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Without the proper design, electrical safety cannot be achieved
6 | How automation will make a big impact on manufacturing plants
Automation is the wave of the future for many manufacturers. Our panel dives deeply to assess how plants can prepare for the many ways in which automation will impact production lines 5 | Design first: the foundation of electrical safety in industrial facilities
| What’s your electrical maintenance plan? Learn how to build one
Businesses
| Can the right maintenance plan boost air compressor performance? By employing preliminary, predictive and preventive maintenance, and air compressor’s performance will be maximized
| How to accelerate predictive maintenance strategies with advanced analytics
Advanced analytics platforms empower maintenance transformation through predictive modeling, helping manufacturers shift from reactive to proactive approaches
| Harnessing robotics to transform manufacturing in the face of challenges
In the face of labor shortages, rising operational costs and pressure to increase production rates, plant engineers are increasingly turning to robotic solutions
70B assists equipment owners and maintenance teams in the development of electrical maintenance plans that deliver operational safety and optimal reliability while minimizing the operational cost of ownership. Courtesy: ABB Electrification, Service Division
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EDITORIAL ADVISORY BOARD
H. LANDIS “LANNY” FLOYD, IEEE Life Fellow
JOHN GLENSKI, Principal, Automation & Digital Strategy, Plus Group, A Salas O'Brien Company
MATTHEW GOSS, PE, PMP, CEM, CEA, CDSM, LEED AP, Senior Vice President, CDM Smith
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Are you a subject matter expert in one of these topics? Would you like to write an article on one of the topics below? If so, please submit an idea to: https://tinyurl.com/PlantEngineeringSubmissions
• Choosing a valve
• EV charging systems
• Expert Q&A: Maintenance
• Expert Q&A: Asset management
• Fall protection
• Lubrication
• NFPA 70B
• Pumping systems
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Design first: the foundation of electrical safety in industrial facilities
Without the proper design, electrical safety cannot be achieved.
In industrial and manufacturing plants, electrical safety isn’t just a set of procedures — it’s built into the fabric of the facility and its systems. Proper planning and thoughtful integration of safety measures during the building’s or system’s design phase are critical.
A manufacturing facility’s staff can show off its adoption of NFPA 70E: Standard for Electrical Safety in the Workplace in many ways. Here are three key strategies:
Amara Rozgus, Editor-in-Chief
1. Plan for both de-energized and live work
Safety-focused facility design starts with understanding operational needs and shutdown tolerances. While de-energized work is ideal, live work may sometimes be necessary to avoid service interruptions.
Safe and efficient operations depend on the reliability of power systems, and maintaining that reliability starts with a robust electrical maintenance plan. NFPA 70B: Standard for Electrical Equipment Maintenance provides a systematic approach to ensure operational safety, minimize unplanned downtime and meet compliance requirements.
2. Incorporate arc flash mitigation strategies
Arc flash hazards represent one of the most severe risks in electrical sys-
tems. Design engineers — specifically electrical engineering consultants — can reduce these risks by specifying advanced equipment and safety features. Technologies such as arc quenching relays, zone-selective interlocking and maintenance switches not only meet minimum requirements outlined in standards like NFPA 70: National Electrical Code but also go above and beyond to safeguard workers. Including arc flash analysis early in the project ensures the selection of devices with appropriate ratings.
3. Design with maintenance and emergency preparedness in mind
Maintenance and safety overlap in facility design. Providing lockable switches, remote operation options for high-power equipment and disconnecting means in sight of critical systems ensures safe maintenance practices. Additionally, incorporating emergency lighting, accessible electrical rooms and clear labeling enhances both safety and operational efficiency.
By engaging with project stakeholders early in the design phase, referencing key standards like NFPA 70 and 70E and investing in advanced safety features, engineers can create facilities where safety is seamlessly integrated. PE
How automation will make a big impact on manufacturing plants
Automation is the wave of the future for many manufacturers. Our panel dives deeply to assess how plants can prepare for the many ways in which automation will impact production lines.
Question: What are the key advantages of implementing automation in a manufacturing plant?
John Glenski: There are numerous advantages to implementing automation in a manufacturing facility. These include cost reduction, increased efficiency, improved quality, enhanced safety, flexibility, sustainability and workforce optimization. Every facility has an opportunity for enhancement with automation.
Brandon Herrington: With the complexities of processes and manufacturing applications, data has become the backbone of every aspect in the environment. Sometimes thousands of data points and calculations were formerly managed and analyzed by an individual or team. With automated systems, this data can quickly be visualized, accessed and decisions made while needing minimal interaction. Critical failures can almost be eliminated by designing in automatic alarm-based logic while still using the same devices and data to streamline a much more efficient process.
Question: How can a company determine if it's the right time to invest in plant automation?
John Glenski: If your facility has challenges in efficiency, quality or workforce staffing issues, it’s the right time.
Brandon Herrington: There really isn't a bad
time to invest in automation. Whether it's investing your time to generate an automated Excel sheet to give the company its statistics for the shift or investing in automated machine systems to enhance the company's operational capacity, it’s easy to establish a return on investment with automation even if it only saves time. Time saved in an industrial environment always equates to money earned in some way.
Question: What are the emerging trends and technologies in plant automation that are shaping the future of manufacturing?
Scott Dowell: We're seeing two major trends shaping the future of manufacturing — modernization and digital transformation.
On the digital transformation side, manufacturers are utilizing artificial intelligence (AI)-enabled smart machines to enhance operational efficiencies, and they’re incorporating predictive maintenance to help extend asset life and predict machine failure before it occurs.
From a modernization standpoint, companies are seeing that aging systems can hamper efficiency and expose them to risk. An effective modernization strategy will align with a manufacturer’s digital transformation goals, laying the groundwork for a smart factory. Businesses are also looking at their energy usage and safety programs, since both can significantly impact productivity and their bottom line.
John Glenski: Plant automation is advancing rapidly, and embracing trends and technologies is crucial for manufacturers to remain competitive. Three of the top emerging trends shaping the future of manufacturing are:
Data availability: Both edge computing and cloud platforms enable real-time data access, allowing for faster decision-making and process optimization.
• AI and machine learning (ML): Both technologies analyze vast amounts of data allowing real time and predictive process optimization, efficiency enhancement and predictive maintenance.
• Robotics: Advanced robotics leverage data to enhance production, automate tasks and increase precision, leading to greater productivity and flexibility.
The future of manufacturing is going to be driven by innovation and efficiency and those that can build solutions focused on those aspects.
Brandon Herrington: Probably the most talked about subject lately has been AI. Automation has historically been a type of AI, but in today's manufacturing it has been adding in many ways. Anything from assisting the design team in writing the code through Q&A-style applications to human-machine interactions that are based. For example, the robot that feeds a human quality inspection may alert the inspector to a potential quality point to check based on tolerances trending close to being exceeded on the prior process. These AI systems can only be as good as the data they are given, which has driven the need for more advanced data collection systems that can access and collect all the data points for decision making.
Question: How can plant managers ensure automated systems are adaptable and flexible to changing production demands?
Scott Dowell: Modernizing your installed base of industrial automation and controls infrastructure allows you to collect the relevant data needed to understand production needs and challenges. AI’s data analysis capabilities can help more accurately forecast demand, and it can identify potential opportunities to optimize production. It can also help present data in a way that’s relevant to make a business decision. However, it’s important to highlight that AI is only useful if there’s data to analyze. If you’re early in your automation journey, the best place to start is by creating a comprehensive plant modernization roadmap to help ensure that any automation solutions best meet your needs.
John Glenski: The best way to ensure adaptability and flexibility are clear upfront standards on those systems, aligned to business objectives.
Brandon Herrington: From the lowest level, dynamic programming will allow the operational level to always change based on production. From
a hardware standpoint extra care in the architecture design and application discussions can ensure the systems can adapt to any needs. Some hardware may only speak one communication protocol where others may have hundreds natively embedded which can allow a wide versatility. This in addition to modular hardware that can have additional input/output (I/O), communication ports and programming abilities added will streamline an always growing and adapting manufacturing environment to keep up with the latest technologies.
Question: What are the most critical considerations when selecting automation technologies for a specific manufacturing process? Describe the challenge and solution.
John Glenski: Choose familiar technologies that fit the process requirements, integrate with enterprise systems and scale effectively within budget.
Process type: Determine if the process is continuous, batch, discrete, high-speed or high-precision, and choose a control system accordingly.
Existing technology and expertise: Stick with technologies the team is familiar with to reduce the learning curve and ensure smooth operations.
System integration and scalability: Consider how the system needs to integrate with existing platforms (such as manufacturing execution systems and enterprise resource planning) and handle data requirements. Cost must be balanced with these factors to meet project needs efficiently.
Brandon Herrington: As with any decision in manufacturing, the most critical aspect is whether it meets the need. Considerations such as: do I need certified hardware? (Class 1 Div 2, UL, etc.)
What will it be doing? Controller, data collection, remote access? What could it need in the future? (Additional IO, remote access, operator interface.) Careful review of device specs and research into the capabilities can help overcome all these scenarios. Some devices may hold multiple environmental design specs. Some may be single-purpose devices such as a programmable logic controller. Data collection, or protocol conversion, where some may have been multi-purpose devices with multiple built-in protocols and the ability to also control decision making. Then you can also use modular platforms to help adapt to some of those changes with IO additions, communications media and even screen addition abilities.
Participants
Scott Dowell Senior Vice President and General Manager, U.S. Industrial and CIG Wesco Pittsburgh
John Glenski, CPM, Sr. Director, Digital and Automation
Salas O'Brien Cincinnati,
Brandon Herrington Field Applications Engineer Red Lion Controls Bowling Green, Kentucky
ENGINEERING SOLUTIONS
1: By leveraging the power of data, sensors and advanced analytics, manufacturers can identify and address potential issues before they become larger problems. Courtesy: Wesco
Objectives Learningu
• Implementing automation in manufacturing facilities have key advantages, including cost reduction, increased efficiency improved quality, enhanced safety and more.
• As more manufacturing plants automation, training is essential as workers need to understand how to properly maximize a machine’s capabilities.
• Automation allows the standardization of a process and enables a data-driven approach to reach sustainability goals.
Question: What are the main challenges faced when integrating automation into an existing manufacturing process?
Scott Dowell: Manufacturers need to take several things into consideration when looking to integrate automation solutions into their existing operations. Automation is increasingly integrating advanced smart technologies, leading to a surge in both data consumption and production. To effectively access and distribute this smart data, a robust network is essential. Naturally, organizations will need to keep cybersecurity top of mind as well. They’ll also need to ensure that any automation solutions can work within the physical footprint of the plant floor, and that new machines and systems can talk to any legacy systems. Training is essential; workers will need to understand how to properly use the machine to maximize its capabilities.
John Glenski: The main challenges of integrating automation into an existing manufacturing process can include:
• Client familiarity: Many clients may not be well-versed in the latest automation technologies, making adoption and effective use more difficult.
• Maintenance resources: Clients may lack the necessary resources or expertise to maintain new automated systems.
• Initial cost: The upfront investment in automation technology can be a significant barrier, especially for smaller operations.
• Harsh environments: In sectors like food and beverage, finding automation equipment that can withstand harsh conditions is a challenge.
• Timing: Determining the optimal time to integrate new technology is critical, especially as automation solutions evolve to address previously unsolvable challenges.
Brandon Herrington: Manufacturing processes are always evolving as well as the technology behind the process. Some facilities may be using hardware or software that is 20 to 30 years old in addition to newer systems that were recently installed so the need to still collect that old data might present some challenges. As they migrate these systems into their Supervisory Control and Data Acquisition (SCADA) systems or even newer decision-making systems, a protocol converter may be needed or even media convertors such as serial to ethernet to access this data.
Question: How can knowledge transfer and training programs be effectively implemented to upskill the workforce for a more automated environment?
John Glenski: There are multiple ways to enhance the workforce as new automation and automated systems come online. This can include training programs implemented with new projects, engaging people in the project process so they feel ownership and enhance training effectiveness. Hands-on training during installation and commissioning also enhances the effectiveness of training. Having new employees with an individual development plan and associated technical training plans help them to see the long-term vision and how they are working towards their goals on a regular basis.
Brandon Herrington: As the technology evolves, the workforce must also evolve. The best way to ensure the new systems are utilized to their highest potential is through training. Engineers and maintainers of equipment often find themselves using many different software for troubleshooting and configuration. One of the best sources is through manufacturer provided training programs and internal scheduled training where the knowledge transfer and brainstorming sessions for process improvements can occur. These sessions may also introduce new features previously unknown to even the power users of a given software or hardware.
FIGURE
Question: How has the rise of robots affected plant automation and what has the feedback been like from plant managers and workers?
Scott Dowell: Many manufacturers continue to contend with labor challenges. Staffing shortages can create unwanted downtime if there aren’t enough people to run the production line, and training — or retraining — workers can be time-consuming and costly. Robots can help businesses navigate these challenges by performing dull, dangerous or repetitive jobs, allowing human workers to focus on more critical tasks. In addition, there is growing interest in collaborative robot technology, which enables robots to safely work alongside plant personnel without the need for costly safety designs and barriers.
Question: What are the ethical considerations when implementing automation in a manufacturing setting, particularly regarding workforce displacement?
John Glenski: Automation should be approached with a focus on enhancing, not replacing, the human element in manufacturing. The goal is to allow workers to use their skills and creativity rather than just physical labor. By making day-today tasks more engaging and meaningful, automation can improve the overall work experience. This human-centric approach ensures that technology serves to uplift the workforce, making their jobs more fulfilling.
We also must consider second-order effects — outcomes that aren't immediately obvious. For example, McDonald's experience with automation, like touchscreen kiosks, demonstrated that initial fears of job losses weren't fully realized as workers shifted to more customer-centric roles. We need to think beyond immediate impacts when implementing automation, focusing instead on how it can enrich both the workplace and employee roles.
Maintenance and Safety
Question: How can automation improve product quality and consistency in a manufacturing plant?
Scott Dowell: In many applications, like steel manufacturing, quality and consistency are critical. Poor-quality products are scrapped, and inconsistent products can either create additional waste or be inefficient. We had a global steel manufacturer that was struggling with excess waste during a production switchover process. They used
AI to accurately predict quality degradation, which delivered more than $8 million per year in savings and greatly improved overall equipment effectiveness. It also had the added benefit of optimizing their energy usage during the production switchover, which improved overall sustainability and reduced their Environmental Protection Agency permitting requirements.
Brandon Herrington: One phrase I've heard many times before is the data doesn't lie. When it relates to quality and consistency, this data can be fed into data-driven decision systems and reduce
FACTORY DIRECT ERGONOMIC WORKBENCHES
ENGINEERING SOLUTIONS
FIGURE 2: By removing the human element from dull, dirty or dangerous work, robots can help improve safety on the plant floor. Courtesy: Wesco
Question: How can we establish a comprehensive preventive maintenance program that complements our automated systems?
u
Insights
uManufacturers are using artificial intelligence (AI)enabled smart machines to enhance operational efficiencies.
uHands-on training during the installation of automation technology enhances the effectiveness of training.
some of the common manufacturing mistakes by creating alerts or modifying a process via monitoring systems when a deviation occurs to prevent quality problems later in the process. An automated process can also ensure repeatability within a system by adhering to specific defined tolerances and setpoints within the process logic. Using trending and historical data these systems can also provide future predictions on capacity and run times to allow management to schedule more efficiently.
Question: How does predictive maintenance play a role in optimizing plant automation efficiency and reliability?
Scott Dowell: Predictive maintenance has the potential to transform industrial operations. Traditional, or reactive, maintenance strategies can lead to machine failure, unplanned downtime and potential injuries. By leveraging the power of data, sensors and advanced analytics, manufacturers can identify and address potential issues before they become larger problems. Predictive maintenance can help extend equipment lifespan and enhance overall reliability. Shifting to proactive maintenance can lower overall costs by avoiding emergency repairs, and detecting potential hazards earlier minimizes the risk of accidents or injuries caused by equipment failures. And enabling data-driven decisions can help optimize the manufacturing process and improve overall efficiency.
Brandon Herrington: A properly designed architecture can allow access to any data point down to the lowest level in a system. This data can then be used to provide trending and alerts to allow scheduled maintenance based on a manufacturer's spec or by a trend that may show a possible future failure. This could allow maintenance teams to be much more data-driven proactive on their preventative maintenance vs reactive only. It can also help in the troubleshooting of systems by allowing addition of data points to the operator interface screen. A great example would be a motor drive status may be added to a diagnostic screen to allow personnel to view all data points at a glance. A notification alert could then also be automatically triggered via the human-machine interface visuals and a text sent to the maintenance team to alert of a fault or even added to a scheduled downtime for inspection.
Question: What are the latest advancements in sensor technologies for monitoring plant equipment and processes?
Scott Dowell: The adoption of industrial internet of things (IoT) technologies has driven advancements in smart sensor technologies, resulting in a greater volume of data and insights generated by end devices. Sensors today can monitor and collect data on a wide variety of machine conditions that can impact performance or potentially indicate maintenance needs. They can collect data on temperature, vibration, voltage, energy usage, pressure and flow rate, among many others. Process-wise, they can also monitor the integrity of network communications and help troubleshoot issues. Taken together, today’s sensors and data collection capabilities can help manufacturers improve operational efficiency, spot machine issues before they become failures and minimize downtime.
Question: What are the best practices for conducting risk assessments and implementing safety measures in automated production lines?
John Glenski: Assemble a multidisciplinary team to systematically assess machinery for potential hazards, such as moving parts or electrical
risks. Document all identified hazards, evaluating both the likelihood and severity of each. Implement appropriate mitigation measures, such as engineering controls, administrative procedures or personal protective equipment (PPE). Regularly review and reassess risks to address any changes in machinery, processes or regulations, ensuring ongoing safety and compliance.
Question: How can we implement a robust safety culture within a highly automated plant environment?
John Glenski: To implement a robust safety culture in a highly automated plant, prioritize clear and consistent communication about safety protocols and procedures. Pair this with regular, comprehensive safety training to ensure all team members have the knowledge and skills to identify and respond to potential hazards. Foster an environment of accountability and continuous learning, where safety is integrated into daily operations and reinforced through frequent updates, drills and employee engagement.
Question: What are the considerations for integrating autonomous vehicles or robots into the plant workflow to enhance efficiency and safety?
Scott Dowell: By removing the human element from dull, dirty or dangerous work, robots can help improve safety on the plant floor. One application, for example, uses robots to take temperature readings and other measurements in extreme environments, eliminating the need to expose humans to those conditions in most cases. Robots are also effective at performing repetitive tasks, which can help reduce ergonomic injuries. Incorporating robots frees up human workers to focus on more critical or higher-value tasks, which can improve productivity and mitigate the impact of labor shortages.
Sustainability
Question: What are the key benefits of implementing automation in a manufacturing or production plant from a sustainability standpoint?
Scott Dowell: Making your manufacturing or production processes more efficient and sustainable can have a significant impact on your bottom line. Older equipment generally consumes more energy, which drives operational costs up. Similarly, if equipment is running when it’s not needed, such as when demand is low, you’ll be wasting power and adding unnecessary wear and tear on your machines. Sensors, smart machines and other automation solutions can help ensure that your lines are running more sustainably and more cost effectively.
John Glenski: I often emphasize to clients that automation is key to bringing sustainability initiatives to life. It provides the real-time insights, data and visualization necessary to demonstrate to stake-
holders that sustainability efforts are achieving the intended reductions and optimizations. Automation not only tracks performance but also validates the impact of these initiatives, ensuring that factories meet their sustainability goals effectively and transparently.
Question: How can automation help in achieving compliance with environmental regulations and standards, and what are the best approaches to stay ahead of evolving regulatory requirements?
John Glenski: Automation not only allows the standardization of a process, but also enables a data-driven approach to reach sustainability goals. Environmental regulations and standards lean heavily on the ability to provide assurance. Automation allows for continuous monitoring of a process with data gathering. This provides the ability to have real-time insight to your performance against set standards as well as the backup data for assurance or audit purposes. Automation also allows for lifecycle monitoring, maintenance and replacement of equipment ensuring the efficient use of resources. An automated facility is one of the best approaches to staying ahead of evolving requirements as one can adjust to those changing requirements more nimbly in addition to giving real time feedback on compliance. PE
What’s your electrical maintenance plan?
Learn how to build one
Businesses need an NFPA 70B-compliant electrical maintenance plan to ensure operational safety and reliability to protect their people, property and processes
Safe and efficient business operations depend heavily on the reliability of power systems. In the United States, NFPA 70B: Standard for Electrical Equipment Maintenance outlines the requirements for an effective maintenance plan for the practical safeguarding of persons, property and processes.
Power system owners and operators now may be expected to meet this standard — along with NFPA 70: National Electrical Code for any new installations and NFPA 70E: Standard for Electrical Safety in the Workplace when designing and implementing maintenance plans.
Even if equipment is installed correctly, it may not be considered safe to operate unless it is maintained according to the manufacturer’s instructions or industry-accepted practices in a manner consistent with NFPA 70B. Owners should be aware that the Occupational Health and Safety Administration (OSHA) can now request documentation that complies with NFPA 70B during site audits and for various certifications.
The primary objective of a robust maintenance planning process is to develop an electrical maintenance plan (EMP) that delivers operational safety and optimal reliability while minimizing the operational cost of ownership. NFPA 70B provides a standard that, when followed, assists equipment owners and maintenance teams in this critical endeavor.
NFPA 70B-2023 for electrical maintenance plans
The NFPA 70B standard describes a systematic approach to electrical system maintenance, starting with the creation of an EMP and emphasizing the importance of preventing unplanned equipment
FIGURE 1: NFPA 70B assists equipment owners and maintenance teams in the development of electrical maintenance plans that deliver operational safety and optimal reliability while minimizing the operational cost of ownership. Courtesy: ABB Electrification, Service Division
‘
NFPA 70B: Standard for Electrical Equipment Maintenance
outlines the requirements for an effective maintenance plan. ’
failures to help drive safe operations and minimize downtime for greater efficiency. It outlines the requirements for an effective EMP, including:
• Roles of responsible personnel.
• Survey and analysis of electrical equipment.
• Documented maintenance procedures.
• Plan of servicing.
• Records-retention policy.
The 2023 revision, which converted the previously published guide to a standard, provides detailed installation and operating condition-based maintenance intervals for many common types of electrical equipment. The condition assessment of the equipment is critically important to the EMP and, ultimately, to the total cost of ownership. The document defines three types of equipment conditions, with the highest of the three categories driving the maintenance interval per NFPA 70B, Sections 9.3.1, 9.3.2 and 9.3.3:
• Equipment physical condition.
• Criticality.
• Operating environment.
In addition to guidance on when the maintenance interval should occur, the standard details when system studies should occur, the content of the maintenance work scope and the type of testing that is approved (NFPA 70B, Chapter 6, Chapters 11 through 36 and Chapters 7 and 8, respectively).
Electrical maintenance plan design
Using NFPA 70B as a guide, let’s explore how an organization creates and executes an EMP and what challenges should be considered before beginning a maintenance planning project.
STEP 1: Complete power system site assessment
The first major step in designing a maintenance plan is a complete power system site assessment per
Courtesy: ABB Electrification, Service Division
NFPA 70B, Section 4.4.1. Each piece of equipment must be evaluated for its condition as defined in NFPA 70B, Chapter 9 of and any other parameters that impact safety and operational efficiency. Equipment characteristics, age and maintenance history may all impact the need for maintenance activities.
Challenge 1: Resource allocation: Allocating sufficient resources, including personnel, time and budget, for the development and implementation of an EMP can be challenging, especially for organizations where resources with the correct skill set may be limited. Personnel who develop and implement the EMP must understand the electrical equipment, its value to the process that it powers and the impact of the environment on that electrical equipment and its respective process.
STEP 2: Define tasks and tests for each equipment scope of work
The tasks and tests for each equipment scope of work at each maintenance interval must be defined in detail according to NFPA 70B, Section 4.4.2. This is critical to determine the proper risk controls for any identified hazards, i.e., what safety measures must be taken should the required tasks expose personnel to electrical hazards, how long the tasks will take and how many trained employees will be required. This information will inform operational management about required shutdown times.
Challenge 2: Complexity of electrical systems: Many organizations operate complex electrical sys-
• What is NFPA 70B and what is its purpose in maintaining electrical systems?
• What are the steps and challenges to creating an electrical maintenance plan?
• What technologies and other resources are available to make the maintenance process easier?
FIGURE 2: Original equipment manufacturer documentation and industry standards can provide data needed to develop an effective electrical maintenance plan.
ENGINEERING SOLUTIONS
‘ Data is the basis for any appropriate maintenance plan and a continuous feedback loop must be employed to improve the plan. This data can come from several sources.’
tems with diverse equipment, making it challenging to develop and document a comprehensive maintenance program that addresses the specific needs of each power system component in a cost-effective manner.
STEP 3: Record keeping and review
During the execution of the maintenance plan, accurate and consistent records must be kept of what tasks and tests were carried out, their results and any discrepancies from plan (see NFPA 70B, Section 8.6). Lessons learned and other findings must be documented and reviewed in an after-project review with enough time to plan or adjust before the next round. The ability to notice trends is important to assess when the next maintenance activity is needed or when equipment may need to be replaced. Good trending depends on good record keeping.
Challenge 3: Compliance monitoring: Ensuring ongoing compliance with NFPA 70B standards requires continuous monitoring and updates to the
Table 1: Maintenance intervals
TABLE 1: An example
Courtesy: ABB Electrification Service
maintenance program, which can be resource-intensive and time-consuming.
STEP 4: Long-term record-keeping
Robust long-term record-keeping procedures must be developed or improved to meet NFPA 70B requirements. This information is critical to retain and keep accessible. OSHA and other regulatory bodies will need these records to confirm the EMP is designed appropriately and has been executed per plan. Appropriate change management procedures must be followed to document adjustments and the impact of adjustments on the original plan considered.
Challenge 4: Change management: Implementing an EMP that meets the NFPA 70B standard may require significant changes in organizational discipline, culture, processes and workflows. Creating or updating the appropriate internal project management system can be a significant internal project in and of itself.
Electrical maintenance is flexible
The standard is not an inflexible document that defines only one way to do things.
NPFA 70B-2023 clearly states that it is not “intended to duplicate or supersede instructions provided by manufacturers.” This simple statement means that to adhere to the standard, the maintenance planning team must locate and synthesize original equipment manufacturer (OEM) documentation from different manufacturers and for a range of models potentially published over many years and with multiple revisions. Faced with this task for a complex power system with a mixture of manufacturers and vintages, organizations can be forgiven if they seek an easier path.
How can you manage and reduce the impact of these challenges while designing an EMP? First, use data to improve the maintenance plan, interval and content. Data is the basis for any appropriate maintenance plan and a continuous feedback loop must be employed to improve the plan. This data can come from several sources.
• OEM documentation and industry standards.
• Lessons learned: Each round of maintenance performed on the power system will return a great deal of information about the equipment. Within a robust maintenance planning process, this informa-
tion helps to determine if the maintenance intervals and scopes of work should be modified (see NFPA 70B, Section 9.1.2).
• Continuous monitoring: Modern equipment is often or can often be equipped to capture data. In some cases, the equipment can push this data to a cloud-based continuous-monitoring system that dynamically informs the maintenance plan. These systems are not new; however, with the prevalence of mobile devices and the comfort level rising with doing business digitally, these types of systems are becoming increasingly available. NFPA 70B-2023 allows continuous monitoring and predictive techniques to be used to determine maintenance intervals and what maintenance is performed, as shown in NFPA 70B, Section 9.1.1. These techniques must be based on OEM recommendations or accepted industry practices.
Ultimately, the maintenance planner must have a defensible and rational explanation for the plan that is put in place based on good data, manufacturer’s recommendation or accepted industry practice. During an audit, when discrepancies with how the NFPA standard may be interpreted and issues arise (and they invariably will), the auditor will look for the intention and thoughtfulness of the plan put in place.
While this may not change the outcome or what has transpired, it is far too easy to find examples of industrial accidents rooted in shortcuts taken to achieve cost reductions without understanding the consequences or what may be perceived as negligence.
A second approach to consider is partnering with a single-source solution provider. While designing the maintenance plan in-house can be tempting to save on near-term costs, consider the potential longer-term cost savings and risk control that come with hiring a qualified partner for the EMP creation process.
Maintenance organizations exist that have both deep maintenance and product manufacturing experience and that also possess the experience of having created similar plans successfully, avoiding costly mistakes and inefficiencies that can plague “home-grown” efforts. The expertise of these organizations may allow them to identify the most cost-effective solutions, navigate potential roadblocks quickly and ensure the plan meets reliability
FIGURE 3: Single-source solution providers bring experience and expertise to help navigate potential roadblocks, identify cost-effective solutions and ensure the electrical maintenance plan meets reliability needs while keeping the total cost of ownership in check. Courtesy: ABB Electrification, Service Division
needs while keeping total cost of ownership under control. In the end, the upfront cost can be dwarfed by the long-term savings they bring through their specialized knowledge.
Future trends in preventive maintenance
Artificial intelligence and digital solutions are changing many aspects of our lives. Preventive maintenance is no different. Companies around the world are developing technologies to evaluate equipment operating conditions and model future potential needs to determine maintenance activities. Soon, based on predictive monitoring algorithms, operation processes may automatically adjust production schedules, contract maintenance work and order parts while adjusting for shipping constraints. This could be the last word in the justin-time methodology.
Many technologies on the horizon or recently released enable such a digital future. Solid-state automatic transfer switches, industrial battery backup systems, on-site solar power generation and intelligent microgrids connected with aggregated virtual power plants and utilities are just some examples of these trends in the electrification space.
Additionally, many solutions are available to retrofit nondigital equipment to be a part of this digital future. Traditional equipment maintenance
Insightsu
Electrical maintenance plan insights
uIf your manufacturing facility has an electrical maintenance plan, this will help you ensure that you’re meeting the requirements. u If you don’t have an electrical maintenance plan, review the codes, standard and guidelines that will help your team create one.
ENGINEERING SOLUTIONS
ENGINEERING SOLUTIONS
in ensuring the safety, reliability and efficiency of power systems. The NFPA 70B standard provides a comprehensive guide for creating and implementing an EMP, but it also
other isolated equipment. Like fall protection requirements, If any damage is spotted, employees should tag it, remove the PPE from service, and report it to management.
presents several challenges, including resource allocation, system complexity, compliance monitoring and change management.
These challenges can be mitigated by using data-driven strategies, continuous monitoring and, most importantly, partnering with a single-source solution provider. These providers bring a wealth of experience and expertise, helping to navigate potential roadblocks, identify cost-effective solutions and ensure the plan meets reliability needs while keeping the total cost of ownership in check.
Training is another crucial factor. Ensure the team follows a detailed and regular training schedule to educate on the hazards associated with arc flash and how to properly use the equipment. This is a good place to revisit the equipment selection criteria, especially after there has been any upgrades or changes to the electrical system.
Power system owners and operators must take proactive steps now to design and implement an effective EMP. Don’t wait for an audit or accident to highlight the importance of preventive maintenance. Contact a single-source solution provider and take the first step toward ensuring the safety, reliability and efficiency of your power systems. Your future self will thank you. PE
Lastly, fostering a company culture towards safety can greatly improve employee safety. Each person is their own safety critic and having safe operations top of mind is going to mitigate the risk of serious injury or death on any job site. PE
Jarred Richter is an electrical technologist at Hedgehog Technologies, a CFE Media and Technology content partner.
Ryan Roth is Global Product Manager for ABB Electrification Service.
FIGURE 4: Jarred Richter providing training on arc flash PPE safety.
Courtesy: Hedgehog Technologies
Can the right maintenance plan boost air compressor performance?
By employing preliminary, predictive and preventive maintenance, and air compressor’s performance will be maximized
Arotary screw compressed air system is essential to a business’s smooth operation. Proper, consistent maintenance ensures it runs reliably and efficiently, minimizing downtime, reducing repair costs and extending the compressor’s lifespan.
To achieve this, focus on the “three Ps” of air compressor care:
• Preliminary maintenance, or the steps one can take before installation.
• Predictive maintenance, which provides a picture of how the compressor’s peak performance.
• Preventive maintenance, which includes the routine, ongoing review and upkeep of the compressor.
Together, these steps prevent problems and address issues before they escalate.
Maintenance
begins before installation
While it might seem counterintuitive, a topflight maintenance program begins long before the compressor comes through the door. Choosing the right machine and determining its ideal location will impact a compressor’s performance.
Size is a critical first step; simply put, users need to select the right compressor for the job. An undersized compressor can overtax the machine and shorten its lifespan. Similarly, a compressor too
large for the operation — even if accounting for future growth — may be less efficient. An air audit by a certified professional can help you determine the correct capacity for the operation.
Location also matters. The operating environment plays a critical role in compressor maintenance. Do you operate in the scorching southwestern deserts or are you located in the often-frigid northern states? Is a facility sited in an arid climate or one where rain or snowfall are measured in feet, not inches? Does the facility generate significant dust and particulates, such as found in paper mills, or do you operate a pristine pharmaceutical operation?
All these location factors will play a role in maintenance processes and schedule. As you can guess, the dirtier the environment, the more frequent service calls need to be and the more vigilant you need to be tracking filter and cooler cleanliness.
Predictive maintenance: staying ahead of problems
Once a compressor is installed, predictive maintenance becomes key. This involves establishing a baseline for the compressor’s fluid and vibration profiles.
Vibration analysis tests and tracks a compressor’s optimum vibrations. Every compressor has a unique vibration signature and identifying that signature when first installed provides a baseline for the life of the compressor. Over time, if excessive vibration or other deviations from the machine’s normal profile are detected, potential problems which can shorten the lifespan of the compressor may be brewing.
Objectives Learningu
• Understand the importance of comprehensive air compressor maintenance. Learn how preliminary, predictive and preventive maintenance contribute to the reliability, efficiency and longevity of a rotary screw compressed air system.
• Identify key factors for compressor installation and maintenance. Understand how proper sizing, environmental conditions and strategic placement of a compressor impact its performance and maintenance requirements.
• Review typical maintenance steps. Gain knowledge of the tools and techniques like fluid sampling and regular system checks to prevent issues and ensure optimal air compressor performance.
Spencer Hall, Hitachi Global Air Power, Bartow, Florida
ENGINEERING SOLUTIONS
FIGURE 1: Vibration analysis is one predictive maintenance tool to monitor the health of rotary screw air compressors. It is best to record a baseline vibration profile soon after the compressor is installed.
Courtesy: Hitachi Global Air Power
FIGURE 2: Replacing dirty air filters is vital to keeping a compressed air system running efficiently. If a compressor is operating in a dusty or excessively dirty environment, filters and coolers will need to be cleaned and changed more frequently. Courtesy: Hitachi Global Air Power
Higher vibrations, for example, can be traced to failing bearings or gears or a decaying rolling element.. Higher vibrations can also be traced to misalignment, motor faults, mechanical looseness or broken motor mounts.
Ideally, a baseline vibration measurement should be recorded within the first few weeks or months of operation. A solid predictive maintenance program should include annual vibration measurements.
Fluid sampling is another predictive tool. Regular sampling of compressor fluid can reveal issues like bearing wear, fluid breakdown and ingestion of contaminates. Again, establishing a baseline soon after installation allows you to spot deviations that might indicate a developing problem.
Preventive maintenance means routine checks
Beyond preliminary and predictive is preventive maintenance. Guidelines for proper preventive maintenance can be found in the air compressor’s manual. Keep in mind the manual is only a guide and proper maintenance depends on unique operating circumstances. Your certified compressor maintenance technician can help set up a program that fits your specific needs.
Key preventive maintenance areas to monitor include:
• Lubricants: Use original equipment manufacturer (OEM)-recommended lubricants to avoid issues like varnishing and overheating.
• Filters: All filter elements have a maximum usable saturation point and eventually need replacing. Over time, contaminants build up on filter elements (including coalescing filters, as some solid particles, however small, are always present). Eventually, this buildup reduces the efficiency of the element. This efficiency loss causes larger pressure drops and allows more contaminants to pass through.
• Coolers: Coolers should be cleaned as often as needed. If the compressor is located outside near pollinating trees or indoors in a dirty, dusty environment, you may need to clean coolers more often to keep efficiency in check.
• Cooling water: In water-cooled compressed air systems, the cooling water needs to be checked at regular intervals and maintained to a certain standard — such as a certain pH and sediment value.
• Condensate system: If a condensate drain fails — which it can do — water can make its way into the downstream process and potentially damage sensitive equipment. Air can also escape through the drain, leading to reduced efficiency.
• Valves and couplings: The minimum pressure check valve (MPCV) should be disassembled and cleaned on a quarterly basis and rebuilt once a year. If the MPCV is not adequately maintained, you can run into all sorts of issues, such as the compressor not starting or unloading properly. Coupling elements shouldw also be inspected regularly (quarterly) and replaced as needed. Couplings can fail and cause excessive vibrations, as well as damaging the pump and motor.
• Motors: Electric motors have bearing greasing requirements spelled out by the manufacturer unless equipped with sealed bearings. Even sealed bearings need to be monitored through routine predictive vibration measurements. Proper greasing can keep contamination out, temperatures down and repairs manageable.
Because the lubricant and filters you use in a compressor are vitally important, careful attention must be paid to them.
Lubricant maintenance
Lubricants have three primary functions in rotary screw air compressors: they coat bearings, seal rotors and reduce or dampen heat. Other important functions include the prevention of varnishing or the formation of crystals that can raise internal compressor temperatures. Heat and varnish are the two primary enemies of rotary screw air compressors and the two are directly related. High temperatures create more varnish, which in turn creates more heat. It can become a vicious cycle.
Use only OEM-recommended lubricants in the system because they are specifically engineered for a machine. There are hundreds of compressor lubricants, dozens of lubricant manufacturers and even more resellers. To begin, start by considering the components of which the lubricant is made. Each lubricant has a primary ingredient, commonly referred to as a base stock. Each of these base stocks has different properties and pros and cons. Components include:
• Hydrocarbons (mineral oils).
• Hydrotreated hydrocarbons.
• Synthetic hydrocarbons (PAO).
• Polyglycol blends/diesters.
• Polyglycol/polyol esters (PAG/POE).
Ideally, you should choose a polyglycol lubricant whenever possible. These products are the crèmede-la-crème of compressor lubricants. While they have a higher upfront cost, they are the premier lubricants and come with virtually zero downside.
Air compressors using these lubricants produce biodegradable condensate, reducing a company’s environmental footprint and costs for condensate disposal. Polyglycol lubricants also do not varnish and, in fact, remove existing varnish that may have
been built up in the compressor. This helps create a more energy-efficient machine and prolong the compressor’s life.
Air filter maintenance
For compressed air filters, there are three types:
Particulate filters remove particulates from the air stream by trapping contaminants on the media. The filter element design and material determine the size of the particles it can trap, so particulate filters have varying degrees of filtration.
Coalescing filters remove water and aerosols of liquids like oil by coalescence. Coalescence is the process of trapping smaller droplets along the media until they combine into larger drops that fall out of the air flow. The structure and type of media determine how much aerosol can be removed, so they also have varying degrees of filtration.
Some filter designs act as both particulate and coalescing filters. With these designs, one filter with a single element can handle both types of filtration.
Activated carbon filters are used to remove oil and hydrocarbon vapors from compressed air and reduce oil carryover to 0.003 mg/m³. These filters are most typically used where removing taste or odors is critical, e.g., food processing and pharmaceuticals.
Degrees of filtration
The level of contaminants removed can vary widely in compressed air filters. The following is a breakdown of the degrees of filtration:
Coarse particulate filters can only remove large particles from the air stream. Depending on filter materials and design, the smallest particles they can remove will be anywhere from 5 to 40 microns.
Coarse coalescing filters can reduce oil carry-
can accumulate on the rotors of an air compressor’s air end if nonoriginal equipment manufacturer or poor-quality lubricants are used resulting in damage. Courtesy: Hitachi Global Air Power
FIGURE 3: Varnish
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Detecting and preventing air leaks
In addition to the preventive maintenance checklist above, identifying and repairing air leaks should be an ongoing focus in any facility. Air leaks can significantly increase energy costs and reduce efficiency. Based on data from the Compressed Air Challenge, 50% of compressed air generated is wasted. Of this wasted 50%, 33% is attributed directly to leaks, with another 8% wasted due to elevating the system pressure to compensate for leaks. As a point of reference, a quarter-inch air line leaking to 100 psi (7 bar), can cost thousands of dollars a year and reduced efficiency.
Insights
Maintenance insights
u To ensure your rotary screw air compressor operates smoothly and efficiently, it’s important to focus on three key types of maintenance: Preliminary (before installation), predictive (monitoring performance trends) and preventive (regular upkeep).
uProper sizing, optimal location and consistent checks on vibration, fluid and key components will extend the compressor’s lifespan and reduce downtime.
u By following a comprehensive maintenance plan, you can prevent costly repairs and keep your compressor running at peak performance.
over to as little as 5 mg/m³. In most cases, coarse filters don’t provide high quality air. However, they can help remove moisture and keep large particles from fouling compressed air tools and instruments (unless those tools or instruments require higher quality air, of course).
Fine filters are typically the minimum size needed where applications or equipment need high quality air. Fine particulate filters can remove particles as small as 1 micron. Fine coalescing filters can limit oil carryover to 0.1 mg/m³. Superfine filters are used when the highest quality air is needed, for example, for food production, pharmaceuticals, spray painting and instrumentation. Superfine (sometimes called micro) particulate filters can remove particles as small as 0.01 micron. Superfine coalescing filters can limit oil carryover to 0.01 mg/m³.
All degrees of filtration can collect larger particles and aerosols than they are optimized for. That might tempt you to just use filters with the highest degree of filtration needed — but you shouldn’t.
When filtering larger contaminants with finer filters, the buildup and loss of efficiency can happen much more quickly. (An active carbon filter could become clogged in hours, for example.) This can lead to unnecessary costs for replacement elements.
To find leaks, many manufacturers conduct air audits. Regularly auditing a system for leaks — especially during quieter times when they’re easier to detect is best. The audible frequency range of hearing for the human ear is 20 hertz (Hz) to 17 kHz; ultrasonic sound begins at 20 kHz. The suggested setting of an ultrasonic leak detectors used for compressed air leaks is 40 kHz — higher than what can be heard by the human ear. Many users find that most leaks are small and only located by using an ultrasonic leak detector.
Maintaining the maintenance plan
Finally, maintaining a solid preventive maintenance program requires good record-keeping. Writing detailed logs can help a company stay ahead of potential issues. Consistent logging helps you spot patterns in machine performance and helps you manage the total cost of ownership. If you are keeping good logs, users can share that information with their service tech to be sure he/she has a full picture of a compressor’s health. Typically, a service tech should be servicing each compressor roughly every quarter for routine maintenance. Also, inspect a compressed air system daily (if possible) to make sure things are running as they should.
As air compressor technology becomes more advanced, the importance of routine inspections and a robust maintenance program — including preliminary, predictive and preventive steps — are essential for keeping the system running at peak performance. PE
Spencer Hall is Field Service Engineer at Hitachi Global Air Power.
FIGURE 4: Regular maintenance from a professional service technician keeps a compressed air system running smoothly and reliably. Courtesy: Hitachi Global Air Power
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PREDICTIVE AND PREVENTIVE MAINTENANCE
Kelly Kolotka, Seeq, Seattle
How to accelerate predictive maintenance strategies with advanced analytics
Advanced
analytics platforms empower maintenance transformation through predictive modeling, helping manufacturers shift from reactive to proactive approaches
In every plant throughout every industry, sound maintenance procedures are vital to ensure safe and efficient manufacturing operations.
An average manufacturer faces more than 800 hours of equipment downtime per year and unplanned outages cost the industry as much as $50 billion per year globally.
The rise of continuous and automated monitoring technology in more recent times ushered in a new era of proactive maintenance efficiency, employing predictive maintenance procedures to guide plant upkeep efforts. This is accomplished by using both real-time and past performance data to foresee potential equipment issues before failure and then proactively schedule at-risk components for maintenance.
Objectives Learningu
• Understand the difference between reactive (runto-failure) and proactive (preventive and predictive) maintenance.
• Learn strategies to efficiently create and verify predictive models.
• Apply advanced analytics platforms for data aggregation, insight creation and modeling.
Asset-intensive industries in particular — such as oil and gas, chemicals, pharmaceuticals, mining and power — rely on heavy equipment for day-today operations and unplanned outages can wreak havoc on the bottom line. By keeping equipment running reliably, manufacturers can minimize surprise downtime and increase production, quality and throughput while adhering to safety and environmental standards.
However, achieving this requires thoughtful maintenance planning and practices.
Preventive maintenance procedures, which require servicing equipment at regular intervals, gained prominence decades ago and opened the door to proactive maintenance strategies. This provided unquestionable upgrades over reactive run-to-failure methods, but the approach introduced new costs in the form of unnecessary maintenance or simply inefficient allocation of technicians’ time-maintaining assets without any need for service.
The run-to-failure mindset is actively being replaced by intentional inspection strategies, critical sparing programs and data-driven approaches to prioritize not only what work gets done in the field, but also how it is executed. By leveraging digital tools and employing these methodologies to shift from reactive to proactive maintenance, leading organizations have reduced unplanned downtime and improved maintenance labor productivity, resulting in profitability growth by up to 10%.
Identifying opportunities for predictive maintenance
Predictive maintenance strategies are effective for preemptively identifying signs of equipment degradation, ineffective energy use and other negative process implications for both rotating and static equipment.
In many manufacturing environments, a single engineer or maintenance manager is responsible for hundreds, if not thousands, of assets. With such a magnitude of equipment, the task to effectively monitor, prioritize, schedule and perform maintenance is daunting without supportive systems in place.
In a recent survey by McKinsey & Co. of senior leaders at asset-intensive manufacturing companies, 99% claim to have embarked on a maintenance transformation journey in the past five years.
However, these initiatives frequently fail to meet expectations due to the large volumes of data spread across disparate sources, a lack of work and workflow management vision and gaps in workforce enablement.
Data plays a critical role in predictive maintenance to monitor the asset health of a unit, plant or even enterprise. This information comes from real-time field sensor data, in combination with retrospective information from process historians, enterprise resource planning, manufacturing execution and other similar database resources.
By aggregating and analyzing this collective information within a powerful advanced analytics platform, eliminating unplanned downtime becomes a more attainable goal for manufacturers. The addition of artificial intelligence (AI) agents to help develop monitoring tools accelerates the technique further by empowering subject matter experts (SMEs) to achieve more in a shorter span of time.
Once predictive monitoring is in place, the next step is to prioritize maintenance efforts to ensure the highest impact equipment — from both safety and profitability standpoints — have proactive maintenance procedures in place. This decreases the probability of an unplanned equipment outage and therefore minimizes the potential consequences, including poor reliability, inability to meet production targets, off spec quality, safety issues and overages in maintenance spending.
Data-driven models for asset reliability
Robust monitoring systems and data access are enabling drivers for data-driven and risk-based maintenance. To detect when an asset is operating
outside its typical bounds, normal operating baseline data is needed. For some equipment, such as pumps and compressors, original equipment manufacturers often specify ideal operating limits. In other cases, the normal operating window must be established using historical runtime parameters, with anomalies removed from the baseline. These historical datasets must often contain years’ worth of information to account for seasonal impacts, unit throughput capacity and other changes in operating events.
Developing the right model based on the sensor and process data available requires time from an SME with a strong understanding of the equipment and the overall system. Advanced analytics platforms simplify model creation by empowering teams to filter out downtimes, identify behavior corresponding with previous maintenance events — e.g., just after the last time a heat exchanger was cleaned or following the most recent compressor overhaul — and compare time periods with similar operation. The evolution of AI in process monitoring platforms has accelerated development and scaling of models and algorithms further, increasing insights available while reducing SME time required.
Even with robust models in place, individual equipment strategies are constantly evolving due to other changing conditions within a manufacturing facility. For example, an asset’s criticality calculation may shift with a change in lead time for replacement components, asset health of a spared system or new economic drivers that impact unit profitability. Models that monitor fleet health can provide alerts for engineering, operations and maintenance teams to help them operate equip-
FIGURE 1: A tree map image in Seeq highlights the plants with high cycle counts in the last month, one of many views in Phillips 66’s dashboard that highlights equipment requiring operational changes or inspection. Courtesy: Seeq
‘ Once predictive monitoring is in place, the next step is to prioritize maintenance efforts to ensure the highest impact equipment have proactive maintenance procedures in place. ’
ENGINEERING SOLUTIONS
the U.S. Chemical Safety Board subsequently issued BAHX operating best practices to prevent the future occurrence of similar safety and environmental incidents.
Adhering to these recommended industry standards required monitoring the number of cycles and temperature differential within each heat exchanger, to notify operations staff when limits were exceeded, prompting appropriate action.
By leveraging the thermocouple data from the inlet and outlet of the hot and cold flow streams of each heat exchanger, the approach temperatures and running cycle count were calculated over six years of data for more than 100 heat exchangers. The calculation also accounted for the temperature differential severity because the likelihood of thermal cyclic fatigue at a brazed aluminum joint increases with higher temperature gradient, which can lead to failure.
After creating the initial analysis, the team was able to scale the calculations across a custom asset hierarchy to proactively monitor more than 100 BAHX using a dashboard (see Figure 1). Every day, the reliability team receives an asset health report and they can take preventive measures operationally or mechanically to preemptively mitigate the risk of catastrophic failure.
Proactive monitoring for rotating equipment: compressors
Saudi Arabian Oil Co. (Saudi Aramco), one of the world’s largest integrated energy and chemicals companies, used the same advanced analytics platform to predict centrifugal gas compressor failures. Historically, the company monitored temperature and vibration excursions solely in its alarm management system.
ment properly, prioritize maintenance reasonably and keep production plans on track based on current constraints.
Proactive monitoring for static equipment: heat exchangers
Phillips 66, a large multinational energy company, used Seeq — an industrial analytics, AI and monitoring platform — to develop a monitoring tool for its fleet of brazed aluminum heat exchangers (BAHX). A catastrophic failure occurred in 2016 at another company in the same industry and
However, the team needed a predictive tool to track gradual deviations in compressor sensor data to avoid system trips, rather than the reactive approach of relying on its alarm system.
The predictive models that were developed monitored temperature and vibration to identify abnormal behavior, deviations and aggressive oscillations. First, the signals were cleansed for high-frequency noise, outliers and periods of bad data. Next, baseline behavior was determined by finding a dynamic threshold based on yearly averages with a margin of error. Then, daily average values were
FIGURE 2: Table (top) and trend (bottom) view in Seeq of a historical compressor trip event used to validate Saudi Aramco’s predictive model. The model would have predicted an anomaly over a month before this trip occurred. Courtesy: Seeq
compared to the rolling yearly average to identify anomalies and the system generated alarms when abnormal conditions were detected.
This strategy was deployed on a fleet of compressors with more than 600 sensors to give the user enough time to investigate temperature and pressure excursions before a compressor trip. Then, the appropriate actions could be taken by operations and maintenance teams to avoid the trip altogether. The model was validated using historical trip event data to determine whether the exceedances would have been flagged with enough time before the trip and in several cases, anomalies would have been identified a full month before (see Figure 2).
By implementing this tool, the company has saved hundreds of thousands of dollars on reactive maintenance and downtime losses, decreased flaring events and improved the reliability of its compressor fleet. The team monitors all 600 sensors to identify compressor anomalies and predict potential failures.
Transitioning from reactive to predictive maintenance
Many large and small manufacturers in numerous industries have tried and failed to implement predictive maintenance strategies with existing toolsets. The task is incredibly daunting with the complexity and volume of assets that must be monitored.
However, advanced analytics platforms significantly simplify data aggregation from multiple sources and insight creation, providing the building blocks for predictive modeling. With a clear company vision, accessible data, an empowered workforce and the right software tools, manufacturers can successfully deploy predictive maintenance strategies to increase uptime, reduce financial and environmental liabilities and improve operational safety. PE
Kelly Kolotka is an Analytics Engineer at Seeq, where she helps industrial organizations leverage their time series data with a focus on scaling calculations across numerous assets.
Insightsu
Predictive maintenance insights
uSound maintenance procedures are critical for manufacturers to ensure safe, efficient operations and reduce costly unplanned downtime, which can cost the entire industry up to $50 billion annually.
u By leveraging predictive maintenance strategies and advanced analytics, manufacturers can proactively address equipment issues, improve asset reliability and increase profitability while meeting safety and environmental standards.
MATERIAL HANDLING
Mark Feie, Salas O’Brien, Cincinnati
Harnessing robotics to transform manufacturing in the face of challenges
In the face of labor shortages, rising operational costs and pressure to increase production rates, plant engineers are increasingly turning to robotic solutions
Plant engineers are currently grappling with labor shortages, rising operational costs and relentless pressure to increase production rates. To address these challenges, many are turning to robotic solutions. According to the International Federation of Robotics, the global average of robot density in manufacturing industries have reached 126 robots per 10,000 employees — nearly double the number from five years ago. By taking on hazardous tasks, ensuring consistent product quality and operating around the clock, robots are an attractive solution. But implementation is rarely “off the shelf” and requires careful planning and customization. From the initial assessment and design phase to installation, integration and ongoing support, each step of a turnkey robot project demands meticulous attention to technical requirements, environmental conditions and long-term scalability to successfully integrate robotics into its operations.
The most common compelling reasons that prompt industrial manufacturing to turn to robotic solutions are:
Increased productivity. Robots significantly boost productivity by performing tasks more quickly and efficiently than human workers. Operating continuously without breaks, they help companies meet production targets and deadlines more consistently.
Consistency, repeatability and accuracy. Robots excel at performing repetitive tasks with precision. Unlike human workers, who may experience fatigue or variability in performance, robots deliver consistent accuracy every time.
Quality assurance. Robots can be programmed to detect defects and deviations in real time, ensuring that only products meeting stringent quality standards move forward in the production line. This proactive quality control helps reduce waste and rework and, ultimately, lowers costs.
Increased production speed. Robots can handle multiple tasks simultaneously and complete them more quickly than human workers. This enables companies to scale up operations and respond swiftly to market demands, giving them a competitive edge.
• Understand the key benefits of robotic solutions in manufacturing.
• Identify the steps involved in a turnkey robotics project.
• Explore the considerations for implementing robotics.
Key
benefits of robotic solutions
Recently, Salas O’Brien worked with an international plastics manufacturer that wanted to modernize its facilities. With a simulation-led design, the team was able to help it use robotic solutions to enhance efficiency while seamlessly integrating with existing equipment.
Improved workplace safety. Robots perform hazardous tasks that pose risks to human workers, such as handling heavy materials, working at extreme temperatures or dealing with toxic substances. This creates a safer workplace and reduces the likelihood of costly accidents and downtime.
Job creation and career building. Contrary to the misconception that robots take away jobs, they actually create new opportunities. As robots take on repetitive and hazardous tasks, human workers can transition to more skilled roles requiring problem-solving, oversight and maintenance of robot-
ic systems, leading to the creation of high-value jobs and career growth in fields such as robotics engineering, programming and maintenance.
Typical applications for robotic implementation
Working with a major consumer brand, Salas O’Brien collaborated with the client to optimize its capital by enhancing efficiency. The design team employed simulation-led design to achieve this goal, crafting a blueprint that allowed the client to streamline its facilities from 52 to 26 while still meeting volume forecasts.
Robotic solutions have already transformed the manufacturing landscape in some sectors, such as assembly and testing in the automotive industry, but there are still a lot of wins to be had in helping plants achieve greater efficiency and address a shrinking workforce.
Some of the most common applications are:
Picking (primary packaging). High-speed pickand-place robots can efficiently handle products to be case-packed. These robots load items such as blister pack cells or other packaging materials, manage
flow-wrapper infeed flights and form matrices on outfeed conveyors. Using proprietary picking software integrated with vision systems, these robots can identify the location orientation and type of parts and assign tasks to the appropriate robot for precise handling.
Case packing (secondary packaging). Robots excel in case packing by efficiently grouping and packing products into cases for distribution. Lowerto mid-speed pick-and-place systems ensure consistent packing quality of cartons, bottles, jars, pouches and bags by optimizing space use within cases and placing tier sheets between layers to reduce damage during transportation and enhance overall packaging efficiency.
Palletizing (tertiary packaging). Palletizing robots automate the stacking of products onto pallets, preparing them for shipment. These robots can manage a wide range of products and packaging configurations. For example, they can handle a single infeed to one or two pallet build stations, multiple in-feeds to corresponding pallet build stations with a stationary robot or a single infeed to multiple pallet build stations with a robot on a linear track. This automation enhances safety and efficiency in
Robotics solution implemented by
for confidential cheese manufacturer that needed to rapidly cool 40-pound cheese blocks without using traditional cartons or cases. Courtesy:
FIGURE 1:
Salas O’Brien
Salas O’Brien
ENGINEERING SOLUTIONS
‘ A common misconception is that the OEM is responsible for all machine safety concerns, including risk assessment.’
the loading process, significantly reducing the risk of injury associated with manual palletizing.
Warehouse picking. In warehousing, robots are revolutionizing the picking process by swiftly and accurately retrieving items from storage and preparing them for shipment. These robots navigate through the warehouse, locate products and deliver them to packing stations significantly reducing the time and effort required for manual or robotic picking.
Co-packers. In environments where many operators are used to repackage products into multi-packs or promotional items, such as toothpaste co-packed with a toothbrush, robots can efficiently handle the repackaging process by swiftly combining products into the desired configurations. The flexibility of robotic systems also allows for quick adjustments to different product combinations, making them ideal for handling diverse and frequently changing packaging requirements.
Labeling, case/tray erecting. Robots also are used in labeling and case or tray erecting processes. They apply labels with precision and consistency, reducing errors and ensuring that all packages are marked correctly. Additionally, robots can erect cases or trays from flat blanks, preparing them for filling and packaging operations.
Insightsu
Robotics
insights
uThere are many advantages of implementing robotic systems, including increased productivity, improved consistency and accuracy, enhanced quality assurance, faster production speeds, improved workplace safety and the creation of new career opportunities.
uExecuting a turnkey robot project can be done from the initial application and engineering and design phases to installation, operator training and ongoing after-sales support. This will help them appreciate the meticulous planning and customization required for successful robotic integration.
Kitting. In kitting applications, robots can pre-organize items for robotic case packing or assembly. This process is particularly useful in industries such as electronics, where multiple small parts need to be combined into a single package.
Machine tending. Robots are used increasingly for machine tending, where they load and unload parts from machinery. This application is common in computer numerical control machining, injection molding and other automated manufacturing processes. By automating these tasks, robots free human operators to focus on more complex and value-added activities.
Assembly. In assembly operations, robots perform highly repetitive tasks such as welding, screwing and fitting components together. They provide precision and repeatability, ensuring that each product is assembled to exact specifications. This automation enhances product quality and consistency while reducing assembly time and labor costs.
These typical applications demonstrate both the versatility and impact of robotic solutions in various
sectors of manufacturing and where plant engineers can look for robotic solutions to resolve challenges in their own processes.
Steps performed during a turnkey robotics
project
One recent client — a top cheese manufacturer — needed to rapidly cool 40-pound cheese blocks without using traditional cartons or cases. To address this, the Salas O’Brien team implemented four customized robotic cells to automate the entire process. The team meticulously planned and executed each step, from loading the cheese blocks into reusable trays to quickly cool them and then palletizing and restacking empty trays.
The turnkey method allowed engineering experts to execute this complex installation plan in phases without causing any disruptions to the client’s daily operations. As a result, the client’s manufacturing process has become more efficient, sustainable and significantly more cost-effective.
Typical steps in a turnkey robotics project are:
Pre-bid — application engineering. The initial phase involves thorough application assessment, starting with plant walk-throughs to identify potential areas for automation. During these inspections, engineers seek out bottlenecks that hinder production efficiency and look for highly repetitive activities that could benefit from robotic solutions. This comprehensive analysis forms the foundation for creating a customized automation plan tailored to the plant's specific needs.
After order — engineering and design. Once the order is placed, the focus shifts to detailed engineering and design. This phase includes performing risk assessments and safety audits to ensure that the proposed robotic solutions not only enhance efficiency but also maintain a safe working environment. Engineers work closely with clients to design systems that seamlessly integrate with existing operations and address identified bottlenecks and repetitive tasks.
Installation — FAT. During the installation phase, the robots are programmed and a factory acceptance test (FAT) is conducted. This process ensures that the robots function as intended and meet all performance criteria. Operator system training is also a critical component of this phase, providing plant personnel with the necessary skills
to operate and maintain the new robotic systems efficiently. This training helps to ensure a smooth transition and optimal use of technology.
After-sales support. Post-installation, robust support is essential to maintain the performance and longevity of robotic systems. This after-sales support includes warranty services, ongoing training and aftermarket assistance to address any issues that may arise. Continuous support ensures that the plant can fully leverage the benefits of automation and maintain high productivity levels over the long term.
Engineering considerations for robotics applications
The Salas O’Brien team worked with a chemical company to design a new chemical reactor and resin loading system using robotics and tied them in with existing equipment and utilities. This required careful environmental considerations such as space constraints, dusting control and temperature fluctuations.
Some of the most common considerations when implementing robotics into existing facilities include:
Production rates. To ensure efficiency, determine the maximum steady-state production rates, including any surge requirements. Consider plans for upgrading upstream equipment speeds. Assess the number of products and patterns for flow-wrapper infeed flights, blister packs, cartons, cases or trays. Evaluate part orientation from pick to place and the need for flap containment, partitions or layer sheets.
Ensure parts are presented to the robot consistently; if not, vision systems may be needed. Use picking software to optimize pick order, part orientation and load balancing for multiple robots handling homogeneous or different parts individually or in groupings.
Environmental considerations. The operating environment significantly impacts robotic design and function. Determine if high-pressure or high-alkaline washes are required, particularly in protein processing. Specify ingress protection (IP) requirements, such as IP67 for low-pressure spray or IP69K for high-pressure spray, in meat and poultry environments. If the robot cannot meet IP69K, an approved enclosure jacket may be necessary. Consider the use of NSF-H1 certified food-grade grease for raw food handling or if it is a plantwide standard.
Assess operational temperature ranges, whether hot (>113°F) or cold (<32°F) and humidity levels (>80% relative, noncondensing). For corrosive environments, determine which parts of the robot interface with corrosive products and whether an exterior coating or an approved jacket is needed.
Proposed robot’s physical characteristics. Determine the maximum payload, including end-of-arm tooling (EOAT) and any offset loading conditions. To select the appropriate model, assess the required reach for the application, including the robot's inner and outer reach and the installation area's clear height. Evaluate wrist capabilities to handle the application without unnecessary stress from load offset or unsuitable center of gravity.
Ensure the robot’s speed aligns with production rates, including surges. Redesign EOAT if needed to handle multiple parts, potentially lowering the overall pick rate. This might require a secondary device to pre-form an array or a larger payload robot, which typically reduces speed. Try modifying pack or pallet patterns to make the process more robot-friendly.
Special processes or standards to consider. If manual operations require part inspection, decide whether a 2D or a more expensive 3D vision system will replace the operator's inspection. For industries needing 100% product serialization, such as pharmaceuticals, secondary vision systems must validate the correct product is picked, packed or palletized. Compliance with the Food and Drug Administration Food Safety Modernization Act is essential, focusing on sanitary and clean design, food-grade grease and wash-down capabilities.
Determine if part manipulation, such as stacking, staggering or inverting parts, is required for secondary operations. Address dunnage concerns by identifying all necessary materials, such as case partitions, layer sheets or pads, case flaps, poly liners, pallet types, slip sheets, tier sheets and top caps. These considerations ensure robotic systems are well-integrated, compliant with standards and capable of optimizing production processes.
Risk assessment when considering robots
A common misconception is that the original equipment manufacturer is responsible for all machine safety concerns, including risk assessment. In reality, the end user (manufacturer) is typically
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ENGINEERING SOLUTIONS
Failure to perform a risk assessment can result in severe penalties in many countries.
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responsible for performing risk assessments and mitigation. This is logical because the manufacturer decides when, where and how to deploy and operate its equipment.
For example, if a manufacturer purchases a new palletizing robot for its food and beverage operation, it is the responsibility of the manufacturer to perform the risk assessment and mitigate identified hazards.
Risk assessments are essential because they help identify hazards that can seriously injure machine operators and other employees. Robots can pose significant dangers to human operators and mitigation helps reduce the likelihood and severity of machine-related injuries. Additionally, failure to perform a risk assessment can result in severe penalties in many countries.
Risk assessments should be conducted in several scenarios:
• When a robot or other industrial machine is introduced to the process.
• When processes are modified or machine usage changes.
• When new hazards are identified.
In these cases, a risk assessment determines the risk and appropriate mitigation measures.
Integrating robotics into manufacturing processes presents a powerful solution to many of the industry's current challenges. From boosting productivity and ensuring quality to enhancing safety and creating new job opportunities, robots offer numerous benefits.
However, successful implementation requires careful planning, thorough risk assessments and ongoing support. By understanding the technical requirements, environmental considerations and special processes involved, plant engineers can effectively harness the power of robotics to optimize their operations and stay competitive in a rapidly evolving industry. PE
Mark Feie is a Senior Robotics Application/Packaging Engineer at Salas O’Brien.
Typical Side Stream filtration using a booster pump.
Ewww.orival.com • filters@orival.com
very cooling tower has its unique dirt conditions, space constraints and other special characteristics. Filtration systems must take these into account in order to maintain particle free water. Orival filters are versatile enough to meet these criteria. They remove a wide range of dirt down to micron size, of any
specific gravity, even lighter than water. Typical examples include: airborne particles, microbiological growth, bugs, sand, scale, algae, rust, etc.
Line pressure powered, they permit use of the existing cooling tower pump, lowering initial system cost. The fully automatic self cleaning cycle takes
Typical Side Stream filtration of basin using a recirculating pump.
Typical Side Stream filtration using existing pump.
seconds and does not interrupt flow. Reclaim units recirculate rinse water making filtration a zero discharge operation. For more information and system design assistance, contact: Orival, Automatic SelfCleaning Filters, 213 S. Van Brunt St., Englewood, NJ 07631. (201) 568-3311, (800) 567-9767, Fax: (201) 568-1916.
Busbar 101: A Guide to Getting Started with Busbar Power Distribution
Rittal North America
The adoption of busbar power distribution systems on a global scale has accelerated in the last few years. Research estimates that the market for copper busbar power panels in North America alone will grow by nearly 7.5% annually through 2032, an increase that’s driven by several key factors.
One such factor is a global shift in safety regulations to help prevent instances of arc flash. A recent study found that there are roughly 30,000 arc flash incidents in the United States each year, many of which are powerful enough to cause significant injury to workers and costly damage to equipment.
This is pushing regulatory agencies to revise compliance guidelines. The short-circuit current ratings (SCCR) index outlines the appropriate level of short-circuit current electrical equipment can carry to help avoid electrical fault or arc flash, and recent changes to the SCCR have made it challenging for manufacturers to safely install and operate traditional block-and-cable power distribution.
While compliance and safety are major players in the move to busbar power, the need to optimize the use of space inside an industrial enclosure and the demand for faster, more efficient configuration and installation are also leading the charge toward busbar power.
Rittal’s new Busbar 101 guide provides an introduction to busbar power distribution, the benefits of busbar compared to blockand-cable, ways that busbar can help reduce costs, and the ideal applications for busbar.
CLICK here and download the guide to get started now.
The democratization of automation takes center stage at IMTS
ASTEPHANIE NEIL • EXECUTIVE EDITOR
rtificial intelligence, together with the adaptive data cloud, has profoundly changed operations in the warehouse and on the factory floor.
The ability to analyze data across the entire value chain is improving productivity, aiding maintenance operations, and creating new serviceoriented business opportunities. That was the message Microsoft’s Kathleen Mitford delivered in her opening keynote at the International Manufacturing
Technology Show (IMTS) 2024 in Chicago this past September.
From combing through CAD libraries to applying natural language models to maintenance records for delivering stepby-step instructions on how to fix a robot or even a jet engine, manufacturers have undergone an AI transformation. Everyone — from the CIO to the engineer to the operators — can access programs like Microsoft’s Copilot to act as a generative AI assistant.
The democratization of AI is an inevitable part of the factory floor going forward. “Basically, if [manufacturers] have not started on their AI journey, they’re late,” said Mitford, Microsoft’s corporate vice president of global industry marketing, in an interview with Automated Warehouse.
And if organizations are late with AI, they will miss out on the next evolution of AI, which is the democratization of automation.
Photo courtesy of IMTS
AUTOMATED WAREHOUSE
Automation democratization
During IMTS, there were examples of new products and services that unite AI and automation via programming, remote diagnostics, workcell workflows, and even self-service marketplaces to design and buy a machine online.
Here are just a few examples on display at IMTS that showcase these emerging areas of innovation:
Osaro: The Osaro Robotic Bagging System is an e-commerce robotic setup that can accurately scan and identify disparate items in a tote, effortlessly handle new SKUs, and quickly adapt to changing inventory. This allows the robot to pick and place multiple items into the auto-bagging machine and then to the conveyor to go out for delivery.
What’s different here is the company’s AutoModel. It allows AI to learn on the fly versus having to be trained, which is time-consuming, according to Brent Barcey, Osaro’s senior vice president of corporate development. Its rapid AI system allows for dynamic changes in the inbound and outbound flow of goods and the
integration of new peripherals, enabling the order-fulfillment line to adapt and evolve in real-time, ensuring continuous efficiency and productivity.
Olis Robotics: The company’s videobased remote diagnostic system watches a robot 24/7 on the packaging line or warehouse. Power over Ethernet cameras are set up around a cell, and when the visual system detects an issue, it saves the video files to allow an engineer to see what happened and even remotely take action.
Working with Universal Robots (UR), FANUC, and Kawasaki robots, the diagnostic system can connect to multiple robots through the robot controller. It also connects to the PLC that provides stats on what’s been going on for the past minute or past 24 hours.
“This is a pretty comprehensive diagnostic suite for automation,” said Olis CEO Fredrik Rydén, noting that the data allows for predictive maintenance as well. “When you have facilities that have a lot of volume of products going out the door, you want to keep them
Osaro’s Robotic Bagging System uses AI to learn on the fly. Stephanie Neil
running. This is a tool to ensure you can do that.”
In addition, by partnering with collaborative robot providers like UR, the goal is to make the robot experts more efficient, especially in the face of a labor shortage.
“What UR has been spearheading is the ability for anyone to adopt automation by making it easy to program the robots. Now it is easy to keep them running as well,” Rydén said.
Tulip Interfaces: This no-code system offers an almost effortless way to build applications, which could be workflows, traceability, dashboards, or machine monitoring, for example. The common data model includes templates for different applications that are available for download and includes application program interfaces (APIs) to connect other applications.
As part of the system, the operator is provided instructions, as well as
continuous feedback to show errors that may have occurred during a repeatable process. In addition, the Tulip starter kit provides pre-built applications that can be implemented in multiple ways. This allows small and large manufacturers alike to adapt the system to their processes.
“The goal is to democratize this so you don’t need to be an engineer to do it,” said Natalia Gutierrez, product marketing manager at Tulip.
Vention: When it comes to designing a machine, Vention is incorporating AI into the process to make suggestions on the next component – which is added automatically to expedite the design process.
On the automation side, Vention released a machine motion AI controller with NVIDIA Jetson. The low-power system is designed for accelerating machine learning applications and enables robots to learn in the cloud.
Stephanie Neil
“We’ll have a robotics model in the cloud that will learn from the operation that is running to give you a better program for your robot for more efficient operation.” said Carl Hajal, Vention’s senior software and robotics segment manager.
He noted that Vention differentiated its AI offering by applying it both on the controller and in the cloud. When programming a robot, Vention has also added a co-pilot that can write a program for the engineer and push it into an existing script to update it.
Hajal claimed that this should accelerate programming by about 50% for engineers.
Welcome to the automation marketplace
Vention is known for its self-serve platform, which allows OEMs to design automated equipment, robot cells, and tooling online, while providing real-time bill of materials and pricing information before the equipment is shipped out for assembly on site.
Now, with the proliferation of tools and cloud-based services that make automation accessible and easy to use,
self-serve marketplaces are popping up from different technology providers. igus: The motion plastics company makes flexible cables, chains, linear bearings, slides, actuators, motors, and more. The differentiator for igus products is its self-lubricating material, a proprietary blend, said Felix Brockmeyer, igus CEO.
Over the years, customers have asked igus to assemble its parts into entire systems. Now, the company has an internal startup, called RBTX by igus, which is an online marketplace that connects users with suppliers of compatible, cost-effective robotic components using simple tools.
“It started with small and midsized manufacturers and OEMs in mind, but now everybody is our customer base,” Brockmeyer told Automated Warehouse. “There is a need in the market to offer simple automation instead of what normally is overkill.”
To that end, pricing for specialized robot applications such as pick and place, material handling, machine loading and unloading can be offered at lower price than a traditional feature-rich system.
“There wasn’t an offering in the market to address people that just want to do simple automation tasks,” said Brockmeyer.
The igus robot control includes the company’s own open-source software, which can be downloaded for free to start writing programs before buying a robot. There are also application-specific overviews including videos showing how it works.
“It’s automation for anybody,” Brockmeyer said.
Universal Robots: The UR Marketplace was also a talking point at IMTS. It is a one-stop shop to choose and purchase cobots, components, and services. The platform offers a range of equipment from the UR ecosystem and a quoting and ordering management process and 24/7 call support. AW
For more news on AI and digital transformation in the warehouse, visit Design World’s sibling site Automated Warehouse at: automatedwarehouseonline.com
igus CEO Felix Brockmeyer at IMTS 2024. Stephanie Neil
The digital transformation of ABB’s instrumentation warehouse
STEPHANIE NEIL • EXECUTIVE EDITOR
The addition of robots, motion control, and digital twin tools leads to a 90% improvement in overall logistics efficiency.
ABB’s Measurements & Analytics factory in the Italian village of Ossuccio — situated on the shores of Lake Como — produces pressure transmitters that enable industrial companies around the world to measure, monitor, and control applied force. This technology is key for both safety and efficiency and is a fundamental component in industrial digital transformation.
Today, the Ossuccio factory exports the majority of its components to other ABB factories around the world through its logistics center. It’s a midsize operation that has relied on warehouse workers to prepare products for shipment.
But ABB, like its industrial customers, continues to strive for efficiency through innovation — regardless of the size of the operation. So, the company used its own in-house automation, robotics technology and simulation capabilities to modernize the historic facility, which has been on Lake Como since World War II.
The modernization effort included the addition of ABB’s OmniVance FlexBuffer robot system, an advanced automated storage and retrieval system (ASRS) that manages all of the warehouse loading and offloading activities. According to the company, the robot not only transformed the warehouse into a fully
ABB’s OmniVance FlexBuffer automated storage and retrieval system can handle a variety of box sizes with the same robot gripper.
Autonomously transport materials up to 4,200 lb with the industry’s most comprehensive autonomous mobile robots and fleet management software.
AUTOMATED WAREHOUSE
Adoption of the AS/RS has alleviated the physical strain associated with manually handling heavy boxes.
automated operation, but it has also led to 90% improvement in overall logistics efficiency.
“We wanted to improve logistics at the Ossuccio site while also enhancing the entire manufacturing process,” said Mariafrancesca Madrigrano, general manager of the ABB Measurement & Analytics factory. “Upgrading the existing warehouse was an important project that we did together with our colleagues in robotics in order to align with the current state-of-the-art automation.”
ABB configures its own robots
The solution consists of two FlexBuffer systems connected by a conveyor, each one equipped with ABB robots. The control architecture includes ABB Group’s B&R Industrial Automation PLCs and HMIs to drive the conveyor system and robot control from ABB’s OmniCore control platform.
“These are palletizing/depalletizing robots handling a combination of either boxes or totes within a combined
The
application,” said Craig McDonnell, business-line managing director of ABB Robotics. “In this application, the FlexBuffer system is managing the inbound or outbound location of the totes, balancing of the tote or boxes between two separate buffering systems, and the complete software architecture to manage that.”
To that end, FlexBuffer allows for easy transitions between buffering,
storing, and sequencing tasks. It combines temporary storage and sequencing functions to provide additional functionality over traditional ASRS.
The mixed-item variant of the FlexBuffer enables the user to store a wide variety of box sizes, all being handled with the same robot gripper. And the dynamic racking positions all boxes with minimal loss of space.
ABB Ossuccio factory specializes in the production of pressure transmitters.
The application at the ABB warehouse is an example of the scalability of the system, as ABB robotics are typically found in larger e-commerce sites, McDonnell said.
“Over recent years, we've found there's a big need for manufacturing processes to drive greater efficiency,” he explained. “Like in this plant, they were using a lot of robots in the end processes, be it welding or whatever it might be that you need for that specific process.”
“But the intralogistics feeding typically was the last part to be automated in many of these smaller factories. And the trouble was, it just ends up being too custom,” added McDonnell. “So, we've spent quite a bit of time coming up with a standardized modular system that you can use in small to medium-size facilities.”
Digital twins and digital transformation
The system was designed in ABB’s RobotStudio, a simulation tool for robot applications, which created a complete digital twin architecture. This reduces commissioning time as well as enables remote access after the installation.
“In the digital twin, we build a complete duplicate all the way down to the deep robot motion in the actual runtime engines. Then you have much quicker commissioning times and troubleshooting assistance,” McDonnell explained.
While the decision to deploy the ASRS in the warehouse was driven by customer needs, the digital transformation aspect was an extra benefit.
“The reason digital transformation is important is because the goal of ABB
is to serve the customer better,” said Madrigrano. “The big advantages have been that we’ve reduced the possibility of human error, and we’ve reduced throughput time.”
And the entire workforce benefits. Adoption of the system has enhanced working conditions for operators, alleviating the physical strain associated with manually handling heavy boxes.
In addition, many people were reallocated to other manufacturing areas that required additional manpower, giving the factory a greater flexibility during peak production times. AW
Scan the QR code to see ABB’s newly automated Ossuccio site
www.youtube.com/watch?v=gxc8-o8-WAA
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NEW
The Data Driven Warehouse
How real-time data collected at every touch point smooths out operations
Emerging technologies are revolutionizing supply planning, enhancing supply chain efficiency, agility, and resiliency. Real-time data and advanced analytics driven by connected assets and systems help identify potential disruptions, mitigate risks and make informed decisions. We will discuss key insights into today's supply chain challenges.
What are today’s supply chain challenges?
The constantly evolving global supply chain landscape poses a range of challenges for businesses today that can impact their operational efficiency and effectiveness. Here are the biggest challenges:
• Business disruptions and market volatility: Over the past five years, supply chain operations in various industries faced unexpected events, which resulted in reactive responses. This can impede the ability to meet demand, leading to lost revenue, increased costs, and a decline in overall profit margins.
• Demand predictability: Social media, COVID driven direct-to-consumer (DTC) models, market volatility, and now inflation have made traditional demand forecasting insufficient. Operations are leaning on outdated forecast approaches that also lag and fail to respond adequately to current market dynamics.
• Holistic inventory visibility and optimization: Inventory management is complex and dynamic. The end of 2022-2023 saw excess inventory across many organizations due to COVIDrelated supply chain constraints. This led to higher costs, lower margins, and waste. The long term impact will lead to lost sales, and loss of differentiation, loyalty, and market positioning. Adopting an integrated approach and leveraging advanced technology and best practices, businesses can overcome these challenges - improving supply chain efficiency and resilience.
What is lacking in today’s supply chain strategies?
Supply planning today involves technology, data analysis and stakeholder collaboration. While technical and data analytic advancements have been made, there are still several areas that need improvements in the industry:
• Accurate transparency of data
• Dynamic supply planning and execution based on integrated intelligence and automated decision-making
• Convergence of network modeling, scenario and traditional planning and planning
Businesses want to improve supply chain visibility, predict, and mitigate risks, and optimize performance. Incorporating advanced concepts can enhance agility and resilience, meet customers’ evolving needs, and optimize performance. Below are a few advanced technologies and characteristics that must be included in an organization’s growth plans for supply chain optimization.
• Artificial intelligence and machine learning: Artificial Intelligence (AI) and Machine Learning (ML) can help businesses analyze data, find patterns, and make proactive decisions to mitigate risk. Many planning solutions have already integrated AI/ML into their core plans, but further integration of this can enhance algorithms. This could include detecting shifts and anomalies -- optimizing execution, automating operations such as key planning processes and real time decisions, and more.
• Digital twins and advanced simulation: Digital twins and simulation create virtual versions of physical assets, processes, and systems. These outputs can be used to evaluate scenarios and risk, identify key constraints, optimize, and evaluate alternative configurations.
With data and AI/ML, digital twins can continuously evaluate supply chains and networks, informing businesses in an unprecedented way.
• Automation and autonomous systems: The targeted deployment of automated storage retrieval systems (ASRS), autonomous mobile robots (AMR) and other assets with IoT connectivity, RFID asset tracking and machine vision can mitigate risks ranging from labor shortages to inventory loss. Working in tandem with digital twin and AI/ML, these assets comprise self-optimizing systems that drive higher output and efficiency by learning from both physical and simulated scenarios in the connected warehouse.
The future of supply chain planning requires digitization, automation, connectivity, and data-driven decision-making. Organizations that embrace these technologies create agile, transparent and efficient supply chains that are resilient to market changes and disruptions. AW
You can read more in our recent whitepaper, Synchronizing Supply & Demand in 2023 and Beyond.
HORMEL FOODS FACTORS
OEMs
INTO ITS SUSTAINABILITY STRATEGY
Sustainability Report: Hormel Foods reduced packaging by nearly 1.7 million pounds in 2023
Many food and beverage manufacturers have committed to environmental, social, and governance (ESG) programs, stating specific goals around lowering emissions, addressing sustainability across the supply chain, reducing product and packaging waste, and providing a more inclusive workplace.
Hormel Foods is one of those companies focused on ESG and making a positive impact on the world. With over 20,000 employees and over 40 manufacturing facilities providing products to 80 or so countries, the company has a real responsibility that must be tracked — which it does. Known for its many brands, including Planters, Skippy, SPAM, Hormel Square Table, Justin's, Jennie-O, and more than 30 others, the company recently released its 18th Global Impact Report, highlighting areas of the organization where continuous improvement and responsible business practices made a difference in 2023.
To measure its accomplishments, Hormel set 20 qualitative and quantitative goals it expects to achieve by the end of 2030, tracked by a program it calls the "20 by 30 Challenge." While it covers many ESG angles, from a sustainability perspective, there's an effort to cut back on nonrenewable energy use, greenhouse gas (GHG) emissions, water use, and solid waste sent to landfills.
Another top priority in the sustainability category: Reduce packaging.
A deeper look at package design
A key highlight of the company's 2023 progress includes reducing product packaging by nearly 1.7 million pounds. According to company officials, this was accomplished by optimizing packaging design and improving shipping efficiencies.
Stephanie Neil Executive Editor
The redesign of the Planters brand plastic bottle resulted in a projected annual savings of 440,000 pounds of plastic.
packaging oem
An example is the redesign of the Planters brand plastic bottle with a projected annual savings of 440,000 pounds of plastic, along with tweaks to avoid any issues with the recycling cleaning process. This follows work in 2022 when the Hormel engineering team redesigned Justin's peanut butter jars to use 30% less plastic, which will amount to over 165,000 pounds of materials saved annually, the company said. The packaging for Hormel Square Table entrees was also redesigned to include 25% of material from postconsumer recycling, saving over 382,000 pounds of material annually, and the thickness of the board for Jennie-O ground turkey boxes was reduced, generating over 1 million pounds of material savings annually, according to the company website.
When redesigning packaging where "less is more," the idea for the change may come from Hormel's R&D packaging team, a supplier, marketing, or even a customer request, but implementing the change is a collaborative effort, which includes machine builders.
"They are integral to the success of many of these projects," said Oliver Ballinger, senior scientist, packaging R&D at Hormel Foods, in an interview with Packaging OEM. Working with packaging engineers and the production team, new designs are tested on the packaging line and OEM feedback is provided on how changes perform on the equipment.
The design engineers utilize CAD and different 3D and simulation software for strength comparison of sustainable materials, Ballinger explained, noting examples of weak points on a bottle or digital top load strength. But much of the change comes from the creative solutions — the "what if" questions asked by engineers that lead to the ultimate solution.
The "what if" simulations can be done to determine where material distribution needs to be to maximize the strength of a bottle and accurately portray what the strength will be once bottles are physically produced, Ballinger said. "Without that technology, or with inaccuracies in that technology, it adds time, complexity, and cost to need to physically produce trial molds for bottles to be manufactured and tested just to find out they didn't meet the strength requirements or had quality defects."
After successful completion of those evaluations, the material goes through a series of pre-commercialization tests before full approval. If new equipment is utilized, a parallel path of factory acceptance testing (FAT) occurs with the equipment.
Food waste factors in
New sustainable designs are not only focused on reducing packaging waste but also food waste.
"We don't want to make a sustainable packaging change and have that change drastically reduce the shelf life of the product and therefore result in more food waste," said Ballinger. "The same goes for proper package and product sizing. If we find out that consumers struggle to eat through a one-pound package of lunch meat and product consistently gets thrown away, then we need to look at making that package smaller to fit the need of the consumer."
When new materials are used, they go through evaluations, including barrier, abuse, machine runnability, shelf-life, etc., before they become viable.
New equipment can be brought in pending the kind of product changes and equipment capabilities. "But in general, we try to make changes that work on current equipment," said Ballinger.
As a result, OEMs always factor into the sustainability equation to make the necessary changes required on existing — or new — equipment. OEM
Oliver Ballinger, senior scientist, packaging R&D at Hormel Foods. Hormel Foods
The redesign of Justin’s peanut butter jars uses 30% less plastic, amounting to over 165,000 pounds of materials saved annually.
• Available Sizes Flange and Cylindrical Nuts
• Accuracy Class 5, 7, & 10
• Machined Journals
• State of the Art Metrology and Inspection
• Integrated Ball Screw Motors
- NEMA 08, 11, 14, 17, & 23
• Applications
- Medical Lab Automation
- Optical Sensor Adjustments
- Pick and Place
- Packing Line Push Systems
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• Customization Available
Stephanie Neil • Executive Editor
AMBIENT IoT & GENERATIVE AI TO GIVE PACKAGES A “VOICE”
Using natural-language technology, batteryfree smart tags, and a smartphone, Wiliot’s data platform can provide supply chain analysis and report on the state of the product inside the package.
What if your package could talk? Imagine the story it would tell about its supply chain journey, including handling and transport conditions, carbon footprint, and even the state of the product inside the package. Today, technology is available to make "talking packages" a retail reality, and Wiliot, an ambient IoT data carrier, is a company that is making it happen.
Unlike an RFID system that requires dedicated readers, ambient IoT harvests energy from the radio waves generated by everyday devices like smartphones and tablets. It then uses this energy to communicate with other devices or applications.
According to research and advisory group Gartner, ambient IoT is one of the technologies that will play a significant role in the future of digital organizations by enabling new ecosystems, new business models based on knowing the location or behavior of objects, smarter products with new behaviors, and a much lower cost of tracking and monitoring.
Wiliot battery-free Bluetooth sensor tag. Wiliot
packaging oem
Understanding its potential, Wiliot is taking its ambient IoT platform a step further by integrating natural-language technology with its IoT Pixels which are stamp-sized, battery-free smart tags that can be affixed to products, packaging, containers, crates, pallets, and more. Communicating via Bluetooth, these IoT Pixels provide information such as location, temperature, humidity, and carbon footprint to the Wiliot cloud where the data is analyzed.
Recently, Wiliot expanded the breadth of this offering by announcing the launch of WiliBot, a generative AI (GenAI) chatbot that enables naturallanguage conversations with any ambient IoT-connected product. When GenAI is combined with this source of real-time ambient physical world data, manufacturers, warehouses, retailers, and eventually consumers, can have important conversations with the products they make, source, distribute, and ultimately purchase.
A new kind of packaging language
According to the company, with WiliBot, individuals can converse with products and supply chains using a smartphone to ask specific questions such as: What's the shelf life of this product? How did it get to the store? Which product should I stock next, and why? Is this product safe to stock, and why? What is the carbon footprint of this product, and why is it so low or so high?
"Ambient IoT and generative AI are increasingly symbiotic technologies," explained Wiliot CEO Tal Tamir. "Ambient IoT generates vast amounts of data about trillions of everyday things, and GenAI can uniquely make sense
Wiliot’s Ambient Data Platform revealed that food shrink accounts for roughly 5% of goods in the food chain.
WiliBot answers supply chain questions. Wiliot
of all that data. On the flip side, GenAI learns by analyzing vast amounts of data. To a real extent, that data has so far been finite, but ambient IoT presents massive new physical world datasets that a GenAI platform like WiliBot — and others — can use to describe products, materials, supply chains, and everything connected to the internet."
For example, the Wiliot-developed AI and machine-learning algorithms can identify supply chain events — such as sensing that shipments of produce or pharmaceuticals have been handled at unsafe temperatures — and automatically generate alerts or AI responses that allow businesses to course-correct or optimize operations.
According to Wiliot, the importance of the linkage between ambient IoT and AI was demonstrated during recent projects with leading food retailers. In the projects, the Wiliot Ambient Data
Platform revealed that food shrink (food that is lost, damaged, or spoiled before it reaches store shelves) accounts for roughly 5% of goods in the food chain.
The Wiliot platform can solve twothirds of these food shrink issues, the company said, ensuring a safer food supply, higher customer satisfaction, and lower costs. And WiliBot will now democratize access to these insights across the organization.
"Although Wiliot's work in generative AI is relatively recent, the company has long been a pioneer in artificial intelligence and machine learning for deriving insights into ambient IoT data," Tamir said. "As more companies have begun rolling out Wiliot's Ambient Data Platform, we've been asked how GenAI capabilities might make the transformation even easier. Our answer is WiliBot, the real-world combination of ambient IoT and AI."
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Timeline for testing the technology Wiliot is currently piloting WiliBot with its key enterprise customers with a broader rollout scheduled for 2025.
In the future, this convergence of ambient IoT and generative AI will be made available to consumers in-store and at home through an ecosystem of mobile apps enabling consumers to converse with their products. The ability for the package or product to "talk" will provide more insight and understanding of the overall carbon footprint, materials composition, ethical sourcing compliance, quality and safety, and more, the company said. OEM
KHK USA offers the broadest selection of stock metric gearing in North America. Designed for use in industrial automation applications, conveyor systems, packaging equipment, robotics, and general machinery applications, KHK’s selection of spur gears, helical gears, internal ring gears, gear racks, bevel gears, screw gears, worms & wormwheels, ratchets & pawls, gear couplings, right-angle gearboxes, and gear lubrication systems are available in various materials and sizes. KHK’s website offers free 3D CAD models for all gear products, complete product specifications, and 24/7 shopping. With KHK USA, stock gears are delivered from stock, with no minimum order or credit card surcharges.
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Stop waiting and get rolling with American-made miniature ball screw assemblies from PBC Linear. Our ball screw production process offers a substantial reduction in lead times and costs compared to other available options, avoiding costly downtimes! PBC Linear is recognized for their high-quality standards for screw-driven technology. When ordering lead screws or ball screws, customers should expect to receive a complete screw and nut set that’s out-of-the-box ready to be incorporated into your next project application.
Choose between 5, 7, and 10 grade accuracy for either 6 mm, 8 mm, or 10 mm ball screw sizes with various available leads. Contact PBC Linear for a quote at +1.815.389.5600 or visit pbclinear.com to learn more.
American Manufactured Miniature Ball Screws from PBC Linear
CaSe Study
Auto manufacturer protects isolated workers in paint booths with Grace Lone Worker Advanced Monitor
Challenge: A major car manufacturer identified a risk for its workers working in isolated paint booths. Because the worker was working alone and apart from other workers, it would be difficult to summon assistance if they were to become in distress without a means to alerts others.
Solution: A worker-worn Grace SuperCELL®SC500 Intrinsically Safe Pendant and Grace MS2000X were interfaced with the manufacturers fire alarm panel to relay alarms to plant protection.
ReSult: The system provides not only a one-way distress alarm from the worker, but also the Grace MS2000X ability to send fire panel alarms back to the workers SuperCELL®SC500 Safety Pendant.
SummaRy: The worker in the paint booth carries a SuperCELL®SC500 Intrinsically Safe Pendant, capable of motion sensing and manual panic button activation using Grace’s secure radio signal protocol back to the MS2000X.
This customer facility is in a tornado prone area of the country where TAKE SHELTER alerts are common, as well, FIRE and ACTIVE SHOOTER alarms had no way of communication to the worker in the paint booth.
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The Grace MS2000X Advanced Fixed Facility Monitor, with 24-hour battery hour back-up, has (4) common collector inputs interfaced with an existing fire panel alarm panel. Three (3) of the MS2000X inputs are used to receive separate outputs from the fire alarm panel for FIRE ALARM, TAKE SHELTER, and ACTIVE SHOOTER.
In addition, MS2000X has (4) Form-C 6A @ 28VDC, 6A @ 125VAC relay outputs used to follow the ALARM, TAKE SHELTER, and ACTIVE SHOOTER alarm input from fire alarm panel to loop back into the fire alarm panel acting a means of acknowledgement to the fire panel alarm.
This system solution is subscription free and does not require a cellular signal or internet connection. Separately, Grace offers subscription based remote cloud monitoring solutions as an add onto this solution.
www.GraceLoneWorker.com
CaSe Study
Industrial condition monitoring with DEWESoft
Challenge: In modern manufacturing, time is money, and downtime is every company’s worst nightmare. When something fails, it can shut down the assembly line for hours as they diagnose and correct the fault, costing valuable time and money.
Solution: DEWESoft’s condition monitoring solution provides a solution to catch problems like a failing bearing or a worn-out motor before the failure occurs by monitoring temperature, vibration, speed, and current draw for variations and then notify the technicians of a problem before it becomes downtime.
ReSult: Modern industrial facilities can spend more time producing and less time fixing, saving valuable time and resources, by allowing for predictive maintenance, rather than reactive maintenance.
SummaRy: DEWESoft provides a large array of solutions for condition monitoring. From monitoring strain on a component of a bridge to measuring the temperature of a bearing within a motor, DEWESoft has hardware to collect the data and software to measure and analyze it.
Using DEWESoft’s Historian, it is possible to set up long term monitoring on an assembly line, HVAC systems, buildings, and other structures within an industrial facility. Historian can be viewed remotely through a web-client and provides a long-term database to monitor incoming data and provide notifications via email or SMS when something is failing. Historian can even be integrated into your existing SCADA, CMMS, and ERP systems via MQTT or directly via InfluxDB’s API.
DEWESoft’s software provides a highly flexible solution for recording and analyzing data, allowing localized monitoring of machinery. The software provides options for everything from simple FFTs to rotor balancing to modal analysis to allow maintenance teams and manufacturing engineers to get the clearest picture possible of their systems’ health. The software can be integrated into your existing databases or even communicate directly with PLCs on the manufacturing floor via a wide array of communication plugins including OPC UA, Modbus TCP, and Serial Com.
CaSe Study
Petrochemicals Plant Achieve Sustainability Goals and Lower Total Cost of Ownership with Flow Loop Optimization.
Challenge: Flowserve helped a petrochemicals plant operator optimize energy usage of a cooling water system with five parallel VS3 pumps (rated 600 kW each) connected to a cooling tower in an open system. They needed to minimize energy consumption across all operating scenarios.
Solution: Flowserve’s Energy Advantage Program determined the most cost-effective, impactful upgrade was to retrofit the CW pumps with a custom hydraulic end. The improvements were validated through CFD analysis and factory tests prior to final on-site validation of the savings.
ReSult: They reduced combined power consumption by approximately 3810 MWh per annum. The estimated annual savings from reduced energy consumption was $230,000 with approximate CO2 savings of 2285 metric ton per annum. They also increased redundancy (5oo5 to 4oo5 operation) and reliability through higher NPSH3% margin.
SummaRy: To help businesses rise to the challenges of decarbonization and energy reduction targets, Flowserve has developed the Energy Advantage Program (EAP). The program incorporates proven engineering expertise, an innovative data-driven optimization of flow loop operations and defines a mutuallyagreed-upon set of commitments to reduce efficiency costs and/or achieve carbon and efficiency goals.
Within the EAP, Flowserve performs engineering analysis, project management, and execution of aftermarket upgrades, tailored to the industry, application, and other site variables. The plant operator’s commitment is the collaboration on data, process information, and implementation. In addition to the petrochemical industry, Flowserve’s EAP is already companies realize measurable results in a wide variety of industries and applications — coal-fired power plants, pipeline, steelworks, and nuclear, just to name a few.
Scan the QR Code to get in touch with Flowserve’s EAP engineering team to find out how we can help you achieve sustainability goals and lower TCO with an enhanced holistic flow control approach.
CaSe Study
Steel and mining company relies on ABB monitoring technology to cut downtime
Challenge: The mill experienced unexpected breakdowns which lead to loss of production and money.
Solution: Our team installed ABB AbilityTM Condition Monitoring for powertrains on all the main mill drives. This solution assesses the health and condition of the drive to prevent potential downtime and minimize the risk of unexpected failure.
ReSult: The monitoring system collects information from the drive and uploads it into the ABB cloud, where it is processed to calculate specific key performance indicators (KPIs). The main KPIs measured include availability, reliability, stress from environment and operations, and environmental conditions.
SummaRy: ABB’s condition monitoring technology helped a Canadian steel company improve uptime and reduce unexpected shutdowns by monitoring key performance indicators (KPIs) like availability, reliability, and environmental stresses. Installed on main mill drives, ABB’s solution enabled predictive maintenance, identifying potential issues before breakdowns occurred.
After testing on one drive lineup, the company expanded the system plant-wide, recognizing its benefits in sustainability and efficiency. This digitalization approach aligns with ABB’s commitment to enabling low-carbon operations and sustainable productivity in industrial sectors.
For more details, view the full article here
https://global.abb/group/en
CaSe Study
Kaishan Compressors Cut $15,000-a-Day Downtime, Tame Rugged Texas Environment
Challenge: Extreme dust and exceptionally high environmental temperatures presented major challenges to a company’s existing rotary screw air compressors. And due to their age, it was nearly impossible to find replacement parts in a timely manner.
Solution: Kaishan USA installed two KRSP-200 premium single-stage rotary screw air compressors, working in tandem, to replace the aging units.
ReSult: Quiet, efficient compressor operation with little to no downtime.
SummaRy: The environment at Strategic Materials in Midlothian, TX, would be challenging for any rotary screw air compressor. The glass recycling and reclamation business generated a lot of dust, and temperatures were hot. Texas-hot.
Two aging compressors were on their last legs. Downtime was constant. Service was a nightmare, according to Jason Plummer, Strategic Materials’ plant manager, and getting parts was even worse.
“If we don’t have a compressor, we don’t run,” Jason said, adding that downtime was running $15,000 a day.
When one of their units finally quit, their local distributor recommended two Kaishan KRSP-200 premium single-stage rotary screw air compressors that work in tandem. The decision was easy: the price was better than other major brands, and the deal included an unmatched lifetime warranty on the airend. Plus, it was quiet.
A corporate environmental health and safety inspector measured the noise level at about 70 decibels, about the level of a vacuum cleaner. “The other compressors we had, it sounded like you were standing next to a diesel truck,” Plummer stated.
Most importantly, the compressors are performing beyond expectations. “As long as we keep them cleaned out and keep the filters changed and everything, they’re running great,” Jason said.
CliCK or scan QR to watch the case study video.
CliCK or scan QR to read the full case study.
Phone: 251-257-0586 • www.kaishanusa.com
CMMS Mobile and Checklists Organizes Work Orders for Ethanol Facility
Challenge: Preventative maintenance (PM) work orders were being printed every Friday at the West Burlington, Iowa, Big River Resources LLC corn-based ethanol facility. Each work order included a checkbox for technicians to mark when the job was completed. This excessive amount of paperwork needed to be filed for later documentation.
Solution: Add MAPCON Checklists to all PM work orders.
ReSult: Using MAPCON Mobile, the company streamlined both the PM work order processing and the annual audits.
SummaRy: MAPCON had a better way — Mapcon Checklists Mobile CMMS Software.
The customer implemented the checklist feature to each of their preventative maintenance work orders. These checklists could be as simple as complete, day of the week completed, or could even document certain important readings from the plant machinery.
This multi-functional tool alleviated the need to store file cabinets full of paper — saving time, manpower, and ultimately making the work in the field easier.
PM at your fingertips
The technicians have every PM at their fingertips thanks to the MAPCON mobile app. They perform their work and check off each necessary component of the work order PM as it is done.
Airport Prevents Safety Incidents and Downtime with Smart Pump Monitoring
challenge: An airport’s jet fuel transfer operation team faced safety risks, related to disintegrating pump coupling shims during intermittent operation; this was complicating maintenance coordination and stressing the coupling with multiple start/stop cycles.
solution: RedRaven’s permanent monitoring system enabled continuous expert monitoring. A sudden vibration increase prompted immediate action, preventing a potential safety incident.
Result: Timely alerts helped the operator avert a catastrophe, increasing plant safety and eliminating costly, unplanned downtime.
summaRy: An airport’s jet fuel transfer operation team faced safety risks, relating to disintegrating pump coupling shims during intermittent operation. This was complicating maintenance coordination and stressing the coupling with multiple start/stop cycles. They decided to deploy RedRaven, Flowserve’s predictive maintenance service. Soon after deployment, RedRaven and Flowserve’s monitoring specialists detected a sudden pump vibration spike and alerted the operator of potential danger. They were immediately able to plan and proactively address the potential coupling failure and prevented what could have been a catastrophic safety incident in the jet fuel transfer area.
The timely intervention not only safeguarded the plant and its personnel but also averted substantial financial losses by eliminating unplanned downtime. The implementation of RedRaven’s monitoring system proved its value by providing real-time insights, enabling proactive responses, and ensuring seamless operations; this underscores the critical importance of advanced monitoring technology in industrial settings, where a single moment of oversight can lead to dire consequences. Constant monitoring by systems and personnel continues to enable the operator to mitigate risks and optimize operational efficiency — reinforcing the value of investing in cutting-edge solutions for industrial safety and productivity.
to learn more about RedRaven
CaSe Study
Properly Sizing Industrial Compressed Air Systems— For Today and the Future
Challenge: A food and beverage manufacturer had a 100 hp oil free rotary screw air compressor that was frequently used below optimal operating thresholds, resulting in breakdowns and halted production.
Solution: Following an air audit, a new 45 hp scroll compressor was added as the new primary air source for typical usage, while the 100 hp remained available for infrequent peak usage.
ReSult: The customer saw a reduction in their electricity bill and breakdown occurrences while seeing an increase in the system’s efficiency.
SummaRy: One of the most challenging parts of installing a compressed air system can be correctly sizing it for both today and years now—while maintaining optimal efficiency. There isn’t a one-size-fits-all solution, choosing the wrong air compressor(s) can significantly increase costs due to wasted energy or even production problems.
A California-based food and beverage manufacturer was experiencing recurrent breakdowns with their 100 hp oil free rotary screw air compressor that delayed production.
Beyond a physical inspection, an air audit was conducted to fully understand production demand.
Results showed operations typically peaked at only 40% of current capacity, with 80% capacity only being reached twice a month. Their current 100 hp compressor was most often running well below threshold, resulting in increased condensation and suboptimal compressor operations.
Our system analysis determined that while a 25 hp compressor was all that was needed for typical peak demand, a 45 hp scroll compressor was installed for future growth.
Utilizing the new, smaller compressor for regular production results in a significantly more efficient system—saving the company energy costs, as well as reduced downtime. And the 100 hp compressor can be used as necessary when air usage peaks.
CliCk or scan QR to learn more.
CaSe Study
How Collaborative Palletizing Transformed a Meat Processing Line
Challenge: A meat plant’s end-of-line palletizing was a persistent bottleneck. Manual work was labor-intensive and error-prone, limiting output. To achieve growth goals, they needed a faster, more reliable solution.
Solution: The collaborative palletizing demo showcased its flexibility and efficiency, convincing the plant to invest in a tailored solution. The Motion Automation Intelligence team analyzed the production line, box sizes (9–30 pounds) and existing PLC system.
ReSult: The collaborative palletizing system led to record-breaking production outputs, exceeding their initial goals. It also improved labor allocation, freeing up two to three employees for more engaging and value-added roles in the plant.
SummaRy: When a major meat manufacturing company sought to supercharge their end-of-line production, they turned to Motion Automation Intelligence for a collaborative palletizing solution. The current production line was too slow and labor-intensive.
Impressed by Motion Automation
Intelligence’s collaborative palletizing technology, the company requested a demo, which proved to be a game-changer. It showcased the flexibility and efficiency of collaborative robots, convincing the plant to move forward with a customized solution. The turnkey collaborative palletizing system was designed for seamless integration:
• PLC integration: The system interfaced directly with their existing PLC, enabling real-time monitoring of cycle rates, cartons produced, and overall system performance.
• User-friendly interface: The intuitive interface made it easy for operators to manage and monitor the palletizing process.
The results? Record-breaking output and a happier, more engaged workforce. The project’s success solidified Motion Automation Intelligence’s reputation as a trusted partner, leading to further collaborations. This case study demonstrates how collaborative palletizing can revolutionize meat processing—boosting efficiency, freeing up valuable human capital,
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