by Gary Mintchell | Oct 1, 2024 | Process Control, Standards, Technology
I have two pieces of news regarding The Open Process Automation Forum. These came just as I was wondering if the organization had been making any more progress. I have unfortunately seen enough of these open automation standards attempts to wonder if this one will go much farther—especially given the maturity of the market.
This group started as a response to the high cost of upgrading automation systems in the field in the process industries. Where I see more opportunities would be in the discrete manufacturing area where the old trend of larger and more complex systems seem to be reversing to a more manageable size for the automation with the requirement to tie the systems to information networks.
My second piece, following this one, reports on an analysis of OPAF’s proposed system orchestration standard.
Philosophy aside, OPAF has made another step forward by launching the O-PAS Certification Program.
The Open Group Open Process Automation Forum (OPAF) has developed the O-PAS Standard, a standard of The Open Group, which uses existing and emerging standards whenever possible, making it a standard of standards. The standard enables the development of fit-for-purpose systems consisting of cohesive functional elements acquired from independent suppliers and integrated easily, via a modular architecture characterized by open standard interfaces between elements.
O-PAS certified products allow end users to build open, interoperable, and secure systems with products from multiple suppliers, offering greater flexibility in obsolescence management, system upgrades, and technology infusion.
Jacco Opmeer, Co-Chair of the Open Process Automation Forum at The Open Group and Principal Automation Engineer at Shell says, “Certification provides the credibility that the fundamental qualities open systems will bring are measurable, and this will support the realization of many of the values the Open Process Automation Forum has been promoting.”
Hideki Murata, head of the Systems Integration Planning Dept. at Yokogawa Electric Corporation, commented, “Yokogawa welcomes the O-PAS Certification Program as this will allow us to officially certify our products designed for the O-PAS Standard. We expect the program will accelerate the development of the O-PAS ecosystem by enabling end users to select certified products with confidence. This will help the industry move forward with open, interoperable, and secure products and systems.”
Within the O-PAS Standard, there are Profiles that define the various segments of the architecture. The O-PAS Certification Program is based on these Profiles and for each Profile, the Supplier must attain independent verification of its claims of conformance. The Connectivity Framework and the Global Discovery Server Profiles are currently ready to be certified against, and The Open Group is anticipating that more Profiles will be available by the end of the year.
by Gary Mintchell | Sep 30, 2024 | Events, Manufacturing IT, News, Software
I think I’ve been to all twelve Inductive Automation Ignition Community Conferences in Folsom, CA. It’s possible I missed one. They are always enjoyable. It’s truly a community where people share ideas and show success stories. The partner ecosystem for Ignition consists of strong, smaller, innovative companies and creative systems integrators.
To quote from the press release, Now in its twelfth year, the Ignition Community Conference (ICC) brings together industrial professionals from around the world to network, collaborate, and learn more about Ignition — an industrial automation software platform for SCADA, HMI, IIoT, MES, and more — and the ecosystem of technology solutions that work with it.
Highlighting the first day, executives Colby Clegg and Carl Gould previewed the release of Ignition 8.3. Yes, the last version was 8.1. This is a significant update even further integrating with IT technology. Founder Steve Hechtman explained to me when we first met 20 years ago how Ignition was built from the ground up to be IT friendly—unique for a SCADA application. They continue the tradition.
The update, scheduled for January 2025 release, features a redesigned Gateway user interface said to be faster, more intuitive, and easier to navigate. Upgrades to the Ignition Perspective Module include integrated drawing tools, a flexible form generation component, and the ability to design applications for offline use.
Another upcoming feature called Event Streams will allow users to map event data from sources to handlers, giving them new ways to push, transform, filter, and batch data. Also included are a new, public historian API and a new Power Historian that’s embedded in the Ignition platform, along with many other new features, and will be actively supported for five years after its release.
System integrators who leverage the Ignition platform to create exceptionally innovative and successful projects, are featured with Firebrand Awards. This year’s awards featured these applications.
NeoMatrix Inc., which helped Lucid Motors implement a real-time factory information system that provides data on manufacturing performance to enable data-driven decisions, optimize processes, and improve overall operational performance.
Deloitte, which implemented a modern SCADA/MES system, realizing Goodman Fielder’s initiative to enhance production efficiency and replace manual processes at their three largest bakeries.
IDOM, which implemented a real-time automation orchestrator for the entire production process at the pharmaceutical company Cinfa, including a Unified Namespace that allows applications to exchange information in a decoupled architecture.
Saint-Gobain CertainTeed, which deployed the Vision Module-based FaCTory+ MES solution, which pulls in production orders from SAP, tracks 24-hour performance, compares current and previous production runs, and more.
Fermi National Accelerator Laboratory, which created a library of standardized objects with heavy use of User Defined Types (UDTs), allowing it to easily monitor and control a large-scale experiment analyzing the properties of neutrinos.
Madkour Group, which built a system providing real-time data from remote locations and reporting and analytic tools for the National Project for Developing the New Valley in Toshka, which aims to reclaim vast desert areas as part of Egypt’s overall plan to cultivate three million acres in total.
All of the winners’ and finalists’ project submissions, including videos and written case studies, can be viewed in the online ICC Discover Gallery.
The event sold out once again packing about 900 people into the Harris Center in Folsom. Inductive Automation made the difficult decision to leave their home of the past 12 years and move to the SAFE Credit Union Convention Center in Sacramento, California. Located in downtown Sacramento, about 30 miles from Folsom, the SAFE Credit Union Convention Center is a fully remodeled, state-of-the-art venue with over 240,000 square feet of space, and within walking distance of many hotels, restaurants, and entertainment options.
During the Closing Keynote session on September 19, Project Manager Nick Barfuss made a surprise announcement that Inductive Automation will soon launch a unified, browser-based interface for end users, integrators, and IA staff and distributors.
Known as Inductive Automation Workspaces and launching in 2025, the new interface will streamline the Ignition sales process with self-service or assisted-service modes, and empower organizations to access and manage their licenses, support plans, roles, and organizational structure.
Workspaces will launch with features for creating organizational units; creating and sharing estimates, quotes, and orders; managing licenses and support plans; making purchases in local currency; and more.
During the Closing Keynote session, Co-Directors of Support Services James Hunt and Marcus Bellamy announced that Inductive Automation will be extending its software support hours by nearly 50 percent in Q1 of 2025. The two leaders explained that the company is adding more support engineers at its offices in the US and Australia, which will expand the support hours from 6 AM to 5 PM PST to 6 AM to 11 PM PST.
During the Main Keynote session, Chief Technology Evangelist Travis Cox discussed the tenth anniversary of Inductive University, the free online industrial automation training platform that the company launched during ICC 2014.
Cox said that Inductive University (IU) has become one of the company’s most popular training resources and has seen fantastic growth. Since launching a decade ago, IU has had over 10 million video views, almost 8 million tests (known as “challenges”) have been taken, over 100,000 user accounts have been created, and 30,000 Ignition credentials have been earned. Cox also said that these IU numbers represent hundreds of thousands of people who have gained new knowledge that helps them turn their ideas into reality.
During the Closing Keynote session, Co-Directors of Support Services James Hunt and Marcus Bellamy gave a glimpse of what lies ahead for IU, saying that their team will be adding over 70 new videos to IU in 2025, as well as adding learning paths that are specific to skill level.
by Gary Mintchell | Sep 30, 2024 | Workforce
The Human Factors and Ergonomics Society features research into such things as how humans focus on displays and controls, how humans work to lift, reach, and twist in various occupations. The Society has been mostly academic, but Susan Kotowski, outgoing President, has led an initiative to reach out to practitioners fostering joint collaboration into research.
The sessions I attended explained research using video-based experiments evaluating tools such as exoskeletons that might alleviate any of a variety of work-related injuries.
I thought maybe I would meet engineering grad students, but Kotowski told me members of the Society hold a variety of titles and jobs, usability, goal, jobs, tasks, processes, fit to person using them, designing to people, span every industry, cognitive and physical.
The conference was dubbed ASPIRE, which is both an appropriate word and a letterism standing for Advancing Systems and Practices through Innovation, Research, Education.
I mostly attended sessions in the Occupational Ergonomics track. Some of the research focused on hands—the best way to grip, move, assemble tools and parts. Other research focused on exoskeletons. The goal is to reduce muscular/skeleton injuries and repetitive lifting injuries.
Much of the research turns out to not be practical. Seeking more collaboration with industry will help focus research into more useful channels.
Talking with researchers in the hall, I was told that exoskeletons have so far been oversold. They are OK for straight lifting, but if the subject is also given a cognitive task problems ensue. Further, any movements other than straight, say requiring twisting or turning, are not viable.
by Gary Mintchell | Sep 26, 2024 | Manufacturing IT, News, Organizations
My long-time colleague Julie Fraser is still at it. I remember the room where the Manufacturing Enterprise Solutions Association International (MESA) announced its first Metrics That Matter study. It was 2006.
The Manufacturing Enterprise Solutions Association International (MESA) is working with Tech-Clarity, Inc. on the next iteration of its long-standing Analytics that Matter research program. Formally launched during the MESA Smart Manufacturing NOW virtual event, this research will review manufacturers’ progress in performance metrics and analytics and explore the value manufacturers and producers can gain from using artificial intelligence (AI).
MESA and Tech-Clarity will conduct a survey to understand the goals, challenges, and successes companies have for their analytics and AI initiatives. They will share the findings in a research report, infographic, and webinar during the first half of 2025. The survey will be open for manufacturers’ responses later in 2024. To date, the program has three sponsors: Aegis Software, Epicor, and GE Vernova. The program is capped at six sponsors, so additional sponsors are welcome. For more information about sponsorship, please contact Julie Fraser at Tech-Clarity, [email protected].
Making Analytics and AI Matter is the continuation of an 18-year MESA initiative focused on uncovering the value of analytics through an online survey of manufacturers and producers worldwide across process, batch, and discrete industries. Tech-Clarity, MESA, and the sponsors will collaborate to develop the survey. The 2024-25 study continues work that began in 2006 under Julie Fraser’s guidance. This round extends it to reflect the growing role of not only metrics and analytics but AI and generative AI in manufacturers’ success.
Fraser will again lead the research program, supported by MESA’s Knowledge Committee and Analytics Working Group. Some questions will be based on previous MESA Analytics studies so the team can analyze trends and progress. In the last study, industrial analytics showed the quickest time to impact among various IT projects, and more respondents had live advanced analytics projects in 2022 than in previous surveys. New questions will focus on the impact of GenAI, what types of analytics work best where, and what helps AI to deliver its full value in production companies.
MESA’s International Knowledge Committee and Analytics Working Group Chair Chris Monchinski of InflexionPoint says, “We have seen the value of this analytics research over the years. It shows progress in manufacturers’ technology use and business understanding. Now, we will explore both traditional metrics and analytics and the uptake of the newest AI and GenAI technologies to deliver manufacturing insights. MESA’s Analytics Matter podcast has supported these topics for several years. Now, we will have new quantitative research to understand where the value lies.”
“Manufacturers have long known there is more they could do with their data. This research aims to demonstrate what they are doing to analyze their data to create actionable insights and high-value improvements from descriptive, diagnostic, predictive, and prescriptive analytics and current AI approaches. MESA Members and study sponsors will get invaluable learning from sharing experiences,” Tech-Clarity’s Vice President of Research for Operations and Manufacturing Julie Fraser remarked. “We are grateful for the sponsors who have already stepped up to ensure this industrywide research can continue in this time of rapid progress in AI and looking forward to welcoming a few more sponsors to the team.”
MESA conducts this study with a research partner every few years. In November 2024, look for a press release inviting manufacturers and producers to take the survey. Then, in 2025, we will announce the release of the findings report, infographic, and webinar. MESA members and sponsors will have special access and rights to these survey deliverables.
Tech-Clarity is an independent research firm dedicated to making the business value of technology clear. We analyze how companies improve innovation, product development, design, engineering, manufacturing, and service performance through the use of digital transformation, best practices, software technology, industrial automation, and IT services.
Manufacturing Enterprise Solutions Association (MESA) International has been helping the global manufacturing community use information technology to achieve business results through premier educational and research programs, best practice sharing, and networking since 1992. MESA is a 501(c)6 not-for-profit trade association. The Manufacturing Enterprise Solutions Association (MESA International) is a global community of industry thought leaders actively driving business improvement through the effective application of technology and best practices.
by Gary Mintchell | Sep 24, 2024 | Manufacturing IT, Operations Management, Software
MachineMetrics positions itself in the analytics space translating from operations to ERP. It has released a scheduling solution called Production Schedule Intelligence touting scheduling accuracy, work-in-process optimization, and on-time delivery.
This solution integrates real-time data and predictive analytics into operations connecting directly to both ERP and machines.
Key Features and Benefits
- Dynamic Schedule Optimization: Continuously assesses and adjusts production schedules based on real-time operational data, dynamically adapting the schedule to address machine downtimes and other production interruptions.
- Real-Time Adjustments: Visualizes your scheduled OTD targets and predicts completion dates in real-time.
- Interactive Production Order Management: Users can easily edit and re-sequence production orders through an intuitive drag-and-drop interface, with immediate feedback on schedule health.
- Real-Time Impact Analysis: The system flags potential delays and adjusts work-in-process calculations dynamically, enabling proactive schedule management and empowering plant managers to make smart decisions based on real data.
- ERP Data Utilization: Integrates seamlessly with ERP systems to use planned start dates and cycle times as reliable baselines for adjustments.
by Gary Mintchell | Sep 12, 2024 | Cloud, Manufacturing IT, Operations Management, Software
I seldom do case studies here. I don’t have time to do a proper set of interviews that would emphasize team rather than product. This one came from Rockwell Automation’s company Plex. Gathering appropriate data and displaying it in ways that boost decision making constitutes a recurring problem for operations management. This story details establishing real-time reporting, insight into inventory tracking, and visibility across production.
The client company, Advanced Vehicle Assemblies, LLC (AVA) is known for its unique, complementary manufacturing processes that enable the production of complex metal assemblies. Founded in 2021, AVA has expanded significantly and now ships approximately 52.2 million parts annually.
The problem statement from AVA CIO Rob Arrowsmith: data was not easily accessible, and functions difficult to learn.
The result: real-time data is accessible, and online learning resources are abundant and easy to follow.
[Note: what follows was written by Plex marketing. I did not edit out all the adjectives and adverbs. It is a good story of actually implementing a complex software application in a short amount of time.]
AVA split from its former sister company in June 2020 and this transition kicked off an urgent search for a new ERP system. They were temporarily covered under a shared service agreement from their previous affiliation, but the end date was nearing. As a result, the company looked for an ERP solution that minimized hardware maintenance — a stark contrast to their previous experience — and could be implemented within their tight timeline.
Alongside the frequent maintenance required by the old ERP system, AVA also faced the fact that the old system did not include Manufacturing Execution System (MES) integration. The absence of real-time production reporting and inventory tracking led to reliance on manual processes, causing significant delays and a lack of trust in the collected data. As AVA aimed for rapid independence and organizational rebuilding following the split, the selection of a new ERP system became a critical aspect of their strategic focus.
As it navigated the landscape of ERP options during the summer of 2020, AVA conducted surveys, evaluations, and demonstrations to help identify their top priorities with the help of user feedback. Despite the tight timeframe, the culmination of this rigorous process led them to select Plex as their new ERP system in late 2020. This choice marked a pivotal step for Advanced Vehicle Assemblies, LLC as they embraced a new ERP system that promised to streamline operations, enhance efficiency, and support their journey towards becoming a thriving, independent enterprise.
Embarking on their ERP system revamp journey, AVA utilized the Milan, Michigan facility as their first Plex implementation site in December 2020. This location shared the outdated ERP system with AVA’s sister company, adding an extra layer of complexity to the transition. Knowing time was of the essence, Milan aimed to go live on Plex within 60 days.
To ensure a successful transition, AVA enlisted the support of Plex implementation services, who assigned a project manager to the Milan site. This project manager brought a deep understanding of the project’s parameters and the urgency of a rapid go-live timeframe. To bolster their efforts, the Plex team tapped on outside consultants to assist with the critical data cleansing phase as it was loaded into Plex. Employee training sessions and workshops were also prioritized, acknowledging the importance of preparing users for the impending changes.
As the go-live date loomed, an impressive collaboration unfolded, with up to seven Plex team members present at the Milan location during each shift. This emphasis on teamwork from all sides underscored the collective commitment to a successful implementation. Despite the challenge of a 60-day timeline, the Milan site successfully implemented Plex within the desired timeframe. Employees showcased resilience and adaptability as they mastered the main Plex functions, navigating the natural learning curve that comes with migrating to a new manufacturing solution.
The Plex implementation brought about a transformative wave of improvements for AVA, revolutionizing their operational landscape. One of the most notable enhancements was the establishment of real-time production reporting and inventory tracking. The newfound ability to access data in real time instilled a heightened sense of awareness of inventory for AVA, enabling employees to address issues promptly, fostering agility in their responses and elevating overall operational efficiency.
Furthermore, the implementation of Plex significantly augmented visibility across production. With operators more engaged and proactive on the shop floor, AVA witnessed quicker problem resolution. The benefits of Plex extended beyond the shop floor as it empowered AVA to successfully grow its business while maintaining a lean operational structure, minimizing the need for additional personnel to manage the Plex ERP system. Additionally, key Performance Indicators (KPIs) became more visible and dynamic, seamlessly integrating into Plex as native components rather than being extracted from external Excel sheets.
Plex also eliminated the necessity for financial consolidation software, streamlining processes and making contextual data easily available. The intuitiveness of the Plex system unlocked this accessibility, making it easy for users to navigate and find the information they need. The cloud-based nature of Plex, coupled with its highly configurable background settings, provided a foundation of flexibility that empowered AVA to continue to test and implement improvements. This adaptability positioned Plex as a transformative tool that not only met AVA’s original expectations for their ERP system but exceeds them into the present and future.
After the Plex implementation, Advanced Vehicle Assemblies, LLC has gone on a revolutionary journey marked by significant improvements across various facets of their operations. The shift from an outdated ERP system to Plex resulted not only in material improvements but also newfound capabilities and efficiencies. Perspectives have also evolved across departments, emphasizing the importance of collaboration and data utilization.
For AVA, the most significant achievement with Plex has been the ability to attain complete independence. Upon completion of the implementation, internal surveys affirmed the success of Plex as it earned high marks for reliability, speed, and ease of use. The adoption and integration of the software extends beyond that of the Milan, Michigan location, with AVA employees able to take on the remaining Plex implementations internally with little to no Plex support required on site.
As AVA looks towards the future, the success of the Plex implementation stands as a testament to the company’s resilience and adaptability, setting the stage for continued growth and operational excellence for years to come.
