Pe 17 07 by Modiconlv

14 AI and process improvement 32 Data drives predictive maintenance

PlantEngineering.com

Doubling down on digital manufacturing One companyâ&#x20AC;&#x2122;s journey to IIoT started before the concept had a name 26

...and neith FREE SOFTWARE with simulator

“The Do-More software is more user friendly than any I have ever used before. PID, Modbus communications, Filters etc... All very easy to use!” SK in ENDERBY, BC

UP TO 36 BUILT-IN DISCRETE I/O POINTS

INTEGRATED HIGH-SPEED I/O MOTION CONTROL INCLUDED

BRX PLC featured is BX-DM1E-36ED23 priced at $494 20-pt in and 16-pt out discrete, 4-ch in and 2-ch out analog input #2 at www.plantengineering.com/information

her will you! Modbus®

EtherNet/IP ASCII

(pronounced “Bricks”)

Starting at

$199

(BX-DM1-10AR-D)

Performance at a Low Cost The new BRX controller redefines what it means to be a PLC. Programmable Logic Controller - sure, but for BRX we prefer Performance at a Low Cost. You won’t find a micro PLC with this many features, at this price, and with the Do-more can-do attitude anywhere else!

INTERNAL RAM AND microSD DATA LOGGING ONBOARD SERIAL/ETHERNET COMM PORTS

This under-budget overachiever was designed and is manufactured in the U.S. and comes with built-in data logging, versatile motion control, onboard serial communication with Ethernet option, an additional hot-swappable communications port, and integrated discrete, high-speed, and analog I/O (select models). Four form factors are available to choose from with various built-in I/O configurations; the BRX PLC units are also expandable with up to 8 additional I/O modules (depending on model). Expandable I/O starting at $36

(most models)

HOT-SWAPPABLE COMM PORT (optional)

So if you are ready to experience a new kind of PLC, one where price doesn’t dictate performance, then you should check out the new Do-more BRX controllers. Save money and build it strong with BRX!

www.BRXPLC.com

NBOARD ANALOG

1-800-633-0405

www.AutomationDirect.com

PLC

The new

doesn’t know it’s a micro controller...

For a new kind of PLC: Performance at a Low Cost

PROGRAMMING SOFTWARE

STARTING AT

Powerful, flexible and easy to use

$199.00

DESIGNER

FREE!

(BX-DM1-10AR-D)

1-800-633-0405

input #1 at www.plantengineering.com/information

www.AutomationDirect.com

COMPRESSORS

CSuccess ustomer Story Sweet Savings!

A compressed air audit opens a world of savings opportunities PROBLEM:

One of the world’s leading candy and gum manufacturers had no idea how much their compressed air system was costing them. Four compressors (totaling 290 hp) supplied the air needed for pneumatic controls, packaging, and wax line extrusion applications. Excessive water in the compressed air lines, steep maintenance costs,

and high noise levels had them looking for a new solution.

SOLUTION:

A comprehensive Air Demand Analysis (ADA) established a demand profile for the plant and showed how they were using compressed air throughout the week. It also identified areas of waste and inefficiency. By installing a 100 hp variable frequency drive compressor and two 75 hp fixed speed compressors, they would have all the air needed—with one of the fixed speeds acting as a back-up. This split system solution would bring energy—and noise levels—well under control. A Sigma Air Manager 4.0 master controller could provide on demand energy reports so they would always know how their system was performing and what it was costing.

RESULT:

In just over 9.5 months, the project has paid for itself. Annual energy costs

have been cut by more than 800,000 kWh. Part of these savings came from reducing the plant pressure from 125 psi to 100 psi. Additionally, the new energy efficient dryers installed have taken care of the moisture concerns. Needless to say, these savings couldn’t get any sweeter.

Specific Power of Previous System: . . . . . . . . . . . . . . . . . . . . .47.16 kW/100 cfm Specific Power of New System: . . . . . . . . . . . . . . . . . . . . . . . . .17.77 kW/100 cfm Annual Energy Cost of Previous System: . . . . . . . . . . . . . . . . . . . . . . . . . $128,756 TOTAL ANNUAL ENERGY SAVINGS: . . . . . . . . . . . . . . . . . . . . . . . . . . . . .$80,235 Utility Incentive:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .$80,200

Let us help you measure and manage your compressed air costs! input #3 at www.plantengineering.com/information

Kaeser Compressors, Inc. • 866-516-6888 • us.kaeser.com/PE Built for a lifetime is a trademark of Kaeser Compressors, Inc.

customer.us@kaeser.com

Size matters. Especially with gearmotors... Too small = premature failure Too large = high cost & low efficiency Unsure of your drive size? Then go online to PT Pilot®. Simply enter the parameters of your hoist, conveyor, or travel car. PT Pilot® will automatically calculate the optimal horsepower, speed, and gear unit – with or without a VFD. PT Pilot® also provides documentation, pricing, and a 3D CAD drawing for every selection. Visit ptpilot.com.

ptpilot.com | 864-439-7537 input #4 at www.plantengineering.com/information

JULY/AUGUST 2017

SOLUTIONS

COVER: An important part of Faurecia’s vision for its plants was creation of what it calls Digital Management Control, designed to create a paperless shop floor. Image courtesy: Faurecia

INSIGHTS 8 | Strategic management: 8 steps to success 10 | Rewarding operational improvement: Target changes, not just numbers 14 | Artificial intelligence can produce tangible process improvements 16 | More Insights: Web Exclusives

Notable 18 | A look at the month’s manufacturing trends

Research 20 | 2016 Energy Management Study

Energy management in small to mid-sized facilities

Editor’s Insight 22 | Change is messy—and essential

INNOVATIONS 58 | New Products 63 | More Innovations: Web Exclusives 90 | A fresh approach to compressed air savings

Cover Story 26 | Doubling down on digital manufacturing

A Tier 1 automobile parts manufacturer knew change was needed in their facility. They began the journey toward the Industrial Internet of Things even before the concept had a name.

Maintenance Solutions 32 | Beyond the hype: Data will drive predictive maintenance

Merging the virtual world with real plant floor issues is the issue.

Electrical Solutions 36 | Electric motors and generators: Sizing up the difference

Two sides of the same coin, they still offer different mechanics, and benefits.

39 | More Solutions: Web Exclusives

APPLIED AUTOMATION A4 | Research team developing Tesla coil designs

Researchers at The Geek Group National Science Institute have set out on an ambitious program of research and experimentation seeking to discover new uses for Tesla coils.

A9 | Implementing wireless process sensing Installing a wireless sensing system may seem complicated, but following these four basic steps can simplify the required effort.

PLANT ENGINEERING (ISSN 0032-082X, Vol. 71, No. 6, GST #123397457) is published 10x per year, monthly except in January and July, 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. PLANT ENGINEERING copyright 2017 by CFE Media, LLC. All rights reserved. PLANT 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 CFE Media, LLC, 3010 Highland Parkway, Suite #325, Downers Grove, IL 60515. E-mail: customerservice@cfemedia.com. Postmaster: send address changes to PLANT 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, $145/yr; Canada, $180/yr (includes 7% GST, GST#123397457); Mexico, $172/yr; International air delivery $318/yr. Except for special issues where price changes are indicated, single copies are available for $30.00 US and $35.00 foreign. Please address all subscription mail to PLANT 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.

www.plantengineering.com

PLANT ENGINEERING

July/August 2017

•

WHY WE DO IT

CLEAN AIR MATTERS

Farr Gold Series® Dust Collector

camfilapc.com/videos/fgs

Handte EM Profi Coolant Mist Collector for machining

camfilapc.com/videos/profi

Dust, Mist and Fume Collectors AIR POLLUTION CONTROL

www.camfilapc.com • e-mail: filterman@camfil.com • 866-354-8794 input #5 at www.plantengineering.com/information

DIGITAL REPORTS Plant Engineering is excited to introduce our new Digital Reports Sponsored by: Mitsubishi, Yaskawa

Sponsored by: Gates, New Pig

2017 DIGITAL REPORT Maintenance

2017 Digital Report

Safety

MOTION CONTROL

www.plantengineering.com/ DigitalReport/MotionControl Sponsored by: FS Elliott, Kaeser

www.plantengineering.com/ DigitalReport/MaintenanceandSafety Sponsored by: Beckhoff, Bosch Rexroth, ePlan, Hilscher

2017 DIGITAL REPORT

2017

D igital R epoRt IIoT:

COMPRESSED AIR STRATEGIES

Machines, Equipment & Asset Management

www.plantengineering.com/ DigitalReport/AirCompressedStrategies Sponsored by: Maple Systems, Pepperl+Fuchs 2017 D igital R epoRt

HMI

www.plantengineering.com/ DigitalReport/HMI

www.plantengineering.com/ DigitalReport/lloTMEAM Sponsored by: Kepware, Rittal 2017 DIGITAL REPORT IIoT: OPERATIONS & IT

www.plantengineering.com/ DigitalReport/lloTOpsandIT

GUARANTEED SOLUTIONS To Your Specific Bulk Material Conveying Problem

FLEXI-DISC

FLEXICON

PNEUMATI-CON

Tubular Cable Conveyors

Flexible Screw Conveyors

Pneumatic Conveying Systems

Convey free- and non-free-flowing bulk materials at low cost

Convey fragile bulk foods and non-foods gently

Convey free-flowing materials short to long distances

• Convey free-flowing and difficult-to-handle materials that pack, cake, seize or smear • Prevent separation of blends • Convey short to medium distances • Conveyor routing at any angle, through small holes in walls or ceilings • Only one moving part contacts material • Fast disassembly, thorough cleaning • Stationary or mobile units, including tilt-down models • Economical to purchase, install, operate and maintain • Single or multiple discharge points • Minimal power usage • 3-A and USDA compliant or industrial models

• Slide fragile materials gently through smooth stainless steel tubing using lowfriction polymer discs attached to stainless or polymer-coated stainless cable • Prevent separation of blends • Short to long distances • Durable discs in 4 and 6 in. (100 and 150 mm) diameters • Available CIP accessories • Single or multiple inlets/outlets can be removed/relocated and the cable-disc circuit lengthened/shortened/re-routed • Minimal power usage • Evacuates material, minimizing waste and cleaning time

• Single-point “up-and-in” installations to crossplant systems with multiple pick-up and discharge points and automated controls • Positive pressure and vacuum dilute phase systems complete with blowers, rotary airlock valves, pick-up adapters, filter receivers, cyclones, fill/pass valves, wands and weigh batching controls • Short to long distances • Wide capacity range—feed small packaging lines to silos and railcars • Single or multiple inlet and discharge points • Total evacuation of supply vessel and the conveyor line for accurate weighments, minimal waste and easy cleaning

Stand-alone units to weigh batching configurations to automated plant-wide systems backed by Flexicon’s Lifetime Performance Guarantee*

See the full range of fast-payback equipment at flexicon.com: Flexible Screw Conveyors, Tubular Cable Conveyors, Pneumatic Conveying Systems, Bulk Bag Unloaders, Bulk Bag Conditioners, Bulk Bag Fillers, Bag Dump Stations, Drum/Box/Container Dumpers, Weigh Batching and Blending Systems, and Automated Plant-Wide Bulk Handling Systems

USA sales@flexicon.com 1 888 FLEXICON

+56 +44 +49 +34 +61 +65 +27

2 2415 1286 (0)1227 374710 170 8 187 613 930 020 509 (0)7 3879 4180 6778 9225 (0)41 453 1871

input #6 at www.plantengineering.com/information

FF-0704

CHILE UK GERMANY SPAIN AUSTRALIA SINGAPORE SOUTH AFRICA

INSIGHTS INSIGHTS Strategic management: 8 steps to success

Bridging the gap between strategy and asset execution.

Rewarding operational improvements: Target changes, not just numbers Rewarding teams for achieving reliability goals sets the stage for sustainable performance.

Q&A: Artificial intelligence can produce tangible process improvements Infosys senior VP Sudip Singh discusses how artificial intelligence will impact manufacturing, and why there’s a disconnect between digital transformation and digital adoption.

Energy management in small- to mid-sized facilities.

41%

number of manufacturers who believe their energy management goals are achievable; that

compares to 52% who are less confident in that success.

More Insights

www.plantengineering.com

NOTABLE

RESEARCH 2016 Energy Management Study

A NASA pioneer is honored by Infor

The ‘do-or-die’ nature of the digital plant

The latest PMI numbers show continued growth is messy. Change “ Change is inconvenient. Change requires courage, and it also requires capital. Change is not an end it itself; it is the means to a greater end.

”

Bob Vavra, CFE Media

PLANT ENGINEERING

July/August 2017

•

INSIGHTS By Matthew Popovacki, T.A. Cook

Strategic management: 8 steps to success Bridging the gap between strategy and asset execution.

o maximize profitability in a competitive, global environment, organizations are expected to consistently deliver on production demands while maintaining optimal performance. However, maximizing assets and bridging the gap between strategic vision and the tactical planning and execution of activities is a constant challenge. Often, corporate and asset-strategic vision is considered from a long-term perspective, while the planning and execution of activities are seen as part of a short-term facilitation process. Unfortunately, the separation of strategy from planning and execution in this way means that the potential gains from aligning and managing initiatives between functional disciplines (such as health and safety, asset integrity, operations, procurement, shutdowns, capital projects, maintenance, and reliability) are either ignored or not fully exploited.

Challenges Integrated strategic management (ISM) model. Image courtesy: T.A. Cook.

â&#x20AC;˘

July/August 2017

PLANT ENGINEERING

Buzzwords, such as integration, are often referred

to within the oil and gas industry as the solution for attaining optimal asset performance management. However, the challenge many organizations currently face is that they do not fully understand the path, approach, and level of effort it takes to achieve true integration and optimal asset performance. There are a variety of misconceptions many organizations share which present a continual challenge when trying to implement the best approach. In addition to the previously mentioned mistake of distinguishing between strategic planning as longterm while planning and execution as short-term, another fault is assuming things will just come together on their own. Many sites believe that multiple strategies or corporate goals for the different functional areas will align naturally, or that if all the major elements are in place within the organization, then processes will integrate on their own. Other sites falsely presume that if the worst performing processes are enhanced, that will be enough to attain the overall asset performance potential. These misconceptions typically lead organizations to focus all their attention on addressing major gaps within individual functional areas. Unfortunately, monopolizing time and energy in this way does not correct the deficiencies that could still exist between multiple functional areas. While improving performance within an individual area will help the efficiency within the management of an asset, it is not sufficient to maximize the performance across the overall asset. To be successful, an organization must integrate all the elements that drive optimal asset performance. Fortunately, there are tools and practices to help do just that. www.plantengineering.com

“To be successful, an organization

The Integrated Strategic Management model

One such tool, an Integrated strategic management model (ISM), can make the unification process more clear and effective. An effective and structured approach is essential for an asset strategy. The plan must account for the organization’s initiatives to ensure that the asset’s longterm strategy and tactical use during planning and execution are aligned and supportive of one another. Demonstrated in the image, managers can take steps to bridge the gap between corporate goals and optimal asset performance, as defined in this model. Each step in the ISM model should be considered using the following core criteria: Step 1 - Define the overall organizational strategy The long-term strategy must take into account the overall organizational safety, regulatory, production, maintenance, and upgrade requirements for the assets. Step 2 - Outline the roles and responsibilities by functional area The roles and responsibilities of all functional areas should be outlined clearly, including the newly defined activities associated with the safety, production, planning, reliability, integrity, and maintenance of an asset. Step 3 - Set up the structure of the organization Roles for individuals within the proper functional areas must be aligned so that best practice spans of control and the newly assigned activities are managed effectively. Step 4 - Optimize the functional areas A staged approach should be used to identify current gaps and incorporate best practice principles into the design and implementation of processes for all different functional areas (e.g., HSE, asset integrity, operations, procurement, shutdowns, capital projects, maintenance, and reliability). This should enable the effective management, alignment, integration, and sharing of resources throughout the entire organization. Step 5 - Outline the resource requirements by functional area The milestones, level of effort, and time needed to perform all of the individual tasks within each field must be defined. Functional resource requirements based on activity levels also should be established. www.plantengineering.com

Step 6 - Merge the long-term functional area plans and integrate planning A Level 2 schedule consists of a clear outline of the timing for all future production goals with major maintenance events for a determined time period. A long-term Level 2 schedule should be developed at five-year intervals. Major milestones dates and the resource and time requirements should be broken down by month for all functional areas to support all the activities of production and maintenance.

must integrate all the elements that drive optimal asset performance. Fortunately, there are tools and practices to help do

”

just that.

Step 7- Implement a long-term, integrated plan The long-term schedule should be used to manage the activities and resources available to deliver on milestones. Any variances to the plan, with both activities and resource requirements, should be identified to establish action plans and mitigate any gaps between the long-term plan and the delivery of production and the previously agreed-upon asset maintenance deliverables. Step 8 - Manage and sustain performance Results must be monitored frequently against the plan to address any variances between expectations and reality. This will help ensure that optimal asset performance and financial objectives can both be attained and sustained.

Put in the work

Successful strategies do not just get executed by themselves. To reach goals, organizations must increase visibility across multiple functional areas and integrate their processes. To be effective, they must adopt a more holistic, tactical, and structured approach focused heavily on integrated planning, so that the large gaps typically found between longterm strategic visions and actual performance can be minimized. Incorporating a structured approach such as an ISM model allows organizations to engage all the functional area processes and eliminate silos that exist between departments. It also enables companies to take advantage of the synergies within the different functional areas and deliver on strategies that will represent a more profitable and optimal performance of assets in the long-term. Leveraging the ISM model will ensure the “sum of the parts is greater than the whole” and that real sustainability will be achieved. PE Matthew Popovacki is a senior manager with T.A. Cook. PLANT ENGINEERING

July/August 2017

•

INSIGHTS

By Michael W. Blanchard, CRE, PE, Life Cycle Engineering

Rewarding operational improvements: Target changes, not just numbers Look past KPIs to reward proactive behavior.

ewarding individual operators, and operations as a group, means recognizing them for their performance and acknowledging their contributions to their organization’s goals. Group recognition typically is tied to lagging metrics, such as asset reliability. On the other hand, operator behavior usually is linked to leading metrics, such as percentage of inspections completed. To understand how to shift the operating culture by rewarding the reliability-boosting behaviors, we first need to consider how to identify the appropriate key performance indicators (KPIs) and which behaviors positively affect them.

the metric selected, plant operators must understand how their decisions and actions impact the KPI and the bottom line. Rewarding teams for achieving reliability goals sets the stage for sustainable performance. It is KPIs and leadership that will support and manage a new proactive process. It also requires incorporating data-driven process management that not only measures results, but also emphasizes process measures (leading indicators, for example). People must be held accountable. Efforts to improve reliability should be recognized and results from the proactive approach should be rewarded.

Asset reliability

Changing an organization’s culture is usually the biggest obstacle to sustaining asset reliability. Although changing from a reactive to proactive culture is difficult, it is achievable. It requires monitoring and rewarding operating discipline to established processes and policies. By changing daily behavior to proactive, organizations are essentially changing to a reliability-centered culture. When proactive behavior is reinforced and driven systematically, it becomes a way of life. To help facilitate the change to proactive, organizations need to enforce discipline to process, and change KPIs and the recognition system to reward proactive tasks rather than “firefighting” tasks. So a “good job fixing the equipment so fast” comment needs to be replaced with “that proactive action prevented us from taking the line down for a week.” A characteristic of a KPI is that it can be measured daily yet can have a significant impact on operations. KPIs provide a complement of leading and lagging indicators that effectively communicate the daily operations of a production plant. Quarterly AU and financial reports are merely the scorecard for the KPI results. These metrics tend to be lagging KPIs. Since these are so closely related to the bottom line, they are good candidates for team goals. Dashboard tools can effectively communicate KPIs and progress toward goals. Leading KPIs are performance measures that can be used to indicate potential issues so corrective actions can be taken. Leading KPIs are predictive in nature

The inherent reliability of an asset is established once custody has been turned over to operations. Plant operators then are tasked with running the production equipment safely and efficiently while also preserving reliability. Asset reliability can be tracked using asset utilization (AU) or overall equipment effectiveness (OEE) metrics. Reporting of AU or OEE is usually done monthly or quarterly, making them lagging KPIs. However, if the window of measurement is minimized (i.e., each shift, daily), the KPI becomes leading. Regardless of

Calculating OEE

The standard formula for calculating overall equipment effectiveness (OEE) is:

Availability x Performance x Quality

Availability is calculated as Run Time divided by Planned Production Time. Performance is calculated as Ideal Cycle Time x Total Count, divided by Run Time Quality is calculated as Good Count divided by Total Count Source: oee.com

•

July/August 2017

PLANT ENGINEERING

Key performance indicators

www.plantengineering.com

The Secret To Keeping Electronics Cool! NEMA 12 Cabinet Coolers

A bad choice could cost you thousands!

The NEMA 12 Cabinet Coolers for large heat loads up to 5,600 Btu/hr. are ideal for PLCs, line control cabinets, CCTV cameras, modular control centers, etc.

Look Familiar? When hot weather causes the electronics inside a control cabinet to fail, there is a panic to get the machinery up and running again. The

• Measures 8" (203mm) high

operator might choose to simply open the

• Mounts top, side or bottom

panel door and aim a fan at the circuit boards.

• Enclosure remains dust-tight and oil-tight

In reality, the fan ends up blowing a lot of hot, humid, dirty air at the electronics and the

NEMA 4 and 4X Cabinet Coolers

cooling effect is minimal. If the machinery

NEMA 4 and 4X Cabinet Coolers for large heat loads up to 5,600 Btu/hr. They are ideal for PLCs and modular controls.

repeated failure is great since the environment

• Enclosure remains dust-tight, oil-tight and splash resistant

presents a shock hazard to personnel.

• Suitable for wet locations where coolant spray or hose down can occur

starts functioning again, the likelihood of is still hot (and threatens permanent damage to the circuit boards). Worse yet, that open panel door is an OSHA violation that

The Real Solution!

Watch The Video

Stop electronic downtime with an EXAIR

Type 316 Stainless Steel Cabinet Coolers

Cabinet Cooler® System! The complete line of

Type 316 Stainless Steel Cabinet Coolers for NEMA 4X applications are available for heat loads up to 5,600 Btu/hr.

can ship now. They mount in minutes through

• Resists harsh environments not suitable for Type 303/304

for all models. All Cabinet Coolers are UL

• Ideal for food and chemical processing, pharmaceutical, foundries, heat treating and other corrosive environments

Mini NEMA 12, 4, and 4X Cabinet Coolers The mini NEMA 12, 4 and 4X Cabinet Coolers for small heat loads up to 550 Btu/hr. are ideal for control panels, relay boxes, laser housings, electronic scales. • Measures 5" (127mm) high • Mounts top, side or bottom • Enclosure remains dust-tight and oil-tight

low cost Cabinet Cooler Systems are in stock and an ordinary electrical knockout and have no moving parts to wear out. Thermostat control to minimize compressed air use is available

www.exair.com/79/44079.htm

Listed to US and Canadian safety standards.

The only compressed air powered cooler that is CE compliant! High Temperature Cabinet Coolers

Non-Hazardous Purge Cabinet Coolers

High Temperature Cabinet Coolers for NEMA 12, 4 and 4X applications are available for heat loads in many capacities up to 5,600 Btu/hr.

NHP Cabinet Coolers keep a slight positive pressure on the enclosure to keep dirt from entering through small holes or conduits. For use in non-hazardous locations.

• Suitable for ambients up to 200°F (93°C)

• Uses only 1 SCFM in purge mode

• Ideal for mounting near ovens, furnaces, and other hot locations

• For heat loads up to 5,600 Btu/hr. • NEMA 12, 4 and 4X If you would like to discuss an application, contact:

“It took us three days to get a replacement computer cabinet and we didn’t want to risk another heat failure. Fans weren’t an option since they would just blow around a lot of hot air. Freon-type air conditioners like those on some of our other machines were a constant maintenance project of their own. We purchased EXAIR’s Model 4330 NEMA 12 Cabinet Cooler Jeff Hauck, Lasercraft Inc. Cincinnati OH

System since it was easy to install and requires no maintenance.” input #7 at www.plantengineering.com/information

11510 Goldcoast Drive Cincinnati, Ohio 45249-1621 (800) 903-9247/fax: (513) 671-3363

www.exair.com/79/440.htm @exair

INSIGHTS and tend to communicate change in the production environment. The goal is to use these leading metrics to help analyze expected operational and financial results. Some metrics over time will show little relevance but at least you can track to see if that changes. Leading indicators help you because they: • Correlate operational goals and trends with bottomline performance • Provide additional information for decision making • Anticipate changes in plant conditions.

What are proactive behaviors?

In today’s production facilities, it’s not enough for operators to react and adapt to changes in their environment. Production plant operators need to engage in proactive behavior. When monitoring leading KPIs, operators need to plan ahead and prepare for potential threats and dangers in the future by taking the initiative today. To minimize the possibility of negative effects of proactive behavior, operators must consider both the rewards and possible costs of potential actions. For example, when a daily OEE rate drops below a predetermined level and duration, the operator is challenged with the opportunity to do nothing or take action to revive the process. Utilizing experience, plant expertise, and process troubleshooting guidelines, the operator determines the options, and selects an action after conducting a cost-benefit analysis. If unsuccessful, the process is repeated until the daily OEE rate is back on target.

What proactive behaviors impact asset reliability?

There are many task and organization-focused behaviors that can be seen as proactive, however some have significant impact on asset reliability. Here are some examples of proactive behaviors listed in order from most significant to least: • Addressing behaviors and adverse conditions that threaten safety • Routinely applying root cause analysis (e.g., 5-why) in daily work • Identifying equipment in distress and taking actions to resolve • Gathering evidence for an upcoming root cause analyses • Reporting reliability near misses • Sharing risks to value stream with other operators • Submitting asset reliability improvement ideas • Performing routine equipment care • Using standard procedures and practices.

Reward proactive behavior

Rewarding operators for proactive behavior sets the stage for sustainable performance. When

•

July/August 2017

PLANT ENGINEERING

reinforcing, explain to the operator exactly what behaviors you value so that those behaviors will be repeated. The words and actions will have surprisingly great impact on operators and will spur them to greater productivity. Reinforce frequently so that employees are continuously motivated and enthusiastic. These guidelines can maximize the effectiveness of reinforcement. • Be specific • Reinforce immediately • Be sincere • Reinforce unpredictably • Reward incremental improvement • Give realistic reinforcement • Personalize the reinforcement. Listen to operators, observe their behavior, become sensitive to their needs, and you will be able to personalize reinforcement for each individual. For example, some people love being acknowledged in public while others might appreciate a private thank you. It doesn’t mean they don’t want the reinforcement, but it’s important to understand what is most meaningful to different people. Consider surveying several operators to determine what rewards they find most attractive. Recognition and approval are among the most powerful reinforcers. Consider using internal communication channels to acknowledge good performance. Monetary incentives are also powerful reinforcers. Recommend the deserving operator for an award, bonus, or raise, linking increased money to improved performance. The size of the monetary reward should be proportionate to the performance. Operators should be rewarded based on the action or behavior’s impact to organizational goals. To generate spread, a non-linear scaling of reward value can be applied. The lowest level award should be equivalent to “lunch for two” or maybe a tank of gas. The next level award should be approximately three times the value of the lowest level. The highest level award should be approximately nine times the value of the lowest level. Sticking with an increasing reward scales allows you the flexibility to match the reward to the behavior. Proactive operators are innovative problem solvers. They preserve asset reliability leading to increased productivity. Sustainability means making commitments. Establishing goals and working towards them can help empower the operator and reinforce the control they have over their area of influence. Sustainability of asset reliability requires that the right actions and behaviors are in place and are rewarded appropriately. PE Michael W. Blanchard is a reliability engineering subject matter expert with Life Cycle Engineering (LCE). www.plantengineering.com

More Choices • Representing North America’s leading industrial brands • Access to over 6.9 million SKUs • Convenient and simple ways to order via mobile, desktop, toll-free calling, or one of our locations

More Expertise • More than 1,700 experienced account representatives • Over 200 field product specialists available to solve your toughest challenges

• Unmatched technical and application support More Solutions • Local parts and supplies inventory for fast turnaround • Repair and fabrication technicians • Account representatives and hundreds of branches located throughout North America for your convenience Scan to watch

Expect More With Motion. http://esp.to/wb8Xon

Call. 800-526-9328 Click. www.MotionIndustries.com Visit. Over 530 Locations

INSIGHTS Artificial intelligence can produce tangible process improvements Infosys exec Sudip Singh discusses how AI can deliver new plant efficiencies.

recent report released by Infosys, a global technology and consulting company, looked at how artificial intelligence (AI) will be used in manufacturing and other business sectors to improve training and operations. The study, called “Human Amplification in the Enterprise” discussed the use of AI in manufacturing as well as the barriers to its adoption. Sudip Singh, senior vice president and global business unit head of engineering services at Infosys, discussed the future uses of AI and the state of the digital transformation with Plant Engineering. Plant Engineering (PE): How do you define the term “artificial intelligence”? Singh: For the purposes of this research, AI was defined as an area of computer science that emphasizes the creation of intelligent machines that work and react like humans. PE: How do the survey respondents think AI will help their business efforts? Singh: Across industries, there is a clear link between an organization’s revenue growth and its AI maturity, and that is also evident in the manufacturing industry. According to our research, 80% of enterprises in the manufacturing and

high-tech sector are undergoing full-cycle digital transformations to become AI-driven and therefore faster, more agile and more efficient. These organizations are looking to AI to provide human-like recommendations for automated customer support/advice (60%); want AI to process complex structured and unstructured data and to automate insights-led decisions (58%); and want to use AI to create a simulated experience that is essential to a decision-making process (48%). PE: There seems to be a disconnection between manufacturers who say they are undergoing a “digital transformation” and the amount of actual transformation. As you analyze the study, where is manufacturing along this journey of digital transformation? Singh: Even though a majority of enterprises in the manufacturing and high tech sector are undergoing digital transformation, few have fully accomplished their stated goals. This is due to a lack of data-led insights on demand (67%); lack of collaboration among teams (51%); and lack of time (40%). And when IT processionals were asked about difficulties in achieving their enterprises’ full-cycle digital transformation, respondents cited IT misalignment (68%); entrenched resistance to change within the organization (59%); and time constraints (51%).

“Discussions around AI tend to gravitate toward negative connotations of the

technology, but we’re doing a disservice by not focusing on the true value of the technology,

”

which is to amplify human potential.

Sudip Singh, Infosys 14

•

July/August 2017

PLANT ENGINEERING

www.plantengineering.com

Cabinet Confidence Ethernet switches simplify network topology construction

Phoenix Contactâ&#x20AC;&#x2122;s expertise and commitment to innovation across a wide range of industries enable you to build your control cabinet with confidence. Our Ethernet switches provide flexibility in any industrial network application, from Gigabit or Fast Ethernet unmanaged devices, to highly advanced managed options. Design confidence into your network topology construction with Phoenix Contact Ethernet switches. Call 1-800-322-3225 or visit: www.phoenixcontact.com/confidence_switches

ÂŠ PHOENIX CONTACT 2017

input #9 at www.plantengineering.com/information

INSIGHTS This suggests there is a disconnect within organizations that undergo these transformations. Until more senior level ITdecision makers buy into the benefits of bringing AI to manufacturing, teams won’t have access to the proper resources to support full-scale implementations, and will therefore deprioritize digital transformation initiatives. Time and again digital transformation projects are abandoned because pockets of an organization are resistant to change, but by getting buy-in from the right advocates, digital transformations can continue, driving innovation forward. PE: How should AI be used in training the current manufacturing workforce?

By The

NUMBERS Among the AI-supported technologies and uses that respondents said would impact their digital transformation are: 79%: Machine learning 66%: Institutionalization of enterprise knowledge 60%: Cognitive AI-led processes and tasks 54%: Automation of decision-making 53%: Building AI-based applications to amplify and improve products and services 46%: Robotic automation Source: “Human Amplification in the Enterprise” report, Infosys

Singh: As AI continues to disrupt the current workforce, it’s critical to move past our conven-

INSIGHTS

PE: In your survey, 43% said that making better use of data for business decisions is a difficult goal to achieve. What should manufacturers do to overcome this barrier?

Web Exclusives

Looking for more trends in manufacturing? Check out these articles at plantengineering.com by typing the headline into our exclusive search engine. IIoT AND THE RISE OF THE COBOTS Collaborative robots, designed to work side-by-side with their human colleagues, often assisting them to perform tasks, accounted for only 1.4% of shipments that year, in an industrial robotics market worth $11.1 billion in total. LEAN MANUFACTURING BECOMING LEANER Today, plant leadership is well versed in all things Lean. The abundance of information and cheap resources available empower plant employees to identify and fix problems on their own. This begs the question, why would a plant manager hire a manufacturing consultant to tell the manager what they already know or could investigate themselves? FIVE CLOUD ERP CONSIDERATIONS FOR COMPANIES The cloud model is an effective, scalable, and economic way to implement business applications. Cloud ERP is designed to allow a company to respond to the challenges it will face years into the future, as well as those confronting it today. Companies looking to use cloud ERP should keep five things in mind before going forward with it.

•

July/August 2017

PLANT ENGINEERING

tional views of education, and instead shift our focus to holistic, continuous, and lifelong learning. This is a shared view across industries, including manufacturing. For example, according to our research, respondents say lifelong learning is extremely important to their organizations. Of the reasons for why lifelong learning programs are important, 61% say it improves their ability to fit into new roles and jobs; 25% say it improves their productivity; and 10% say it prevents skills loss when employees with highly specialized skills retire or switch jobs. Whether AI itself will play a role in training human workers is a facet of AI maturity that remains to be seen.

Singh: Organizations will be unable to experience the benefits of AI until they implement information governance strategies that allow them to make better use of their data. However, this is much easier said than done and we continue to see data projects fail because of how companies are organizing their data. But to capitalize on AI investments, companies need the capabilities to transform insights into actions. Automation will be critical in overcoming this barrier. By eliminating low-level manual processes, organizations can free up human resources, thus amplifying human potential to deliver more value and creativity further up the value chain. PE www.plantengineering.com

The power to transform your job site. UR Control®, our free online rental management tool, gives you unlimited access to your account details and rental information in real time. Keeping costs down and productivity up has never been easier. Total Control® is our proprietary fleet management system that features innovative consumption management tools to help you reduce overall equipment costs by optimizing the amount, time and utilization of equipment on rent. Take control now. Visit UnitedRentals.com/URcontrol or download from your app store.

input #10 at www.plantengineering.com/information

NOTABLE By Bob Vavra, CFE Media

A collection of news and other fun items

Embrace the digital plant to build a bridge to the future

Katherine Coleman Johnson, who story was featured in the movie “Hidden Figures,” was honored at the Inforum event sponsored by Infor in July. The company named its artificial intelligence platform Coleman. Image courtesy: Infor

Hidden Figures no more; Infor names AI platform for NASA mathematics pioneer The debut of Infor’s artificial intelligence (AI) platform is as notable for the legacy of its name as it is for its functionality. At its annual Inforum event in New York City, Infor introduced Coleman, the industry-specific AI platform. It is named in honor of Katherine Coleman Johnson, a physicist and mathematician for NASA whose story was part of the popular 2016 movie “Hidden Figures,” about three African-American mathematicians whose work was critical to the U.S. space program in the 1960s. Katherine Coleman Johnson’s family was recognized during Inforum’s opening ceremony July 11 at the Javits Center in New York. In a statement, her family said, “We are excited and honored that Infor would choose our matriarch to help them represent innovation, analytical might, and a continued push for excellence. She symbolizes for many a beacon of resilience, a source of courage, and a promise of what’s possible. For Katherine Coleman Johnson, the value is in knowledge shared, not in what is known.” “Infor spent many years automating processes that followed clear rules, such as accounting and manufacturing processes,” said Infor CEO Charles Phillips in a statement. “We are now leveraging machine learning and our access to large amounts of data to assist users with less structured processes, such as complex decisions, conversations, and predictions.” PE

•

July/August 2017

PLANT ENGINEERING

Digital manufacturing has moved beyond the hype to become essential to production’s future. “Companies now understand they have to embrace digitalization. It’s a do-or-die thing,” said Raj Batra, president of the Siemens digital factory division at the opening ceremony of the 2017 Siemens Automation Summit in Boca Raton, Fla., on June 27. “What this means for us is taking billions of intelligent devices and creating a bridge between digital and real world to increase value.” Despite the established potential to improve operational efficiency and to lower production costs, Batra said the adoption of digital manufacturing hasn’t yet caught up to the potential. “Many people have started, but the pace isn’t fast enough, especially in small to mid-sized manufacturers,” Batra said. “In some cases, it’s a capital issue. Some people just don’t know where to start. Some are just missing the boat.” Making the case for digital manufacturing requires plant leadership to understand that change is not just inevitable. It’s essential. “Companies large and small understand they have a lot to gain, and they understand the risks of betting on the status quo,” Batra said. “These are transformative changes. If you are not disruptive, you are going to be disrupted.” In a data-driven environment, Batra cited two sets of data to make his point. On the one hand, there are expected to be 1 trillion connected devices by 2030, and the digital economy will encompass 25% of the world’s economy by 2020. While half of the world’s data was created in the last year, Batra noted that, “Industry hasn’t kept pace with what we see in the consumer world.” On the other side, those companies that haven’t changed have become the dinosaurs of the economy. Batra said that more than half of the Fortune 500 companies in 2000 no longer exist. PE

By The

NUMBERS

56.3%

The July PMI Index from the Institute for Supply Management. While the PMI was down 1.5 percentage points from June’s reading, it still is more than 10% higher than the index’s baseline for manufacturing growth. The PMI has not been lower than 54.8% in the first eight months of 2017.

www.plantengineering.com

MovinCool is another innovative product from DENSO.

15 Years. 150,000 Miles. 850 Events. 1,500+ Facilities.

This Road Warrior’s Cooling Still Hits the Spot Day after day, year after year, MovinCool spot air conditioners have been proven to be the toughest, most effective and longest-lasting in the industry – in even the harshest environments. Fully self contained – simply roll them in, turn them on and set the programmable temperature controller. No matter the demands, let our MovinCool road warriors keep you and your operations cool and productive. Learn more about MovinCool:

800-264-9573 MovinCool.com/facility

MovinCool and Spot Cool are registered trademarks of DENSO

input #11 at www.plantengineering.com/information

M More RESEARCH research 2016 ENERGY MANAGEMENT STUDY

Plant Engineering covers several research topics each year. All reports are available at www.plantengineering.com/research

Energy management in small- to mid-sized facilities

ore than half of respondents to the Plant Engineering 2016 Energy Management Study work at a manufacturing facility with fewer than 250 employees. Below are five key findings regarding energy management within small- to mid-sized industrial facilities:

1. Energy audits: Forty-one percent of small- to mid-sized

facilities conduct regular energy audits. Of those facilities, 38% perform them annually, 15% twice a year, and 6% quarterly. Aside from audits, 69% of plants monitor energy usage regularly.

2. Reducing usage: On average, small- to mid-sized manufacturing facilities are trying to reduce their energy usage by 9.05%. Forty-one percent of respondents believe that

their goals are achievable, while 52% are less confident but still optimistic.

3. Implementation: Twenty-four percent of respondents

from small- to mid-sized facilities reported success with implementing an energy management program, while 26% are just starting to employ one.

4. Local utilities: More than half of small- to mid-sized

facilities work with their local utility companies to develop energy strategies, 75% of which reported a cooperative partnership. Twenty-seven percent of small- to mid-sized manufacturing plants have a peak-load sharing program with their utilities, all of whom said it has been an overall successâ&#x20AC;&#x201D;58% of which experienced no problems along the way.

5. Challenges: Top challenges to ener-

gy management programs in small- to mid-sized facilities include buy-in from management (33%), acquiring resources from corporate/management (32%), and educating workers on the goals and objectives (32%).

Electricity, natural gas, and fossil fuels are most commonly monitored monthly by small- to mid-sized facilities, while compressed air is usually monitored on a continual basis. In addition to these main sources, 22% of these facilities use co-generation energy, and 20% use solar energy. Source: Plant Engineering

View more information at www.plantengineering.com/ 2016EnergyManagement Amanda Pelliccione is research director at CFE Media.

facilities conduct safety audits in an effort to 76% ofenforce implemented safety procedures.

Source: Plant Engineering 2017 Safety Study

plant engineers expect their 2017 salary to 75% ofincrease compared to their 2016 earnings.

Source: Plant Engineering 2016 Salary Survey

facilities are experiencing difficulty with 33% ofacquiring the necessary resources to enhance their energy management programs.

Source: Plant Engineering 2016 Energy Management Study

â&#x20AC;˘

July/August 2017

PLANT ENGINEERING

The average plant outsources 18.6% of their maintenance operations. Source: Plant Engineering 2017 Maintenance Study www.plantengineering.com

ONE SOURCE FOR

POWER

Your Northeastern Region Cat® Dealer is your single source for all of your power systems, compressed air and temperature control needs 24/7 – 365 days a year. Whether it is an emergency outage or a planned maintenance, we’re your one stop for commercial, industrial, institutional and manufacturing power systems solutions. In addition, we have all of the ancillary equipment including distribution cables, transfer switches, load banks, distribution panels and cable ramps. We’re the premier source for all your temporary power requirements… anytime, anywhere. To learn more, visit NECatDealers.com/power

SALES • RENTAL • SERVICE • PARTS SINCE 1927 Alban CAT www.albancat.com Baltimore, MD 800-492-6994

SINCE 1948 Cleveland Brothers

SINCE 1923 H.O. Penn Machinery

SINCE 1960 Milton CAT

SINCE 1916 Ransome CAT

www.clevelandbrothers.com Murrysville, PA 800-538-1020

www.hopenn.com Poughkeepsie, NY 844-CAT-1923

www.miltoncat.com Milford, MA 866-385-8538

www.ransome.com Bensalem, PA 877-RANSOME

input #12 at www.plantengineering.com/information © 2017 Caterpillar All rights reserved. CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow,” the “Power Edge” trade dress as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission. www.cat.com www.caterpillar.com

INSIGHTS

By Bob Vavra, Content Manager

PlantEngineering.com

Change is messy—and essential We’ve just moved into our new offices here at CFE Media, and we find ourselves creating new habits in our new surroundings. One big thing is the location of the coffee. It is essential to have a clear path to the coffee, and this is especially true for me before 8 a.m. If I do not have a clear path to coffee before 8 a.m., the day will not go well for me, or for anyone brave enough to interact with me. A lot of this move involves putting things in the right place, getting used to new chairs, and adjusting the workspace to meet our specific needs. The essential tools haven’t changed, but we’re using them in a different environment, and new ways of working together must be formed. How will the new conference room enhance our use of technology, for example? And then there’s the issue of learning new street addresses and phone numbers and extensions—all of which we have for you within this issue, so please update your phone lists. Moving into a new office hasn’t always gone smoothly, and there have been a lot of things we needed to adapt to and a lot of organizational decisions that had to be made. So why bother? In the end, it came down to one basic issue: We needed to change. Change is messy. Change is inconvenient. Change requires courage, and it also requires capital. Change is not an end it itself; it is the means to a greater end. It involves analyzing your current situation and concluding that the mess, inconvenience, uncertainty, and cost will be worth it in the end. I think that’s the part many manufacturers overlook today. Changing to a digital manufacturing plant certainly has all the pitfalls cited above, and quite a few more. Changing your process is a hard thing to contemplate, especially if things generally are going pretty well. Given the recent data about manufacturing, it would seem things are going pretty well.

•

July/August 2017

But there are plenty of arguments for change, not the least of which is that change also is inevitable. Not too many manufacturing companies want to be on the bleeding edge of technological innovation— although my experience is that most of the better manufacturers are. Those who already have adopted digital manufacturing see the benefits, and this will give them a decided edge in a very competitive marketplace. Those still on the sidelines must decide to change. The ability to carve away costs and improve efficiencies in your operations and supply chain make the digital plant the way we will be manufacturing well into the rest of this century. Call it the Industrial Revolution or call it the Industrial Internet, but adopting the available technologies and strategies are essential to manufacturing reaching its full potential in this global marketplace. Change is not a straight line. Very few messy, inconvenient things are. What is required is the will to change, followed by the will to see that change through to its planned conclusion. That will require your team to embrace the change, and that also can be messy and inconvenient. Your team will look to you to lead them through it. But change does not have to come all at once. It can be a process of testing and trying and failing and trying and succeeding and replicating success. We toss words like “continuous improvement” around a lot because that is the mindset in any good organization. Change is different. Changing means deviating from the path of continuous improvement and looking for something more. There is not enough change in manufacturing today, and change is needed. If U.S. manufacturing falters, it won’t be because regulations are too stringent or taxes are too high or tariffs are unfair. Manufacturers of all sizes can see the clear benefit of the technological changes available today. They must act for one simple reason: Change is not good; change is better. PE

PLANT ENGINEERING

www.plantengineering.com

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

CONTENT SPECIALISTS/EDITORIAL BOB VAVRA, Content Manager BVavra@CFEMedia.com EMILY GUENTHER, Associate Content Manager EGuenther@CFEMedia.com AMANDA PELLICCIONE, Director of Research APelliccione@CFEMedia.com CHRIS VAVRA, Production Editor CVavra@CFEMedia.com

EDITORIAL ADVISORY BOARD H. LANDIS “LANNY” FLOYD, IEEE Life Fellow H.Landis.Floyd@gmail.com SHON ISENHOUR, Partner, Eruditio LLC sisenhour@EruditioLLC.com DR. SHI-WAN LIN, CEO and co-founder, Thingswise, LLC Industrial Internet Consortium (IIC) board member shiwanlin@thingswise.com DAVE REIBER, Senior Reliability Leader, Reliabilityweb.com dave.reiber@reliabilityweb.com DAVID SKELTON, Vice president and general manager Phoenix Contact Development and Manufacturing dskelton@phoenixcontact.com BILLY RAY TAYLOR, Director of commercial and off-highway manufacturing The Goodyear Tire & Rubber Billytaylor@goodyear.com LARRY TURNER, President and CEO, Hannover Fairs USA lturner@hfusa.com MARK WATSON, Senior director, manufacturing technology, IHS Markit Mark.watson@ihsmarkit.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.plantengineering.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 in nature or that 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 content manager prior to submission.

Learn more at: www.plantengineering.com/contribute

Roman Bair Lead Automation Systems Integrator Gettle Incorporated

“Phoenix Contact switches are very robust and easy to install.” Gettle Incorporated puts its confidence in Ethernet switches from Phoenix Contact. “We use fully managed Ethernet switches because of the user-friendly software. It allows us to manage our networks to fit our applications.” Our Ethernet switches provide flexibility in any industrial network application. Simplify the challenge of the network topology construction with Gigabit or Fast Ethernet options, from basic unmanaged switches to highly advanced managed devices. Call 1-800-322-3225 or visit: www.phoenixcontact.com/confidence_switches

input #13 at www.plantengineering.com/information

EXTREME PROTECTION AGAINST FRICTION, WEAR AND DOWNTIME

Lubriplate

SYNXTREME HD SERIES GREASES THE ULTIMATE IN MULTI-PURPOSE GREASES If you’re still using conventional petroleum-based greases, you’re missing out on the many benefits of Lubriplate SynXtreme Synthetic Greases. They provide a level of performance and versatility we could only dream about just a few years ago. Engineered to provide superior performance throughout a wide range of applications and conditions, these super multi-purpose greases can help you significantly reduce, consolidate and simplify your grease inventory. In fact, they may be the only greases you’ll ever need.

100%

Synthetic, Ultra High-Performance, Calcium Sulfonate Complex Formula.

-45 ˚ F to 450 ˚ F 3X

Effective Lubrication Temperature Ranges.

Better Shear Stability and Oxidation, Resistance for Long Lubricant Life.

Backed By:

Lubriplate ®

ESP

Complimentary Extra Services Package

Complimentary Plant Surveys Toll Free Tech Support Hotline Lubrication Software Color Coded Charts & Machine Tags Lubrication Training Programs Follow-Up Lubricant Analysis

Newark, NJ 07105 / Toledo, OH 43605 / 800-733-4755 LubeXpert@lubriplate.com / www.lubriplate.com input #14 at www.plantengineering.com/information

SOLUTIONS COVER STORY Doubling down on digital manufacturing

As a company looked to embrace the use of data, the basic concept was to connect machines to a common data management system.

MAINTENANCE Beyond the hype: Data will drive predictive maintenance As the industrial world begins to leverage Big Data analytics, use cases are emerging as success stories for other organizations. One growing area is data analytics around machine maintenance.

ELECTRICAL Electric motors and generators: Sizing up the difference

Faraday's Law of Induction is a law of physics designed to accurately predict and measure how a magnetic field will interact with an electric circuit to produce an electromotive field (EMF). EMFs convert other forms of energy, such as mechanical energy, into electrical energy.

Top Blog Posts for so far for 2017: 1.

The Art of Dryer Sizing

Some Like It Hot…Your Compressor Room Doesn’t

Choosing Between an Air-cooled or Water-cooled Compressor

Receiver Tanks for Small Compressed Air Systems

This Is Why You Don’t Use PVC

Find the latest on compressed air’s current trends, best practices, and common mistakes on www.KaeserTalksShop.com.

Sign up to follow Kaeser’s blog today. You’ll receive a notification every time we publish a new blog entry. And you’ll definitely learn a thing or two. input #21 at www.plantengineering.com/information

Kaeser Compressors, Inc. customer.us@kaeser.com www.us.kaeser.com (866) 516-6888

ngineering the Change

L&T Technology Services (LTTS) is a leading global pure-play engineering services company, built upon a 75 year old legacy and heritage of the Larsen and Toubro. We are engineers who believe in engineering better products and discovering novel ways to build a sustainable future. We provide practical, economical, and scalable business solutions in the form of Engineering Research & Development (ER&D) services to help customers achieve faster time-to-market for their end products and services, innovate to create new products and solutions, reduce cost of development and meet increasing regulatory requirements more effectively. LTTS has 13 delivery centers across the globe, six of them in the United States. We also work closely with international scientific institutions to continually source ideas for engineering solutions. Tech Panorama™ is our largest internal innovation event and serves as a platform for employees to showcase their skills to ideate and innovate on a variety of topics related to major industries and technologies.

L&T Technology Services delivery center in Peoria, IL

industries, and is proud to provide services and solutions to 52 Fortune 500 customers.

Digital Portfolio Through our Digital Engineering (DE) portfolio, we provide end-to-end support through the entire lifecycle of design, engineering, planning, production, warehousing and distribution of products. Our Smart Products & Services along with Smart Manufacturing offerings provide seamless integration of physical and virtual worlds across the industry and technology eco-system. LTTS has developed mature solutions such as IoT platform UBIQWeise™ and smart buildings framework iBEMS in emerging technology areas to support our customers. The UBIQWeise™ platform provides insights on information such as operational efficiency and preventive maintenance schedules by collecting operational data on a near real-time basis, which is then sent to a cloud platform.

Core Engineering LTTS offers high end services and solutions that span the entire engineering life cycle (conceptualization to aftermarket) to all major

Tel: +91 80 6767 5173 • Aniruddha.basu@lnttechservices.com www.lnttechservices.com

input #22 at www.plantengineering.com/information

nformation on Industrial lubricants for your plant operations atâ&#x20AC;Ś www.lubriplate.com... FREE

Log on to our website and find all the information you need about industrial lubricants. From mineral based greases and oils to the latest high grade synthetic fluids, the data is compiled in our Lubriplate Lubrication Data Book that you can download at no cost to you. Also available in digital format are important specification and product information sheets on H1 Food Machinery Lubricants, Environmental Lubricants and more. Complete data on drop points, cold tests, viscosity indexes, ISO grades, AGMA numbers, etc. is included. There is lubricant information available regarding compressor fluids, hydraulic fluids, bearing lubricants, power transmission fluids, specialty lubricants, high grade greases and more. If you have a specific question you may also talk with a lubricant representative at 1-800 733-4755 or e-mail lubeXpert@lubriplate.com input #23 at www.plantengineering.com/information

LUBRIPLATE LUBRICANTS CO. Newark, NJ 07105 / Toledo, OH 43605

ortable Air Conditioners Outshine Other Methods of Spot Cooling in Industrial Facilities and Office Environments MovinCool educates engineers with its expert field support team. Plus, on MovinCool.com engineers can learn firsthand from videos, whitepapers and case studies in how industrial cooling units bring cool, refrigerated air to production lines without the need to spend hundreds of thousands on 100 or more tons of cooling. Do you find that certain areas of your plant or facility are often fitted with fans or local evaporative coolers even though your facility is equipped with a large-capacity central air conditioning system? If so, something needs to be done about it. When excessive heat builds up in localized areas, it lowers employee productivity, which causes product quality and cycle times to suffer and the performance of equipment to suffer, shortening their lifespan, and in some cases OSHA violations can occur. Fans or cross-ventilating windows seldom provide adequate cooling, plus can blow dust, grit, and other foreign matter through the air, contributing to possible eye injuries or equipment wear.

In addition to cooling people and equipment, MovinCool provides process cooling to reduce production time.

Evaporative coolers aren’t much better. They provide cooling, but don’t perform well in humid climates and throw moisture into the air, which, again, is detrimental to equipment life cycles and employee comfort. Through years of experience and training, MovinCool educates engineers on how to measure, manage, and maintain a comfortable work environment. The company has found that portable spot air conditioners specifically developed to meet the needs of the application will solve the problem. Portable spot air conditioners are compact, self-contained units that combine a compressor, condenser, and evaporator in a single cabinet. Industrial engineers will easily learn the quick and easy installation, compact size, cost-effectiveness, and flexibility of portable spot air conditioners— they are customizable. Whenever a change is needed the cold-air duct can be extended up to 80 feet long, allowing easy installation on crowded factory floors or for remote cooling of difficult-to-reach areas.

input #24 at www.plantengineering.com/information

info@movincool.com movincool.com/industrial-cooling

electing a managed switch for your EtherNet/IP network? Here are the key features you should consider.

With so many Ethernet switches available, and all the feature sets that can be employed on devices, users need to focus on the functions essential for a successful EtherNet/IP network installation. • Common Industrial Protocol (CIP) profile for easy integration into the EtherNet/ IP programming environment, enabling switch configuration and critical diagnostics directly from the control system. • EtherNet/IP promotes the DLR redundancy mechanism to realize recovery times of three milliseconds or less. This ensures nearly bump-less switch-over, an essential for high-availability networking. With native DLR redundancy support, the switch is integrated into the ring. • Device faceplates, when used in coordination with Add-on Instructions (AOI), provide easy HMI implementation to enable quick access to switch diagnostics and configuration. They are suitable for use in field-level operations, in support of machine operators who usually do not have access to the web interface of the switch.

• Availability of a port-based DHCP server will ensure that a chosen IP address is assigned to a replacement device on the network edge. This option eases the replacement of field devices, in the event of failure, that need to retain an established address. • The presence of an SD-card option provides the ability to easily save switch configurations, making multi-unit replication easy and simplifying the process should a device ever require replacement. • Fiber and Gigabit options provide installation flexibility irrespective of media or required transmission speed. The managed switches in the 7000 series from Phoenix Contact were designed specifically for use in Ethernet networks where the EtherNet/IP automation protocol is used, and where redundancy, easy deployment, and extensive diagnostic functions are paramount for a high-availability automation network.

input #25 at www.plantengineering.com/information

info@phoenixcon.com www.phoenixcontact.com/usa 717-944-1300

eed answers to common gearmotor questions at your fingertips? Tired of looking up multiple sources for answers to common engineering questions pertaining to gear units and gearmotors? SEW-EURODRIVE’s online Technical Notes can be a real life-saver when you need answers. Technical Notes provide quick access to many engineering topics such as how to properly mount a torque arm, how to determine and design for inertia, or how to properly design your machine to use a hollow shaft gear unit. Need answers on how the speed, mounting position, environment, and duty cycle can affect the thermal rating of a gear unit and how to protect against too much heat? That’s one of many in-depth documents you can find by visiting www.seweurodrive.com and clicking Technical Notes. In addition, you can find a full library of parts lists, dimensions, and gearmotor data online or by using one of our mobile device apps.

Selecting a custom reducer or gearmotor is fast and easy! PT Pilot® is our cutting edge online selection tool that provides all of the following features. No installation or purchase is necessary. 5

Quotation with Net Price

Online Ordering

Open/Save Quotations

Open Co-workers Saved Quotations

Parts List/Dimensions

2D or 3D Electronic CAD Files

Drive Application Calculator and Formulas

Includes Thermal and Mechanical Ratings

Visit www.seweurodrive.com for quick access to PT Pilot® and engineering Technical Notes.

ptpilot.com seweurodrive.com input #26 at www.plantengineering.com/information

AVO Training Institute is one of the most recognized and utilized electrical training providers worldwide. AVO instructors have decades of combined years of electrical experience, and each one of them is hand-picked for their expertise AND teaching ability. Our instructors are articulate, organized, responsive to student needs, and passionate about the topics they teach. Our curriculum is designed to facilitate student learning. Class sizes are small so our instructors can ensure students get exactly what they need. Our training centers are set up with substations, buried cable ﬁelds, switchgear, motor controls, relays, transformers and more. Every student is required to successfully perform each task under instructor evaluation in order to pass the class. AVO courses are recognized by the International Electrical Testing Association (NETA) for Continuing Education Units – CEUs.

Each AVO Training Institute student has hands-on time with the equipment.

Visit www.avotraining.com for more information.

input #27 at www.plantengineering.com/information

Carlo Gavazzi puts knowledge at engineers’ ﬁngertips 24/7, on various web-based platforms GAVAZZI APP is multi-language, free of charge, and puts most of the power of our website at engineers’ ﬁngertips: data sheets, user manuals, brochures, inventory, pricing and a quick means to quickly email links to most of these to others. CarloGavazziNA YouTube Channel provides engineers with both short and long format videos on various product series. They were designed to quickly provide the type of content, which engineers are looking for, which can be easily shared. Online Training Modules: This Fall, Carlo Gavazzi will be rolling out three levels of product training modules (Basics/ Principles, Product Breadth and Markets/Applications) for our most popular Sensing, Switching and Control product lines. input #28 at www.plantengineering.com/information

Tel: 847-465-6100 www.GavazziOnline.com

The Evolution of Predictive Maintenance Predictive maintenance stems from the need to monitor and trend assets in order to maintain consistent machine running capabilities and has come a long way from time based statistics. Regular analysis and downtime based on machine health is a must in order to stay competitive. This means instituting a predictive maintenance system. For companies looking to implement a PdM strategy, cost is a high barrier to entry comprised of expensive equipment, days of training and annual maintenance fees. At GTI Predictive Technologies, we developed our PdM system around the user-friendly iPad. Customers download only the apps they need, (vibration, balancing, alignment, thermography, etc.) and receive free upgrades making this a scalable solution for businesses. info@gtipredictive.com 603.669.5993 www.gtipredictive.com

Tutorials and demos of our apps are available on our GTI Predictive Technology YouTube Channel. Don’t lose money from damaged assets and downtime. Let GTI help you develop a PdM strategy today. pe201708_eduEngHlf_GTI.indd 1

input #29 at www.plantengineering.com/information

7/19/2017 10:42:17 AM

PRUFTECHNIK: Best Practices Training and Seminars Alignment and Condition Based Asset Monitoring Qualifications are always a major plus point in competition. PRUFTECHNIK North America has therefore compiled an extensive range of Factory Approved training seminars to help you align and monitor your critical machinery assets. These seminars walk through the use of our “Best in Class” Award Winning Laser Alignment and Condition Monitoring tools and incorporate software mastery of Alignment Reliability Center and OMNITREND Condition Monitoring Software. PRUFTECHNIK Factory Certified seminars explicitly focus on the everyday use of equipment and software, and understanding of “best practices” alignment and condition based asset monitoring. For example you can learn all about laser alignment and geometric measurement as well as vibration and roller bearing diagnostics.

267-337-6021 • sherry.myers@pruftechnik.com www.pruftechnik.com/us/seminars.html

input #30 at www.plantengineering.com/information pe201708_edEngHLF_prftechnikf.indd 1

6/29/2017 11:25:14 AM

The Kobelco KNW Series Oil-Free Air Compressor; Oil-Free, Risk Free Industries such as Food and Beverage, Pharmaceutical, Electronics, Medical Products and Packaging have discovered that the higher the quality of compressed air that they use, the better their product and lower cost to produce it. Kobelco KNW Series oil free compressors provide ISO 8573.1 Class 0 compressed air quality. Learn about the steps to clean dry air - Download a typical Clean Dry Air System drawing: http://knw-series.com/resources/ typical-clean-dry-compressed-air-system/. All Kobelco KNW Series oil free compressors are delivered ready to run and are designed for 24/7 operation. They are available in air or water cooled conďŹ guration to best suit your requirements. The Kobelco KNW Series can be custom built to your speciďŹ cations and is also available as a standard design package.

KNW-Series.com 800-394-6151 Portland, Oregon USA

input #31 at www.plantengineering.com/information

Connecting Engineers to IIoT and Industry 4.0 by providing reliable Condition Monitoring Technologies and Training Programs. With nearly 50 years experience in the industry and a world leader in Machinery Condition Monitoring, SPM Instrument has a singular company focus that makes us different. Our entire focus is on developing World Class Products for World Class Reliability and Maintenance. As a full-range supplier, we exclusively develop and market all the technology to measure, analyze and present condition data from complex machinery. Our innovations enable our customers to utilize the potential of the worldâ&#x20AC;&#x2122;s most efďŹ cient condition monitoring solutions. Our rugged/lightweight portable instruments and intelligent on-line systems connected through our Condmaster Ruby software or integrated into a plants DCS, PLC or PAC for IIoT and Industry 4.0 are supported through our regional and local plant-site trainings and vibration certiďŹ cation team.

www.spminstrument.com

input #32 at www.plantengineering.com/information

Top 10 Must-Have’s When Designing “Receipt-to-Process” Pneumatic Transfer Systems for Powder & Bulk Materials As all processes vary, so does the pneumatic conveying technology used to move powders, pellets, flakes, granules, dusty powders, and other bulk materials from source to destination. When properly defining pneumatic conveying technologies, it is important to define all parts of the bulk material handling system, including the heart of the system, the vacuum receivers. Consider the advantages and disadvantages of dilute vs. dense phase conveying, and respective dilute phase positive pressure conveying vs. dense phase positive pressure conveying. To learn more about the Top 10 design considerations for the dust-free transport of powders, bulk ingredients, and combustible dusts to your processing or packaging line, download the whitepaper at www.vac-u-max.com/case_histories.cfm?case=34.

www.vac-u-max.com info@vac-u-max.com 973-759-4600 or (800) VAC-U-MAX

pe201708_eduEngHLF_VACUMAX.indd 1

6/20/2017 10:01:27 AM

input #33 at www.plantengineering.com/information

CFE Media’s

New Products for Engineers Database Looking for new products? Look no further! The New Products for Engineers Database is a platform that provides an opportunity for engineering and technical professionals to access the latest NEW product information for the manufacturing, commercial construction, and manufacturing control industries.

Start searching now!

www.plantengineering.com/NP4E

CFE Media’s

Global System Integrator Database CFE Media’s Global System Integrator Database is an interactive community of global end-users and system integrators hosted by Control Engineering, Plant Engineering, and our global partners in Asia and Europe. The newest version of the online database is even easier to use. Features and updates:

• Relevancy score indicates how closely

• New feature allows an end-user to

• Users can now preview the most

• The most relevant data about an

an integrator’s qualifications match a user’s search criteria pertinent data of a system integrator before clicking to view the full corporate profile

“

request a quote for a project directly from the database site

integrator’s engineering services appear on one page on their corporate profile— other details are organized by tabs.

As a systems integrator there are quite a few options available for online advertising. They vary in functionality and design, but the Global System Integrator Database has been our go-to. It is easy to use, professionally designed, and has given us a great deal of exposure to clients we wouldn’t normally be able to reach. We have had more clients contact us with this solution than any other System Integrator Database combined. We not only going to renew our profile this year, we plan on upgrading.

”

William Aja, Panacea Technologies

Find and connect with the most suitable service provider for your unique application.

www.plantengineering.com/global-si-database

eNewsletters

Plant Engineeringâ&#x20AC;&#x2122;s electronic newsletters deliver news and information on the latest trends in manufacturing in every corner of the plant floor. Applied Automation Education and Training Energy Management IIoT: Machines, Equipment and Asset Management IIoT: Operations and IT IIoT: Process Control and Automation Maintenance Connection New Products for Engineers Showcase Oil & Gas Engineering PLANTMAIL! Plant Safety Predictive and Preventive Maintenance Product Focus Whitepaper Connection

Get your plant ahead of the curve. Subscribe today:

www.plantengineering.com/newsletters

input #34 at www.plantengineering.com/information

THIS IS

2017_PLE_eNews_QuarterPage.indd 1

IMPROVED PRODUCTIVITY Save time with Parkerâ&#x20AC;&#x2122;s condition monitoring solution by wirelessly receiving measurements direct to your desktop without interrupting production.

Work smarter and be more productive

Quick review of measurements without interrupting production Respond faster to machines needing service Access from anywhere with an internet connection Email, text, or in-system alert notifications of issues

SCOUTTM Cloud Software and SensoNODETM Gold Sensors Learn more at Parker.com/conditionmonitoring

input #35 at www.plantengineering.com/information

2/13/2017 11:

INNOVATIONS NEW PRODUCTS

See more products in the New Products for Engineers Database.

www.plantengineering.com/NP4E

A fresh approach to compressed air savings Even though an industry expert noted, “No one ever gets fired for using too much energy,” the waste involved with compressed air use in manufacturing is significant. Changing that situation requires clearing the air, literally and figuratively.

$2,000 per day The amount of electrical savings achieved in one Ford production plant from implementing an energy management team focused on changing the way compressed air was used and educating workers on the cost.

More Innovations

www.plantengineering.com

PLANT ENGINEERING

July/August 2017

63 •

INNOVATIONS Wireless digital flowmeters A new line of digital flowmeters with wireless capability use a Zigbee mesh network protocol to measure and monitor your compressed air use, trends, and historical data. Each meter has a range of 100 ft and transmits data to an Ethernet-connected gateway. Each meter and gateway are configured for security and have 128-bit encryption for wireless transmissions. Measuring compressed air is the first step toward identifying high compressed air use areas, compressed air leaks, and optimizing air use. Each meter ships with the wireless to Ethernet gateway, power supplies, and installation tools. Digital flowmeters with wireless capability for schedule 40 iron pipe are now available in sizes ranging from Â˝ in. to 4 in. They are CE and RoHS compliant and also can be ordered for schedule 80, 10S, or Type L copper pipe. EXAIR www.exair.com Input #201 at www.plantengineering.com/information

Valve positioner The EP500 is an ergonomically designed electropneumatic valve positioner. This positioner offers outstanding accuracy and industry-leading reliability with an ease of installation, calibration, and operation. The EP500 has a cast aluminum enclosure that is suitable for outdoor installations. It uses simple forcebalance control technology and can be mounted onto pneumatic actuators with strokes between 10 and 70 mm. With two gauges to indicate the supply air pressure and the output pressure to the pneumatic actuator, zero and span adjustments are accomplished easily. Additional features include improved calibration capabilities, IP65 rated weatherproof enclosure, NAMUR mounting, and an easily accessible and electrical access cap with compression style wiring connectors. A mounting kit is included. Spirax Sarco www.spiraxsarco.com Input #202 at www.plantengineering.com/information

input #36 at www.plantengineering.com/information

â&#x20AC;˘

July/August 2017

PLANT ENGINEERING

www.plantengineering.com

The Largest Inventory of Stock Springs

Submit new product releases to our New Products for Engineers Database plantengineering.com/NP4E

Same Day Shipping

Switch-rated connector system The Woodhead ArcArrest 30A switch-rated connector system is designed to safely de-energize machinery, lighting, and power distribution systems. The ArcArrest system simplifies lockout/ tagout procedures and helps protect against injury due to hazardous energy released in industrial operations. The Woodhead ArcArrest switch-rated connector helps prevent hazardous energy release while energizing or de-energizing machines, and during lockouts for service and maintenance. The connector assemblies incorporate high value features including finger drawplates and plug caps. A contoured housing design makes the ArcArrest system suitable for conveyors, process equipment, and packaging machines in food processing applications requiring frequent wash downs.

STOCK and CUSTOM springs for MRO and OEM applications The leading spring source for quick and cost effective repairs ISO 9001:2008 SAME DAY SHIPPING ON OVER 35,000 STOCK DESIGNS

ORDER ONLINE!

www.centuryspring.com

800-237-5225

input #37 at www.plantengineering.com/information

Molex www.molex.com Input #203 at www.plantengineering.com/information

Refrigerated air dryers The FLEX Series of energy saving refrigerated air dryer utilizes the latest advancements in heat transfer technology, and offers an innovative approach to efficiently remove liquid from compressed air. Phase change material (PCM) harnesses latent heat produced as it converts from solid to liquid or liquid to solid. While latent heat is being absorbed or released, the process is isothermal (no temperature change) and the energy from the heat is used to change the form of the material. The PCM has high latent heat properties, meaning it absorbs a lot of heat at constant temperature as it melts or freezes and stays colder for longer periods of time. Designed with a 3-in-1 heat exchanger, the PCM encapsulates the refrigeration and compressed air circuits. SPX Flow www.spxflow.com

Wire Diameter Availability .004” and .010”

Mauldin Products Offers Wire EDM Cutting Serving America’s leading manufacturers for well over half a century.

Maudlin is thoroughly experienced in a wide range of applications for Wire EDM Cutting – including tool and die cutting, labyrinth rings, flex elements, turbine wheels, feelers/feeler calipers, metallurgical testing, key ways, washers, bushings, retainer rings, stator rings, and armature rings.

Your part may be a great fit for this particular application – call us to find out!

281-532-7237

Input #204 at www.plantengineering.com/information

http://www.maudlinproducts.com/wire-edm-cutting www.plantengineering.com

July/August 2017

•

input #38 at www.plantengineering.com/information

Olive oil is good for you. Compressor oil is not.

INNOVATIO

Protect your product, your packaging and your reputation.

Premium Efficient OIL-FREE Compressors

800-394-6151

input #39 at www.plantengineering.com/information

knw-series.com

Rogers Machinery Company, Inc.

Proudly Made in the U.S.A.

CAU T ION 9 out of 10 Engineers specify the wrong VRF insulation Be the one who does it right. Insist on Aerocel® EPDM. Here’s why: VRF

condenser unit

XXXXXXXXXXXXXXXXXXX

Continuous 257° service temperature Exceeds VRF ductless split system temperature of 248°

Non-corrosive Use on copper, aluminum and stainless steel without corrosion

Best water vapor resistance Takes colder operating temperatures of VRF systems without water absorption

Lowest VOC emissions Works in sustainable construction and areas where fumes are undesirable

Best size range available ID from ¹⁄₄" up to 2¹⁄₈" Wall thickness of ¹⁄₂", ³⁄₄", 1", 1¹⁄₂", 2"

Real UV resistance No weather barrier needed, reduces installed cost and improves long-term investment

Fire Resistant VRF systems are widely used in high-occupancy buildings that require exceptional fire-safety

Comes Standard NO EXTRA CHARGE

input #40 at www.plantengineering.com/information

Get your FREE SAMPLE of Aerocel EPDM ®

simply visit www.aeroflexusa.com/vrf today

Done once. Done fast. Done right.

Call today for the name of your nearest distributor: 1-866-237-6235 | Or visit www.aeroflexusa.com

ONS OPTIMIZE YOUR CAPEX AND OPEX BY STREAMLINING YOUR PLANT OPERATIONS

Voltage testers THe ET60 and ET250 voltage testers use standard replaceable test leads for added convenience. The ET60 voltage tester requires no batteries as it measures ac/dc voltage up to 600 V in electrical circuits, outlets, light fixtures, and anywhere else ac/ dc voltage testing is required. The ET250 voltage and continuity tester incorporates an LCD display, measures ac/dc voltage up to 600 V and can test GFCIprotected circuits.

Presenting W.A.G.E.S - An Industrial Energy Management Solution from L&T Technology Services

Send in your business queries to info@LntTechservices.com

Scan to Learn more about W.A.G.E.S (WATER, AIR, GAS, ELECTRICITY, STEAM). www.LntTechservices.com

Klein Tools www.kleintools.com Input #205 at www.plantengineering.com/information

input #41 at www.plantengineering.com/information

Introducing the double-door safety switch. Double down on worker safety with this revolutionary design. Our new device includes an internal barrier that isolates fuses by separating the line-side power and switch base from the fuse base, offering greater safety when changing or evaluating a fuse.

Learn more about the new Eaton double-door safety switch at eaton.com/doubledoor.

input #42 at www.plantengineering.com/information

INNOVATIONS

industrial air control Our complete line of industrial damper products allows you to choose the right tool for the right system. Whether it’s modulating control, shut-off, isolation, equipment or personnel protection, we have the right product for all of your applications.

input #43 at www.plantengineering.com/information

The MD III™ System includes all you need for complete Energized and De-Energized Testing of Motors, Generators & Transformers Combine the power of Motor Circuit Analysis (MCA™) and Electrical Signature Analysis (ESA) to evaluate and trend your entire motor system Auto diagnosis within instrument providing an immediate health status report Route-based testing and trending – ideal for Predictive Maintenance Excellent Post-Sale Service and Support Worldwide Training – Earn CEUs / IACET Accredited

Reports provide indication of early winding faults, rotor problems, incoming power issues, electrical and mechanical motor condition and driven load mechanical condition

Motor Testers

www.alltestpro.com

Low-voltage switchgear The ReliaGear UL 1558 low-voltage switchgear features Emax 2 circuit breakers with embedded logic capabilities that make the switchgear safer and more compact, flexible, and reliable. New switchgear features Emax 2 circuit breakers for greater safety, compactness, flexibility, reliability. ReliaGear UL 1558 LV switchgear has been tested to UL, CSA, and American National Standards Institute (ANSI) standards, and is ANSI C37.20.1 compliant. The equipment incorporates UL 1066-compliant Emax 2 air-insulated circuit breakers, which offer among the most advanced data communications and automation power-distribution technology in the world. These circuit breakers enable ReliaGear UL 1558 LV switchgear to improve safety, occupy less space by reducing size, adapt more readily to changing applications by being modular, and increase service life by as much as six times for greater reliability.

Finally – Predictive Maintenance Made VERY Easy! The ideal instruments for troubleshooting, quality control and predictive maintenance of electric motors, transformers and generators.

input #44 at www.plantengineering.com/information

ABB www.abb.com Input #206 at www.plantengineering.com/information

•

July/August 2017

Ethernet/IP encoders The Sendix F58 encoders combine certified Ethernet/IP support with patented mechanical and electro-optic technologies that ensure accuracy and reliability. These new optical absolute singleand multi-turn Ethernet/IP encoders have a diameter of 58 mm. The Sendix F58 encoders have a RPI time as low as 1 ms, which allows them to transmit position data about five times faster than many conventional encoders. This speed advantage makes the F58 encoders particularly well-suited to packaging, textile, and printing applications—or any application with fast machines that could be even faster with a position sensing upgrade. Kuebler www.kueblernews.com Input #207 at www.plantengineering.com/information

M More INNOVATIONS Web Exclusives Looking for more product innovations? Check out these articles at plantengineering.com by typing the headline into our exclusive search engine. SIX TIPS FOR REDUCING MAINTENANCE COSTS: One of the best decision for any facility is to implement a preventive maintenance program. Any ongoing maintenance saves both time and money. That doesn’t mean it is not an expensive part of doing business. One way to increase your return on investment (ROI) in maintenance costs is to reduce what you’re spending. THE BENEFITS OF TESTING A 3-PHASE ELECTRIC MOTOR: A three-phase electric motor is often able to run for many years before any serious problems occur. Testing the motor on a regular basis as part of a preventative maintenance program helps extend the life of the motor. If problems happen to occur, it is possible to test the motor on-site to determine what happened and how to correct the issue.

HD ENV - A NEW ERA IN VIBRATION MONITORING ®

Providing earlier pre-warning than any other vibration monitoring technology • maximized planning horizon • extended component lifetime • reduced repair costs • minimized unplanned downtime

Get started right away - use your existing transducer installation.

spminstrument.us 1-800-505-5636 input #45 at www.plantengineering.com/information

INNOVATIONS Liquid-to-air heat exchangers A new line of tube-to-fin, liquid-to-air heat exchangers are made with the industryâ&#x20AC;&#x2122;s highest density fins to maximize heat transfer from liquid to air, allowing the liquid to be cooled to lower temperatures than other heat exchangers on the market. The heat exchanger fins and tubes are made of copper and stainless steel to be suitable for a variety of fluids, including water, dielectric fluids, and custom-designed heat transfer fluids. Each of the seven heat exchanger sizes is available with or without a fan. A heat exchanger is a device that allows heat from a fluid (either a liquid or a gas) to pass to another liquid or gas without the two fluids having to mix or come into direct contact. Advanced Thermal Solutions Inc. www.qats.com Input #208 at www.plantengineering.com/information

Mobile portable compressor The M58 is designed to deliver 210 cfm at 100 psig for rental houses, construction, demolition, sandblasting, repair trucks and other demanding applications. The portable compressor has a powder coated, fully weatherproofed steel cabinet built to withstand harsh conditions. It also has a singlepoint lifting ball for easy mounting or dismounting. The eye-level curbside instrument panel is equipped with a smart electronic controller with a protective metal cover. The 28-gallon fuel tank is designed to provide extended operation up to 10 hours. Kaeser www.us.kaeser.com Input #209 at www.plantengineering.com/information

input #46 at www.plantengineering.com/information

â&#x20AC;˘

July/August 2017

Submit new product releases to our New Products for Engineers Database plantengineering.com/NP4E

Automatic case packer The XpressPack automatic case packer is designed to run high volumes of medium-to-large sized cartons in a single-layer, single-row configuration. XpressPack’s high speed operation handles up to 10 cases per cycle. It is ideal for the beverage market and is also a good choice for cereal and laundry detergent boxes, as well as foils and plastic wraps, and parchment paper. The XpressPack is perfect for standard five-panel folded carton, glue-end styles. Designed for simple setup and changeovers, the XpressPack can accommodate carton sizes ranging from 8-in. wide by 8-in. long through 24-in. wide by 28-in. long. Special machines for other sizes can be custom-engineered. Heavy-duty welded steel frame construction provides durability and long life, while the dual vector drives eliminate the clutch-brake system.

See all our products at:

klsummit.com

WSI Global http://wsiglobal.com/express-pack/ Input #210 at www.plantengineering.com/information

Looking for new products by category?

Quality Service Expertise

Check out the New Products for Engineers Database and search hundreds of products, with new innovations added every day. Look for this logo on the Plant Engineering home page.

Save Time and Money by Using Ultima Series Enjoy the economic, machine and lubricant-life benefits of using the right Summit synthetic oil in the right application. Summit’s synthetic Ultima Series air compressor lubricants offer drain intervals of 12,000 plus hours under normal operating conditions. Talk to our experts and find out if Ultima is the right lubricant for your compressor.

( 800.749.5823 Klüber Lubrication NA LP

July/August 2017

•

input #47 at www.plantengineering.com/information

INNOVATIONS By Bob Vavra, Content Manager

Reliability is everything

Gerald “Gerry” Bauer

President, EccoFab - Rockford, IL

 Sullair.com/GerrysStory

It doesn’t quit. It doesn’t even think about quitting. In fact, it doesn’t think of anything but the job at hand.

Sound familiar? Our compressors are a lot like the people who use them. Discover the complete line of Sullair stationary air compressors, featuring the legendary Sullair air end.

A fresh approach to compressed air savings Take a systematic approach to uncovering and fixing waste

oe Ghislain sees the issue of compressed air waste in manufacturing from two perspectives. That is impressive on its face, because compressed air waste is often the most invisible, and thus the most insidious, energy waster in a manufacturing plant. Ghislain is a longtime board member for the Compressed Air Challenge (CAC), a consortium of compressor manufacturers, suppliers, consultants, and utilities. The group’s stated goal is “Helping you enjoy the benefits of improved performance of your compressed air system.” Ghislain also is a North American regional senior manager for the Ford Motor Co., and one of his areas of emphasis is Lean supplier optimization. In both roles, the goal is optimization. In speaking to Kaeser Compressor’s “Pressure and Profit” seminar at Guaranteed Rate Field in Chicago in May, Ghislain said the language of optimization is different depending on where you are in the plant. “If you’re an engineer, you talk about psi, you talk about kilowatts,” he said. “When you talk about dollars, you put it in perspective.” As he noted, “Nobody ever got fired for using too much energy.” The cost of estimated waste of compressed air is staggering. While compressed

To learn more about our complete line, including air treatment products, contact your local distributor or visit our website.

input #48 at www.plantengineering.com/information

CFM

Cubic feet per minute is a measurement of the velocity at which air flows into or out of a space.

•

July/August 2017

air generation accounts for about $5 billion in energy costs annually, Ghislain said CAC research shows that only about 50% of that is put to productive use. He said about one-third of all generated compressed air is dissipated in leaks, and the remaining losses are split between over-pressurizing a system to compensate for leaks and generally wasteful uses of compressed air, such as using a hose to clear debris from the plant floor. Getting more from your compressed air system requires a fresh approach. “You have to take an actual systems approach. You need to align supply and demand,” Ghislain said. “It’s knowing about what’s driving the cost and driving efficiency. You need to get out of the compressor room and out into the plant facility.”

The Red Coats are coming

At Ford, this has meant establishing an energy management team whose responsibility it is to look for ways to optimize energy usage and reduce waste. At a number of Ford’s stamping plants, the energy teams wear red coats, and Ghislain said they were charged with aggressively pursuing both energy awareness among line workers and finding waste in the process. The first step is to create a baseline for energy usage that accounts for all factors, including critical machines and seasonal factors. “The guys in the facility will know which ones are the critical systems,” Ghislain said. “You also have to understand winter versus summer usage, because loads can change. These are dynamic machines and they are effected by those kinds of things.” A dynamic control system is equally important. “The whole purpose of a control system is to run the compressors in

PLANT ENGINEERING

www.plantengineering.com

Submit new product releases to our New Products for Engineers Database plantengineering.com/NP4E

By The

of compressed air—fell from 5,400 cfm to just 600 cfm. There was a similar success story at Ford’s Woodhaven stamping plant, also in Michigan, where the focus was on fixing the leaks in the system. Plant officials

NUMBERS Typical components of demand:

and the energy team in place at Woodhaven began by estimating the cost of air leaks and using ultrasonic detection to find and then fix the leaks. There were leaks found in stamping press dies, for example, and this allowed for the

According to the Compressed Air Challenge, the actual use of compressed air in manufacturing is split 50-50 between useful purposes and waste. The breakdown: 50%: Production 33%: Compressed air leaks 8%: Over-pressurizing the system to compensate for leaks 8%: Inappropriate uses of compressed air. Source: Pressure and Profit presentation

the most efficient way possible,” Ghislain said. “The controls system has to operate the right compressors under the right conditions.” Another big issue is maintenance. “It’s always considered a necessary evil,” Ghislain said. “It seemed I never could do the maintenance. When we had the money, I couldn’t shut down. When we could shut down, we didn’t have the money.” One way to address maintenance is with a comprehensive predictive maintenance program. “A predictive maintenance system pays for itself,” Ghislain said. The efforts at Ford produced both tangible and subtle results. At Ford’s stamping plant in Monroe, Mich., the Red Coats helped drive a cultural change in the way line workers thought about and approached energy usage. As a result, compressed air use fell from 17.4 million cubic foot per day to 9.0 million cubic foot per day and electricity savings topped $2,000 a day. The non-production use—that 8% of inappropriate use July/August 2017

PRUFTECHNIK is a leading single-source solution provider for machine laser alignment, condition monitoring and nondestructive testing. PRUFTECHNIK’s technical innovations optimize the availability of your production assets—and stop small amounts weighing heavily on your bottom line.

www.pruftechnik.us

input #49 at www.plantengineering.com/information

INNOVATIONS reduction of pressure drops at various points in the system. After the study and repairs, air use fell by 18% and air pressure dropped by 5 psi in the plant. That allowed plant officials to shut down a large 800 hp

compressors and six smaller compressors and rework the controls system so the larger compressors used less energy. The plant saved about $400,000 a year and reduced their energy usage by 7.9 million kWh.PE

Power Meets Profitability Guaranteed. The Model 1020 is not only incredibly powerful—recovering up to 5 tons of even the heaviest materials per hour—it’s also uniquely portable, so it goes almost anywhere. With a 99% efficiency rating, noise levels below OSHA standards, and a performance guarantee, it’s more than a cleaning system; it’s a business asset.

8 compressed air system design pitfalls Proper design is as important to a successful compressed air system as proper operations. Joseph Ghislain of Ford Motor Co. and the Compressed Air Challenge cited eight things to watch for in a proper system design:

1. Using only full load calculations for savings

2. Using average cost of kWh for off-peak savings

3. Assuming all unregulated

VAC-U-MAX 1020MFS 10 & 15 HP Continuous Duty Vacuum • 50% more vacuum power than other industrial vacuums • Move mountains of material through hundreds of feet of hose • Vacuum rates up to 10,000 lbs per hour • One-man portable, fits through a 34” doorway • Versatile: Portable Vac or Breakaway Central Vac • XP electrics and HEPA filtration available

demand when calculating artificial demand

4. Assuming pressure flow controllers negate the need for a good compressor control system and strategy

Let us solve your industrial vacuum cleaning challenges. Visit vac-u-max.com/vacuum or call 800-VAC-U-MAX.

5. Implementing capitol solutions before doing the “low cost” opportunities

6. Buying only VSDs and/or using them as base load.

7. Not adjusting centrifugal compressor savings for winter and summer temperature differences WET/DRY • AIR OPERATED AND ELECTRIC DRUM-TOP • CONTINUOUS DUTY • COMBUSTIBLE DUST CENTRAL SYSTEMS • CONTINUOUS-BAGGING • LIQUID & SLUDGE • FLAMMABLE LIQUIDS SUBMERGED RECOVERY • METALWORKING • PHARMACEUTICAL • STEEL SHOT INTERCEPT HOPPERS & PRE-SEPARATORS • INDUSTRIAL HYGIENE SOLUTIONS

input #50 at www.plantengineering.com/information VAC3509 Product 4.5x7.5_VC 1.indd 1

8. Not using utility rebates.

8/29/2016 8:24:59 PM

•

July/August 2017

MEDIA SHOWCASE FOR ENGINEERS Your place for new products, literature, Apps, Videos, Case Studies and White Papers. POWER + CONTROL

Custom Engineered Solutions

Connection

Up to 5 contacts for POWER + 6 contacts for CONTROL Kaeser’s custom engineered compressed air systems are built to specification for the most challenging installation environments. Available as skids or custom enclosures these complete systems are designed for superior energy efficiency, exceptional reliability, and simple maintenance no matter what the installation limitations may be. They eliminate accessibility, space, and weather constraints and greatly reduce construction and installation time.

Provide electrical power and control motor drives, communicate alarms Power or monitor process Contact parameters with only 1 connection. Auxiliary Contact

meltric.com 800.433.7642

www.us.kaeser.com • 866-516-6888 Input #100 at plantengineering.hotims.com

Ratings up to 250A, 600V, Type 4X

Input #101 at plantengineering.hotims.com

Input #102 at plantengineering.hotims.com

CMMS Full-Featured CMMS Starting at Only

$ 30

The Ultimate Air & Gas Leak Detector

per Month!

AccuTrak® VPX-WR

Find Compressed Air Leaks Fast! • Also any Gas, Refrigerant or Vacuum • Rugged Design for Harsh Environments • Sealed to Resist Water, Oil, Dust, Chemicals • Professional’s Choice for Air Leak Surveys (800) 922-4332 mapcon.com 

Input #103 at plantengineering.hotims.com

www.plantengineering.com

Input #104 at plantengineering.hotims.com

SuperiorSignal.com/PE Input #105 at plantengineering.hotims.com

PLANT ENGINEERING July/August 2017 PLANT ENGINEERING Month 2014

• • 69 69

Sensor Brackets and so much more...

Please request your...

AIR POLLUTION CONTROL

2D / 3D CAD Files Catalogs Stock & Customs

Dust, Mist and Fume Collectors Camfil APC is looking for more reps and dealers. Do you have what it takes? Camfil APC’s sales volume nearly tripled from 2009 to 2015. We are a growing company with a strong financial backing. Camfil APC is a division and proud member of the Camfil group, a $800 million international conglomerate. As a rep, your commission is self-determined! The harder you work, the more money you make. Camfil APC does not determine your commission level in a contract like most competitors do. You decide how much money you make!

softnoze com

PRODUCTMART

Mount | Apply | Position | Protect

WORLD LEADER IN SENSOR INTEGRATION COMPONENTS

Input #109 at plantengineering.hotims.com

Need Work Benches

In Stock-Factory Direct

Learn more at www.camfilapc.com/reseller

workbenchmarket.com Input #110 at plantengineering.hotims.com

stay informed

e-mail: filterman@camfil.com • 800-479-6801 Input #106 at plantengineering.hotims.com

OIL MIST & SMOKE IN YOUR SHOP? www.mistcollectors.com Tel: 1-800-645-4174

Input #107 at plantengineering.hotims.com

Stay current with technology and trends in electrical, mechanical, maintenenace and automation. To subscribe, visit

www.plantengineering.com/subscribe

Input #111 at plantengineering.hotims.com

Go online to view the weekly Top 5 Reader Favorites! www.plantengineering.com Input #108 at plantengineering.hotims.com

•

July/August 2017

Input #112 at plantengineering.hotims.com

PLANT ENGINEERING

www.plantengineering.com

Place next to your computer or go online to plantengineering.com for hot links to these companies.

Remove at Line

7 st 201 u g u July/A

For more information on how to advertise in Plant Engineering’s Internet Connection, call Jim Langhenry at 630-571-4070 x2203 abb.us

donaldson.com

rogers-machinery.com

ABB is a leader in power and automation technologies that enable customers to improve performance while lowering environmental impact. ABB Inc.

Compressed air purifications solutions, compressed air filters, dryers and process water chillers. Donaldson Company Inc.

Manufacturer of rotary screw and reciprocating air compressors, fixed and variable speed drives, rotary and centrifugal compressors, blowers, and vacuum systems. Rogers Machinery

aitkenproducts.com

Dynatect designs and manufactures a complete line of components to protect equipment and people. Dynatect

Aitken Products manufacturers and distributes high-quality industrial heaters. Aitken’s products are for a variety of industrial applications and are available when needed. Aitken Products Inc.

a3automate.org The Association for Advancing Automation is the global advocate for the benefits of automating. Association for Advancing Automation

atlascopco.us Atlas Copco produces and markets compressed air equipment and generators, construction and mining equipment, industrial tools, assembly systems, services and rentals. Atlas Copco

automationdirect.com AutomationDirect offers over 16,000+ industrial automation products through their free catalog and online superstore including PLCs, operator interfaces, drives, enclosures, sensors and more. AutomationDirect

avotraining.com For almost 50 years, AVO has been helping organizations create safe and reliable electrical systems. AVO Training Institute

dynatect.com

emaint.com eMaint improves the way over 50,000 users worldwide manage, monitor, and control assets for a connected world. eMaint Enterprises

flexicon.com Flexicon designs and manufactures bulk handling equipment and custom-engineered and integrated plant-wide systems. Flexicon Corp.

vac-u-max.com VAC-U-MAX specializes in design and manufacture of pneumatic systems and support equipment for conveying, weighing and batching of dry materials. VAC-U-MAX

lubriplate.com

Yaskawa is the world’s largest manufacturer of ac inverter drives, servo and motion control, and robotics automation systems. Yaskawa America Inc.

Lubriplate manufactures more than 200 high quality lubricants, including high performance synthetic lubricants and NSF-H1 lubricants for food processing and beverage. Lubriplate Lubricants Co.

mhia.org MHIA is the leading non-profit trade association representing the U.S. material handling and logistics industry. Material Handling Industry of America

camfilapc.com

Noria is a worldwide leader in providing lubrication consulting services and training. Noria Corp.

centuryspring.com

www.plantengineering.com

uecorp.com UEC provides innovative, customizable power distribution and monitoring solutions. Universal Electric Corp.

us.kaeser.com

baldor.com

Century Spring has been supplying quality stock and custom springs, metal stampings, and wire forms for MRO and OEM applications since 1927. Century Spring Corp.

solonmfg.com Solon Manufacturing Co. engineers and manufactures Solon Belleville Springs and pressure switches. Solon Manufacturing Co.

Manufacturer of air system products, including rotary screw compressors, portable compressors, rotary lobe blowers, vacuum packages, refrigerated and desiccant dryers, filters, and condensate management systems. Kaeser Compressors Inc.

Baldor Electric designs, manufacturers, and markets a broad line of industrial energy-efficient electric motors, mechanical power transmission products, and more. Baldor Electric Co. Camfil Air Pollution Control (APC) is a leading global manufacturer of industrial dust, fume and mist collection equipment and is part of Camfil, the world’s largest air filtration company. Camfil APC

seweurodrive.com One of the largest global suppliers of drive technology, SEW-EURODRIVE specializes in gear reducers, motors and electronic motor controls. SEW-EURODRIVE USA

yaskawa.com

noria.com

orival.com Orival is a leading manufacturer of self-cleaning water filters, automatic water filters and strainers, for use as industrial water filters, irrigation filters, cooling tower filters, and more. Orival Inc.

plant engineering

July/August 2017

•

CONTACTS

Advertiser Contacts for plant engineers

Request more information about products and advertisers in this issue by using the http://plantengineering.hotims.com link and reader service number located near each. If you’re reading the digital edition, the link will be live. When you contact a company directly, please let them know you read about them in Plant Engineering.

Advertiser

Page

Reader Service #

Phone #

ABB Motor Service

C-4

800-Help365

www.abb.com/motors&generators

Aeroflex USA

866-237-6235

www.aeroflexusa.com

ALL-TEST Pro, LLC

860-399-4222

www.alltestpro.com

AutomationDirect

C2, IFG, OFG

Web site

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

CONTENT SPECIALISTS/EDITORIAL BOB VAVRA, Content Manager BVavra@CFEMedia.com EMILY GUENTHER, Associate Content Manager EGuenther@CFEMedia.com

1, 2

800-633-0405

www.automationdirect.com

Camfil APC

800-479-6801

www.camfilapc.com

Caterpillar - Northeast

CENTURY SPRING CORP

800-237-5225

www.centuryspring.com

CFE Edu

630-571-4070

http://cfeedu.cfemedia.com/catalog

CFE Media’s Global System Integrator Database

630-571-4070

www.plantengineering.com/global-si-database

STEVE ROURKE, Co-Founder SRourke@CFEMedia.com

CFE Media’s New Products for Engineers Database

33, 54

630-571-4070

www.plantengineering.com/NP4E

TRUDY KELLY, Executive Assistant 630-571-4070 x2205, TKelly@CFEMedia.com

www.NECatDealers.com/power

AMANDA PELLICCIONE, Director of Research 860-432-4767, APelliccione@CFEMedia.com CHRIS VAVRA, Production Editor CVavra@CFEMedia.com

PUBLICATION SERVICES JIM LANGHENRY, Co-Founder & Publisher JLanghenry@CFEMedia.com

DYNATECT

800-298-2066

www.dynatect.com

ELENA MOELLER-YOUNGER, Marketing Manager 773-815-3795, EMYounger@CFEMedia.com

Eaton Corp

412-893-4052

www.eaton.com/doubledoor

Exair Corp

800-903-9247

www.exair.com

KRISTEN NIMMO, Marketing Manager KNimmo@CFEMedia.com

Flexicon Corp

888-353-9426

www.flexicon.com

MICHAEL SMITH, Creative Director 630-779-8910, MSmith@CFEMedia.com

Greenheck

7153596171

www.greenheck.com

KATIE SPAIN, Art Director KSpain@CFEMedia.com

GTI Spindle Technology

603-669-5993

www.gtipredictive.com

PAUL BROUCH, Director of Operations PBrouch@CFEMedia.com

IEX 2017

203-840-5847

www.iexusa.com

IIoT Webcasts

630-571-4070

www.plantengineering.com/lloT

MICHAEL ROTZ, Print Production Manager 717-766-0211, Fax: 717-506-7238 mike.rotz@frycomm.com

866-516-6888

www.us.kaeser.com/PE

Kaeser Compressors, Inc

L&T Technology Services

Lubriplate Lubricants Co

800-733-4755

www.lubriplate.com

MAUDLIN PRODUCTS

281-532-7237

www.maudlinproducts.com/wire-edm-cutting

Motion Industries, Inc

800-523-9328

www.MotionIndustries.com

www.LntTechservices.com

MOVINCOOL

800-264-9573

www.movincool.com

Parker

480-830-7764

www.Parker.com/conditionmonitoring

15, 23

9, 13

Phoenix Contact

800-322-3225

www.phoenixcontact.com/confidence_switches

630-571-4070

www.plantengineering.com

Plant Engineering Electronic Newsletters 56

630-571-4070

www.plantengineering.com/newsletters

Plant Engineering Webcasts

630-571-4070

www.plantengineering.com/webcasts

Plant Engineering Digital Reports

PRUFTECHNIK Inc.

856-401-3095

www.pruftechnik.com

Rogers Machinery

800-394-6151

www.knw-series.com

SEW-EURODRIVE, Inc.

864-439-7537

www.seweurodrive.com

SOLON MANUFACTURING CO.

800-323-9717

www.solonmfg.com

SPM Instrument

800-505-5636

www.spminstrument.us

Sullair Industrial Products

219-879-5451

www.sullair.com

Summit Industrial Products

800-749-5823

www.klsummit.com

TRI TOOL

800-968-2605

www.tritool.com

United Rentals

800-UR-RENTS

www.UnitedRentals.com/Urcontrol

973-759-4600

www.vac-u-max.com

C-3

800-927-5292

www.yaskawa.com

Vac-U-Max Yaskawa America, Inc

•

July/August 2017

PLANT ENGINEERING

www.plantengineering.com

MARIA BARTELL, Account Director, Infogroup Targeting Solutions 847-378-2275, maria.bartell@infogroup.com RICK ELLIS, Audience Management Director 303-246-1250, REllis@CFEMedia.com LETTERS TO THE EDITOR Please e-mail your opinions to BVavra@CFEMedia.com INFORMATION For a Media Kit or Editorial Calendar, e-mail Trudy Kelly at TKelly@CFEMedia.com REPRINTS For custom reprints or electronic usage, contact: Brett Petillo, Wright’s Media 281-419-5725, bpetillo@wrightsmedia.com

PUBLICATION SALES

Tom Corcoran, West, TX, OK TCorcoran@CFEMedia.com 3010 Highland Parkway, Suite 325, Tel. 215-275-6420 Downers Grove, IL 60515 Fax 484-631-0598 Karen Cira, Southeast 879 Autumn Rain Ln. Charlotte, NC 28209 Diane Houghton, AL, FL 38 Charles River Drive, Franklin, MA 02038

KCira@CFEMedia.com Tel. 704-523-5466 Fax 630-214-4504 DHoughton@CFEMedia.com Tel. 508-298-9021 Fax 630-214-4504

Jennifer Wafalosky, N. Central JWafalosky@CFEMedia.com 246 South Franklin St. Tel. 216-409-8314 Chagrin Falls, OH 44022 Fax 440-348-1980 Richard A. Groth Jr., NJ/ E. PA 12 Pine St. Franklin, MA 02038

RGroth@CFEMedia.com Tel. 774-277-7266 Fax 508-590-0432

Jerry Preston, West Coast 8044 E. Sienna Street Mesa, AZ 85207

JPreston@CFEMedia.com Tel. 602-369-3037

Stuart Smith, International SSM Global Media Ltd.

stuart.smith@ssm.co.uk Tel. +44 208 464 5577 Fax +44 208 464 5588

PROVEN WORLDWIDE

30+ Million Pieces of Evidence... and Counting 20 million inverters, 10 million servo axes and 300,000 robots in the field are proof positive that Yaskawa has the engineering expertise, innovative technology and unsurpassed quality to create solutions which inspire complete customer confidence. Great things come in small packages with Yaskawaâ&#x20AC;&#x2122;s V1000 AC Microdrive. Achieve optimum balance of energy input, product output, maintenance risk, and long life with models ranging from 1/8 HP up to 25 HP. No matter how you add it up, nobody equals Yaskawa. Call us today.

Discover how to easily integrate Yaskawa drives into the PLC environment:

http://budurl.me/YAI1067

YASKAWA AMERICA

DRIVES & MOTION DIVISION

input #51 at www.plantengineering.com/information

YASKAWA.COM

1-800-YASKAWA

— ABB Ability™ Smart Sensor

motors that let you know when it’s time for a service. ABB’s new condition monitoring solution revolutionizes maintenance for low voltage motors. ABB Ability™ Smart Sensor monitors key parameters and sends the data to a secure server for analysis. Users can access detailed status reports from their smartphone or PC. The solution enables proper maintenance planning for longer motor lifetimes, lower energy consumption and big reductions in downtime. www.abb.com/motors&generators input #52 at www.plantengineering.com/information