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Innovative Tools for the Evolving Systems Integrator

The personnel challenges facing virtually every industry over the last few years have been nothing short of astonishing. Proper candidates have become increasingly difficult to court and bring on board. New staff in key roles are tasked to accomplish more with fewer floor operators and technology is increasingly leveraged to close the resulting gaps. This is not unique in history although it may seem that way due to the current media deluge surrounding business intelligence and general-purpose visibility software that makes life easier, smarter, and generally more efficient.

Industrial software is again playing a leading role in the current intelligence revolution. Inductive Automation didn’t invent floor supervisory (SCADA) software, nor did they invent the first responsive, general-purpose web software. However, their current offerings certainly do marry these concepts together in a way that hasn’t existed in industry before. Since 2010 their award-winning Vision Module has enhanced the experiences of factory floor users everywhere, easily connecting complex factory controllers to databases, alarm and reporting systems, and intuitive visualization tools. This product is robust, proven, and works very well for users “inside the industrial network” of many facilities. Today this is coupled with the newer Perspective Module which is an equally powerful tool for use in mobile-responsive applications. For situations where a user may be “outside the industrial network” or simply need to utilize a variety of hardware platforms like PCs, phones, or tablets, Perspective provides an ideal solution.

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Ignition Perspective® Module

Human-machine interface (HMI) vendors have been promising a utopia based around web-based technologies for over two decades. The prospect of simply providing a web address to anyone within an organization that leads to a fast-loading, full-power supervisory control and data acquisition (SCADA) system has been on most factories’ wish list for a long time. After all, internet page tools and functionality have far outpaced advancements in SCADA software over the same time. The advancements seem to leap forward every time someone reloads a page, with new widgets and tools available almost daily. When coupled with hardware developments like high contrast screens; enhanced touchscreen operations; and capabilities like Bluetooth, accelerometers, geolocation, and more; a flexible, web-based option has been coveted.

What many casual users fail to understand about HMI solutions is exactly how tightly the software is connected to the factory floor controllers. This connection via high-security networks, VPNs, and masks, can be tricky to navigate, particularly when the architecture is intentionally complex to provide security for the systems. Further, most people don’t realize the architectural complexity of software that link to sometimes multiple databases and remote data sources, where gigabits of proprietary information streams into and out of the SCADA application. It has been the responsibility of the integrators of these solutions to protect would-be users from themselves in a lot of applications. Poorly developed programs could create vulnerabilities to the operation of equipment, expose floor workers to potential risk, and possibly allow trade secrets to escape into cyberspace.

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How to Identify, Quantify, and Mitigate Risk in Industrial Operations

A key responsibility of executives and managers in manufacturing is that of risk management. This refers to the obvious risk of physical operations and staff protection, but it also includes quite a bit more: risk to contracts, availability of brands of the direct employer and those of other clients, reputation(s), regulatory, and risk to public safety and health are all increasing concerns with the operating level of a senior executive or manager.

Risk identification is a critical first step; without which, corrective actions cannot be undertaken or could possibly be misguided. Because risks evolve constantly, it is rare that they can be spelled out in a succinct and comprehensive volume. One obvious solution is to install the correct staff in the tiers immediately below the executives but that often raises questions about the specific qualifications of these employees, their tenure and familiarity with every facet of their role within that organization, and whether an overarching net has been cast to identify and compartmentalize relative risks. Further concerns arise around whether an internal team is free of groupthink and whether they possess the proper experience, qualifications, and motivations. (more…)

The Process Functional Ecosystem

Companies that operate in multi-step, multi-ingredient batch processing operations employ a combination of complex procedures, business and operational systems, and communications. The range of tools and machinery used to process a potentially vast array of ingredients and process steps are what it takes to make processors successful. Entire working cultures emerge from these operations that foster a focus and achieve positive outcomes.

The more specialized the market and operation, the lower number of people who operate within that domain. This doesn’t always allow for regular interaction with a broad spectrum of manufacturing peers, which can leave individuals and organizations feeling they are so unique that they are relatively isolated. They frequently feel little confidence that people outside their close-knit internal group can effectively understand, let alone support them. The possibility exists that they are rare, but they are not entirely unique and there are outside firms that are also closely aligned and, in fact, true peers as well.

ECS Solutions (ECS) operates upon this landscape. They have established a collective corporate consciousness that is aligned with the DNA of their core clients: batch processors. ECS is immersed in the behaviors and characteristics of these clients, and it is reflected in nearly every aspect of their operation. (more…)

Dynamic Perspective Objects with Sepasoft’s Batch Module

One of the most exciting things about Sepasoft’s Batch and Procedure module is that it enables tight integration between the process cell (as it is functionally defined) and the graphical interface (how it is presented to the user). By using the various tools in the Ignition toolbox (creative scripting, querying, and binding), it is possible to create dynamic views that represent the ISA-88 objects of a process cell. As the process cell definition changes (new units, new phases, etc) these dynamic objects automatically update as needed. This allows for less development time, a consistent user experience, and a lower maintenance control system. (more…)

Surviving the Great Resignation

A rapidly decreasing number of technical personnel are available who can install and maintain the higher-end equipment used in manufacturing today. “The great resignation and/or retirement” movement, along with changes associated with the recent pandemic landscape, has sent many highly qualified workers to the exits in search of new and often altogether different opportunities. The stage has been set for decades with the wave of baby boomer retirements churning towards manufacturers. Parallel to this has been the increased reliance on high-tech manufacturing machines and processes. These two situations pair well with the idea of future-proofing low-to-mid complexity manufacturing but, in an interesting juxtaposition, amplify the core problem. (more…)

Case Study: Methodical Approach to a Systems Upgrade

ECS Solutions, Inc. (ECS) recently helped a client with an upgrade by leveraging ECS’ methodical approach to system solutions. Their client has three very similar processing areas known as casting pits. Each was controlled by an independent GE 9030 PLC system, each with a main, and each controlled by a local BLUE Open Studio HMI from ProFace America.

The 9030 PLCs that were installed were robust and accurate for these areas when originally installed. Over a long period of time, the systems were maintained and augmented by several personnel from both inside and outside the organization. The result, as is often the case in legacy automation systems, is system drawings that are littered with hand comments and sketches on paper drawings. These systems also feature code that works…. until it doesn’t due to getting lost in a discarded section of logic that was thought to be disabled but was never removed. These situations are often referred to as “ghosts” or “gremlins” in the code and they can be difficult to troubleshoot. Frequently, the solution is to reboot entire systems to exit from the offending area.

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Read More | Posted In: Case Studies, Metals Industry, PLCs