Innovative Thinking

When do you turn to an automation solutions company — when your current automation system fails?

Many companies regard automation systems with the bare minimum of concern, only closely examining a system when something breaks. Efficiency gets reduced to making equipment run for as long as possible with as little maintenance and attention — and therefore cost — as possible. So when an automation system breaks down, companies often replace the broken pieces with slightly newer parts that function the exact same way.

Every generation of engineers tries to challenge the traditional idea of engineering — it's the nature of engineering to constantly push for more efficient, innovative ways to solve problems. Yet basic fundamentals of entire industries rarely change.

Now, with a new generation of computer-savvy engineers, a tremendous shift has started to transform the manufacturing sphere of engineering.

Some projects seem straightforward and simple in the beginning; more often than not, problems arise that were never considered and end up costing a big chunk of precious time and money. Delays can be avoided by just taking a few steps to minimize risk and increase productivity. In this article we are going to take a look at how uncertainties can derail a project and how to reduce damage to your company’s timeline and budget.

In the first part of How to Adopt OEE More Effectively, we reviewed OEE calculation (Overall Equipment Effectiveness) and how it can be used to improve a plant's performance. This week we are going to talk about how to use it properly.

OEE (Overall Equipment Effectiveness) is used on a global scale to help manufacturing companies improve production and reduce losses. OEE is a measure of how effectively your equipment is being used in your production line. It is not a measure of your plant as a whole, but rather a measure of each machine that is a part of the process.

The goal of OEE is to isolate parts of your production process that can be improved. OEE is best adopted as a measurement tool to help you identify and track the progress of changes in your line. If OEE calculation is about using your equipment effectively, how can you use OEE itself to the best effect?

How do you keep up with your processes – walking from machine to machine?

Integrating your HMIs (Human Machine Interfaces) into an Ethernet networked control system gives you a centralized window into your entire process. It works by gathering data from the control system and distributing it to different areas of the facility. One PC at an operator station or in a control room can lay out real-time processes, report data over time, and make live adjustments to day-to-day operation.

HMI Server/Client Configuration breaks down into just two components: Servers and Clients.

In Remote Monitoring with Telemetry: Part 1,  we reviewed the top 10 advantages of using radio telemetry for remote monitoring. Those benefits included faster response time, lower cost, security, low maintenance, ease-of-use, and more. But there's also more to telemetry than the basics. In Part 2, we'll take a look at transmission distance and signal power for use of telemetery in automation solutions.

Variable Frequency Drives (VFDs) can extend the life of your motors, but how can you extend the life of your VFD? The most expertly specified VFD is only as useful as its operational reliability. This guide reviews variable frequency drives basics of care to ensure long-term productivity and cost-effectiveness.

How many blinking lights register as background noise for the operator on your plant floor?

In the design or planning phase of a project, alarms may be touted as central to the safety and efficiency of a process. But without considering the realistic use for an alarm and taking steps to ensure truly effective reactions, alarms may do more harm than good.

The real danger is that important alarms will get lost in the static. Known as "alarm fatigue," it can dull an operator's sensitivity to alarms when a dangerous or costly situation occurs. 

“Please turn off all personal electronic devices, including laptops and cell phones. Thank you!”

Many of us who have boarded a commercial flight are familiar with this quirk of air travel. If you own a smartphone, it likely features a toggle called “Airplane Mode” somewhere in your settings. Why? And what does it have to do with manufacturing?

The answer is Electromagnetic Interference, or EMI.

Historically, cell phones are considered a culprit of EMI, which can impact the performance of navigation instruments in a plane. In manufacturing, EMI plays an even bigger role in producing “dirty power” that can pollute an electrical system.

This could be a major factor behind your factory’s unplanned downtime when equipment falters or the entire system shuts down.