A supplement to PLANT

ControlENGINEERING
Engineering
and Control Engineering magazines
PLANT ENGINEERING magazines
 C-more Touch Panels
®

6” Color TFT
Higher Performance, Lower Price
$
499. 00
u.s.
EA9-T6CL-R 10” Color TFT
Serial only $
1290. 00
u.s.
EA9-T10CL
Serial and Ethernet
6” Color TFT
$
699. 00
u.s.
EA9-T6CL
Serial and Ethernet
12” Color TFT
8” Color TFT
$
1790. 00
u.s.
EA9-T12CL
$
999. 00
u.s. Serial and Ethernet
EA9-T8CL
Serial and Ethernet
15” Color TFT
$
1999. 00
u.s.
EA9-T15CL
Serial and Ethernet

The popular C-more HMIs have

ALWAYS been a great value, but now
they are better than ever. We have
included some of the latest
technology into the latest EA9 series
C-more panels, and all at a lower cost to CONNECT TO CONTROLLERS WITH DRIVERS FOR:
you. But don’t let the lower price fool you - with a • All AutomationDirect programmable controllers
redesigned, more robust housing, thinner bezel, LED • Allen-Bradley - ControlLogix®, CompactLogix®, MicroLogix™
Ethernet, SLC Series, FlexLogix, SLC® 5/05 Ethernet™
backlights and more communications and data storage
options, the EA9 series offers even more value and performance. • Modbus RTU and TCP/IP Ethernet
• GE SNPX
ALL EA9 SERIES C-MORE PANELS INCLUDE: • Omron Host Link Adapter (C200/C500), FINS Serial
and Ethernet
• 800 MHz processor
• Selected Mitsubishi FX Series, Q Series
• SD memory card slot for data logging
• Siemens S7-200 PPI and S7-200/300 Ethernet
• One USB 2.0 A-type and one USB 2.0 B-type port (ISO over TCP/IP)
• Serial communications interface
• 26MB project memory space Get the App!
(82MB on the 12- and 15-inch units) The C-more Remote HMI App allows remote access and
FULL-FEATURED MODELS ADD: control for mobile users who have a wi-fi or cellular con-
• 10/100Base-T Ethernet communications nection. Available for use on any Apple® or
• Additional SD card slot on 12- and 15-inch models
AndroidTM device.
• Two additional ports, for a total of three serial
communications ports (RS-232, RS422/485)
• One HDMI Video Output
(12- and 15-inch units only)
REMOTE ACCESS AND CONTROL BUILT-IN
• No Additional Hardware required. The C-more
Remote Access feature resides in all EA9 panels
HDMI The C-more EA9 series 12- and
15-inch panels now have an
with Ethernet support, and requires no option HDMI video output port. This
modules. Access real-time data or initiate an
action on a control system from anywhere, allows you to connect HDMI
any time. devices like larger screen
TVs to the C-more panels for
longer-distance viewing of
Research, price, buy at: operator screens.
www.automationdirect.com/c-more

Order Today, Ships Today!

* See our Web site for details and restrictions. © Copyright 2014 AutomationDirect, Cumming, GA USA. All rights reserved. 1-800-633-0405 the #1 value in automation
Contents
A4 Dealing with system
integration issues
System integrators must satisfy the business requirements of
their stakeholders while ensuring the technical integrity of the
project. They must ensure that components, systems, subsystems,
processes, and workflows function together reliably, efficiently, and
economically.
A4
A10 Launching industrial Internet
programs—into the cloud
Cloud service providers shorten the journey to the industrial
Internet by providing access to IT services similar to those
delivered from equipment owned by the user’s organization.

A10
C OMMENT
Integration, automation, and the cloud

I
n manufacturing, you can’t please everyone—
or can you? Trying to meet the often conflict-
ing expectations of every automation project
stakeholder can be a formidable challenge.
Successful system integrators must be as busi-
ness savvy as they are tech savvy. Resources,
equipment access, project timelines, planned
downtime, and personnel training are a few of
Jack Smith the issues that must be sorted out before the first
Editor network is mapped.
The author of this issue’s cover story explains
some of the business and technical issues
associated with system integration projects
and how to deal with them. He emphasizes the
importance of communication and planning from
project inception through completion. Flexibility
and coordination must be maintained throughout
the project. In addition to insight into system
integration issues, the article describes chal-
lenges associated with several project types
and how to overcome them.
The other story in this issue examines cloud
services. In an industrial automation context,
“the ‘cloud’ is the delivery of IT capability
using remote infrastructure accessed via the
Internet; ‘cloud services’ provide access to
IT services similar to those delivered from
equipment owned by the user’s organization.
Companies that specialize in delivering indus-
trial Internet services through the cloud typi-
cally provide solutions that organizations use
to build their industrial Internet programs, the
most common of which include managed secu-
rity, cloud data storage, analytics, applications,
and information delivery (integration).” The
author also explains how security is managed,
the types of services available, and the busi-
ness and technical benefits of partnering with
a cloud service provider.
Manufacturers should approach automation
projects for the right technical—and business—
reasons.

ON THE COVER In addition to best design and installation practices, system integrators can provide full electrical design and documentation.
Courtesy: TriCore Inc.

Applied Automation April 2015 • A3

 C O V E R S T O RY
Dealing with
system integration issues
System integrators must satisfy the business requirements of their stakeholders
while ensuring the technical integrity of the project.
By David McCarthy
Tr i C o r e I n c .
G
enerally speaking, system integrators
ensure that components, systems, subsys-
tems, processes, and workflows (to name
a few) function together reliably, efficiently,
and economically. They can serve process
industries, discrete industries, and every-
thing in between. While striving to please all the stakehold-
ers, it can be challenging to make everyone happy—at the
same time. From time to time, issues can arise that can
make system integration seem like Mission Impossible. To
ensure your project finds its way to mission accomplished,
consider these challenges and how to handle them.
A good beginning makes a good ending
One of the early issues system integrators face is
understanding the business issues that drive a project.
Successful integration projects not only result in solidly
performing automation systems, but also provide solu-
tions to business concerns. Too often, the conversations
are solely about technical issues with technical people.
This narrowed view can lead to projects that succeed
when viewed through a technology lens, but fail miser-
ably in meeting their prime objectives. Only after the why,
what, when, and who of a project are thoroughly under-
stood is it wise to determine how to apply the best techni-
cal solution.
There are also many nontechnical requirements that
must be sorted out early because they can influence
technical decisions. Most projects will likely require a
variety of:
n Materials and system resources
n Unencumbered access to production systems
n A reasonable timeframe for design/build activities
n Adequate production downtime for installation
A4 • April 2015 Applied Automation
n Sufficient time and access to operations and mainte-
nance staff for training.
Each of these items has one or more stakeholders,
whose interests can often conflict with each other and
your project requirements. Navigating these competing
interests can challenge even the most seasoned system
integration firm.
The best approach begins with effective communication
and planning. When you have a firm understanding of the
business drivers, communicate your requirements early
with all of the stakeholders. For example, it may not be
obvious to a facilities manager that you need plant utili-
ties operational during system installation—even if plant
production is otherwise down. You must identify to these
stakeholders all of the resources you need to accomplish
your project, while accommodating any issues they may
have with meeting these needs.
A significant challenge for all parties is that system
integration activities often cause some disruption to
operations during installation. It is essential to develop
a plan for this early. From a system integrator’s stand-
point, performing all installation activities in one continu-
ous downtime window usually requires the least calen-
dar time and can be delivered at the lowest cost. This
approach is often the most disruptive to operations—
particularly production.
Getting stakeholders on the same page can require
creative negotiations. Phased systems installation,
around-the-clock installation, multishift training, parallel
operations between new and old systems, advanced fin-
ished-product inventory accumulation, and even produc-
tion outsourcing can come into play. With some up-front
effort, it is possible to strike the right balance among lost
production, installation savings, resources, access, and
business concerns. After the plan is in place, keep the
stakeholders engaged throughout the process—this is the
best pathway to a successful ending.
Managing risk
After the project logistics are sorted out, a system
integrator can begin to design the physical and func-
Figure 1: In addition to best design and installation practices, system integrators can provide full electrical design and documentation.
All graphics courtesy: TriCore Inc.

tional aspects of the system. There are risks to manage and identifying the physical and logical entry point for
throughout this process and throughout the lifecycle each zone are essential aspects in developing a robust
of the system. It often falls on the system integrator to security strategy.
help manage them—sometimes long after the project is Control equipment operation: The safe and effective
completed. Security, controls, software, and testing are operation of the control equipment over the lifecycle of
important considerations. the system is another risk to manage.
Security risks: Managing security Control equipment must be vetted to
risks is becoming increasingly chal- Control equipment must be ensure conformance with intended
lenging for system integrators. This vetted to ensure conformance use, input/output signal types, power
is due in part to the availability and requirements, corporate standards,
presence of smart devices on the with intended use, input/ and more. Where this equipment
plant floor, and the desire to take is physically installed must also be
output signal types, power
advantage and integrate the informa- considered. There is a big differ-
tion they provide across systems and requirements, corporate ence between equipment designed
platforms. This is a large and growing to be dust resistant and equipment
issue, with many layers and nuances.
standards, and more. designed to resist 80 lb of hose-
PLCs, HMIs, servers, workstations, directed water with airborne corro-
networks, and applications have security vulnerabilities. sives. When shipping the control equipment, excessive
Balancing the advantages of access and integration vibration can damage delicate electronic components.
with the concerns of security is becoming increasingly The effects of this might not be immediately apparent.
complex. Understanding the risks, defining the security Shipping via Air-Ride van or other vibration-reducing
zones, identifying the data that move between the zones, methods will help mitigate the risk of in-transit damage.

Applied Automation April 2015 • A5

 C O V E R S T O RY
Software: Systems usually include various types of
software. One type is referred to as commercial off-the-
shelf (COTS) software, which includes operating sys-
tems, security software, visualization platforms, database
platforms, and more. There is a unique risk associated
with how various COTS software products interact with
each other over time. For example, a routine service
pack upgrade by your IT staff on your workstation COTS
operating system may render
Figure 2: System integrators offer the
ability to collect manually entered data
automatically and generate user-friend-
ly reports, such as logs and trends, from
these data.
your COTS user interface software inoperable. System
integrators frequently deal with issues like this. They can
be a great resource to help manage these activities over
the life of the system.
Customized software: One of the most challenging
parts of any system integration project is customized
software. It can be found running plant-floor control-
lers, graphical user interfaces, customized scripting,
database management, and much more. Ensuring this
software meets the needs of all stakeholders is one of
the largest risks to manage. A solid functional specifica-
tion, thoroughly reviewed by all stakeholders, is the best
approach. This details all automated operations including:
 Interlocks, sequencing, and device activations
 How people interact with the system
 HMI screen definitions, security, overrides, alarms,
configuration, and navigation
A6 • April 2015 Applied Automation
 What data are collected, how it is queried, and how it
is presented
 Any information exchanged with other systems.
A well-written functional specification will serve as a
basis to measure software development as well as to
ensure the system is operating properly over time.
Testing, commissioning: Ensuring equipment,
software, and systems are installed and tested prop-
erly presents its own challenges. A site installation
plan—based on the functional specification and elec-
trical design documents—is needed to keep track of
which devices and functions were tested. This is very
important on large-scale integration projects involving
hundreds or thousands of devices and operations. It is
not uncommon on large projects that certain smaller
areas are initially untested during installation. This
can be due to lack of equipment,
utilities, raw
material, or other
items necessary
to test the opera-
tion. It is essential
to keep track of
these areas and to
involve the system
integrator prior to
putting such areas
into production.
The central design
challenge
A core design chal-
lenge is in how
much to centralize or
decentralize a system,
for both control and I/O systems. It’s a more complicated
issue than it appears on the surface, and one that is
often overlooked. The general rule is that equipment
groups that operate reasonably independently are good
candidates for distributed control. Highly intertwined
equipment groups work best in centralized schemes.
The degree of I/O system centralization is based on the
physical layout of the equipment. These are the rules;
now consider when it’s appropriate to break them.
If installation is done in phases, things get a bit more
complicated. For I/O systems, the physical location of
the process equipment is not the sole determining fac-
tor in this regard. You will also need to consider how the
equipment is phased into operation. If installed in mul-
tiple phases, it may make sense to distribute the I/O per
phase. It really comes down to how much the equipment
in the new phase can affect the operation of equipment
in a previous phase. Distributing the I/O will be the least
 20 MILLION INVERTERS
10 MILLION SERVOS
300,000 ROBOTS
Yaskawa. Proven. Worldwide.

Nobody enjoys a larger installed base of inverters,

servos and robots around the world than Yaskawa.
Our experienced engineers, proven technology and
unsurpassed quality can all be combined to give
proven solutions in which you can have total confidence.

In a recent internal study of 100,000 servo motors

shipped, Yaskawa found that only 7 were returned
for warranty repair. To put that in perspective, a
typical out-of-box failure rate goal for manufacturers
of brushless servo motors is 0.5% (or 500 failures
per 100,000 motors shipped).

No matter how you add it up, nobody equals Yaskawa.

Call us today.

YA S K A W A A M E R I C A , I N C .
DRIVES & MOTION DIVISION
1 - 8 0 0 - YA S K A W A | YA S K A W A . C O M

For more info:

©2015 Yaskawa America Inc. http://Ez.com/yai733
 C O V E R S T O RY

disruptive to existing equipment. From a control stand- of an existing I/O system intact while phasing in newer
point, phased installation of highly intertwined areas portions has its challenges. This will likely require new
does not generally create a need for distributed con- wiring to the new system and parallel operations of old
trol. Phased installation of independent process areas and new systems. For devices electrically daisy-chained
would strengthen the case for distributed control, but using a common power supply, if at all possible, try to
rarely create one for a centralized scheme. keep the entire loop intact on one system or the other.
It gets more interesting when you install an inherent- This will greatly simplify your life.
ly centralized process in phases and expect it to run in Where individual instrumentation input signals must
some temporary manner with manual equipment. After be shared between both systems, there are generally a
the final automated equipment is eventually installed, it couple of options available. Having signals networked
could be incorporated into a centralized control system, between the old and new systems will be the simplest
or be distributed with its own controls. The centralized solution from a wiring standpoint, and there is no loss
approach will have fewer failure points of signal fidelity with this method. The
and a simpler structure when it is up trade-off is a signal time-lag between
and running, but a distributed design Money makes the world systems compared to direct I/O module
could potentially be installed much go round, and system connections. There is also a potential
quicker. hardware cost hit because this approach
With the centralized approach, you integration is no excep- may require specialty communication
must thoroughly retest each unit oper-
tion. For each approach, modules to accomplish. For certain criti-
ation to ensure safe operation of both cal or high-speed parameters, this meth-
the existing and new equipment. In a there are hardware, od may not suffice. In that case, you will
distributed design, much of this test-
ing could be done in advance without
installation, and startup need to pick one system to control and
measure, and have the other request
risk to production. This approach can costs to contend with. and/or monitor these results.
significantly reduce overall installation For output devices that must be con-
time, and could be considered if your trolled from both systems, there are a
installation window is tight. couple of options you can consider depending on the
Money makes the world go round, and system inte- device type. Networking between the old and new sys-
gration is no exception. For each approach, there are tems is one common option. One system would physi-
hardware, installation, and startup costs to contend cally control the device; the other would request activa-
with. Centralized I/O systems tend to have lower I/O tion or deactivation of the device. This is the most secure
component costs due to economy-of-scale factors. method of operation and the easiest to troubleshoot
Distributed schemes tend to have more hardware com- should problems occur during this transition process. This
ponents. Installation costs for traditional hardwired I/O works well for both digital and analog devices.
platforms require a separate wiring run between each If networking is not an option, interposing relays with
field device and its associated I/O module. Distributed dual contacts can be used to allow both systems to
network platforms can allow you to wire from device to simultaneously control a single digital output device,
device without the need for individualized runs back to but care must be taken with this approach. If either sys-
the I/O system. You will tend to pay more for I/O hard- tem requests the device, it will unconditionally activate
ware and cabling media, but your overall costs could unless otherwise interlocked. If wired and designed
be significantly lower. properly, when the cutover is complete, the old system
Centralized control systems tend to have lower con- can be disconnected from the relay, the relay coil can
trol hardware costs compared to distributed systems be removed (a potential point of failure), and the relay
due to fewer controllers in centralized systems. System base simply exists as a terminal block between the I/O
startup costs for both control schemes are more module and field device in the new system.
complicated to determine. Installation phasing and Analog output devices are more problematic and not as
operational expectations can significantly impact these easily amendable to this approach due to potential loss of
costs. It is import to determine up front to what extent signal fidelity. If you simply must control an analog device
this might be the case, as it can be a large influence from two control systems and the systems cannot be net-
on the overall costs. worked, if all else fails, place the control (and associated
measurement, if necessary) in one system, and hardwire
Parallel universes the setpoint or output signal (and any associated permis-
As mentioned earlier, phasing the system installation sives) between them. Old-school techniques would typi-
is one tool to minimize production downtime as well as cally do this with binary-coded-decimal modules on both
a consideration in a centralized or distributed design. ends, although other approaches are also possible.
However, there are some other technical issues to For pneumatically actuated digital devices, pneumatic
address under such circumstances. Keeping portions switching may be used, although this is a less common

A8 • April 2015 Applied Automation

option. Parallel operation is a common and viable instal- hubs in this type of environment. If your network contains
lation option, but not without its challenges. multicast traffic, a managed switch is an absolute must.
Multicast traffic typically comes from smart devices on
Making the right connections plant floor process networks in a connection-oriented pro-
As plant floor devices continue to get smarter, and the ducer/consumer-based technology. EtherNet/IP (Ethernet
cost of both bandwidth and storage continue to plummet, industrial protocol), managed by ODVA, is an application
information exchange on the plant floor and across the layer communication protocol that uses this technol-
enterprise is becoming an essential part of most system ogy. In addition to handling multicast traffic, this class of
integration projects. Industrial networks on the plant floor switch usually provides error logs, control of individual
have special requirements not normally found in traditional port speeds, duplex settings, and the ability to mirror
corporate IT environments. The design and installation of ports. This functionality will help optimize and maintain
robust industrial networks that operate reliably over the the industrial network over time.
lifecycle of your system present unique challenges to sys- If your network is very small and has no multicast
tem integration firms. traffic, you could consider unmanaged switches. They
Unlike an office or home environment, industrial applica- are generally less expensive than managed switches
tions are often electrically noisy places. In addition to high because they lack much of the core functionality and fea-
electromagnetic interference (EMI), these environments tures of their managed switch counterparts. As a general
are subject as a class to temperature ranges, dust, humid- practice for networks of more than a few nodes, if cost
ity, and a host of other factors not normally found in a is not a primary concern, go with a managed switch. You
home or office. will be happy you did.
The first step in designing a robust industrial network
is choosing cable media. So, what’s the right choice? Trending toward the future
ANSI/TIA-1005: Telecommunications Infrastructure System integrators must necessarily face many chal-
Standard for Industrial Premises states that Category lenges when dealing with clients, including project
6 or better cabling should be used for hosts or devices management best practices, stakeholder engagement,
that are exposed to an industrial environment. Category and ensuring stakeholder expectations are aligned with
6 cable is good for up to 1 GB at 100 meters, and cat- business goals. Risk abatement is also a big part of the
egory 6e cable can do up to 10 GB at system integrator’s world, and an ever
that distance. challenging one, particularly on tech-
When installing network cable, shield- Unlike an office or home nology fronts. System integrators must
ed Ethernet cable may perform better environment, industrial follow core design principles and face
in high EMI environments if run outside the inherent challenges when it comes
of conduit. The key to using shielded applications are often time to put these principles into practice.
cable is in proper grounding. Using one electrically noisy places Finally, with the explosion of information
single ground reference is essential. on the plant floor, system integrators
Multiple ground connections can cause must face the challenges of putting an
what is referred to as ground loops, where the differ- industrial network infrastructure in place to best leverage
ence in voltage potential at the ground connections can what these technologies offer.
induce noise into the cable. Use a grounded RJ45 con- While you are likely to encounter many of these
nector only on one end of the cable. On the other end, issues on a system integration project, they are just a
use a nonconductive RJ45 connector to eliminate the sample of the entire universe of issues we deal with on
possibility of ground loops. a regular basis. Technology will continue to evolve, as
If your Ethernet cable must cross power lines, always do will the particulars of the technical issues encountered
so at right angles. Separate parallel Ethernet and power by the system integration community. What remains
cables by at least 8 to 12 in., with more distance for higher constant is the approach to dealing with these issues.
voltages and longer parallel runs. If the Ethernet cable is These best practices should serve you well now and
in a metal pathway or conduit, each section of the pathway into the future.
or conduit must be bonded to the adjacent section ensur-
ing electrical continuity along its entire path. David McCarthy is president and CEO of TriCore Inc.,
In general, route Ethernet cables away from equip- a national system integration firm based in Racine, Wis.,
ment that generates EMI, such as motors, motor control with offices in Santa Fe Springs, Calif., and Mesa, Ariz.
equipment, lighting, and power conductors. Within panels, Before he founded TriCore in 1991, McCarthy served
separate Ethernet cables from conductors by at least 2 in various capacities at Alfa Laval/Tetra Pak, including
in. When routing away from EMI sources within a panel, manager of engineering for its U.S.-based food engineer-
follow the recommended bend radius for the cable, which ing company. McCarthy, who has more than 30 years of
can be obtained from the cable manufacturer. experience in automation, is a computer scientist from
From a network architecture perspective, never use Rochester Institute of Technology.

Applied Automation April 2015 • A9

 CLOUD SERVICES
Launching industrial Internet
programs—into the cloud
Cloud service providers shorten the journey to the industrial Internet.
By Spencer Cramer
ei3 Corp.
I
t’s exciting to think about the enormous business
opportunities created by industrial Internet. However,
harnessing its value on the plant floor necessitates
managing many diverse details. One reason why many
promising industrial Internet programs never get imple-
mented or reach the market is because there is simply
too much technology that must be addressed before the
program can be launched.
Leveraging the cloud
To shorten the journey to successful industrial Internet
programs, many organizations are turning to cloud service
providers for help. Cloud services provide practical, low-
cost, and adaptable solutions to address many aspects of
the industrial Internet (see Figure 1). For the purpose of
this article, the “cloud” is the delivery of IT capability using
remote infrastructure accessed via the Internet; “cloud
services” provide access to IT services similar to those
delivered from equipment owned by the user’s organiza-
Figure 1: The photo shows the network operations center of a typical provider of cloud services. All graphics courtesy: ei3 Corp.
A10 • April 2015 Applied Automation
tion. Companies that specialize in delivering industrial
Internet services through the cloud typically provide solu-
tions that organizations use to build their industrial Internet
programs, the most common of which include managed
security, cloud data storage, analytics, applications, and
information delivery (integration).
Managed security: The stakes are high when a plant
floor connects to the Internet. Data coming from machines
and processes are considered top secret, and access
to the devices that control machines absolutely must be
strictly limited to authorized personnel. There are many
reasons to limit access to control devices—the most
important of which is safety.
Every industrial Internet program should start with a
well-designed and maintained Internet security framework
that incorporates security policies, procedures, standards,
and guidelines. Internet security frameworks require con-
stant attention to identify and respond to vulnerabilities
and threats as they are identified. Working with a team
with experience in providing solutions to this dynamic
requirement is one reason why many organizations see
the value of using a skilled cloud service provider to man-
age their security requirements. Further, working with a
 GET YOUR HANDS ON

TIMES CHANGE. AND SO DO YOUR NEEDS.

THE TIME HAS COME TO

REVOLUTIONIZE
CRIMPING
Redefine how you crimp today!
Visit www.crimpingrevolution.com

Scan this code

©2015 Greenlee Textron Inc. is a subsidiary of Textron Inc.

to learn about
the new EK50ML
Crimper.

1.800.435.0786
 C l o u d S e r v iCeS
cloud service provider with a proven track record of pro-
viding security solutions tailored for industrial Internet pro-
grams gives the organization an even bigger advantage
(see Figure 2).
For example, many industrial machine suppliers rec-
ommend that their customers agree to allow technicians
to have remote access to equipment so the machine
builder can deliver remote troubleshooting and support.
This remote support is usually made possible by using
a virtual private network, or VPN, to connect machines
to programming software on a technician’s PC. These
remote support devices can prevent substantial downtime die wear profiles, consumable usage, and other dynamic
by giving technicians fast access to equipment that con-
trols machines and processes. But the daunting prospect
of unauthorized access through an exploited system vul-
nerability causes many machine owners to block remote
support access. This creates a dilemma
for the machine builder as well as the
owner because the value proposition
of increased uptime that comes with
remote support is too high to ignore.
How can manufacturing organi-
zations allow remote access and
benefit from remote support while
maintaining a high degree of securi-
ty? One way is to rely on a company
that specializes in cloud services to
Figure 2: Internet security appliances,
manage security. Using a third party to
such as the device in the photo, are used
provide a security framework creates
for managed security services specific to
advantages for both manufacturers
and machine OEMs. With solutions industrial Internet applications.
tailored to be delivered by machine
OEMs, manufacturers are assured that no access will
occur without their consent and knowledge. The machine
OEMs can appreciate granular access control with an
audit trail and transparent reporting features. In addition,
when a security framework is in place, even greater ben-
efits for the manufacturer can be delivered, such as cloud
data storage.
Cloud data storage: Critical data can be found every-
where on the typical manufacturing plant floor. The diver-
sity of these data makes it a daunting task for manufactur-
ers to design and maintain a comprehensive data backup
and recovery solution. Cloud data storage services can
address this need by using a secure network connection
to access plant floor devices and remotely monitor values
and make periodic program backups. In a cloud-based
solution, data are stored off-site in compliance with appro-
priate regulations and best practices for data backup and
recovery programs.
There are many types of critical plant floor data, such
as machine programs and the code that runs in the
motion controllers, PLCs, and HMI devices. When any
of these devices fails, it’s invaluable to have a recent
copy available from a secure website. Some machines
run specialized setups, batches, or recipes, from files
stored in an HMI, CNC, or PC on the plant floor. To
A12 • April 2015 Applied Automation
avoid losing the latest and most effective program file,
it’s considered a best practice to have them automati-
cally uploaded and protected.
Another example of critical data is with key process
parameters required by compliance standards. These
monitored parameters can be stored on digital chart
recorders or on local data historians, but an offsite backup
can bring peace of mind knowing that these values will
not be lost. With the right data collection technology in
place, a cloud database can monitor and store production
information, downtime codes, quality test results, tool-and-
machine data. Some industrial Internet specialty cloud ser-
vice companies have complete solutions that include the
agents and software tools necessary to acquire data from
machines and other plant floor equipment.
After secure access for data storage
is set up, the cloud services provider
ensures that the data itself are secure,
private, protected, and backed up.
When a plant floor goes online, the
amount of stored data grows quickly,
and the industrial Internet challenge
shifts from acquiring and storing data
to becoming one of big data analysis.
Analytics: Analytics transform
large sets of data into actionable
information. Many industrial Internet
services create value by perform-
ing complex analysis of data coming
from remotely monitored equipment.
Because of the size of the data used
and scalability needs of multiple users across multiple
platforms, these analytics are best performed in the
cloud. Cloud servers have the computing power neces-
sary to analyze vast streams of data to compute results
using complex algorithms. Different analytics are applied
to meet the needs of different plant floor value streams.
Analytical processing can determine values for predic-
tive failure points, conditional alerts, statistical process
controls, and machine key performance indicators (KPIs).
Examples of these value streams include measuring
quality, tracking production, and assisting maintenance.
One example is monitoring quality inspection devices to
track production tolerances of critical to quality parameters
(CTQs). If monitored quality test results for CTQs start to
change, then analytics can be applied to other machine
parameters to search for a correlation. When a correlative
parameter is found, it becomes defined as a related-to-
quality parameter. To maintain optimum process condi-
tions, these related parameters are then closely watched
using real-time statistical process control methods.
Another good application of cloud analytics is machine
production monitoring. Using cloud data services, it is
possible to monitor a machine’s production speed in real
time. If the monitored machine data include production
information—for example, production speeds, stop times,
and quality results—then it is possible to analyze the data consumable parts are ready for replacement. Six Sigma
to create valuable KPIs, such as real-time machine over- engineers can download sets of machine engineering
all equipment effectiveness (OEE). Having a consistently parameters from Web pages for their experiment without
evaluated, real-time OEE value available is very helpful to having to access local data historians. These different
Lean manufacturing practitioners who use this information users also have very diverse preferences for the way
to guide operational efficiency. their information is delivered.
Monitored equipment data can also be processed by Information delivery: To meet the application needs
cloud-based analytics to proactively detect imminent part of the diverse users, it becomes all too important to have
failure. For example, accelerometers can be attached a great degree of flexibility in the access of information.
to machines to gather equipment vibration data, which The applications must be supported on a wide range of
can be sent to the cloud data storage. By using powerful computing devices including tablets and smartphones. In
computers to analyze these streams of vibration data, it addition to being compatible with a large range of Web
is possible to apply sophisticated calculations and filters browsers (Internet Explorer, Chrome, Firefox, Safari, and
to find root problems early enough to take action before others), it’s important that the applications can deliver
costly failures occur. Proactive failure detection can save information directly to tablets and smartphones through
manufacturers a lot of money through native mobile applications (iPad,
reduced downtime and by avoiding iPhone, and Android devices).
catastrophic equipment damage.
Cloud services provide In addition, industrial Internet infor-
Analytics create value by converting practical, low-cost, and adapt- mation must be delivered to both
data into actionable information. Cloud users and systems. A cloud service
applications create a packaged user able solutions to address provider offers multiple delivery
experience that delivers knowledge many aspects of the industrial options that are in step with the ever-
based on the monitored machine data changing landscape of evolving oper-
and computed information. Internet. ating systems, browser variations,
Applications: Cloud-based appli- and other changes. Users must have
cations are also known as software-as-a-service (SaaS). the information they need on the device they prefer, while
This method of delivering software has been steadily business software and enterprise computing platforms
growing in popularity because organizations know that must be served data in formats that they can easily read.
SaaS allows them to reap the benefits of an application Integration between the industrial Internet applications
without having to take the steps to set up an in-house IT and these enterprise systems is achieved by using Web
infrastructure. Cloud applications for the industrial Internet standards. The preferred solution is for cloud service pro-
deliver knowledge based on the remotely monitored data viders to deliver information to systems by using applica-
and analytically produced information. Most industrial tion programming interfaces (APIs). API methods can be
Internet applications have a defined mission to create defined to provide data for many different purposes. For
value by fulfilling a specific, envisioned business value example, information can be sent directly to business sys-
proposition. The value and return on investment of such tems to read machine production values, job status, stop
applications can be dramatically increased by partnering codes, and OEE values. The same APIs can be used to
with an experienced industrial Internet cloud service pro- create “mash-ups” of data that combine remotely moni-
vider. These companies have the skills, knowledge, and tored data and information from other sources. A plant
experience to add value by contributing to the application’s technician familiar with standard Web HTML code can use
architecture, design, development, and hosting. the API to program a local machine display or performance
There are already countless industrial Internet applica- board. This performance board can be configured to run
tions available to meet specific needs. Examples include on a conventional Web TV connected to the Internet, and
managing and dispatching alerts, viewing monitored source real-time machine data directly from the cloud. If
data, managing quality, and tracking production. In a typ- desired, the machine performance board can show the
ical organization, these applications are used by employ- machine status, speed of production, and a recent history
ees in many different departments including operations, of shift performance.
quality, engineering, maintenance, and management.
The applications are delivered through the Internet, Cloud scalability
thereby making it possible for users to benefit from real- When the benefits of an industrial Internet program are
time plant floor data, regardless of their location. Plant understood, the next question that most organizations ask
managers can use these applications to view machine is, “How fast can I scale up?” Scalability is best achieved
production from their smartphone to see how things are by taking advantage of the benefits in using a cloud solu-
running. Shift supervisors can get a report e-mailed at tion. The cloud service provider will use virtualization,
the end of their shift showing production metrics for the storage as a service, co-location, and other techniques to
shift and stop reasons. Maintenance technicians and provide scalable services for securely delivering data, ana-
production supervisors can receive alerts when machine lytics, and applications.

Applied Automation April 2015 • A13


Multiple benefits
The organization that uses a cloud
service provider for its industrial Internet
program stands to benefit by saving
time, saving money, keeping up to date,
and staying focused. The cloud saves
time because the best cloud service
with minimum
downtime.
Our Allen-Bradley® Remote I/O™/DH+™ gateways
allow you to upgrade to newer PanelView™ Plus
terminals with minimum downtime.
Find out more by visiting psft.com/A12
Where Automation Connects
ASIA PACIFIC | AFRIC A | EUROPE | MIDDLE E AS T | L ATIN AMERIC A | NOR TH AMERIC A
Cloud ServiCeS
providers use a multi-tenancy environ-
ment tailored for industrial Internet
programs. They can bring machine
OEMs and their customers on board in
mere weeks or months because adding
another organization does not require
any additional programming. Time is
+1-661-716-5100
often a critical factor, especially when
the goal of an organization’s industrial
Internet program is to achieve a first-to-
market advantage. In addition to saving
time, risk is reduced because the cloud
service provider has experience deliver-
ing similar solutions.
The cloud saves money because
the cloud service provider spreads its
costs across large pools of services
provided to many users. This large
pool of existing customers means that
services can be provided at a lower
cost than is possible for even large
OEMs to achieve.
The cloud service provider stays cur-
rent with the rapidly evolving require-
ments of technology, including security,
operating systems, smartphones, and
other important details. Organizations
that use these providers automati-
cally stay up-to-date without additional
maintenance cost or resources to sup-
port the system.
Perhaps the most important benefit
of partnering with an experienced cloud
service provider is the ability for the
user’s organization to stay focused on
what’s important to its company. Putting
an industrial Internet program together
is a large and complex undertaking.
By partnering with an experienced
cloud service provider, an organiza-
tion accesses experience while staying
focused on its core competencies.
Each of these benefits makes a com-
pelling case to partner with a cloud ser-
vice provider for the industrial Internet.
When these benefits are combined, it
becomes very clear that the shortest
path to the successful creation of an
industrial Internet program is having
services delivered from the cloud.
Spencer Cramer is president and
CEO of ei3 in Montvale, N.J. He
founded ei3 in 1999 with the vision
to monitor machines through the
Internet. The company’s portfolio of
SaaS applications deliver performance
benchmarking, real-time monitoring,
and predictive analytics. Today, ei3
applications are used at thousands of
sites worldwide. Cramer is a member
of the Sustainable Packaging Coalition
and OMAC. He has a bachelor of sci-
ence in electrical engineering from the
University of Virginia.
A14 • April 2015 Applied Automation
 Although independent research has proven that MOVIGEAR®
from SEW-EURODRIVE reduces startup and operating costs
by 20-30%, actual case studies show that many users are
experiencing 50% or more. MOVIGEAR® also substantially
reduces your inventory via its unique ability to replace several
gear units of different ratios with a single unit. Yes...less really
is more!

movigear.com / 864-439-7537
 }
1. Developing ideas
2. Drafting concepts
3. Implementing solutions More freedom and space for your ideas.

4. Manufacturing machines
5. Ensuring productivity

With increasing engineering tasks and ever shorter time frames, it’s
good to know you have a drive and automation specialist at your side
who can make many of these tasks easy for you. We work with you
through the entire development process of your machine – from initial
ideas all the way to after-sales, from the control system all the way to
the drive shaft. Come discover the future of engineering with us, and
you will find more freedom to explore what really counts – your ideas.

Find out more at www.Lenze.com As easy as that.