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HIGH EFFICIENCY How smart object application programming can boost competitiveness

PRODUCTIVITY Modification of motion control products can provide safer, more efficient operations

LEAN MANUFACTURING Understanding Canadian manufacturing’s three-stage evolution plan

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In brief Movers and shakers Deal makers

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9

INDUSTRY WATCH

Understanding Canadian manufacturing’s three-stage evolution plan Football season is here! Paul Hogendoorn explores the business lessons we can learn from the sports world

10 MACHINE SAFETY

Four best practices for reducing hand injuries

26 BACKSTORY

A look back at the growth of robotics

14

KeePInG UP-TO-dATe

CSA Z432 Safeguarding of Machinery - What’s new in 2016? By Douglas Nix

eFFICIenCY 12 HIGH How smart object application programming can boost competitiveness By Gurvie Waraich

NEW PRODUCTS 21 22 23 23 24 24 25

HYDRAULICS & PNEUMATICS HMI & OPERATOR INTERFACE SENSORS DATA ACQUISITION MACHINE VISION & INSPECTION TEST & MEASUREMENT MOTION CONTROL

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UP YOUR PROdUCTIVITY 18 PUMP Modification of motion control products can provide safer, more efficient operations By Shannon Winkler

20 CYBeRSeCURITY Six must-do action items to minimize your risk of cyber attacks By Alyssa Dalton

www.AutomationMag.com •2015-04-28 October 2015 3 10:04 AM

F R O M

T H E

E D I T O R www.automationmag.com • Vol. 30, No.6 Canada’s leading publication providing industrial automation news and technology information aimed at the discrete and process industries.

“C” for Canada... and its innovation

I

t’s only been a few weeks since classes have started but according to The Conference Board of Canada, our country hasn’t been performing too hot on a recent report card. Last month, Canada received a “C” rating on the board’s How Canada Performs: Innovation report card, ranking 9th among 16 international peer countries. Not terrible, but certainly not the kind of grade that would be proudly displayed on the fridge. But don’t be discouraged yet — the score is an improvement from our “D” grade and 13th-place ranking from the previous report card. Ten indicators were used to evaluate the innovation performance of all 16 countries this time around, including capacity (public R&D), activity (business R&D and investments in venture capital) and results (evidence in terms of patents and labour productivity). The board found that Canada is a middle-of-the-pack performer, receiving one “A”, three “B”s, three “C”s, and three “D”s. Daniel Muzyka, board president and CEO, says the improved grade is largely due to an increase of venture capital investment and a strong showing on entrepreneurial ambition. “While Canada’s overall ranking is slightly better, it masks downward trends in some key innovation drivers and highlights the need for the private and public sectors to improve their innovation game in a much more competitive environment,” he said. (In case you were wondering, the top three countries are Sweden, Denmark and Finland. Here at home, Ontario, Quebec, and British Columbia are the top-rated provinces, while Prince Edward Island and New Brunswick are the lowest-ranked.) The report suggests several methods Canada can pursue to help boost its innovation performance: increase innovation-related spending, implement and use technology, create a healthy business climate, and enhance management skills and expertise. Now, I’m going to throw it back to you — knowing this, do you have what it takes to innovate? •

EDITOR Alyssa Dalton adalton@annexweb.com

ACCOuNT CO-ORDINATOR Kathryn Nyenhuis knyenhuis@annexweb.com

VICE PRESIDENT AND EXECuTIVE PuBLIShER Tim Dimopoulos tdimopoulos@annexbizmedia.com

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ART DIRECTOR Svetlana Avrutin savrutin@annexweb.com CONTRIBuTINg wRITERS Simon Drexler, Paul hogendoorn, Douglas Nix, Nigel Southway, Joe Tavenner, gurvie waraich, Shannon winkler EDITORIAL ADVISORy BOARD Piero Cherubini, Dean, Faculty of Skilled Trades and Apprenticeship, Mohawk College of Applied Arts and Technology Al Diggins, President and General Manager, Excellence in Manufacturing Consortium, and Chairman and CEO, Canadian Manufacturing Network David green, Technology and Business-to-Business Consultant Sherman Lang, Industrial Technology Advisor, Industrial Research Assistance Program, National Research Council of Canada Don McCrudden, Vice-President, Business Development, Festo David McPhail, President and CEO, Memex Automation Nigel Southway, Business Productivity Consultant and Author on Lean Thinking Bill Valedis, Vice-President, Precision Training, Products and Services Inc. Manufacturing AUTOMATION is published seven times a year by Annex Publishing & Printing Inc. 222 Edward Street, Aurora, Ontario L4G 1W6 Tel: (905) 727–0077 • Fax: (905) 727–0017 • PM # 40065710 The contents of Manufacturing Automation are copyright ©2015 by Annex Publishing & Printing Inc. and may not be reproduced in whole or part without written consent. Annex Publishing & Printing Inc. disclaims any warranty as to the accuracy, completeness or currency of the contents of this publication and disclaims all liability in respect of the results of any action taken or not taken in reliance upon information in this publication. Subscription rates: Canada — $40 per year. United States and Foreign — $60(US) per year. Student subscription rate $20 per year. ISSN-1480-2996

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A U T O M A T I O N

U P F R O N T

Eaton’s Power of Authenticity campaign combats counterfeiting

In brief • The inauguration of Shimco’s new headquarters was held at its future 25,000 sq. ft. facility site in Cambridge, Ont., in August, as the manufacturer works to complete its full relocation for this December. • General Mills is selling its Green Giant and Le Sueur vegetable businesses to B&G Foods for about $765 million in cash, noting a decline in frozen foods sales. • Senix, manufacturer of ToughSonic ultrasonic level and distance sensors, has launched a new website in celebration of its 25th anniversary.

With files from The Associated Press and The Canadian Press

Power management company Eaton is aiming to help authorized distributors and contractors source and supply reliable products quickly and efficiently through its new Power of Authenticity campaign. “By offering competitive prices, stocking programs, authorized service centres and loyalty programs, end users are assured that the products they receive are authentic Eaton products,” said company representatives. Eaton says Power of Authenticity is a response to the industry-wide proliferation of counterfeit products of all well-known brands and labels that are putting customers at risk – end users typically need products fast, which can make it tempting to purchase from a third party. In particular, counterfeit electrical products can pose tremendous safety hazards, including malfunctions that can cause overheating or short circuits, leading to fires, shocks or explosions, it notes. “Eaton’s electrical business has adopted a zero tolerance policy for counterfeiting and is committed to stopping the counterfeiting of electrical products worldwide. Through the Power of Authenticity campaign, we aim to help distributors, end users and contractors avoid contact with unsafe carbon copies by offering authorized service and quick and efficient sourcing,” said Rob Griffin, product line manager, molded case circuit breakers, Eaton Electrical Sector Americas. “With these offerings, Eaton helps distributors and contractors alike receive authentic Eaton products by eliminating the downtime, safety, liability and performance issues that may occur when using counterfeit products.” As part of the campaign, Eaton offers stocking and loyalty programs, including the Distributor Advantage Program, which helps authorized distributors use Eaton’s marketleading brands, product innovation and strong sales support organization to grow their business. Other services include Eaton’s replacement breaker module (RBM), a 24-hour delivery guarantee with rebates and technical support for authorized distributors, and breaker service centres. Beckhoff_MA_Nov.indd 1

www.AutomationMag.com • 2014-10-27 October 2015 5 9:24 AM

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Movers & Shakers

ITAMCO reaches 60 years of service

Congratulations to Indiana Technology and Manufacturing Companies (ITAMCO), who celebrated its 60th anniversary in August! Founded in 1955, the Northern Indiana-based manufacturer has grown from a single 4000 sq. ft. plant to two facilities that encompass a total of 485,000 sq. ft. ITAMCO delivers precision-machined components to OEMs worldwide in mining, off-highway vehicles, marine, and aviation. The company specializes in precision gear manufacturing and their capabilities range from mining gearing to production runs of CBN-ground transmission gears. “I believe the success of ITAMCO is due to uncommon perseverance and a true spirit of innovation. Embracing technology while holding to solid and proven principles has given us an atmosphere that is creative, yet built upon a foundation that can be relied upon,” said Gary Neidig, company president. In 2011, the company installed what it says is one of the largest gear grinders on the market in its climate-controlled grinding facility. The Niles ZP 40 gear grinder has taken hours out of the grinding process, reducing production costs for its customers, it notes. While acknowledging the company will always offer subtractive manufacturing like gear grinding, ITAMCO believes that additive manufacturing is the future of its business.

To that end, they have developed an additive manufacturing strategy titled, Strategic Technology Initiative for Additive Manufacturing. Its drive to bring additive manufacturing to its plant floor was enhanced when the company won a funding award from the National Additive Manufacturing Innovation Institute this past July. ITAMCO’s IT development team will be working with Johnson & Johnson, the University of Pittsburgh and the University of Notre Dame to develop an additive manufacturing CAD application. ITAMCO is a privately held company that prides itself on maintaining the principles of its founders, Donald and Noble Neidig. “My uncle and father believed in a cause larger than themselves, and were willing to make sacrifices in order to build for the future of others,” said Gary. In 2013, ITAMCO partnered with the Plymouth, Indiana School Corporation and Ivy Tech Community College to launch the ITAMCO Manufacturing Center on the Plymouth High School’s campus. Students enrolled in the precision tool manufacturing course at the centre will receive credits toward high school graduation and college credits from Ivy Tech. ITAMCO donated $100,000 worth of equipment in addition to technical assistance for the program and recently donated an additional CNC precision machine tool to the large inventory of precision machining tools.

Calling all students! Stratasys 2016 Extreme Redesign contest now open

Stratasys, a global provider of 3D printing and additive manufacturing solutions, is now accepting entries for the 12th annual Extreme Redesign 3D Printing Challenge. Open to students worldwide, this annual 3D printing challenge invites students in engineering, design and art or architecture to design a new product that improves how a task is accomplished or to redesign an existing product. Entries should be mechanically sound, realistic and achievable, and are judged based on: • Sound mechanical design • Compelling description (written and/or video) • Design creativity • Product usefulness • Aesthetics (art and architecture category) Individual students or two-person teams are required to create designs using 3D CAD software and to submit their files in .STL format to 6

Stratasys online, along with a written description and/or a 30-second video explaining the value and benefit of the Extreme Redesign model. The deadline to submit entries is Feb. 4, 2016. Categories include: • Engineering: Secondary Education (middle and high school) • Engineering: Post-Secondary (university, college or post-secondary) • Art or architecture (any grade level) First-place winners in every main category will receive US$2,500 scholarships, and the instructor of the first-place students will receive

October 2015 • Manufacturing AUTOMATION

a demo 3D printer for a limited time to use in the classroom. Second place winners will receive US$1,000 scholarships. The top 10 entries in each category will receive a Stratasys apparel item (value up to $50) and regional semi-finalists will receive a 3D printed model of their design. Each person who enters will receive an official Extreme Redesign T-shirt. New this year, Extreme Redesign is adding the bonus category, “Make a Difference,” which allows students to create or redesign a product that impacts individuals, communities or the environment in a positive way. The winner of this category will receive a US$1,500 scholarship. In addition, the National Coalition of Advanced Technology Centers (NCATC) is awarding a US$1,000 scholarship to an entry of their choice from a NCATC member school in the postsecondary engineering category. Follow the Extreme Redesign 3D Printing Challenge on Facebook and be part of the conversation on Twitter using #ExtremeRedesign.

ABB has named Nathalie Pilon as the new managing director for ABB in Canada, replacing Daniel Assandri. Nathalie Pilon Previous to this role, Pilon was president of Thomas & Betts in Canada. A Quebec native, she brings twenty years of experience in the manufacture, development and marketing of electrical products in Canada. In 2011, Pilon was named one of Canada’s Top 100 Most Powerful Women by the Women’s Executive Network, and in 2015, she received the Leadership Award from the Association of Quebec Women in Finance. Bill Hewitson has been promoted to president of Ruland Manufacturing after serving as vice-president of operations for eight years. He is the third president in the company’s history and succeeds Bob Ruland who will continue to oversee the company as chairman. Hewitson began his career with Ruland in 1995 as a mechanical engineer and has been a “key contributor” behind the growth of the shaft collar and rigid coupling product lines, noted the company. After eight years with Equipment Supply Company (ESCO), the company is promoting Steve Dyer to the position of president. In this role, Dyer will have the responsibility of working with and building relationships with ESCO’s customer base worldwide, while working with sales and customer service staff to manage day-to-day sales activities. Dyer most recently served as the ESCO northeastern sales director. Under his leadership, the northeastern territory has grown over 150 per cent in the past four years, says company representatives. Eisele Connectors — a subsidiary of Eisele Pneumatics GmbH & Co. KG — is expanding into the North American Michael Jones market, naming its first sales director for the region. Taking the helm is Michael Jones, who will lead the sales office and warehouse located in Grand Rapids, Mich. With more than 25 years of experience in the global automotive and industrial manufacturing industries, Jones brings “in-depth knowledge of engineering, product development and sales and marketing to support customers,”according to the company.

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DeaL Makers Transparent, Printex form new packaging company

• • • •

plastic folding cartons, hybrid paper/plastic cartons, rigid clear/printed window affixing, and point of purchase displays. Boasting more than 60-plus years of combined experience, the company operates production facilities in Montreal, Que., and New york, N.y.

Dave Dennison of Transparent Packaging and Dave Heller of Printex Packaging have announced the merger of their respective companies. The new company — Printex Transparent Packaging — claims to be the largest plastic box manufacturer in North America, delivering plastic folding cartons from its three design centres and two manufacturing plants within Canada and the U.S. According to the parties, this merger “works to keep valuable packaging jobs in Canada and the U.S. while offering producers of consumer products consistent quality and faster turnaround times,” adding that the new company is now “uniquely positioned” to supply the industry and bring value packaging on-shore. Selling to the trade as a subcontractor and direct to consumer brand owners, Printex Transparent Packaging offers solutions that can be hand-packed or filled on automated packaging lines. It also works with equipment manufacturers to help automate its client’s plastic folding carton assembly process. Its areas of specialization include:

ISVI signs distribution deal with 1stVision ISVI, a designer and manufacturer of high-resolution camera technology, has announced the signing of a distribution agreement with 1stVision to address the North American automated imaging market with sales and support of its cameras. “North America is a rapidly growing market for ISVI and we felt the need to create more reach in order to address the expanding application areas for our highspeed, high-resolution cameras,” said Gerard White, vice president of ISVI. “We are proud to announce our partnership with 1stVision. With its expert team of automated imaging sales and support engineers, as well as its multiple locations in the USA and Canada, 1stVision is very well positioned and respected in our industry. They bring with them a very high level of professionalism and dedication to serving customers which are totally in line with our own business philosophies.” “ISVI brings to us a product line that will satisfy our clients who are pressing the limits of COTS cameras for high speed, high resolution applications,” added Scott Israel, president of 1stVision. “Because these cameras use standard AI interfaces such as CoaXPress and Camera Link, we can offer an easy to use solution.” ISVI cameras are used in various application areas

including robotics, AOI, 2D/3D metrology, SPI, wire bond inspection, wafer inspection, bio-mechanics, defence, aerospace, and general machine vision. 1stVision has been in business for the past 17 years. With three locations throughout Canada and the U.S., the company sells machine vision products for factory automation, medical imaging and other industrial imaging, machine vision applications. Omron acquires motion control firm Omron Corp. has announced that it will acquire a 100 per cent stake in Delta Tau Data Systems, making it a member of the Omron Group. The acquisition is expected to close early next month. According to Omron, the move is part of the company’s strategy to promote its development of factory automation technology and strengthen its sales capability in the control device business. “Merging products and technologies of both companies will also enable delivery of optimized motion control solutions globally through combined distribution networks,” said Omron representatives. With headquarters in Chatsworth, Calif., DT is a control device company. The manufacturer is said to have powerful development and systems integration capabilities that enabled the company to “develop, manufacture, and market what is widelyechnical recognized as the world’s highest level motion controller,” dubbed earning Visit omega.ca/ PMAC. technical-learning Through the acquisition, Omron aims to reinforce its technology development and engineering capabilities in the field of motion control designed to drive manufacturing equipment. • echnical

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L ean

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Our three-stage evolution plan for manufacturing By Nigel Southway

T

he Canadian economy is in reset mode with the worldwide price drop in oil and declining international demand devastating the export-orientated resource sectors. This has forced a related correction in the previously resource escalated Canadian dollar back to, and maybe even below, reasonable price parity. We are also experiencing instability in our saturated service and retail sectors. This duress has promoted political attention back to the longterm hollowed out manufacturing sectors as a possible area of growth and support for a now fragile Canadian economy. Many of us involved in manufacturing need to take stock of this slightly more favourable outlook and define how our local manufacturing sectors can respond to these new economic opportunities by following this focused three-stage evolution plan: reshoring; Lean automation; and computerintegrated business.

Reshoring and balanced sourcing

It’s happening, in many sectors of business, long supply chains needing much inventory and babysitting of so-called low-cost country labour jurisdictions are out, and much shorter and more sustainable supply chains that put manufacturing and other value-adding processes much closer to the customer (plus helping the planet with more sustainable business practices) are in! The real message of this trend toward de-globalized manufacturing and the recent Canadian dollar downward reset is that the economic landscape is creating a strong need for each Canadian business to “re-run the numbers” to redefine their supply chains and maybe consider a move toward more regionalized manufacturing in the best cost competitive locations within their customers trade zone or bloc. This will provide shortened and agile supply chains closer to the customer with inventory and demand flexibility advantages, as well as the ability to innovate at home much more effectively. It will also require the redevelopment of a local supply base with strong business-to-business relationship building, as well as a sector organized industrial learning system to develop and update the skills and knowledge for a future workforce to support this future manufacturing capability.

Lean automation thinking

However, this reshoring/balanced sourcing approach doesn’t mean that productivity and waste in any form can be tolerated. As transportation and supply chain management costs diminish, local direct labour and business-wide support costs will play a bigger part in the total cost equation

and demand a new approach called “Lean automation.” This will be the differentiator for our future business success. Lean thinking must be applied to all parts of the business operation to identify and eliminate the waste in the non-value-adding parts of the overall business process to reach a simplified and Lean version of the new business process. This includes a rethink of the business processes, facilities, systems and operating practices that can be improved and better integrated. Advanced automation technology and emerging manufacturing sciences must be implemented in lock-step with this Lean journey using innovation strategies for both current and future product designs to better leverage the application of these opportunities. An organization with a slick new product introduction process with effective Six Sigma tools using close-coupled product and process design teams will excel at this type of innovation and commercialization of the next generation of products far better than organizations that do not have such cross-functional teams and toolkits.

Pull it all together with a computer-integrated business

Advanced computerized tools must integrate all Lean and automated business processes to evolve to a computer-integrated business state that will become the ultimate value proposition to both customers and stakeholders. This computerized-integrated business system must integrate all facets of a business from sophisticated customer relationship management tools to seamless product development environments to factory management planning and control systems that will enable rapid deployment and utilization of supplier, factory and distribution resources to provide and satisfy customers. The next generation of business leaders, engineers, investors and the many support agencies and groups must grasp this challenge as together they must learn how to reinvigorate and in many cases reinstall, transform and re-capitalize local manufacturing capability so that it is highly competitive. It will demand a shared future vision about taking local manufacturing to the limit to achieve a Lean and green, customer-focused manufacturing capability that is more sustainable in a world under pressure from environmental changes. Those who can execute such an evolution plan will be the super heroes of the business world in the quest to take manufacturing back to Canada. • Nigel Southway is a productivity consultant, author and past chair of the SME and the principal advocate of the Take Back Manufacturing (TBM) initiative. Visit www.sme-tbm.org to learn more about TBM.

SIRIUS ACT Pilot Devices New portfolio of 22mm push buttons and signaling devices Siemens Canada presents a new portfolio of elegantly designed push buttons, indicator lights and switches that are the embodiment of style, intelligence, and ruggedness.

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Make your picks! BY PAUL HOGENDOORN

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he NFL season is just underway, and I for one am glad Brady’s suspension was overturned. I won’t take sides on the debate — was the punishment too harsh, or the processes too flawed, or was he even guilty of an offense to begin with — but, as a sports fan, and as one of the growing throng of “poolies,” I’m glad he’s in the equation. Being a sports fan, October is always one of my favourite times of the year. The NFL season is only a month old, the NHL and NBA seasons are still clean white slates filled with possibilities and potential for every team (even the Leafs), and baseball games have suddenly become meaningful, even to the casual fan. Sports is competition, and because of the explosion of sports pools, our experience simply as spectators is greatly enhanced; we benefit personally from the experience that competition brings. As I’m going through my picks this morning, I am predicting who I expect to see in the Superbowl (New England and Seattle), who will make it close (Green Bay and Denver), and who the dark horses are (I’ll keep that a secret). Detroit, Dallas, Buffalo and Pittsburgh are emotional favourites for me; I often win or lose a week’s pool when emotion overrules reason. The season’s start is an exciting time — it’s a clean white sheet for everyone: players, teams and poolies alike. In some ways, our manufacturing businesses follow a similar pattern. We have our off-season — a time when things slow down. It’s hard to get our heads in the game, and we are often not operating with a complete team. We look forward, with anticipation and some anxiety, to the beginning of the next business season. New models, new equipment, new planning and new processes, often done in the off-season, are rolled out and launched. All the planning, changes and new things get put to the test when the new season begins. A quarter of the way through the new season, we will know who stumbled out of the gate and who is a pleasant surprise. The teams themselves will have to make adjustments, re-evaluate strategies, personnel and predictions, and so will the poolies. From previous years, I know the choices are staying the course for a while longer, making a few minor strategy adjustments, or making major wholesale changes. Again, not unlike business. Sports pools are fun. Many people I know who are not even fans enough to watch any of the games still participate and get caught up in the pools. Why is that, I wonder? I think it’s human nature. We like to compete, to be put to the test, and to test ourselves. It’s always been that way, but with our statistics and information-saturated world (thanks to the Internet and social media), many more of us are drawn in. I’m not sure if I’d suggest that our very nature has been altered by IT and social media, but I’d certainly suggest some parts of it have been heightened and enhanced. We don’t just want to know things instantly, we want to be able to act on them and test the effects of those decisions and actions immediately. All of this brings me back to a recurring conversation — why haven’t we changed the culture and conditions of our manufacturing workplaces to reflect this new reality? Don’t the same people that now participate in sports pools also work in our factories? I never personally liked the term “gamification” or the objective of “gamifying the workplace,” but people obviously find meaning in sports and they are no longer content to be simply spectators, they have become active participants. Isn’t there a significant competitive advantage to our companies if we could do the same thing in the workplace? The process of change begins by understanding why sports pools are so engaging. Timely information is abundantly available to everyone and each individual is able to act on that information and measure the effect of that action. That’s the day-to-day and week-to-week learning. What we can learn about sports seasons is that every now and then, we have to slow down, plan for the coming new season, and give everyone a clean white slate to start from. All my picks are in and it’s a couple hours before kickoff. A new season has started. Go Patriots! • Paul Hogendoorn (paulh@getfreepoint.com) is co-founder of FreePoint Technologies, “Measure. Analyze. Share.” (Don’t forget to share!) www.AutomationMag.com • October 2015 9 Hiwin_MA_Jan.indd 1

2014-12-17 3:17 PM

M A C H I N E

S A F E T y

Best practices for reducing hand injuries By JOE TAVENNER

I

t’s a common joke that duct tape can fix anything. We often believe our hands can do the same. When we don’t have a wrench, our hands fit the bill. Can’t get into a location with a standard tool? Our hands can get into the tight spot and fix the problem. When our hands become our universal duct tape, we increase the risk of injury by losing focus. To reduce the risk of injury, one should take the following steps: 1. Find the right gloves 2. Keep your eyes on your hands 3. Make it visible 4. Utilize end-user leading indicators

Find the right gloves

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Try, try, try Have employees try gloves being considered for an extended period of time, asking for feedback along the way. Getting feedback from users involves them in the process, thereby increasing ownership. In many cases, the difference between a successful implementation and an unsuccessful one can be the amount of ownership employees feel they have. If you involve them in the decision-making process, address concerns, and utilize their feedback, a smooth transition often follows. Say ‘thank you’ It is very easy to get caught up in day-to-day activities and forget to say thank you. When you have employees that take the time to help support the glove evaluation process, don’t forget to say thank you. Often, small rewards provided frequently, can keep them feeling valued and drive participation. Stock your gloves Many times, we put all our effort into finding the right glove and forget to make it easy for users to access them. When employees can’t find required gloves, their perception soon becomes negative, and a disconnect develops between management expectations and employee perceptions. Developing a successful glove-stocking program is critical to reducing hand injuries.

Keep your eye on the hand

Many times, hand injuries occur when we take our eyes off the task. This is as simple as putting our hands into areas we don’t have a line of sight of. To stay focused on the task, a mental checklist should be used. By taking the time to think through the task beforehand, safe alternatives can be considered. This visualization technique is both tried and true.

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October 2015 • Manufacturing AUTOMATION

Some examples: Do you have all the needed tools for the job? When you don’t have the tools you need, it is common practice to substitute your hands. Think about what you need before you start the job. If you don’t, your hand could quickly become the tool of choice. Can you see your hands during the task? When one hand is out of sight, it can quickly enter pinch points or other high-risk areas. This is especially true when using two hands to complete a task while focusing your attention on only one. Think about what could go wrong and plan for it. You may think this is simplistic but it happens all the time. Are good, safe practices being used? Following your business and regulatory requirements is a cornerstone of staying safe.

Make it visible

When driving in a car, a red light means stop and a green light means go. When you see these colors, you react appropriately to avoid accidents. You can use the same methodology to reinforce safe behaviors. When looking at the source of many lacerations, box-style knives are often brought up. In recent years, many styles have been developed that offer advanced safety features. While these are great solutions, you may want to consider adding a color trigger. Paint it red to let everyone know they are dangerous. Implement a slogan and develop a sustainable communication program to build repetition into the message. As the system matures, build on it to address new challenges. Making high-risk tasks visible can help remind employees to stay focused on the task. Consistently repeating why they have been painted and how you want at-risk employees to behave keeps the message fresh on their minds. As the program grows, it soon becomes an easy way to remind employees to stay safe.

regulatory obligations or good, standard-operating procedures. However, supplementing your existing programs with solid approaches can help reduce hand injuries. Consider further developing these concepts to fit your organization’s needs. •

Joe Tavenner CSP, CIH, CFPS (josephtavenner@yahoo.com) has over 20 years of experience, and holds a bachelor’s and master’s degree in Occupational Safety Management and an MBA in Management. He is currently the director of safety for King’s Hawaiian.

For the most up-to-date news, stories and videos, check us out at

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Utilize end-user leading indicators

When focusing on hand injuries, one of the best ways to help drive improvements is to develop leading indicators to measure them. Typically, leading indicators might involve looking at how many employees are wearing the proper hand protection or other like method. While that is valuable information, it typically yields a number that is meaningful to management but meaningless to end-user employees. Those that are at the most risk feel little-to-no ownership in the numbers being generated. Consider bridging the gap by generating end -user leading indicators. When you develop metrics that have meaning to end-users, it is very easy for them to get involved and drive safe behaviors. An example of an end-user leading indicator might be how many box-knife red lights were found during housekeeping inspections. As we reviewed above, we identified red with box knives, developed a slogan to communicate expectations and now measure it with a leading indicator called “red lights.” By using an end-user leading indicator, you close the loop in the implementation process by generating data that is easily understood and supported by all employees. None of the approaches outlined in this article are meant to replace F&B ad 6.375x9.75 MA final.indd 1 Eaton_MA_Oct.indd 1

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www.AutomationMag.com • 2015-09-15 October 2015 11 11:44 AM

S M A R T

T E C H N O L O G y

HIGH EFFICIENCY How smart object application programming can boost competitiveness By guRVIE wARAICh

I

Images courtesy Schneider Electric

ndustrial automation applications are growing in sophistication and complexity. For Canadian manufacturers, this means they need to spend more time and money on application development. For end-users, applications are often difficult to port to multiple platforms and machine operators suffer because the new applications are not easy to learn. A major issue manufacturers face is that their existing applications aren’t reusable to a large extent. Without the proper tools, application engineers find themselves “reinventing the wheel” every time they need to write a new application. This inefficient approach is no longer sustainable. Canadian manufacturers need to innovate and realize new efficiencies if they want to compete in an increasingly global marketplace. Recent improvements in industrial equipment digitization and connectivity have allowed object-based modelling, an approach that has proven successful in IT, to migrate to the domain of industrial automation. When programmers develop applications using defined object templates, they can significantly reduce the engineering effort required for new applications.

Cost reduction advantages of “objects”

Traditional control programs view a logical procedure as one that takes input, processes it and generates output. In industrial automation, this methodology is called procedural programming. The fundamental issue with this

approach is an underlying assumption that the logic will be developed once to solve a single problem. As applications have grown larger over time, the logic has become more and more complex, making the procedural programming approach increasingly inefficient. Object-oriented design is the new paradigm that addresses these issues and introduces new ways to solve industrial production efficiency problems. Each object is defined with certain attributes and display behaviours. The objects also interact with each other. These characteristics allow best practices to be encapsulated into applications and standardized across different plants. The advantages of object-oriented design aren’t limited to reusability or application portability. Objects are also easier to 12

October 2015 • Manufacturing AUTOMATION

maintain and help save crucial time when implementing changes during the lifecycle of the plant. Consider a scenario where a 10-per-cent change is required in a traditional application. Using conventional tagbased development, 10 per cent of the effort spent on the original development would be required to carry out the changes. However, in object-based development the 10-per-cent effort needs to be applied only to the object template and not the entire application. Automatic change propagation could be carried out once the object is updated, meaning a significant amount of effort could be saved during change management. Object-based systems can be quickly enhanced or modified to respond to market needs and improve competitiveness.

Technical advantages of “objects”

“Objects” contain features associated with the device they represent. That means a motor object, for example, could contain the events, alarms, documents, faceplates, asset management, and control and human machine interfaces associated with that device. A motor object that represents a real-world motor could make use of these characteristics to provide real-time information to an operator. As such, the alarm feature of the motor object could alert the operator to a high winding temperature. This could be a critical piece of information in allowing the operator to avoid burning up the motor windings. In industrial environments, objects could also represent a piping network modelling pumps, valves, and pipes; a control process modelling analogy I/Os and proportional-integral-derivative (PID) loops; a supervision process modelling animated symbols, tags, and alarms; or a functional process entity modelling a charger, an agitator, and a heater — just to name a few possibilities. Smart objects can explore the environment, and can interact with both other smart objects and with humans. This helps users manage tasks in new and intuitive ways. Smart objects can also assist in the simplification of change management and the versioning of objects. The original design of a process application may need to be modified later on, as requirements may change to adjust to a shifting marketplace. Changes can be exercised either for all composite objects or for selected instances only, thereby enabling co-existence of multiple versions of the objects. Changes can also be pushed out to all the object model’s participant projects, such as control and supervision, which ensures that consistency is maintained among objects across multiple projects.

Organizations wishing to migrate to an object-oriented development environment should consider the following short- and long-term steps:

to assemble libraries of objects. Consider how open the control network needs to be in order to accommodate third-party components.

• Immediately: Begin to plan a roadmap. Assess what steps need to be taken in order to evaluate tools that are specialized to the needs of industrial sites. Conduct an assessment of development environment requirements.

• Within the next year: Enlist a trusted partner with expertise in both plant-based architectures and object-oriented development methodologies, and human-machine interfaces (HMI) to help maximize operational efficiencies. •

• Over the next six months: Determine how much work Based in Toronto, Ont., Gurvie Waraich is a PlantStruxure automation_ad.pdf 1 08/09/2015 5:48:02 PM needs toCPX_MPA_manufacturing be done to implement an object model and program manager at Schneider Electric Canada.

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Path to an object-based model

Object-based designs provide a higher level of flexibility and cost savings compared to traditional programming models. The object-oriented concept of “develop once and reuse many times” is the engine that drives the cost savings. By reusing common objects across multiple platforms, software systems can be maintained at just a fraction of the cost of existing, traditional systems. In addition, machine operators are presented with a unified viewing experience which assists in training and a reduction in human error.

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www.AutomationMag.com • October 2015 13 2015-09-15 1:19 PM

C O V E R

S T O R y

KEEPING

UP-TO-DATE CSA Z432 Safeguarding of Machinery — What’s new in 2016? By DOugLAS NIX

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October 2015 • Manufacturing AUTOMATION

A

ccording to a recent paper from Dr. Yuvin Chinniah1, in 2008 alone, three workers were killed everyday working with machinery, adding up to nearly 1,100 fatalities. Similar numbers were seen in the United States in 2005, with about 1,000 worker fatalities occurring due to machinery2. Accidents occur for a wide variety of reasons, but inadequate safeguarding is among the leading causes. Globally, many machinery safety standards have been developed. In Canada, CSA Z432 - Safeguarding of Machinery provides guidance on risk assessment and the design of safeguarding for machines used in Canada. Federal, provincial and territorial government regulators, machine builders, integrators, employers, and users reference this standard across the country. Technical standards go through regular revisions to help keep the content current, and to give the Technical Committees the opportunity to correct problems and clarify issues that users have found when using the document. CSA Group started this process with CSA Z432 in 2014. CSA Z432 has a long history, stretching back to the first edition in 1994. Each edition has advanced the practice of safety in Canada, providing designers, manufacturers, users, integrators and regulators with a comprehensive guide to the design of safe machinery for the Canadian workplace. The third edition, when published in 2016, will further advance this practice in a number of important ways. Harmonization of standards is extremely important for business. The closer Canadian standards get to those of our neighbours and the rest of the world, the lower the technical barriers to trade become. Technical barriers to trade are differences in technical requirements in regulation or in standards that result in the exclusion of products or services from a jurisdiction. CSA has an overriding principle of harmonization where possible with the international standards produced by ISO and IEC or other international or North American standards bodies, aimed at reducing technical barriers to trade. Many Canadian standards are already closely harmonized with the U.S., like the Canadian Electrical Code and the U.S. National Electrical Code, and we are coming closer in many other areas. In this latest edition of CSA Z432, there are a number of significant changes that are being considered to be driven least in part by technical

The closer Canadian standards get to those of our neighbours and the rest of the world, the lower the technical barriers to trade become. harmonization. There is also a proposed adoption of an ISO standard that was driven by this desire for harmonization.

Safety distances

The concept of safety distances for reaching up, over and through guards and guarding systems in the area of machine safety is a critical topic for keeping Canadian workers safe from injury. This is also a frequent area of questions and confusion for end-users, and as such, the CSA Technical Committee has been spending a great deal of time and effort reviewing the safety distance parameters referenced in ISO Standards as it compares to the historic safety distance values within the CSA Z432 document, as well as considering how best to present this information to end-users for maximum clarity. The existing Table 3, Minimum distance from hazard as a function of barrier opening size, has origins in a study done by Vaillancourt and Snook3. For readers familiar with the U.S. OSHA guard openings table, the values in Table 3 and in 29 CFR 1910.217 Table O-104 are not the same nor are they the same as those in ISO 13857. All of the guard opening tables have been used safely for many years, so whether you choose CSA Z432 Table 3, OSHA 1910.217 Table O-10, or ISO 13857 when designing guards, the result is reduced risk to users for openings in guards. The Technical Committee is proposing to adopt ISO 13857, Safety of machinery — Safety distances to prevent hazard zones being reached by upper and lower limbs as a Canadian national standard and incorporate some components of this within the third edition of CSA Z432. This document went through public review in recent months and is anticipated to publish later in 2015. This proposed decision will help Canada stay in step with international guarding requirements, ensuring harmonization with International requirements.

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Risk assessment

Risk assessment has been a part of Z432 since the first edition in 1994. The second edition expanded the guidance provided to users, harmonizing with the approach in ISO 12100-1:2003. This harmonization helped people importing machinery built to International and European standards. In 2012, CSA published CSA Z1002 - Occupational health and safety — Hazard identification and elimination and risk assessment and control. This groundbreaking standard provides organizations with a risk assessment methodology that can be applied to any product, process or service. The standard is part of the CSA Z1000 OHS Management series, however, it

is designed so that it can be used whether an organization has a formal OHS management system or not. The CSA Z1002 approach is also rooted in ISO 12100, and this is the proposed basis for further harmonization in the third edition of CSA Z432.

Functional safety

Clause 8 of CSA Z432 is anticipated to continue as the source of information on functional safety, or “control reliability” as it has been known. The Technical Committee is proposing to harmonize this clause with the International standards, directing machine builders to conduct functional safety analyses using ISO 13849 or IEC 62061 as appropriate.

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Review of safety-related controls post-design is problematic, as there are key pieces of information that are only known to the designers and their organization. To facilitate the use of the standard in evaluating existing machinery, the Technical Committee is proposing that users be allowed to consider the architecture of the safety-related controls alone. This proposed approach would significantly simplify the review process and eliminate the need to address organizational aspects that contribute to functional safety performance but which are not directly related to the architecture of the safety-related controls or the components used in those controls. These proposed changes would bring the Canadian requirements

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into alignment with the rest of world with respect to functional safety requirements, and allow latitude for the types of post-manufacture reviews that are done in Ontario.

Safeguarding devices

Significant revisions are being proposed to Clauses 9 and 10, Performance requirements and Application requirements for safeguarding devices. The content of the existing clauses is being reviewed and revised to bring it into alignment with U.S. and International requirements. The flow and structure of these clauses are proposed to be improved to help users in applying the information.

Lasers in industry

Lasers are frequently incorporated in machinery for metrology, control and for processes like welding and cutting. The previous editions of Z432 included some information related to the use of lasers in these ways, but since Canada did not have a laser safety standard in the CSA Group library, and since federal regulations do not regulate these applications, there was much confusion about the requirements. Since 2004, IEC 60825-1, Safety of Laser Products: Equipment Classification, Requirements and User’s Guide has been adopted as CSA E60825-1. This document is used to certify new laser products but does not include specific requirements for users. For this information, we go to the U.S. ANSI Z136 family of standards. The proposed revisions to the CSA Z432 text cover the classes of lasers from the current edition of CSA E60825-1, and provide guidance on the need for Laser Safety Officers (LSO) in manufacturing facilities in Canada. There is a proposed supporting Annex that includes a flowchart to

October 2015 • Manufacturing AUTOMATION

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approaches can be implemented by almost any business, without the need to “reinvent the wheel.” Involvement in standards writing is a great way for businesses to lead the way, contributing to the economy and their own success in meaningful and lasting ways. •

References

[1] Y. Chinniah, “Analysis and prevention of serious and fatal accidents related to moving parts of machinery,” Saf. Sci., vol. 75, pp. 163–173, 2015. [2] M. T. Bulzacchelli, J. S. Vernick, G. S. Sorock, D. W. Webster, and P. S. J. Lees, “Circumstances of fatal lockout/tagout-related injuries in manufacturing,” Am. J. Ind. Med., vol. 51, no. 10, pp. 728–734, 2008.

help OHS personnel decide on the need for a LSO in their facilities.

Annex material

The Annexes continue to be developed, but the Technical Committee has been working hard to modernize and improve much of what existed, and are proposing the addition of more information that they believe users will find helpful.

Douglas Nix, C.E.T., SM-IEEE, is managing director at Compliance Insight Consulting. He has more than 25 years of engineering technology expertise, though he has focused on risk assessment and machinery safety since 1996. [3] D. R. Vaillancourt and S. H. Snook, “A Review of MachineGuarding Recommendations,” Appl. Ergon., vol. 26, no. 2, pp. 141–145, 1995. [4] “Mechanical power presses. - 1910.217.” [Online]. Available: https://www.osha.gov/pls/oshaweb/owadisp.show_document?p_ table=STANDARDS&p_id=9841. [Accessed: 02-Sep-2015].

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Public review

The normative text — the body of the standard, excluding the Annexes — will be available for public review through the CSA Group Public Review system sometime this fall. Editorial work is now in progress and when completed, the draft will be opened for public review and comment. If you are interested in participating, visit publicreview. csa.ca. Occupational Health and Safety Standards, including CSA Z432, can be found at publicreview. csa.ca/Home/Category/010.

Conclusions

Engineers are trained to provide solutions to problems that won’t endanger the safety of people using the product, process or service that they have designed, and to do that they need data. Business leaders want to leverage existing knowledge to gain advantages over competitors. Workers want to work in safe workplaces and be assured to go home each and every day without injury. Standards like CSA Z432 and CSA Z1002 provide all of that to businesses, engineers, workers and our nation. Leveraging the combined knowledge of the technical expert contributors, CSA Group provides standards that give Canadian businesses the basis to compete effectively, efficiently and safely. Continuous revision of standards ensures that the latest proven

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www.AutomationMag.com • October 2015 17 2015-09-17 2:41 PM

M O T I O N

C O N T R O L

Pump up your

productivity Modification of motion control products can provide safer, more efficient operations By ShANNON wINKLER

T

he automation industry runs smoothly, effectively and efficiently when the right motion control products are employed on operating equipment. There are four important considerations to take into account when evaluating customized motion control solutions. Plant operators and management should consider the four points below when evaluating motion control products for a facility.

1.

employee safety

The primary purpose of motion control technology is to decrease human intervention during mechanical and machinery operation. Work-related musculoskeletal injury is often reported when working in a manufacturing environment. Introducing and continuously using motion control products in any workplace results in little to no strain or bodily injury. With fewer hands-on steps in manufacturing processes, employees no longer have to put themselves at risk while working to maintain productivity of a facility. Once motion control products are introduced, plant managers should expect to see a significant decrease in workplace accidents. This is a positive benefit to share with all plant employees.

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October 2015 • Manufacturing AUTOMATION

An automotive steering and suspension component company in Ontario requires the movement of 2,300 F billets through numerous processes in a work cell. The heat in this environment is, of course, too extreme for humans to work. An industrial process company provided the component company with a custom-engineered motion control solution. To limit contact with this dangerous environment, a compact automation angual motion gripper, attached to arm tooling on an ABB robot, was selected. The grippers move the billets from the heat station, to the roll station, to the bend station and finish at the press station. These are critical process steps for these parts. The grippers play a very important role in moving the parts from station to station accurately and consistently while meeting the drawing specifications. There are numerous advantages to the company such as: • Ensuring human/employee safety – Automation machinery eliminates worker injuries during dangerous tasks in dangerous environments. • Production and productivity – Increased product production with higher volumes at lower cost in less time than other types of machinery or if completed by humans.

• Quality – The automation grippers are consistently accurate and provide repeatability that is otherwise unobtainable due to human error. • Lean and savings – Return on investment (ROI) is immediately impacted after this type of machinery is implemented. There is a reduction in waste, due to the ability of the motion control products to produce more of the product, while accumulating less scrap. There are more financial savings, including the elimination of workers compensation due to employees avoiding unsafe environments that may cause worker injuries.

2.

Cost

Particularly when it comes to purchasing a new product, automation customers are instinctively looking to reduce costs and maintain profitable operations. Although a custom-designed product may require a greater initial investment, purchasing the right solution can save money in the long run. A customized motion control product can be developed to meet the unique motion control specifications of almost any application.

Customers often select a product because of its lower cost, but if it’s not designed for that specific automation application, side load or other improper loading could be induced. This can cause disruption in production and possible damage to the equipment resulting in expensive repairs and unplanned down time. Evaluating a potential purchase based on a total cost throughout the life cycle of the product may result in substantial savings. Partnering with a custom-engineered solutions provider will ensure that the right product is being selected based on budget, needs and the unique specifications of the facility.

3.

efficiency

4.

Quality/reliability

The automation industry is commonly centered on a goal of maintaining consistency and efficiency. The use of automated machines removes the possibility of slowing down a process, or causing any imperfections in the product due to human error. Machines perform the same tasks with the same steps in the same amount of time every time. These automated solutions are useful when production needs are constant. However, custom-engineered motion control products allow a plant manager to speed up or slow down a machine’s production as needed to accommodate fluctuating supply and demand. When searching for a motion control product, overall quality and reliability should be a main concern in the decision-making process. The average off-the-shelf model can have shortcomings in either area. For example, cylinders used in machinery are designed to operate within a certain speed of travel. Using a cylinder at its top speed or beyond its intended use will cause premature machine failure. However, a custom-engineered motion control product can last up to 10 times longer when it is designed for its specific function and environment. Toxic or acidic washes, extreme heat or cold and production speed are all factors that may shorten a product’s life cycle if not properly designed.

managers. Be sure to first look at the length of a product’s life cycle, rather than the initial cost before selecting a motion control solution. Financially, custom-engineered motion control products will ultimately be the best choice in the long term, due to their ability to work in hazardous environments and achieve high efficiency levels while maintaining quality and reliability. Since the automotive component company mentioned earlier is experiencing the many benefits of motion control products, imagine what this technology could do for your plant. Motion control technology can increase the safety of your employees and limit the dangerous contact of those who may be subject to

hazardous working environments. The technology can increase and speed up your facility’s production while delivering high-quality, consistent product at reduced costs. And if your supply and demand fluctuate, your plant manager has the flexibility to speed up or slow down production, as needed. While the financial savings are best seen over the long-term, your plant will still benefit from an almost immediate return on investment, reduction of waste and increase of employee safety. • Shannon Winkler is the product manager with ITT Control Technologies. His responsibilities include managing A COLLABORATIVE customer service and application engineering. ENVIRONMENT

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Which consideration is the most important?

Although each of these four categories should be heavily considered throughout the selection process, ideally employee safety should be the top priority. However, the overall cost of the product plays a large part in the final decision for plant

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C y B E R S E C U R I T y

Cyber check

By ALySSA DALTON

Six must-do action items to minimize your risk of cyber attacks

A

re you working securely? Cybersecurity is a hot-button issue these days and while it’s been commonly noted that manufacturing companies must be proactive in protecting themselves, some organizations may not know where to begin. For insight on how businesses can get started, Manufacturing AUTOMATION spoke to John DiMaria, senior product manager of systems certification for BSI Americas, to get his take on what businesses should keep in mind when implementing a cybersecurity plan.

Complete the initial risk assessment

“Overall risk assessment becomes the underlying foundation of where businesses need to start,” says DiMaria. According to him, this initial risk assessment is critical as it lets the organization understand the context of all systems and processes so it can “hone in on what really needs to be protected.” The assessment should determine what risks are associated with the organization’s entire operational process as well as the types of security controls that are currently in place. The goal is to determine what additional measures need to be implemented based on the “risk appetite” of the organization, he notes.

develop an operational planning system

All data documented in the risk assessment can become useful information when creating an organization’s overall security strategy, says DiMaria. “A glitch in the automation system could actually blow up a reactor, so it’s just not about detecting processes, it’s about having proper measurement systems in place to know when the bells and whistles need to go off,” he says. He references ISO/IEC 27001 - Information security management as a reference point for companies seeking guidance on where to begin. “It gives you a structure to measure your system against and improve on based on the requirements of that standard.” He recalls an instance from one of his previous jobs: “When we automated our systems and moved from manual to computer-operated systems with Internet and outside access, I hate to say it but for probably the first year, we didn’t even think about security. It wasn’t on our mind. We were focused on how much quicker we can get [products] out the door.” Not all security breaches are complicated hacks, says DiMaria, noting that sometimes an attack can be very simple in nature but because an organization didn’t have the appropriate security measures in place, they still occur.

Maintain a unified leadership message

A key element of a cybersecurity strategy — or rather, any business strategy — is to have it that it is regularly reviewed

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October 2015 • Manufacturing AUTOMATION

by top management, he notes. “Top management has to lay out a policy to let everyone in the organization understand what they’re doing as a whole, what is critical to its processes, why it needs to be protected, and how the organization is protecting it,” says DiMaria. This message should be implemented from the top down so a culture of security is reinforced to all employees, he adds.

Communicate security mandate to all levels of staff

Not only does this message need to be driven from the top down but it needs to be rolled out and explained in detail to staff in all different levels within the company, says DiMaria. “We see that some organizations can have a lack of competency,” he notes. “You put somebody in front of an automated control system and teach them how to work it, the right buttons to push and when to push them, but do they really understand the breadth of what they’re dealing with there?” He says it is one thing to teach employees how to use the tools, but it can be detrimental if the worker isn’t taught the security risks associated with their role and responsibilities.

Regular monitoring and documentation

Improvement to an organization must be constant, says DiMaria. As such, regular evaluations and continuous enhancement of processes and systems must be performed to ensure that an organization is keeping up with the latest software and issues in the market, he notes. Internal audits can be a “very useful tool” in measuring how well a particular measure is working within an organization, as the collected data can help illustrate past trends and help predict future progression. “It’s really about finding out issues before they really happen.”

Business continuity plan

So what strategy do you have in place for when an attack does happen? According to DiMaria, it’s imperative that all companies implement a contingency plan to deal with security breaches. “We all know that nothing is 100 per cent. On your best efforts, something is bound to happen sooner or later,” he says. Is this contingency plan documented and tested? Do all employees understand what parts they have to play in the event of a disaster? DiMaria says this plan should also outline the specific steps that have to be taken during and after an attack, as well as recovery time objectives, so that the company can be as prepared as possible during a vulnerable time. •

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HYdRAUL I CS

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Food-safe fittings Festo’s NPQH fitting claim to withstand a range of extreme conditions, including those typically used during food production. The NPQH series is food industry-compliant, heat resistant to 150 C, as well as promising to be resistant to chemicals including common cleaning agents and lubricants, and suitable for high pressure applications. Its electroless nickel plating means the surfaces are abrasion resistant and safe for use in the food industry, notes the company. With straight, L-, T- and Y-shape variants, the fitting’s resistance to microbes and hydrolysis also makes it highly suitable (and FDA compliant) for food and wet areas when combined with PUN-H tubing, adds Festo. www.festo.ca

P n eU M AT IC S consistent accuracy and a smoother work surface. The PHC-S is available in HSK, CAT (standard and two-face contact), BT (standard and two-face contact), and UTS shank styles. They are offered in ø1/4 in. - ø1 in., ø6 mm - ø25 mm, and custom sizes. www.nttoolusa.com

Precision dispenser

The Fisnar DC100 digital precision dispenser boasts more programmable features than any previous Fisnar dispenser, promising the ultimate in user control, according to the company. The DC100 claims to give the user

more control over their dispensing applications, along with bringing more functionality to the desktop dispenser. Alarms can be set to notify the user when material life has ended or fluctuations in dispensing pressure have occurred. www.fisnar.com

Internal mix spray nozzles coat, cool, treat and paint

Exair’s 1/2 NPT internal mix atomizing spray nozzles atomize fluids in a range of spray patterns and liquid volumes for a variety of uses. They combine liquid and compressed air inside of the air cap to produce a mist of atomized liquid that can be adjusted to suit different applications. The nozzles claim to coat, cool, treat and paint a range of products using compressed air and liquids with a viscosity of up to 300 centipoise. Users can choose between various spray patterns. www.exair.com

Slim hydraulic chuck

NT Tool now offers a slim-bodied PHC-S hydraulic chuck for use in tight spaces. According to the company, these PHC-S holders claim to “combine the stability and precision of NT’s dual clamping-point system with the access into narrow work-

pieces previously only possible with shrink fit holders.” The oil chamber around the chucking sleeve absorbs cutting vibrations, promising higher, Yaskawa_MA_Oct.indd 1

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P R O D U C T S

H M I

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EAO has introduced the series 84 Halo Compact, a newly developed multi-functional illumination switching element claims to provide the most common status indication features in a single all-in-one solution. The unit can be used in a range of applications, such as machinery control panels, medical equipment, access control and emergency call boxes, and operator controls. Its switching elements provide ring illumination of five different colours within the lens as well as a white LED that can illuminate the centre of the lens. Moreover, the switching element also makes it possible for as many as eight different status messages to be easily displayed, notes the company. Additional features include bi-colour LED illumination and an integrated electronic switch for maintained action. www.eao.com

Elektrobit, a developer of embedded technology solutions for the automotive industry, has announced EB Guide 6, a software toolkit that allows manufacturers, Tier 1 suppliers and developers to design and develop customized HMI systems. According to the company, Guide 6 represents a complete redesign of the toolkit, integrating new features such as a more streamlined graphical user interface, advanced graphics and voice-, touchscreen and gesture-based controls. The company says Guide 6 helps reduce development time and costs by enabling existing models, animations, widgets and other assets to be reused for different projects, brands or markets, thereby simplifying the process of creating a consistent look and feel. Guide 6 was originally developed for the automotive market, but also has applications in other markets,

October 2015 • Manufacturing AUTOMATION

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including industrial automation, medical solutions and avionics. www.elektrobit.com

Tethered operator interface for HMI access

Software to build customized HMIs

regiSTer noW

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The new Rockwell Allen Bradley MobileView tethered operator interface gives plant and industrial personnel the freedom to take a machine’s HMI with them to make real-time adjustments to out-of-view applications. The MobileView tethered operator interface is ideal for maintenance tasks, machine setup or calibration activities, and other HMI applications that require the operator to see the machine, says the company. The inclusion of a hardwired e-stop button and three-position enabling switch also supports applications that require local safety functionality. www.rockwellautomation.com

Touchscreen controller

Microchip Technology has added the MTCH6303, a turnkey projected-capacitive touch controller for touch pads and screens, to its Human Interface Solutions portfolio. Touch sensors with up to 1000 nodes and diagonals of up to 10 inches are supported. The MTCH6303 provides multi-touch coordinates as well as a readymade multi-finger surface gesture suite that offers pinch and zoom, multi-finger scrolling and swipe interface elements. Its signal processing provides noise-avoidance techniques and predictive tracking for 10 fingers, at scan rates of up to 250 Hz with a minimum of 100 Hz each for five touches. It also combines with Microchip’s MTCH652 high-voltage line driver to achieve a “superior signal-to-noise ratio (SNR) for outstanding touch performance in noisy environments,” notes the company. www.microchip.com

P R O D U C T S

dATA ACQU IS ITIOn

SenSORS Linear position sensor

MTS Sensors has expanded its R-series of magnetostrictive position sensors with a device it says has the “capacity to deliver superior reliability and industry-leading accuracy in even the most demanding work environments.” Utilizing the company’s Temposonics technology, the RT4 is a linear position measurement solution that features two independent sensor elements — each with a measuring length of 50 mm to 2540 mm. Targeted at use in steel processing plants, lumber mills and power generation sites, the sensor employs a Synchronous Serial Interface (SSI), which means that data transfer is less susceptible to the presence of electro-magnetic interference, according to MTS. The sensor boasts a temperature range of up to 100 C for the sensor rod and interconnection cables. www.mtssensors.com

ICS sensors and IP69K cordsets

Carlo Gavazzi has announced two new product lines designed specifically for harsh environments. The ICS inductive proximity sensors comply with or are certified to IP69K, ECOLAB, and FDA standards, and can accommodate both hot and cold temperature. The ICS series sensors have an operating range of 40 C to 80 C, and will work for up to 15 minutes in boiling water, says the company. The three-wire DC ICS series

is available in M12, M18 and M30 316L stainless steel housings, with single or double sensing distance, flush or non-flush mounting, and normally open or normally closed outputs with 200mA PNP or NPN transistor output. The IP69K CONB series cordsets are ECOLAB and UL certified, and are rated from 40 C to 105 C. They are available with two

or five metre lengths, with straight or 90° connector, with non-illuminated or LED versions. www.gavazzionline.com

Dual function position sensor

The Blade25 dual function position sensor from Gill Sensors & Controls promises an innovative design that provides both linear and rotary position feedback in a single package. With the Blade’s dual movement capability, engineers can use one part number when designing into their applications, notes the company. The two-piece sensor claims to measure either +/-45° of rotary movement or +/- 12.5 mm of linear displacement. In both cases there is no contact between the sensing element and the small metal “target,” which acts as the activator and attaches to the moving element in the assembly, notes the company. www.gillsc.com

Step up to the New Generation of Wide Screen Automation Panel PCs

Total plant management solution

Thanks to a new partnership with DPSI, Syscon-PlantStar now offers maintenance management solutions that complement PlantStar’s manufacturing execution systems. Even though both PlantStar and DPSI have multi-tiered software programs, the sharing of information is expected to be will be seamless and intuitive, says Gary Benedix, vice president at PlantStar. In a plastics facility, for example, the PlantStar program will gather a machine’s total run hours, the number of cycles on a mold/tool, and downtime tracking by reason and pass it to the DPSI system for preventive maintenance planning. The ability to link real-time machine data with a preventive maintenance program offers huge benefits to manufacturers that want to stay competitive, he adds. www.plantstar.org

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M A C H I NE

VI S I ON

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INS PEC T ION

8 mm, 16 mm, 25 mm F/1.8 lenses

model, Tamron says it continues to pursue “advanced optical performance and distinguished ease-of-use for customers.” www.tamron.ca

Tamron has released three types of machine vision fixed-focal (8 mm, 16 mm, 25 mm) lenses for 1.1 in.-format 3.1-μm-pixel-pitch imagers, model M111FM08, M111FM16 and M111FM25). These cameras can be used in industrial applications including production equipment, chip mounters, test apparatus, and machining centres. With increasing emphasis on higher-resolution fixed-focal lenses for machine vision, Tamron released a 50 mm F/1.8 lens for 1.1 in. 3.1-μm-pixel-pitch imagers (model M111FM50), earlier this year. With the addition of 8 mm, 16 mm and 25 mm lenses to the 50 mm

Infrared camera

Allied Vision says its Goldeye G-008 short wave infrared spectrum (SWIR) camera is packed with all the features and benefits of the current Goldeye camera family, combined with a smaller resolution sensor. The unit is fitted with a QVGA InGaAs sensor (320 x 256 pixels, 30μm pixel size) and is suitable for the short wave infrared spectrum ranging from 900 to 1,700 nm. It also promises to deliver 346 fps (frames per second) at full resolution. www.alliedvision.com

CRITICAL INDUSTRY DATA IMPORTANT BUSINESS DECISIONS

T E S T

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M E A S U R E M EN T

Uniformance Asset Sentinel claims to boost uptime

According to the company, the unit is ideal for municipal or industrial water, wastewater, pump stations and packaging plant applications. www.omega.ca

Flow transmitters Honeywell Process Solutions (HPS) has launched Uniformance Asset Sentinel, which works to continuously monitor equipment and process health, “assisting industrial facilities to predict and prevent asset failures and poor operational performance.” The technology, HPS says, helps companies reduce unplanned downtime by up to 10 per cent and cut maintenance costs by 15 per cent. The technology works by continuously accessing data from a variety of sources, including process parameters, vibration data and alarms. Predicted or detected deviations from these models are used to generate notifications to facilitate investigation and intervention to minimize the cost and frequency of an event. www.honeywellprocess.com

Flanged magmeter

Omega says its FMG-2000 series of flanged magmeters offers easy set-up, minimal straight pipe, rate and total display for meter mount or remote. It boasts a tamper-evident seal, touchscreen programming, and is NSF-61 approved.

AutomationDirect’s ProSense FSA Series flow transmitters monitor liquid media and provide an analogue output proportional to flow rate for various flow applications. The series is IP65 and IP67 rated and is cULus, CE and ROHS compliant. Its sensing

principle is based on differential pressure to ensure response time of less than 10ms and allow for precise flow measurement, it says. Available in three flow ranges up to 27GPM, the transmitters feature a 4-20mA analogue output, are fitted with a 4-pin M12 quick disconnect and come with 3/4-in. or 1-in. FNPT process connections. The integrated check valve design allows the sensor to be mounted vertically or horizontally. www.automationdirect.com

info@omega.ca

A d • LABOUR MARKET SUPPLY & DEMAND • TRACK KEY WORKFORCE TRENDS • CUS T OMIZED L MI REPOR T S • EVERGREEN INDUSTRY DATA

I n d e x

Advantech Industrial Automation Group..............23 Allied Electronics Inc......................................1 + IBC AutomationDirect.................................................IFC Baumer Inc.................................................... 12 + 16 Beckhoff Canada......................................................5 Carlo Gavazzi (Canada) Inc......................................4 Eaton Canada........................................................11 Encoder Products Company...................................16 Excellence In Manufacturing Consortium.............24 Festo Inc.................................................................13 Harmonic Drive LLC...............................................25 Hiwin Corporation...................................................9 Lafert North America.............................................10 Murrelektronik Canada............................................3 Omega Engineering, Inc.................................. 7 + 24 Omron Automation and Safety..............................19 Pepperl+Fuchs.......................................................17 Rittal Systems Ltd...................................................15 Safety Compliance Workshop................................22 Siemens Canada Ltd.................................... 8 + OBC Yaskawa America, Inc. Motoman Robotics Division..................................21

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OMEGA Introduces Handheld Wireless Bluetooth® Transmitter

2015-09-24 1:27 PM

The UWBT Series of Bluetooth® wireless transmitters turn your smart phone or tablet into a data logging and monitoring device. These transmitters measure different sensor inputs such as thermocouple, RTD, temperature/relative humidity and pH and transmit the data via Bluetooth wireless technology to your smart phone or tablet. A free app is available for AndroidT and iOS devices that is configurable in 9 different languages. The UWBT app allows you to pair with and set up multiple transmitters and view their data in either digital, gauge or graph format. Price starts at $332 Email: info@omega.ca http://www.omega.ca/pptst_eng/UWBT. html

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P R O D U C T S

MOTION

CON T R O L

Machine automation controllers

Omron says its NX701 and NJ101 automation controllers are at the heart of the Sysmac automation platform. Sysmac boasts an “innovative manufacturing environment” by creating a variety of application functionalities with software and connecting Omron and third party factory automation hardware and design tools such as 3D simulator. According to the company, this release of machine automation controllers and peripheral devices enables Sysmac to be adopted at every production site. As the flagship model, the NX701 boasts the industry’s fastest processing speed and large memory capacity for variables of 260 MB. It features an Intel Core i7 quad-core processor and two embedded 1 Gbps EtherNet/ IP ports. Meanwhile, Omron says the NJ101 is the first basic automation controller with up to two axes or no axis and is ideal for machines without or with a low number of axes. www.omron.com

will enable context save and restore across its MSP430 FRAM microcontroller (MCU) family, including the new MSP430FR6972 MCU. This technology, it notes, allows instantaneous wakeup with intelligent system-state restoration after an application unexpectedly loses power. In addition, the MSP430FR6972 MCU with TI’s CTPL

technology includes integrated smart analogue and digital peripherals to help minimize system cost, power and size, it adds. These features include an LCD controller, a 12-bit differential analogue-to-digital converter (ADC) with internal window comparator, and a 256-bit AES accelerator. www.ti.com

Pick and place unit

The Schunk PPU-E 15 is a linear motor driven pick and place unit that is designed for electronic and small part assembly applications. With a width of 60 mm and media supply via the back panel, it allows several units to be mounted side by side. If rotary indexing tables are used, more units can be arranged in a circle, or a smaller table diameter can be used. The PPU-E 15 requires 0.6 seconds to complete a cycle with a horizontal stroke of 145 mm, and a vertical stroke of 45 mm. That includes a payload of 1 kg, and 2 x 50 ms gripping time. At its peak, the PPU-E 15 achieves 100 picks per minute, according to the company. www.schunk.com

247 Lynnfield Street Peabody, MA 01960 800.921.3332 www.HarmonicDrive.net

Microcontroller with LCD

Texas Instruments has announced Compute Through Power Loss (CTPL) technology which it says

Electromate Industrial* 6221 Highway 7, Unit #15 Vaughan, Ontario, Canada L4H 0K8 www.electromate.com

Harmonic Drive is a registered trademark of Harmonic Drive LLC. Robonaut image courtesy of NASA/JPL-Caltech. * Electromate Industrial Sales is the exclusive Canadian distributor of Harmonic Drive® products (except the Province of Alberta).

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B A C K S T O R y

The world of industrial robotics 2008 In anticipation of Manufacturing AUTOMATION’s 30th anniversary next year, we will be digging through our archives for a look at various topics we have covered over the years to see how they have transformed our industry. But what good is it to simply look behind? Backstory will work to provide you with a fuller understanding of each theme by offering industry perspectives on where we’ve been and where we’re going.

T

he way automation has transformed over the last decade is by moving from centres focused on mass batch manufacturing to a focus on on-demand manufacturing. Due to the market demand for customization of products, there is a need for SKU proliferation, which in turn leads to a need for more flexible automated solutions within manufacturing. It’s in every company’s best interest to optimize their operation. Of course, I would suggest the best way to do this is to adapt robotics, but I am slightly biased. In all seriousness, robotics have the capability to help a variety of organizations — across a variety of verticals — transform their operations. In short, the robotics trends over the past decade have led to smaller, more flexible pieces of automation that are purpose built for specific processes. This allows for more flexibility within the manufacturing process, which means it is more capable of supplying a variety of items. The best example is cellphone manufacturing, where the phones that go to specific regions are all slightly different. Smaller, purpose built automation cells can handle these alternate SKUs, where the automation of yesterday targeted at mass production required more time-consuming tooling changes or manual intervention to accomplish the same task. The next stage of automation is the continuation of the trend towards purpose-built autonomous solutions: the automation of material transport using self-driving vehicles. The technology has arrived to automate exceptionally complex material handling environments giving organizations the capability to centrally control all material handling inside of their facility. Using self-driving vehicles to automate materials transport will support warehouse employees on the floor with task completion and also enable the human workforce to focus on the complex challenges that humans are good at solving.

2004

1988

2008

— Comments by Simon Drexler, director of Indoor Industrial Solutions at Clearpath Robotics. His role focuses on planning and development of future products within robotics automation.

1998

2013

2010

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October 2015 • Manufacturing AUTOMATION

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