Inductive Automation Announces Ignition Firebrand Awards

Inductive Automation Announces Ignition Firebrand Awards

Inductive Automation has selected the recipients of its Ignition Firebrand Awards for 2019. The announcements were made at the Ignition Community Conference (ICC), which took place September 17-19. I get to see the poster displays and chat with the companies at ICC. I love the technology developers, but it’s fascinating to talk with people who actually use the products.

[Disclaimer: Inductive Automation is a long-time and much appreciated sponsor of The Manufacturing Connection. If you are a supplier, you, too, could be a sponsor. Contact me for more details. You would benefit from great visibility.]

The Ignition Firebrand Awards recognize system integrators and industrial organizations that use the Ignition software platform to create innovative new projects. Ignition by Inductive Automation is an industrial application platform with tools for the rapid development of solutions in human-machine interface (HMI), supervisory control and data acquisition (SCADA), manufacturing execution systems (MES), and the Industrial Internet of Things (IIoT). Ignition is used in virtually every industry, in more than 100 countries.

“The award-winning projects this year were really impressive,” said Don Pearson, chief strategy officer for Inductive Automation. “Many of them featured Ignition 8 and the new Ignition Perspective Module, both of which were released just six months ago. We were really impressed with how quickly people were able to create great projects with the new capabilities.”

These Ignition Firebrand Award winners demonstrated the power and flexibility of Ignition:

  • Brock Solutions worked with the Dublin Airport in Ireland to replace the baggage handling system in Terminal 2. The new system has 100,000 tags and is the largest Ignition-controlled airport baggage handling system in the world.
  • Corso Systems & SCS Engineers partnered on a pilot project for the landfill gas system of San Bernardino County, California. The pilot was so successful, it will be expanded to 27 other county sites. It provides a scalable platform with strong mobile capabilities from Ignition 8 and Ignition Perspective, plus 3D imaging from drone video and virtual reality applications.
  • ESM Australia developed a scalable asset management system to monitor performance and meet service requirements for a client with systems deployed all over Australia. The solution leveraged Ignition 8, Ignition Perspective, MQTT, and legacy FTP-enabled gateways in the field.
  • H2O Innovation & Automation Station partnered to create a SCADA system for the first membrane bioreactor wastewater treatment plant in Arkansas. The new system for the City of Decatur shares real-time data with neighboring water agencies as well as the mayor.
  • Industrial Networking Solutions created a new oil & gas SCADA system in just six months for 37 sites at ARB Midstream. The solution included hardware upgrades, a new control room, and a diverse collection of technologies with cloud-hosted SCADA, MQTT, Ignition Edge, and SD-WAN.
  • MTech Engineering developed an advanced real-time monitoring and control system for the largest data center campus in Italy. The project for Aruba S.p.A. had to work with huge amounts of data — and was done at a much lower cost than was possible with any other SCADA solution.
  • NLS Engineering created a single, powerful operations and management platform for more than 30 solar-power sites for Ecoplexus, a leader in renewable energy systems. The solution provided deep data acquisition, included more than 100,000 tags, and led to the creation of a platform that can be offered to other clients.
  • Streamline Innovations used Ignition, Ignition Edge, Ignition Perspective, and MQTT, to facilitate the automation of natural gas treating units that convert extremely toxic hydrogen sulfide into fertilizer-grade sulfur. The solution increased uptime, reduced costs, and provided access to much more data than Streamline had seen previously.
Inductive Automation Announces Ignition Firebrand Awards

Smart Factory Demonstrats Quantifiable, Real-Time Benefits of IIoT and Digitizing

A mere 2.5-hour drive south on I-75 June 13 brought me to the Schneider Electric plant in Lexington, KY that manufactures load centers and other electrical devices. Schneider Electric marketing people invited me down for tours and festivities marking the unveiling of this brownfield manifestation of Smart Factory using the latest of IIoT, AR, digitalization, and other smart manufacturing principles.

Highlights:

• Schneider Electric Lexington facility is a showcase for sharing IIoT integration strategies with End Users, Machine Builders and Partners

• Lexington plant strategically integrates connected EcoStruxure solutions to enhance efficiency and provide end-to-end operational visibility throughout supply chain operations

• Smart Factory has tracked quantifiable benefits from IIoT implementation, including a 20% reduction in mean time to repair and a 90% paperwork elimination

If this plant is to demonstrate “in real time how its EcoStruxure architecture and related suite of offerings can help increase operational efficiency and reduce costs for its customers”, I asked the natural question—“What is EcoStruxure?”

I’ve heard the term for many years, but being a little slow on the uptake, I’ve never really understood what is meant. So, they set me up with an interview with Vice President Domenic Alcaro. Refreshingly, EcoStruxure is neither a platform or a product. Alcaro told me, “EcoStruxure is a phenomenal way to explain our value structure.” The foundation block consists of connected products (connectivity being a key word). The intermediary block is what they call Edge Control. However, whereas many people look at Edge and think hardware, Schneider Electric considers it basically software. Think the InduSoft HMI product, if you will. Atop the model then are apps and analytics.

Back to the plant:

In operation for more than 60 years and employing nearly 500 people, the Lexington factory is truly a showcase of modern integrated digital experience. Among the benefits realized include empowering operators to gain visibility into operations maintenance, driving a 20% reduction in mean time to repair on critical equipment, and process digitization eliminating paper work by 90%.

“We understand the value of IIoT and the positive business impact that innovation and digitization can have on our operations – particularly in our global supply chain. As a living example of how our EcoStruxure solutions deliver benefits to our customers, we are gaining those same benefits in our operation and sharing that knowledge,” said Mourad Tamoud, Executive Vice President, Global Supply Chain, Schneider Electric. “With our latest Smart Factory showcase, we are able to demonstrate this value in real-time, show the solutions at work and share the tangible benefits that we ourselves are seeing from our own IIoT investment as we accelerate our Tailored Sustainable Connected 4.0 digital transformation.”

As part of the Smart Factory program, Schneider Electric exemplifies brownfield implementation for customers who may be facing the same challenges with their existing production facilities. The team is able to offer strategies and talk through the challenges they faced to help customers exploring IIoT connected technologies overcome those same hurdles toward their modernization goals. By sharing their experience in leveraging EcoStruxure solutions, visiting customers can better understand the value of the brownfield modernization and the resulting operational efficiencies.

In this production environment, these solutions have demonstrated operational and quantifiable value since their implementation:

• EcoStruxure Augmented Operator Advisor – Delivered a 20% reduction in mean time to repair on critical equipment where it has been implemented.

• EcoStruxure Resource Advisor and Power Monitoring Expert – Delivered 3.5% YOY energy savings in the Lexington facility in addition to $6.6 Million in regional savings since 2012; sophisticated reporting capabilities and increased transparency also drive operational performance.

• AVEVA Indusoft Web Studio – Delivered powerful Edge digitization of paper processes to eliminate paper work by 90% and cloud connectivity has enabled digital dashboarding of a critical process.

• RFID OsiSense – Eliminated 128 daily fork truck miles and eliminated $500,000 in Work in Progress (WIP) inventory with a 33% first year ROI.

• AVEVA Insight Data – Unlocked and shared silos of data in a mobile manner reducing downtime in critical processes by 5% with ROI of less than 6 months.

• Magelis GTU/GTUX HMI – Provided agile operator management of the process and vivid visual of the process onsite and via mobile devices.

Among the tidbits of information I picked up on the tour include:

Extensive use of Ethernet and IP networking. Interesting in that the very first conversations I had with a Modicon VP 20 years ago concerned how Ethernet was the network of the future. In 1999 that was revolutionary thinking. Today—it’s the backbone. Hat tip to Mark Fondl.

Great use of data tracking involving RFID tags, MES software, Ethernet connectivity, and visualization that coordinates all the products and containers throughout the company-wide power-and-free conveyor system.

Oh, and a Megelis computer/HMI collecting data from sensors and passing it on uses Node-RED for programming. It’s only the second instance of Node Red I’ve seen in automation.

Finally, Schneider Electric plant management correctly combines digitalization with Lean principles enhancing their daily stand ups and feeding continuous improvement.

Impressive facility. When our politicians and east coast journalists go ripping on American manufacturing, they should be forced to take deep dives into plants like this one.

Inductive Automation Announces Ignition Firebrand Awards

MES Application Conforms to Your Processes

Manufacturing is tough, says FactoryFour, a startup in the MES space. Managing it shouldn’t be, it follows up.

Param Shah, co-founder and CEO of FactoryFour, told me that he and his partner researched build-to-order and configure-to-order manufacturing in the orthopedic device market they discovered that manufacturing planning was done by a combination of paper and spreadsheets.

Further research showed that typical MES platforms required the manufacturer to configure its processes to conform to the workflows and parameters of the software. People really didn’t want to do that. They would simply ignore the cumbersome software and opt for something familiar and flexible.

FactoryFour’s simple value statement goes like this:

Today’s manufacturing software is manual and complicated. Manually managing the 100 little tasks that go into pushing products out the door causes unnecessary production errors and delays.

Managing it shouldn’t be complicated. Simple and automated. The freedom to focus on improving processes, eliminating bottlenecks, and growing revenue. Everything else is automated.

The manufacturing Shah studied was highly manual. In the orthopedic space where custom pieces are manufactured, order process errors are common. Employees find it hard to keep track of where products are in the manufacturing system.

FactoryFour uses native cloud technology. It customizes order intake, using it to inform the manufacturing system. In that system, engineers configure workflows, draw it up then put in software. Therefore the software conforms to the manufacturer’s workflow. The use barcode, RFID, etc., to track the process. FactoryFour connects to other software systems as required.

The Workflows allow rules and an “if this then that” process. It can, for example, integrate with shipping apps and APIs. If shipping stage goes active, it will call up software and generate shipping documents, find UPS tracking number, send to customer automatically. If error is called, it will notify and assign tasks.

Its API connects data to SAP, Epicor, Oracle, and the like. It tracks human labor through scans.

The company’s focus is on custom manufacturing and configure to order with high traceability needs. Channel includes consultants, SIs, and hardware companies.

I asked about usability. “Our first hire was UI UX person,” Shah told me. “We are extremely visual, using colors and designs effectively. Screens are intuitive, geared to technicians with only one or two buttons on a screen not 60.“

This is a young company that just completed its A round of financing looking to shake up the MES market.

Inductive Automation Announces Ignition Firebrand Awards

Open Source Faces Off Versus Proprietary Software

Two Polish software developers engage in conversation weekly on The Podcast. One wrote the original version of Nozbe the Getting Things Done app I use. Michael Sliwinski talked of using open source software to help him write his app and start his company. His Apple developer Radek Pietruszewski in episode 157 discussed how they wrote a piece of database code they dubbed WatermelonDB and released it into open source on GitHub.

I talk about the benefits of open source as an introduction to things I gleaned from last week’s annual trip to the Sacramento, CA area and the Inductive Automation Ignition Community Conference. Community was the operative word as the gathering of several hundred (I never heard an exact count, but the rumor was there were more than 600) integrators and users crowded into the Harris Center in Folsom for conversation, training, and updates.

On a side note, I’ve been unusually swamped with my annual project of assigning referees to high school and US Soccer youth contests. It seems as if half of the preliminary work I put in assigning before the season were washed away in an unusually wet late summer. Rescheduling is hell. Referees are tired of hearing from me. But I have only 2.5 weeks left in the high school season and two weeks beyond that will close the club season. Then I take a six-month break. Therefore, my energy level for writing has been sapped and the frequency here and on my podcast have suffered.

Founder and CEO Steve Hechtman betrayed his usual laid back demeanor talking about company growth and especially the latest release—Ignition 8—to be released in a few months. I have few details, but developers solved many platform problems caused by integrators pushing the envelop of HMI SCADA software.

Chief Strategy Officer Don Pearson told how the company has always embodied the OT/IT convergence meme with Hechtman coming from an OT background as an integrator and co-developers and now co-directors of software engineering Carl Gould and Colby Clegg were trained in IT technologies.

Pearson began the discussion of open source that continued throughout the conference. While Inductive Automation has always been a proponent of open standards—it still fully supports OPC UA, for example—it is also an open source user and contributor. The technologies strongly promoted at the conference were MQTT (a transport protocol) and Sparkplug (an information carrier in this case used to communicate Ignition tag information from source to consumer). Developer Cirrus Link has placed Sparkplug in the open source Eclipse Foundation.

Speakers talked with assurance about open source, but there was a thread of defensiveness in the discussion, too. Pearson quoted Maeterlinck, “At every crossroad on the way that leads to the future, each progressive spirit is opposed by a thousand men appointed to guard the past.” Eclipse Foundation Executive Director Mike Milinkovich proclaimed, “Software is eating the world, and open source is eating software.”

I like both open source and open standards. They both have propelled industry enabling innovation and limiting lock-in. I remember downloading the first Java JDK in the 90s and trying out the eclipse platform in early 2002. All pretty cool stuff. The Inductive Automation adoption of open source is refreshing in the industry.

Here are a few bullet points from the Carl-Colby show introducing Ignition 8:

  • Building on the past, but with a new beginning
  • New platform:
  • Revamped tag system to reduce memory overload
  • New scripting app
  • Subscription and data model
  • Extensibility
  • Dynamic writable UDT parameters
  • Deployment architecture, true project inheritance
  • Project resource management
  • Ignition perspective, new mobile module, built up from ground new

I really should add that while Ignition is very good software, most of the people at the conference told me that they were enticed into the system by the pricing. From the beginning, Inductive Automation decided to upset the software pricing model prevalent in the industry. It is a growing company…

Sepasoft

Inductive had acquired an MES company, integrated with Ignition, and has now spun it off into a separate company run by Tom Hechtman, brother to Steve. Its modular software includes many typical MES applications such as track and trace, workflow, OEE, recipe management, and more. Hechtman discussed a Lean Six Sigma tool kit. He noted the staff has doubled in the nine years since acquisition. It is an ISA 95 and B2MML solution. And also now a MESA International member.

Other notes from the conference

Table top exhibits from the conference sponsors were always packed with curious engineers seeking solutions.

Opto 22’s VP Marketing Benson Hougland told me they can’t build the Groov EPIC PLC fast enough for demand. That product combined with Ignition is a powerful control and SCADA platform—as sales attest.

Albert Rooyakkers, founder/CEO of Bedrock Automation told me that his sub-$1000 controller is selling well. Bedrock specializes in secure and hardened controllers—ideal for power, pipeline, and other such applications. He told me, “Secure SCADA with Ignition is coming.” His key word is secure.

Inductive Automation Announces Ignition Firebrand Awards

The ERP Buyer’s Profile for Growing Companies

Who buys enterprise software applications, how and why? I ran across this article by a contact of mine, Gabriel Gheorghiu, Founder and principal analyst at Questions Consulting, with a background in business management and 15 years experience in enterprise software. I thought it would be most useful. I’m not an ERP analyst, but I have some background and training on the financial side of things. I think this analysis fits with other large-scale software acquisition projects, though, including MES/MOM, analytics, asset performance, and the like.

This will summarize some interesting points. I highly recommend reading the whole thing.

Before we begin, my brief take on enterprise software applications. How many of you have been involved with an SAP acquisition and roll out? How many happy people were there? Same with Oracle or any other ERP, CRM, MES, APM, etc. application. Why did using Microsoft Excel seem to go better?

Well, the big applications all force you to change all your business processes to fit their template. You build Excel to fit what you’re doing. It’s just not powerful enough to do everything, right?

Gheorghiu conducted interviews with 225 companies who were all looking for enterprise resource planning (ERP). The goal of this survey was simple – listen and learn from what these companies had to say about their individual decision-making strategies. We all agree that this is not a simple task. But we also agree that selecting the best ERP software is a critical factor for business success.

Here is why the research phase of this process is considered to be so vital:

  • It has the greatest impact on all the subsequent phases and consequently, your final decision.
  • Research begins at home – in other words, the first step is to determine your company’s specific and unique needs.
  • Once your company has thought through and determined its software requirement, then and only then does the process to evaluate vendors and their offerings begin. This can be a very challenging step because many companies are not equipped with the time, knowledge, or tools to perform this step.

Buyer Profiles: Who’s Looking for ERP and Why?

One problem for analysis is that many are not doing business in just one industry. The breakdown of companies in our business sample, by industry, was as follows: manufacturing (47%), distribution (18%), services (12%), construction (4%), retail (3%), utilities (3%), government (3%), healthcare (3%), and other (10%). However, to complicate matters a little, 20% of manufacturers also manage distribution and some distributors include light manufacturing in their operations, like assembly.

“Companies looking to invest in business software may very well be addressing this additional challenge – looking for a comprehensive package that integrates all aspects of a business. ERP software systems are powerful and comprehensive but are not necessarily known for their agility and ability to accommodate many disparate functions.”

Gheorghiu identifies as a strong influencer consumerization, which changes focus from organization-oriented offerings to end-user focused products. “This was a highly significant turning point in the IT marketplace. By developing new technologies and models that originate in the consumer space rather than in the enterprise sector, software producers opened up the market to a flood of small and medium-sized businesses looking for more cost effective, and less complicated solutions to run their businesses.”

The consumerization of software (as noted above) has precipitated the move by many companies away from enterprise IT towards more streamlined and user friendly consumer-oriented technology. This change is equally relevant for ERP software and manufacturing companies have participated in this very significant development, albeit more cautiously and slowly than SMBs.

Most industries follow a “purposeful implementation” strategy, managing software adoption as a series of “sprints in a well-planned program” rather than insisting on the “all or nothing” approach.

For example, a small company looking to invest in software might decide to begin with an accounting system which can be used alongside point solutions and spreadsheets. As companies grow and their transactions become more complex, they may find that they have also outgrown their initial software selections.

The chart below provides a visual analysis of the mix of software that is currently utilized by our business sample:

Some relevant comments we extracted from our survey included:

  • The CEO of a small services company mentioned that he was “tired of the hodgepodge of systems”
  • A manufacturer considered their current arrangement to be “very siloed.” Reconciling the inventory balance is a “constant battle.”

Buyer Behavior: How are Companies Approaching ERP Selection?

The selection process is most successful when companies adhere to some basic selection rules: involve as many direct stakeholders as possible and keep business priorities and strategies firmly in mind when making the final decision.

Feature Functions

A software change can trigger a vast administrative upheaval within the company. It is important to carefully analyze the business case for the change and whether it supports the level of disruption as well as the implementation time and spending that will be required. Even if the change may be entirely justified, a well thought out analysis is well worth the time and effort.

The Vendors in the Spotlight

According to our survey results, the chart below identifies the vendors under consideration by the companies surveyed. A majority of companies (53%) were not, for the moment, looking at specific vendors. However 47% of respondents had narrowed their search to specific vendors.

Who’s Involved in this Decision Selection Process?

Our sample results indicate that the people in charge of the selection process are distributed as follows: employees in the finance and accounting departments (23%), IT department employees (23%). The other important categories were independent consultants helping companies with the selection process (17%), operations managers (17%) and presidents or CEOs (12%). It is worthwhile mentioning that project managers and business analysts only made up 5% of the total.

By far, the most effective method of choosing a software is to employ a collaborative system whereby the actual stakeholders of that system (the end-users) have a direct voice in the decision outcome. As the front-line users of the system, their insight and knowledge is very valuable. Their input along with all the other stakeholders input will produce the best possible outcome of this process.

An ERP system is a major business investment and is best handled with the appropriate amount of time and diligence given to the process.

The advent of cloud computing has indeed radically changed the landscape for deployment of business software. According to a recent press release by Gartner, “by 2020, a Corporate “No-Cloud” policy will be as rare as a “No-Internet” policy is today”. In other words, cloud deployment will become the default by 2020.

Our survey results, in fact, support Gartner’s analysis. Ninety-five percent of companies responded that they were open to a cloud deployment model, while just over 50% were willing to also consider on premises ERP. Of this latter group of respondents, 65% of them were manufacturers and distributors. This makes sense of course, given that these industries made significant investments in hardware and IT personnel and may not be as ready or as willing to move to the cloud model.

As for the preference for cloud computing (as demonstrated by our responses), we argue that it reflects the very strong tendency in the market to opt for simpler, more streamlined and less expensive computing solutions. As more information and assurances of security and stability by cloud providers enter the marketplace, more and more businesses will be convinced that the many benefits of the cloud outweigh some of their remaining concerns. Gartner’s prediction that cloud will increasingly be the default option for software deployment looks to be right on course.

Conclusion

An important consideration for companies embarking on an ERP software selection process – the average lifespan of an ERP system is approximately 5 to 10 years. If we consider important factors like the investment of capital, time, and loss of productivity that the selection and replacement of an ERP system requires, perhaps all companies would be more willing to invest the necessary effort in this process.

Follow this blog

Get a weekly email of all new posts.