.controleng.com

On the next pages, see: Advice from survey respondents; Women in engineering; The future of work; and Engineering career ROI.

Personal performance

Job satisfaction factors

CONSIDER THIS

Criteria for non-salary compensation

What should get emphasis

The survey asked respondents what areas do and should get emphasis within their organizations. There continues to be a significant disparity between what does and what should receive emphasis. Top two areas that do get emphasis are budget, profits, financials (a 2018 addition based on write-in entries in 2017), and automation and controls. The top two areas that should get emphasis are automation and controls as well as customers and sales (another new entry in 2018). See Figure 6. The 2018 respondents noted that training and education should get more than three times the emphasis it currently does.

Download the full 2018 Career and Salary Report at www.controleng.com/CE-research for respondent regions, titles, functions, company size, staffing, energy, cybersecurity, outsourcing, and salary and non-salary compensation benchmarks by age, education, number of years with employer and industry, by job title, by job function, and by employees managed.

10%

15%

20%

25%

Figure 6: In the areas of operations, budget, profits, financials get the highest emphasis, but automation and controls should receive the highest emphasis.

CONTROL ENGINEEERING

May 2018

â&#x20AC;˘

2018 CAREERUPDATE

Advice: Education, workplace strategies, tips Control Engineering career advice was offered by those taking the 2018 survey. Education and workplace strategies were the biggest topics, followed by engineering tips.

ducation and workplace strategies are among engineering career advice offered as a write-in option on the survey for the 2018 Control Engineering Career and Salary Report; 146 respondents offered writein advice which was then grouped for analysis and presentation into six categories: education, workplace strategies, attitude, communication, project management, and engineering tips. (See graphic on engineering skills needed to advance.) While many pieces of advice could be grouped into more than one category, only one category was chosen for each in this tally. Classification is subjective, but, even so, it’s interesting to note increasing emphasis on workplace strategies and engineering tips. Engineering career advice follows by category; download the full report for more.

Career advice: 2018 vs. 2017 Advice type Education Workplace strategies Engineering tips Attitude Communication Project management

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May 2018

2018

2017

38%

47%

Education

Always try to keep learning new skills and knowl34% 26% edge throughout your career. 13% 3% Complete education and 7% 10% obtain certifications. 4% 7% Constantly study new methods and implement 4% 7% them as necessary. Develop deep technical mastery in at least one area. Engineering is the application of science. Engineers take the challenge to convert science to technologies to uplift the living standards of humanity. For engineering students, obtain an internship with a company in your area of interest. Real-world job experience is a must have to move from student to job holder. Get a combination of electrical/electronics and mechanical degrees. Get a degree in software. Get an MBA or a Master’s Degree in your engineering field. Get automation and robotic and specialized safety training for robotics and electrical, especially arc flash; companies and not even OSHA take this seriously. If we are going to get youth interested in a trade we need CONTROL ENGINEERING

to be pushing this in schools in grades 4-6. Science, technology, engineering, and match (STEM) careers, yes, but what about plumbing, electrical, and craft trades? If you hook them early then STEM will work, but you have to get them to want to work with their hands. We do not pay our teachers enough or supply schools with the proper funds to get what it takes to excite the kids to want more. Get specialized in something that is in demand. Get training in data communication for control systems applications. Get your PE license. Never stop studying codes, standards, reading white papers, and industry publications. Go into mechanical engineering. (I have to maintain and get the junk they select running.) I believe it’s critical to keep technical knowledge and skills current, and to be constantly learning. Industrial Internet of Things (IIoT) is among the best options to choose after completing engineering from electronics/instrumentation/EEE/ECE. In manufacturing, study mechanical, industrial, and electrical engineering with PLC programming mixed in. Industrial or manufacturing engineering is probably the best all around area, and then take certain classes to fill in the rest. Keep your skill set relevant. Go to seminars, webinars, and association meetings as often as possible. Learn as much programming as possible. Question everything. Just because an expert says something doesn’t make it correct; only makes it an educated guess based on history and experience.

Workplace strategies

1) Use both left- and right-brain development skills. 2) Always think about automation. 3) Think about application of engineering knowledge to save the Earth and help people live happily. Aim for versatility. Always ask questions to understand why you do what you do, and do your best. Always keep your eyes open for more opportunities even if you believe you are happy where you are at. Be flexible, to function across multiple disciplines. www.controleng.com

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2018 CAREERUPDATE

Look for business rationale in everything you do. Be sure to find a mentor. Consider automation as a career to use your engineering skills. Find something that you enjoy doing. It’s the time of your life; don’t just be looking forward to retiring! Follow the money. Get a job where they value your talent in an area where you like to live. Get as much field experience as possible by actually performing the jobs that operators and maintenance workers do. Invest in your 401(k). KEYWORDS: Engineering Jump on the opportunity to be a part career of a company that is investing in new Engineering job advice includes technology and is driven to stay ahead of education, work strategies, and the curve. New challenges are what make engineering tips. engineering such a rewarding career! Never stop learning new things or challenging yourself. Manufacturing isn’t a dirty word, and Learning objective style is a job in manufacturing can be technically good. challenging and rewarding. Never stay satisfied and always CONSIDER THIS improve. Become an obsessed, candid, What advice that has served you well you would offer that wasn’t and empowered leader. provided here? Really evaluate a job offering prior to accepting the job offering. Find a ONLINE place that wants to invest in technology If reading from the digital edition, click on the headline for more training. advice in a longer online version Start with a small company and get a of this article. Find the full 2018 lot of experience and/or start a business. Control Engineering Career and Success will come if you work for pride Salary Report at and accomplishment and not only money. www.controleng.com/CE-research.

M More ANSWERS

Skills needed to advance Engineering skills Project management skills Communication/presentation skills Computer skills

Language skills Marketing/sales skills Finance/accounting skills Other Don't know

10% 20% 30% 40% 50% 60% 70%

Control Engineering asked subscribers what skills they need to advance. The 307 respondents ranked the following as most important: engineering skills, project management skills, communication and presentation skills, computer skills, and team-building skills. Courtesy: 2018 Control Engineering Career and Salary Report

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May 2018

Advanced control systems can give more efficiency to the processes. The most important thing to be successful is to have a good management system and produce product the market needs. Be familiar with different programming languages and software; Be worldwide minded. Broaden your views and skills. Being too focused and working in a silo creates gaps between you and colleagues and impedes successful implementations. Operations technology and information technology people must come together. Develop an interest in industrial automation. Get involved, get hands on, and understand reallife applications. Information flow efficiency is and will be the critical competitive advantage. Try automation. Use the general engineering way of thinking.

Attitude

Always do the best job you can. Be curious; Be inspired; Be strong and courageous. Do what you love, then what you’re doing really isn’t work. Don’t quit. Hang in there; Keep on trying and eventually you will win; Stay flexible. Stay positive and focus on each day. Enjoy today.

Communication

Develop the ability to communicate. Listen for management fads and work buzzwords into presentations even if they don’t have anything to do with your product. Most of all, anything you engineer, picture yourself having to maintain it. That person will reward you with respect and trust. Network with peers. Practice soft skills (communication, project management, mentoring) and core engineering disciplines.

Project management

Team-building skills

Engineering tips

CONTROL ENGINEERING

Engineering is all details, but don’t miss the project’s big picture among those details. Learn to adequately justify the need for equipment improvements and automation to sustain and improve your business. Perform adequate upfront engineering to minimize costly unknowns during project. Think more of managing people and processes. Too many engineers fail to value the people part. ce

Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media, mhoske@cfemedia.com, and data provided by CFE Media research director, Amanda Pelliccione, apelliccione@cfemedia.com. www.controleng.com

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2018 CAREERUPDATE

Reworking the gender balance Women in STEM: Bringing more women into the artificial intelligence (AI) and Internet of Things (IoT) industries can help reduce some of the ingrained bias in development.

e•Work’s third Women in AI dinner was held in London in February 2018. This regular networking event celebrates women in artificial intelligence (AI) and showcases their achievements. The speakers are women, but these are not women-only events. Diversity is about inclusivity, not segregation. There are not enough women working in tech, let alone in AI. In the U.K., for example, 83% of people working in science, technology, engineering and math (STEM) careers are men, according to figures presented at UK Robotics Week 2017. It has been reported that less than 10% of coders are women, despite Ada Lovelace being widely considered to be the first computer programmer. Re•Work is attempting to improve the gender balance in the burgeoning AI community by organizing dinners with female expert speakers who talk about their work at the cutting edge of emerging technology. Re•Work founder Nikita Johnson and her team are careful not to dwell on traditional “women’s challenges.” Instead, Re•Work is focusing on technology and research, showcasing women in AI in a way that overrides traditional preconceptions. Bias and preconception are ingrained in society, which means they are ingrained in the AI applications data. The first presentation by Silvia Chiappa, senior research scientist at DeepMind, was about innovating towards algorithmic fairness.

Curing the bias virus

M More

ANSWERS

KEYWORDS: artificial

intelligence, IoT, gender gap Too few women join STEM industries. Bias and preconception are deeply ingrained in society, and in data used in AI applications. Accepting AI requires transparency about how the system has been designed to help minimize potential bias.

ONLINE Read this article online at www.controleng.com for more information about AI and additional articles from Internet of Business.

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May 2018

Machine learning already is used to make and support decisions or processes that affect people’s lives: in hiring, education, lending, and in policing and law. Judges and parole officers use algorithms to predict the likelihood a defendant or prisoner will reoffend. It is critical to ensure the algorithms are not biased toward or against individuals from particular social or racial groups. The big challenge is it is impossible to take the bias out of historical/precedent data (which reflects preconceptions that existed in society at the time), so DeepMind is innovating ways to increase algorithmic fairness. In AI terms, it is ineffective to disregard sensitive factors like race or gender, or

CONTROL ENGINEERING

give them a negative weighting, because this can have a negative impact on system performance. It may not increase fairness because these factors are correlated with other attributes. There is a positive correlation between race and neighborhood. This underlines the importance of contextualizing problems: identifying conscious and unconscious bias and looking for solutions. Biases cannot be eliminated, but can use them to work towards a fairer society, said Chiappa. The second presentation was from Cecilia Mascolo, professor of mobile systems at the University of Cambridge and The Alan Turing Institute. She covered potential applications for built-in computational units on smartphones and wearables, particularly in countries with little cloud platform access. Possibilities include using a smartphone’s AI capabilities to support health care applications. Voice recognition can be used for mood monitoring and early diagnosis of Alzheimer’s disease. Constant monitoring and/or the collection of detailed location data, have privacy implications. Mascolo said more localized computations could reduce privacy concerns.

Self-diagnosis in wind turbines

The final presentation was from Fujitsu’s lead deal architect, Marian Nicholson, who discussed the application of deep learning in advanced image recognition. Examples include teaching wind turbines to recognize a defective blade. Fujitsu’s work starts from the premise that humans are predominantly visual conceptualizers (babies recognize images and relate them to their surroundings). Image recognition is important for autonomous and semi-autonomous vehicles, delivery drones, and more. Nicholson noted recent headlines about the dangers of AI and said organizations can choose to use technology for good. Fujitsu’s mission is to build technology that will benefit society, she said. AI acceptance requires transparency about data, how the system works, and—critically—why it was designed, along with the ability to identify and minimize bias. The power and potential of AI are balanced by the responsibility to used it safely and fairly, she said. ce

Joanne Goodman, Internet of Business. This article originally appeared on Internet of Business’ website. Internet of Business is a CFE Media content partner. Edited by Chris Vavra, production editor, Control Engineering, CFE Media, cvavra@cfemedia.com. www.controleng.com

2018 CAREERUPDATE Peter Dizikes, MIT News Office

Task force on future workplace MIT launched its task force on the Work of the Future, an Institute-wide effort to understand and shape the evolution of jobs during an age of innovation.

IT launched its Task Force on the Work of the Future, an Institutewide effort to understand and shape the evolution of jobs during an age of innovation. MIT’s provost Martin A. Schmidt announced the task force’s mission in a letter to the MIT community. “The MIT Task Force on the Work of the Future takes as a guiding premise that addressing the social and human implications of technology should not be an afterthought, but instead should be a first concern that pervades how we design, innovate, and take our ideas to market, as well as what we teach our students, the technologists of tomorrow,” Schmidt wrote. The task force’s project is a vital part of examining the strength of our civic fabric, said L. Rafael Reif, MIT president. “In profound and pervasive ways, the technologies humans invent in the present will set the terms of our shared future. The global race to advance those technologies has thus become a race to determine the nature of society itself. Through the work of the task force, we hope to help the nation reflect on what kind of society we aspire to—and come together to make it real.”

Make a future workplace

Since at least the Industrial Revolution, new technologies have created and replaced jobs at large scales, while altering many other forms of work. New developments in artificial intelligence, automation, information technology, 3-D printing, and other areas of innovation are reshaping traditional jobs and have the potential for further change. Faced with an uncertain landscape and growing concerns about the issue across the political spectrum, the MIT Task Force on the Work of the Future will conduct an empirical, interdisciplinary, and global study of the subject, to understand work and its possible future trajectories. The task force aims to enlighten the linked evolution of technology and human work and will issue findings to guide the development and implementation of policy, and suggest how society can continue to offer broad opportunity and prosperity. The new initiative will build on existing MIT scholar research and and tap into the Institute’s unique range of scholarship. The MIT Task Force on the Work of the Future consists of a faculty and student research team of more than 20 members, as well as an

www.controleng.com

The task force leadership team consists of (right) David Autor, Ford Professor of Economics and associate head of MIT’s Department of Economics; (left) David Mindell, Frances and David Dibner Professor of the History of Engineering and Manufacturing, and professor of aeronautics and astronautics; and (center) Elisabeth Reynolds, executive director of MIT’s Industrial Performance Center (IPC) and lecturer in the Department of Urban Studies and Planning. Courtesy: Melanie Gonick, MIT

external advisory board. Additional researchers will supplement the efforts of the core task force members. Fields include engineering and cognitive science, economics, management, political science, anthropology, education innovation, and the history of technology. The task force leadership team includes David Mindell, Frances and David Dibner Professor of the History of Engineering and Manufacturing, and professor of aeronautics and astronautics. Mindell, an engineer, historian, and entrepreneur who has written multiple books about human-machine interactions, said he is “honored” to be co-chairing the task force. “I believe it is the most important thing MIT can be doing right now, as the world is clamoring for sober, informed assessments on how we can shape the future of technology and work.” MIT also is launching the MIT Intelligence Quest (MIT IQ), an interdisciplinary project to study and develop human and machine intelligence. The task force’s KEYWORDS: Career training, ability to draw upon the latest develworkforce development opments from MIT IQ will help it stay MIT formed a task force on the informed about the leading edge of intelWork of the Future. ligence research and its possible workThe task force will integrate technology, expertise in the social place applications. ce

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Peter Dizikes, Massachusetts Institute of Technology (MIT). Edited by Chris Vavra, production editor, Control Engineering, cvavra@cfemedia.com.

and human sciences, and public policy. The task force also will use MIT’s Intelligence Quest (MIT IQ), which is studying human and machine intelligence.

CONTROL ENGINEEERING

May 2018

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2018 CAREERUPDATE

Gary Miller, Miller Resource Group

Career return on investment

Engineer your career for maximum return. Review and implement six (sometimes painful) best practice tips to achieve a satisfying and productive career return on investment (ROI).

ngineers know life is about effort, and six best practices can engineer a faster return on career investment (ROI). Control engineers are familiar with Sir Isaac Newton’s third law of motion that every action has an equal and opposite reaction. Programming a programmable logic controller (PLC) is like that, right? If this condition is met, then another event will occur. This doesn’t appear to play out for your career as we’ve learned in decades of interviewing professionals. Some of the outcomes are digital like money. You do the work and you get paid. Some paid fairly, others not so much. You also could be seeking or enjoying the work itself, status, responsibility, contribution, job security, or work-life balance. Aren’t these things the most difficult to measure even though they are sometimes the most valuable? Whatever the intent, the outcomes, and the measurables, they are uniquely yours. It’s your time and your investment of effort. That investment can be modest—hoping for a small, safe return like a savings account or certificate of deposit. It can be all-out aggressive like a venture capital-backed start up with potential for big gains coupled with a high risk of failure. Six suggestions and ideas follow for engineering a career for maximum ROI.

M ANSWERS

KEYWORDS: Engineers, career tips Engineering career advice Develop skills needed to reach your career vision Remain in charge of your career destiny. CONSIDER THIS What steps have you taken to engineer your career goals this week, this month, or this year?

ONLINE If reading from the digital edition, click on the headline for more resources. www.controleng.com/magazine See related career advice in this issue and the full 2018 Career and Salary Report online. www.controleng.com/CE-research

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1. Start a career direction with a vision

Andrew Carnegie, the great steel magnate of early Industrial America, once hired a consultant to observe him for a week and make recommendations for how he could improve his performance. At the end of the week, the consultant gave Carnegie one piece of advice. Every night, before leaving the office, write down the six most important things to accomplish tomorrow. Carnegie claimed this simple tactic helped him grow his enterprise more than any other behavior. If that’s true, and in fact, if a simple habit of making a “to do” list for a day is a career (and industry) game changer, why couldn’t one benefit from making a “to do” list for life? Who has responsibility for painting the picture of what you want to be when you

CONTROL ENGINEERING

grow up? If not you, then who? If not now, then when? Finding the answer doesn’t need to be any more complicated than sitting down with a yellow tablet or new computer document and brainstorming. In 15 to 30 minutes, perhaps early with coffee or late with a glass of wine, write down everything you can possibly imagine you’d ever want to be, do, or have. Quickly, they start falling into categories like, career, financial, physical, recreation, family, spiritual, philanthropic, etc. If one or two categories seem popular, then make separate lists. For this exercise, focus on career goals. What do you want to accomplish? Do you want to lead? Do you want to invent? Do you want to help build a company? Do you want to use your leadership to advance in a big corporation? What’s the grandest vision you’ve ever had for yourself? This is the place to stretch, be crazy, and go for it. The result should talk about career possibilities. The bigger the stretch, the bigger the possibility. If you never think of it, it’s unlikely to happen. If you do think of it, it might happen, especially if you write it down. It’s yours, and the career paper is likely to affect every other list you make for financial, recreation, house, family, and other areas. It’s that important.

2. Invest in yourself

Jim Rohn, the renowned motivational speaker, said, “Work harder on yourself than you do on your job.” What steps can you take to obtain higher returns? The first is to develop a curious mindset about the known world. If you’re an engineer, how much do you think about influence, leadership, selling, and economics? How many books on these subjects do you read? What do the leaders of great companies read? What do you listen to in your car during a commute? Listening to books on these topic while driving. Keep asking: Have you attended seminars in your field? Taken an outside class? Have you considered continuing your education? Would you join Toastmasters to improve public speaking skills? Daniel Pink’s book, “To Sell is Human” suggests that all people are in sales, and a good salesperson always looks for opportunity and to increase value. If you don’t place a high value on yourself and work on increasing it, the world will not rush to do it for you. If you want to be a most valuable engineer (MVE), you’ll have to do the work. Consider asking www.controleng.com

Adrian Williams (right), automation recruiter, and Gary Miller, president, Miller Resource Group, discuss strategies to help engineers meet career goal expectations. Courtesy: Miller Resource Group

your manager, or even an outside mentor, about how to make a larger contribution.

3. Develop subject matter expertise

It’s wonderful to be passionate and fascinated by a subject at the same time. A common interview question is: “Tell me something you’re passionate about.” I don’t care too much about the topic; I’m looking to see if the passion muscle is there. The same passion and thirst for knowledge I apply to my golf obsession also is applied to the dynamic of interviewing and learning how the best matches are made. Any subject about communication, behavioral psychology and economics, leadership, hiring, selection, and personality profiling are all areas of interest for me. Those—layered with a strong interest in automation and technology advancements—have created a calling card for me with some notoriety. What’s your area of expertise? If nothing grabs you, then keep searching, reading, and investigating. Soon, a topic will reach out and grab you. Relate back to the initial concept of vision and write it down to improve the odds it will happen so you can say, “In five years, I’ll be known for my expertise in (fill in the blank).”

4. Customer, team, you

In business, there are two things: marketing and politics. Marketing is any topic that involves serving a customer. Engineering, marketing, and even accounting all relate back to the customer in one way or another. Politics is anything not focused on the customer and is usually self-centered or turf-related. Where will I sit? Whose cube is in a better place? Will I get promoted? Will I ever get a parking space? Is our team shining in eyes of management? What will our bonuses be? These questions can be asked and answered, but don’t spend one minute more than required. Venting to peers about political problems is a developmental ball and chain. Keep asking, “How can my areas of focus or learning help a customer solve problems?” or, “Am I helping my team get better, so we can help more customers solve more problems?” Be that person in the marketing camp. Zig Ziglar, an inspirational speaker, said, “You can get everything in life you want, if you just help enough other people get what they want.”

5. Practice self-promotion

There are books about self-promotion, and while this topic isn’t the key to success, it is nonetheless important. If you had a world-changing invention, it

www.controleng.com

Engineer a more satisfying career ROI FOLLOW THESE six best practices for a better return on investment (ROI) in an engineering-related career, according to Gary Miller, president, Miller Resource Group. 1. Start a career direction with a vision: write and review career goals. 2. Invest in yourself: advance skills needed to achieve the vision. 3. Develop subject matter expertise to add value. 4. Address customer needs first, team second, and yours third. 5. Practice self-promotion. 6. Own it by being CEO of your career, vision, and the journey. would be a good idea to let someone know. The same is true for your career. There’s a chance you may do all you can do to elevate your value but not be in the right organization to capitalize. If you’re visible, perhaps someone else will give you that chance. Without egotistical selfaggrandizement, it’s acceptable, and even expected, to complete and update a professional LinkedIn profile. Speaking at conferences, writing articles, blogging about passionate topics help build a personal brand. Public speaking may not be for everyone and writing can be a big step, but don’t ignore the LinkedIn calling card. If you are ecstatic with your work environment, you’ll be telling the world, and that helps your team and company. It’s a no-lose proposition.

6. Own it

Great leaders take responsibility for everything and never place blame. The same applies to you as the CEO of your career. You’re responsible for the vision. You start there and ensure you have the capacity, capability, resources, and energy to make it happen. After deciding direction and taking the first step, lead toward your destiny. Getting on a new path likely will involve change, discomfort, trial, error, and learning. Congratulations. You’re on your way! Gary Miller is president, Miller Resource Group. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media, mhoske@cfemedia.com. CONTROL ENGINEEERING

May 2018

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ANSWERS

CONVERGING IT/OT Ashish Khushu, L&T Technology Services

Understanding the convergence of IT and OT Information technology (IT) and operations technology (OT) are converging to improve manufacturing operations, and offer benefits such as improved productivity and security.

nformation technology (IT) and operations technology (OT) coexist in many facilities, but they often don’t work together. It’s vital to understand the importance of converging IT and OT to optimize operations and to achieve the benefits of implementation. Gartner defines OT as: “The hardware and software that detects or causes a change through the direct monitoring and/or control of physical devices, processes, and events in the enterprise.” OT is considered the backbone of modern-day smart factories. It controls the infrastructure that powers the plants and keeps factory lines running. The importance of OT is augmented as more machines and their components are connected. The

IT/OT convergence

Internet of Things (IoT) is blurring the gap between the top floor and shop floor by providing deep visibility of the factory floor in an instant. IT is essential to all smart enterprises. From customer relationship management, to management information systems to emails, everything runs on an IT infrastructure. The worlds of IT and OT have coexisted, but often in silos, since the start of modern manufacturing. However, with the advent of the Industrial Internet of Things (IIoT) and integrating network sensors and associated software with complex physical machinery, the divide between IT and OT is rapidly dissipating. A report released by Gartner in 2011 stated the worlds of IT and OT are converging and the benefits would include optimized business processes, enhanced information for better decision-making, reduced costs, lower risks, and shortened project timelines.

Learning from IT/OT implementation

Caption While practical examples of IT/OT convergence are not new, it’s only now that strong technology and business reasons are driving companies to this convergence. The convergence of IT/OT will offer out-of-the-box integration solutions for plant automation, asset management, and manufacturing execution systems with IT apps, while providing scale and heightened security for networks. Courtesy: L&T Technology Services

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Many lessons can be learned as there are more advancements in technology to improve IT and OT implementation including: Scale of implementation: Connecting billions of devices simultaneously was a major technological challenge in the past. This issue got resolved a decade ago with IPv6 that enabled trillions of devices to be connected and operate at the same time. Manufacturing plants also need thousands or tens of thousands of assets to be connected which brings in the aspect of the scale of implementation. This is the first lesson from IT implementers to those managing OT. Enterprise IT implementations over the years have matured and have tested operating infrastructures where thousands of connected devices with different functionalities handle communications in a mesh network operating 24/7 seamlessly. It is possible to connect devices across different locations and scale this connectivity to thousands of assets. Security: It’s possible to implement networks and get them to operate with the highest www.controleng.com

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The evolution continues. 2018.

input #14 at www.controleng.com/information

ANSWERS

CONVERGING IT/OT possible security. After all, security threats posed to them would probably be the most severe given the rewards involved for hackers. For example, when money is withdrawn from any ATM of any bank from any location across any country, it dispenses money in a predictable time. This activity involves various processes including:

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IT and OT have different backgrounds, but their conjoined

• Identifying, authenticating, and calculating how much the withdrawer has and how much the user can withdraw • Dispensing money based on the denominations of currencies available in the ATM • Simultaneous update of the bank account • Sends the withdrawer an instant text message of the transaction and balance.

applicability

The system does all of this in a very predictable manner. Billions of transactions occur day arises from the after day in a secure and cohesive fashion. This is how the IIoT functions; the internet is connecting numerous disparate devices with many cyberIIoT. security measures. Stability of the infrastructure: Enterprise IT has been around for decades and its wide adoption across industries has been made it possible because of the assurance of a predictable response in terms of quality and time, substantiated by individual/organizational experiences on daily basis. The reason for this is the infrastructure’s stability. This is where architectures come into play. Stability has its own challenges such as adopting and changing technologies, platforms, products, evolving standards, proprietary products and standards, software, compliance, and regulatory challenges among others. The biggest lessons can be learned when companies or users are required to adopt or evaluate new technologies or standards. Architecture of the underlying hardware platform, KEYWORDS: Information connectivity infrastructure, applications technology (IT), operations and software that are chosen to buy or technology (OT) build, are primarily responsible for the The challenges with IT/OT stability of the infrastructure. implementation The guiding principles, in this case, The benefits of IT/OT must be architectures that should be convergence scalable, modular, interoperable, and Improving productivity easily managed. More importantly, the and security with IT/OT implementation. architecture should allow partners and vendors who build or supply compoCONSIDER THIS: nents to easily fit them into the archiHow can IT/OT convergence benefit your facility operations? tecture. The starting point should be the use cases that define the roadmap ONLINE: based on priorities and complexities. Read more articles about The interplay of the solutions architecIT/OT convergence at www.controleng.com. ture and the architecture of the enabling

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hardware and network infrastructure will help make this journey a lot smoother.

Learning from IT/OT challenges

IT and OT have different backgrounds, but their conjoined applicability arises from the IIoT. However, there are two key challenges for both parties including retentive control of systems and machines and employee safety. Sound security solutions should be in place with features including: • Identifying and authenticating all devices and machines: All devices within the system, be it within the plant or on the field, should be ensured. Only approved devices and systems should communicate with each other. This would lessen the risk of hacking, insertion of rogue and untrusted devices into the network, and mitigate unwarranted control of any systems or machines. • Encryption: Encrypting all communications between IT/OT devices would ensure privacy of the data being relayed. • Data integrity: Ensuring the integrity of the data generated from these systems is a high priority. Though smart analytics are a major driver in IIoT adoption, these are worthless if the data is inaccurate. Manufactured goods also contain embedded software or firmware. Enabling the remote upgradation of these softwares and firmwares would ensure their integrity.

The future of IT/OT

There are plenty of opportunities going forward, as more devices start to join the IIoT network. The converging IT/OT will offer out-of-the-box integration solutions for plant automation, asset management and manufacturing execution systems with IT applications such as supply chain and enterprise resource planning (ERP) apps at the enterprise level and provide analytics. If the present trends continue, it is very likely that the separation between IT and OT would fade until they become potentially one and the same. To ensure this, it’s vital both sides consider the other’s expertise and point-of-view and work together toward the the same goals of providing optimal security and productivity. ce

Ashish Khushu, CTO, L&T Technology Services, CFE Media content partner. Edited by Emily Guenther, associate content manager, Control Engineering, CFE Media, eguenther@cfemedia.com. www.controleng.com

2018

Engineering Awards in Manufacturing

Thank you to all the individuals

2 0 17

who attended the 2018 Engineering Awards in Manufacturing dinner honoring the 2017 Engineering Leaders Under 40 winners, Control Engineering 2018 Engineersâ&#x20AC;&#x2122; Choice Award winners and honorable mentions, Plant Engineering 2017 Product of the Year winners, and the 2017 Plant Engineering Top Plant winner.

2018

Event Sponsor

Companies in Attendance Advanced Technology Services ANSTO AutomationDirect Avanceon Baldor Electric Co. Beckhoff Automation Bedrock Automation BioMarin Bosch Rexroth Chevron CMMS Data Group Dataforth Corporation DL Manufacturing Emerson energybank Eruditio EXAIR Corporation FasTest Inc.

Fluke Digital Systems General Motors - Warren Technical Center Hubbell Lighting Infor Global Solutions Ingersoll Rand Compression Technologies & Services IRISS Kepware LUDECA Inc. MartinCSI Metalux-Industrial, Eaton MH&W International Corp. New Pig Corporation Panacea Technologies Panduit Phoenix Contact PRUFTECHNIK

PTC RedViking Regal Beloit America, Inc Rockwell Automation Schneider Electric Sensata Technologies Siemens Sullair, LLC Taylor Guitars Tosibox Trihedral Engineering Limited United Electric Controls Unitronics Yale Materials Handling Corporation Yaskawa America Inc.

ANSWERS

POWER RELIABILITY Alan Sappe’, Cory Myer, Moritz Krink, Phoenix Contact

Secure circuit protection Push-in fuse terminal blocks provide short-circuit protection; seven design considerations can help your next implementation.

very systems manufacturer—from machine builders to process engineers—must consider circuit protection. Operators can reduce wiring time by selecting fuse terminal blocks with push-in connection technology. In machine building and systems manufacturing, 5x20 mm and 6.3x32 mm cartridge-type fuses are common. Fuse link cartridge design is part of DIN 41571, the international standard for miniature cartridge fuses.

Fuse terminal blocks, connections

Driven by key trends in cost efficiency and miniaturization, a variety of fuse terminal blocks have been developed, including 4-mm² multi-level fuse blocks for 5x20 mm cartridge fuses and 6-mm² fuse blocks for 6.3x32 mm cartridge fuses. Disconnect terminal blocks include housings to match the fuse block, for field application design flexibility. Fast and easy push-in connection technology is gaining acceptance in many KEYWORDS: markets and industries. Seven advantages Power protection, industrial compared to traditional connection techfuses nologies include: Short-circuit protection is 1. Pressure-spring principle operaavailable in push-in fuse terminal tion. With a leg spring, the conductor is blocks. plugged into the terminal without the need Push-in connection technology to first open the terminal point. The leg is gaining acceptance. spring pushes the conductor against the Advantages compared to traditional connection current bar, enabling the conductor to be technologies. inserted with 50% less insertion force compared to other spring technology products. CONSIDER THIS This reduces wiring time and delivers reliWhat advantages can new push-in fuse terminal blocks able connections and time savings for the bring to your applications? builder and end user. 2. Compact housing design. Taking ONLINE advantage of a high-density housing width If reading from the digital edition, click on the headline for of 6.2 mm and reducing the number of termore resources. minal blocks required from five to two can www.controleng.com/magazine save 18.6 mm of space per assembly (66% See related system when compared to the standard 31 mm). integrator capabilities in 3. Terminal block accessories. ProfesGlobal System Integrator sional marking clearly identifies terminal Report. www.controleng.com/ points and conductor locations. Global-SI-Database

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Electrical overloads or short circuits in machines can cause system downtime. Circuit protection increases safety and reliability. Courtesy: Phoenix Contact

4. Simple intuitive fuse terminal block assemblies. Field operation and replacement of a blown fuse element should be fast to minimize system downtime. Automotive flat-type C fuses are used in automotive and machine building manufacturing. A fuse terminal block for compact-type C fuses according to ISO 8820-3 and DIN 72581-3 is available. Flat type C fuses are color-coded to denote current strength. Automatic devices can be switched on/off, and current paths can be enabled using an operating element. Fuses must be replaced after tripping. 5. Less terminal width. Terminal width is significantly less conventional miniature circuit breakers. This saves space in the control cabinet. Flat type C fuse terminal blocks are available with a cross-section of 6 mm², supporting nominal current of up to 30 A, common for many electrical devices. 6. Standard testing. IEC 60947-7-3 terminal block tests are described in the fuse terminal blocks standard. Specific tests are performed on fuse terminal blocks, including testing for environmental, shock and vibration performance. 7. Testing power dissipation. To determine temperature limits, fuse terminal blocks have thermocouples to monitor temperature. The plastic part value must be below the relative temperature index (RTI) value (130°C for Polyamide 6.6). The temperature for metal parts must not exceed 85°C. ISO 8820-2 recommends a maximum load current of 70% and DIN 72587-3 a maximum load current of 80%. ce Alan Sappe’ is product marketing manager, industrial cabinet connectivity business unit, Cory Myer is product specialist for fast connections, industrial cabinet connectivity, Phoenix Contact USA; and Moritz Krink is product manager terminal blocks, industrial cabinet connectivity, Phoenix Contact GmbH & Co. KG; Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media, mhoske@cfemedia.com. www.controleng.com

2nd Annual

June 5â&#x20AC;&#x201C;7, 2018 Hyatt Magnificent Mile, Chicago, IL

The Midwest Industrial Internet of Things Event

h t t p s : / / i o m - m w. i n t e r n e t o f b u s i n e s s . c o m

input #15 at www.controleng.com/information

#IoBMan

ANSWERS

ROBOT SAFETY STANDARDS Carole Franklin, Robotics Industries Association

Global robotics standards update Keeping standards up to date with technology: Industrial robot safety standards remain in development to help lower risk for those integrating, implementing, using, and maintaining robotics.

ometimes it seems safety around industrial equipment, including robotics, can be very complicated. Technical experts in the robotics industry have developed national and international industry standards that can help remove a lot of the mystery around robots and safety. As technology continues to improve, so must the standards documents. As of March 2018, a number of new or updated standards documents are in development by technical experts globally. A few robot safety standards efforts for robot manufacturers, integrators, and end users are explained below.

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What happens when when an

employee must interact with the robot

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system, whether loading or unloading? International standards

The Robotic Industries Association (RIA) works within the ISO framework to support the development of international standards on robotics. The ISO group responsible for global robotics standards is ISO Technical Committee (TC) 299, Robotics, and it has published an international standard (IS) on safety requirements for industrial robots and robot systems, as well as supplemental documents that provide guidance on topics such as collaborative robot safety and safety design for manual load/unload stations. Safety Standard: ISO 10218-1,2:2011. This document, published in 2 parts, describes safety requirements that the robot manufacturers and systems integrators must meet. Requirements for the robot, which robot manufacturers must meet, are the topic

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of Part 1 of 10218. Part 2 addresses requirements to systems integrators for developing an overall robot system that will help keep a safe environment for human workers in the area. This document is crucial for robot manufacturers and integrators to obtain, understand, and use. Suppliers to the robotics industry, and end-users of robot systems, are encouraged to understand these documents, as well, to help them be at their most effective in doing business with robot manufacturers and integrators. Currently, the 10218 standard is undergoing a periodic updating and the update is planned for publication in 2021. New ISO Technical Reports: ISO/ TR 20218-2, Safety Design for Manual Load/Unload Stations. This document is designed for use with the 10218 standard. ISO/TR 202182:2017 aims to resolve the difficulties that might arise when safety requirements for industrial robots clash with safety requirements for ergonomics. One safety requirement for traditional (safeguarded) industrial robot systems is to surround the robot cell with perimeter fencing to a height of 1,400 mm. But what happens when an employee must interact with the robot system, whether loading or unloading? An expectation of lifting the input or output to a height of 1,400 mm is unreasonable from an ergonomic standpoint. How can those involved resolve and minimize these separate but related two sources of risk (robot system vs. ergonomic risk)? This ISO TR was developed to help answer that question. This document is most useful for integrators and users of robot systems. The ISO/TR 20218-2 technical report was published in December 2017. ISO/DTR 20218-1, Safety Design for End-Effectors. www.controleng.com

This document is designed for use with the 10218 standard. The ISO/DTR 20218-1 is still in the publication process—that’s what the “D” means in its designation code: Draft. The goal of this document is to describe safety best practices regarding end-effectors (end-ofarm-tooling, or EOAT). The industrial robot itself cannot do any work; it must be integrated into an overall robot system, including end-effectors, which manipulate the workpiece and perform the work. Some end-effectors are suitable for collaborative work (near humans), and some are not—the risks they present are too high. This document examines a wide range of end-effector types, lists examples of potential hazards from end-effectors, and gives guidance to reduce risks associated with end-effectors. This document is useful to integrators of robot systems as well as suppliers of end-effectors and tool changers. Industrial robot end users may also find it valuable information to help keep their workers safe around end-effectors. The ISO/DTR 20218-1 is expected to be published later in 2018. ce

Carole Franklin is director of standards development at the Robotic Industries Association (RIA). The RIA is a part of the Association for Advancing Automation (A3), a CFE Media content partner. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media, mhoske@cfemedia.com.

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KEYWORDS: Global safety standards, robots Safety Standard: ISO 10218-1,2:2011 is being updated. ISO/TR 20218-2, Safety Design for Manual Load/ Unload Stations was published in December 2017. ISO/DTR 20218-1, Safety Design for End-Effectors is expected later in 2018. CONSIDER THIS U.S. robotic safety standards are harmonized with global robotic standards.

ONLINE If reading from the digital edition, click on the headline for more resources including links to related articles. www.controleng.com/robotics www.robotics.org

Simplify Machine IP Integration Maintain your factory-set IP addresses when integrating with the customer’s IP network by using the EIPR IP Router. • Reduce installation time • Eliminate IP conflicts • Easily comply with your customer’s IP requirements EIPR IP Router Learn more at www.ccontrols.com/machine input #16 at www.controleng.com/information

ANSWERS

ROBOTIC SAFETY John Ritter, Rite-Hite

Create safe, efficient barriers Automated machines and robots can create potentially dangerous hazards for workers; barriers can be designed to lower risk and not impede operations.

dvances in machining and robotics have increased operational efficiency in manufacturing operations. Production and profits would plunge if all manufacturing were done by hand. While the advantages of machines are undeniable, these automated systems can create potentially dangerous hazards for workers who operate and/or interact with them. Facilities can and should protect workers by implementing safeguards at critical points of interaction. Recent regulatory and protocol changes by national and international governing bodies such as OSHA, British Standard European Norm (BS EN), and the Robotics Industries Association (RIA) reflect a conscious effort to protect employees working these advanced machining technologies. Facility managKEYWORDS: Machine safety ers have options to comply with standards Automated machines pose and improve worker safety. The proppotential dangers to workers. er safeguard depends on the application. Presence-sensing devices and It’s critical to determine risk if a facility is physical barriers can lower risks and not productivity. introducing a new automated operation.

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ONLINE Click the head to read online at www.controleng.com for more information and another photo.

Determine potential risk

Even before RIA updated its machine guarding regulation, R15.06, several years ago to make risk assessments mandatory, assessments have always been a good idea. Point-of-operation guarding represents the intersections of human and machine, and safety and efficiency. Most situations require a machine operator to interact by loading or unloading materials or components and “running” the machine, so installing perimeter guarding is rarely sufficient. Point-of-operation details include process layout or design, system limits, properly identifying all associated hazards, and devising Automated barrier doors protect workers methods for hazard from dangerous machine work cells and from elimination and risk fumes, sparks, and debris. Courtesy: Rite-Hite reduction.

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The distance formula in OSHA guidelines can assist in determining the best machine-guarding device. The formula is: DS = K (T) + DPF. DS stands for safety distance; K stands for the maximum speed an individual can approach the hazard; T stands for the total time to stop the hazardous motion; and DPF stands for the depth penetration factor of the safeguarding device. Per this formula, the safeguarding product has a prescribed location based on a number of factors, including secondary hazards that might harm a machine operator. This formula makes a big difference in determining which safeguarding device a facility should implement.

Presence sensors, automated barriers

The most basic devices used for safeguarding manufacturing operations are presence-sensing devices such as light curtains and laser scanners. Operations from Tier 1 automotive to small machine shops and fabrication facilities commonly use them. When the infrared beam is tripped, the automation ceases. These devices can provide acceptable safety for some applications, but workers must adhere to OSHA’s distance formula to reduce risk of injury. This can lead to larger work cells. Because an infrared beam can’t be seen, a worker who has no intention of entering the hazardous area can accidentally trip them, resulting in unintended delays in operations. A fast-acting automated barrier door or roll-up curtain can eliminate exposure to dangerous machine movements and secondary process hazards, potentially eliminating risk and the severity of exposure. When they are coupled with safety interlocks (up to PLe, Cat. 4 per EN “ISO 13849-1 – Safety of Machinery” when integrated properly), automated barrier doors and roll-up curtains offer an increased level of protection for point-of-operation guarding. They contain secondary hazards such as smoke, flash, splash, mist, or flying debris associated with automated welding operations by placing a barrier between machine operators and machine movement. ce

John Ritter, product manager, Rite-Hite Doors. Edited by Chris Vavra, production editor, Control Engineering, CFE Media, cvavra@cfemedia.com. www.controleng.com

2018 Global Automation & Manufacturing Summit GAMS Agenda REGISTRATION: 11:30 a.m. to 12 p.m. LUNCH: 12 p.m. to 12:30 p.m.

September 12th Join Control Engineering, Plant Engineering and Hannover Fairs USA for the Global Automation and Manufacturing Summit, part of the Industrial Automation North America (IANA) pavilion at the 2018 IMTS Show at McCormick Place in Chicago. This one-day summit is designed to bring plant managers, control engineers, and manufacturing business leaders together to highlight plant improvement opportunities and deliver strategies that manufacturing personnel can take back to their plants and implement immediately. Sponsored by:

KEYNOTE: 12:30 p.m. Global manufacturing: The race to serve 7 billion potential customers, and how to win the race.

In a global, competitive manufacturing environment, how can American manufacturers compete? The same way they’ve lifted the U.S. economy out of the Great Recession: By being smarter, leaner (and Leaner) and using technology and data to point the way to a better manufacturing strategy.

SESSION 1: 1 p.m. to 1:45 p.m. Cybersecurity: How far do we need to go?

The problem of security for (IIoT) is one of the most discussed issues as manufacturers look to deploy this technology solution. We’ll look at the real issues, perhaps debunk a few myths, and talk about the common-sense ways manufacturers can secure their data and their operational integrity. The presentation will be led by Dr. Richard Soley, chairman of the Industrial Internet Consortium, Chairman and Chief Executive Officer of OMG (Object Management Group) and executive director of the Cloud Standards Customer Council.

SESSION 2: 2 p.m. to 2:45 p.m. Embrace your robot: A guide to the future

No longer a science fiction story, robots are real, valuable to manufacturing, and winding up in more plants than ever. How can you find the best way to utilize robots in your plant? Listen to our experts who will discuss the practical ways robots can enhance manufacturing—and all the ways humans are still vital to your operation. The panel will be led by a representative from the Robotics Industries Association (RIA), a CFE Media Partner.

SESSION 3: 3 p.m. to 3:45 p.m. IIoT in discrete manufacturing: Managing the process

When it comes to IIoT, manufacturers in discrete industries, particularly in the metalforming and CNC industries, have a different set of expectations from those in the process industries—and a different set of challenges. We’ll talk with industry experts to look at how to get the most out of IIoT, and how to use data to improve operations, supply chain and safety.

SESSION 4: 4 p.m. to 4:45 p.m. Maintenance and IIoT: Follow the numbers

The data generated by IIoT can point a maintenance professional to a problem on the plant floor— if he’s looking at the right numbers at the right time. More sophisticated analytics are helping maintenance teams focus on the right data at the right time, and we’ll talk with them on how this strategy can lead to more uptime and better safety. The presentation will be led by Sal Spada, research director for discrete manufacturing for ARC Advisory Group.

COCKTAIL AND NETWORKING RECEPTION: 5 p.m. to 7 p.m.

After a great day of information, continue the discussion in the lobby. Cocktails, light snacks and conversation about the day’s events will follow.

ANSWERS

INSIDE PROCESS: INTEROPERABLE CONTROLS Mark T. Hoske, Control Engineering

Open Process Automation status update The Open Process Automation group, part of the Open Group, continues to work on standards to help enable interoperable process controls. ExxonMobil Research & Engineering, BASF, Saudi Aramco, and ARC Advisory Group offered a progress update in February.

he Open Process Automation (OPA) initiative, an effort to make process controls more interoperable, was discussed by ARC Advisory Group, Saudi Aramco, Open Process Automation, BASF, and ExxonMobil. The following experts reviewed progress as of the 2018 ARC Forum, in February. • Harry Forbes is analyst at ARC Advisory Group. • Abdullah Alkhalifah is senior engineering consulting at Saudi Aramco Engineering Services. • David DeBari is OPA program prototype lead engineer. • Michael Krauss is senior automation manager, control systems technology, at BASF. • Don Bartusiak is chief engineer, process control, at ExxonMobil Research & Engineering.

Manufacturing software changes

Forbes cited a major automation supplier CEO who said customers do not want to live in a plant where they have to manage application software across thousands of devices. Vendors are doing that as they replace switches by virtualizing them. It’s a time of breakthroughs, not incremental improvements. Software is eating the world. Cloud software is eating the enterprise, the edge, and the embedded space. Cloud technology can see and

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Harry Forbes, an analyst at ARC Advisory Group, said software development tools for the cloud are moving into industrial automation and other areas. Forbes moderated a panel on open process automation at ARC Forum 2018. Images courtesy: Mark T. Hoske, Control Engineering

interact with lower-level systems. Software is becoming smaller and more secure. Software development convergence is happening at opensource speed. Software development is flattening what historically has been in different classes. State-of-the-art cloud software development and software operations (DevOps) technology will penetrate embedded system and embedded industrial automation, development, deployment, orchestration and monitoring, and updates will elevate end-user expectations for industrial automation software. Software management at scale and over the software lifecycle are requirements shared by the cloud, enterprise, Industrial Internet of Things (IIoT), and OPA. “Keep an eye on cloud. It’s coming down to where we live, work, and manufacture,” said Forbes.

Open automation

Alkhalifah said the OPA initiative aims to enable production of data-centric, standardsbased, open, secure, and interoperable process automation systems. Alkhalifah is responsible for process automation and helps develop standards and technologies to address process challenges. www.controleng.com

Our last project came in behind schedule and over budget. The next project is even bigger. It’s going to be a monster unless we do things differently.

IT’S IMPOSSIBLE

It’s time for Project Certainty. Emerson’s transformational approach to capital project execution provides a fresh, new look at projects so that you meet your original budget and schedule targets. Using a combination of innovative products and services, Emerson provides a path to reduce complexity, eliminate cost, and accommodate late changes. Reset design, engineering, and project management to make your project more predictable and reliable. Learn more at www.emerson.com/project-certainty. input #17 at www.controleng.com/information The Emerson logo is a trademark and service mark of Emerson Electric Co. © 2018 Emerson Electric Co.

ANSWERS

INSIDE PROCESS: INTEROPERABLE CONTROLS Cloud software development tools are eating into all other areas touching industrial automation, as the graphic shows, according to Harry Forbes, an analyst at ARC Advisory Group, at ARC Forum 2018.

input #18 at www.controleng.com/information

The Saudi Aramco process automation system (PAS) lifecycle management program has a long-term objective of an open data-centric process automation concept to enable technologies, industrial initiatives and standards, said Alkhalifah. In 2010, faced with obsolescence, the company looked at its supplier model, spare parts management, in-house technical support, and reliability driven replacement, all of which presented challenges with a long-term view of using proprietary architectures. Doing so pointed to obsolescence at various levels: inputs and outputs (I/Os), devices, controllers, and human-machine interfaces (HMI) all with different lives for expiration. A new plan sought to eliminate multiple layers and make a flat network, decouple controllers, and replace the control system with a reliable communication framework. The new solution sought to avoid wholesale replacements and distribute control capabilities throughout the architecture. The safety system at the bottom would not be touched. I/O modules were I/O only and connected to a real-time databus. Controllers were hardware and software-based. These attributes require a datacentric, open standard, using a publish/ subscribe communication protocol, servers for HMI and controller virtualization, a high availability computing platform, interchangeable basic I/O, hardwareor software-based controllers, built-in cybersecurity, and application portability. After joining the Open Group, Saudi Aramco has been working on an inhouse system for the end of 2018. The company solicited participation in a demonstration system to help with the learning curve.

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May 2018

Based on the learning curve, the company began to realize that using a data distribution service is not as simple as expected. A lot of time is required forming an information model. Saudi Aramco is committed to working with the Open Automation Forum on a data-centric, publish/ subscribe collaborate automation platform based on open technology. The hope is to preserve current investments and use commercial-off-theshelf (COTS) technologies and provide mechanisms for easier integration or partial replacement.

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CONTROL ENGINEERING

Proof-of-concept system uses a real-time advanced computing platform. It controls a simulated process unit using proportionalintegral-derivative and

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constraint control. OPA program status

DeBari gave an OPA status update. OPA creates a system of systems puts a distributed control system as just another peer among other elements in the OPA architecture vision, rather than a top of layer hierarchy. A running proof-of-concept system uses a real-time advanced computing platform. It controls a simulated process unit using proportional-integralderivative (PID) and constraint control. The demonstration took I/O and logic and broke it into three distributed control nodes (DCNs).

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TRO N O C

ANSWERS

INSIDE PROCESS: INTEROPERABLE CONTROLS Because most process controls run faster than the application requirements, this slows down to 100 milliseconds, deemed as fast as would be needed to run anything. Interoperability’s definition and objective: Ability of two components to exchange meaningful information and interoperation among vendors to allow integration of the best components and to foster competition and innovation in the marketplace, permitting customization and fit-for-purpose solutions.

‘

Configuration and application portability allows sharing configurations from one

’

application to another.

Interchangeability is when a component can be replaced with another from another vendor without modification. A Raspberry Pi 3 can be swapped with an Intel prototype DCN. It was redeployed without changing IEC 61499 control logic and without re-engineering the control logic. (IEC is the International Electrotechnical Commission, a global standards organization.) Configuration and application portability allows sharing configurations from one application to another. Preserving asset owner’s custom configuration, intellectual property (IP), and aid the use of leading-edge capabilities, allows integration of best-inclass components. Application development flexibility would have an app store concept to support use of best-in-class algorithms, open the market to innovation, and preserve custom configurations. ExxonMobil’s vision for OPA is to have technical readiness by 2021. More participants are encouraged, and the organization seeks partners for collaboration and field trials because ExxonMobil’s needs may differ from other users. (Additional end users involved in OPA include Dow, DuPont, Georgia-Pacific, Merck, and Statoil, among others.)

New approach needed

Krauss at BASF offered a perspective on NAMUR with help from Don Bartusiak, ExxonMobil and the Open Group. NAMUR is a German acronym for the user association of automation technology in the process industries. Krauss asked, “Why is a new approach needed?” This effort is the culmination of 20 years of megatrends: fieldbuses, asset management, computer-

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May 2018

CONTROL ENGINEERING

aided engineering (CAE) for integrated engineering, distributed control systems, standard data exchange for CAE and DCS, and SAP-R/3 integration of DCS among others. “More disruptive changes are needed because we’re not there yet,” Krauss said. “We’re lacking platforms interfaces and data models.” NAMUR Open Architecture is proven and accepted, highly available, and designed for mature systems for sustainable operations with a long lifecycle. The architecture is not open; if technologies are integrated slowly or not at all, there’s no room for trial and error. Will the industry lose the ability to innovate? Open architecture covers the field level, basic automation, manufacturing execution systems, and enterprise resource planning. The module-type package (MTP) is a standard nonproprietary description of modules for process automation. The MTP addresses plant engineering and the process control level. Bartusiak said the groups are working on finding common ground around user needs and coalescing efforts in one reference architecture. Compared to the traditional OSI model, this collapses levels 1-3. NAMUR functional requirements can be supported by the OPA architecture and gateways can be provided to existing (legacy) devices. The difference is the trajectory to the ultimate solution. The Open Group, ZVEI (the German Electrical and Electronic Manufacturers’ Association) and NAMUR agreed on a memorandum of understanding (MOU) in October 2017 to share work documents in process. Goal is common promotion and internationalization of standards into IEC standards. There’s no conflict, he suggested; the groups are coalescing to a critical mass for change. Bartusiak also mentioned there’s a critical mass among end users for change and a wider spirit of compromise and cooperation, with determination to learn from earlier failed efforts, such as MAP (before its time) and fieldbus wars (which had many vendors protecting their own interests).

Benefits of open process automation

At another session at the ARC Forum, Kenny Warren, vice president of engineering, ExxonMobil Research & Engineering, said that OPA efforts benefit end users and automation vendors. For end users, the benefits of open process automation include: • Support reuse of control system applications • Increase value creation • Enable continuous innovation • Solve system integration issues • Be safe and intrinsically secure • Empower workforce and reduce total cost of ownership (TCO). www.controleng.com

For suppliers, open process automation benefits include ability to: • Reach new markets and customers while remaining relevant to existing customers • Create new goods and services • Grow the bottom line by increasing margins and reducing costs.

‘

For NAMUR, open architecture covers the field level, basic automation, manufacturing execution

’

systems, and enterprise resource planning.

Warren said this is important to ExxonMobil and other companies supporting The Open Group because tests and trials will improve data acquisition and analytics. They can monetize operations and provide a globally consistent above-site approach, constancy, and transparency over time.

Open instead of closed

Replacing a closed layer with open one will widen the path to increased productivity, Warren suggested. The industry today is less like the hardwaredefined architecture of 1980s. The internet, cloud, robotics, machine learning, and AI, need a standards-based, open interoperable digital architecture. Because the industry is changing at faster speeds and innovation are vital, Warren said. He closed by asking, “Where will you be in 10 years?” ce

Mark T. Hoske is content manager, Control Engineering, CFE Media, mhoske@cfemedia.com.

M More ANSWERS

KEYWORDS: Interoperable controls, Open Process Automation Open Process Automation, part of the Open Group, is working on interoperable process controls. NAMUR is working on a similar effort. Cooperation seems likely to increase after an MOU. ONLINE Need to catch up? Search on ExxonMobil at www.controleng.com to see prior coverage on this topic.

CONSIDER THIS Preserving investments in automation seems likely to increase efficiency, add functionality, and speed upgrades. CONTROL ENGINEERING

May 2018

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input #20 at www.controleng.com/information

ANSWERS

INSIDE PROCESS: USING PROCESS MODELS Philip Lyman, CRB

Why build a process model? See 10 reasons for using a process model with more info online.

process model can be anything from a simple spreadsheet to a complex model that includes all aspects of a real-world manufacturing plant. However, the best model does not include everything. It only includes what is necessary to answer questions. One question to consider is: Under what circumstances is a model and simulation project likely to add the most value? 1. Determine equipment number and sizing for a facility design. For example, how many bioreactors and purification trains are needed to meet the 10-year forecasted demands? 2. Check for process bottlenecks. Most processes are very complicated—lots of equipment and resources. Sometimes, the bottleneck varies over time or as a function of process variability. Knowing where a bottleneck is and how to constrain it can help improve throughput.

M More ANSWERS

KEYWORDS: Process model, process modeling Determine equipment number and sizing for a facility design Check for process bottlenecks Map material flow into a large facility. ONLINE Link to additional online resources, process modeling and related content at www.controleng. com/archives, under May 2018.

3. Size a utility system. Manufacturing plants often have many utility demands, some of which may be poorly characterized. Factors such as sanitization schedules and preventive maintenance can affect the delivery of critical utilities. Without the availability of these utilities, when needed, the throughput and/ or the product quality may be impacted. Rather than guessing a value, simulation allows for quantifying and fixing the level of over-design. 4. Optimize the layout. Alternative layouts can be quantitatively compared with a model so the best one in terms of operability and cost can be selected. 5. Determine staffing. When does it make sense to add another operator or another shift? 6. Optimize a laboratory. This may mean changing the layout, adding the right number of pieces of test equipment, or streamlining operations. 7. Clean each piping segment. Cleaning in place could be a bottleneck in a complicated piping network.

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8. Map material flow into a large facility. Raw materials must be moved from the warehouse for weighing and dispensing and then onto solution prep. If they are late, the buffer could be late, and the product batch may be impacted. Conversely, if materials are too early or the buffer prep scheduling is too conservative, extra inventory and associated costs could result. 9. Reduce costs. Understand all the elements of the cost structure. Where should attention be focused to reduce the cost? Is it focused on the easy way to change elements, or is it focused on the elements with the biggest impact. 10. Learn more about the process being modeled. This insight often leads to unexpected improvements. For example, one client was pleased to learn how to increase capacity by 25% without a costly capital project. If any of these items describes your manufacturing plant, consider process modeling and simulation as an efficient method of learning new ways to improve processes and operations. ce Philip Lyman is director of process simulation at CRB, a CFE Media content partner. Edited by Jack Smith, content manager, CFE Media, Control Engineering, jsmith@cfemedia.com.

The top 10 reasons why you should build a process model. Courtesy: CRB

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INNOVATIONS

NEW PRODUCTS FOR ENGINEERS

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Portable oscilloscope probe saves battery life The IkaScope WS200 has a 30 MHz bandwidth and 200 MHz sampling rate and is an ergonomic tool designed to provide quick and reliable diagnostic in many on-the-field applications. Ikalogic’s ProbeClick allows the probe tip to sense pressure and start/stop a measurement automatically. This feature also allows battery life savings, as the power consuming circuitry only operate when the probe tip is pressed and being used to transmit a signal. Isolated measurements gives IkaScope yet another advantage over traditional oscilloscopes. Even when a USB is plugged in to recharge its 420 mAH battery, an integrated transformer guarantees isolation from the USB’s ground. This avoids ground loops from occurring and protects both the measured device as well as the oscilloscope. Ikalogic, www.ikalogic.com

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Wireless sensors for temperature, vibration tracking Nikola Labs’ PfM predictive maintenance sensor system is designed to capture vibration and temperature (two of the biggest predictors of equipment malfunction) to monitor the condition of operating equipment and ultimately optimize maintenance programs for industrial and manufacturing facilities. PfM consists of completely wireless sensors for temperature and vibration tracking that is remotely powered by and communicate with transponders. It is able to predict equipment failures and monitor in extreme and remote conditions. It also monitors points of weakness to help operators better determine when to fix versus replace. Nikola Labs, www.nikola.tech Input #201 at www.controleng.com/information

Safety-based communications protocol Rockwell Automation’s Allen-Bradley Guardmaster GuardLink safety system is a safety-based communications protocol designed to help operators reduce and improve machine diagnostics and downtime while increasing productivity. Connect safety devices in series while providing access to individual device diagnostics. This system provides safety, diagnostics, remote reset and lock command over one fourconductor cable with up to 32 devices per link. Customers can greatly reduce installation cost, with up to 38% reduction in wiring, when using GuardLink. Rockwell Automation, www.rockwellautomation.com Input #202 at www.controleng.com/information

Precision limit switches AutomationDirect’s Metrol mini stopper and stopper bolt precision limit switches are designed to improve safety application. Mini stopper limit switches incorporate a mechanical stop along with the limit switch function, eliminating the need for a separate stop in many applications. With 10 micron repeatability, long service life, and high contact force, these stainless steel switches are ideal for use in precision indexing/positioning applications. Stopper bolt limit switches can take the place of a stop bolt and a separate switch for indication. Metrol stopper bolt precision limit switches incorporate a mechanical stop along with the limit switch function and provide two tasks with one device by housing a high-accuracy switch in a stopper bolt. AutomationDirect, www.automationdirect.com

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May 2018

CONTROL ENGINEERING

Input #203 at www.controleng.com/information

Multi-volt timer NSI Industries’ Tork 1109A dual voltage mechanical timer features voltages ranging from 120 to 277 V ac, replacing all single voltage switches. This multi-volt timer is cULus certified to control all LED products in indoor (1109A) and outdoor (1109AO) applications. This reliable timer is designed for residential and commercial use for a variety of loads requiring automatic on and off during a 24-hour cycle when operation is required at the same time every day, saving energy, money, and providing safety and security. Designed for a minimum ON time of 20 minutes with a minimum OFF setting of 75 minutes, the timer’s dial accommodates up to 12 pairs of tripper tabs. The timer also features a manual override. Built to withstand harsh environments, the product features a sealed motor, eliminating elements from interfering with the timer operations, which extends unit life. A removable door allows for easy installation and the timer is lockable for added security. Short circuit rating is 120/208-277-V, 5KA. The timer features a NEMA 1 rated indoor lockable enclosure, and the outdoor model has an indoor/outdoor NEMA 3R rating. NSi Industries, www.nsiindustries.com Input #204 at www.controleng.com/information

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Emerson Automation Solutions . .P2 . . . . . . . . 17 . . . . . . .www.emerson.com Fluid Components International, LLC . . . . . . . . . . . . . .P3 . . . . . . . . 18 . . . . . . .www.FluidComponents.com Load Controls Inc.. . . . . . . . . . . . . .P8 . . . . . . . . 22 . . . . . . .WWW.LOADCONTROLS.COM

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May 2018

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INNOVATIONS

BACK TO BASICS | PROJECT DESIGN Frank Lamb, Automation Primer

Six tips for designing and building a small controls project Ordering and specifying parts, building the system, and programming should be considered to make building a small controls project as smooth as possible.

M More

ANSWERS

small, properly executed controls project can be expensive and time consuming. The skills often required to do even a small project such as computer-aided design (CAD), wiring, design, and programming are different skill sets. The six steps below can help make design and building easier.

1. Specifying parts

3. Ordering parts

Procurement of parts may involve some shopping around. Of course price is important, but don’t spend too much time trying to save a few pennies. Lead-time is also a consideration. Keep all documents and paperwork for received components. Some may end up in the project binder, and packing lists can be used to reference purchase orders and possible returns later.

4. Building the system

design, control system A small controls project may require assistance. Consider wiring, panel fabrication, and bracketry in the design and build phase. Knowledge software is required for PLC or HMI systems.

Describe the project on paper with as much detail as possible. Identify requirements—and potential future/expansion possibilities—in the document. Determine availability of utilities such as pneumatics, 480/120 V power, cubic feet per minute (CFM), and amperage. This should provide enough information to determine if a programmable logic controller (PLC), individual discrete control components such as temperature controllers, timers, counters, or a human-machine interface (HMI) is needed.

ONLINE

2. Designing the system

5. Programming and software design

KEYWORDS: project

Read this article online at www.controleng.com for more info and links to other posts from Automation Primer.

This step requires some knowledge of electrical and mechanical design. For a small project items can be sketched by hand to determine sizes; one-line diagrams can be created for electrical requirements.

There are a lot of skills and tools required for wiring, panel fabrication, and bracketry. Among these are panel layout (drilling, tapping, and “pinging” drill points), panel prep (cutting of din-rail, wireway, and component cutouts), wiring (ferrule crimping, wire stripping, and labeling), possible millwork, and painting. There are also legal requirements that must be met for wire sizing, grounding, and cabling/conduit outside the enclosure (field wiring). For systems involving a PLC or HMI, knowledge of the platform’s software is required here. This software can often be expensive so it should be taken into account during the specification design phase. Will the customer have the software? Is there a licensing fee involved? Is there local support for troubleshooting or modification, or can the customer do it themselves?

6. Starting up and debugging

Most experienced programmers know not to worry too much about small mistakes during the programming and software phase, they will be discovered and fixed easily after the system is powered up. This is where the system gets fully tested before going into production. Larger systems may need a factory acceptance test (FAT) and a site acceptance test (SAT). ce

Aspects such as ordering and specifying parts, building the system, and programming should be considered when designing and building a small controls project. Courtesy: Frank Lamb, Automation Primer

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CONTROL ENGINEERING

Frank Lamb is the founder of Automation Consulting LLC, and is on the Control Engineering Editorial Advisory Board. This article appeared on Automation Primer’s blog. Automation Primer is a CFE Media content partner. Edited by Chris Vavra, production editor, Control Engineering, CFE Media, cvavra@cfemedia.com. www.controleng.com

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