Best Manufacturing Software Systems

One of the things we want to do with this blog is it to help our readers find relevant information that can help them to improve their business.  One good source I have found is a site called Software Advice.  MES, Supply Chain, OEE, or Quality management are all covered on this site.

Software Advice recently held a roundtable discussion on the state of the manufacturing software industry.  Teaming up with four industry experts, they reported on the leading trends taking shape in 2010. In general, they find this year to be more active than 2009. Buyer interest and purchase activity is up across the industry, from large sophisticated companies to smaller companies implementing an enterprise system for the first time.

They attributed the increased activity to two main reasons.  First, the 10-year anniversary of purchases made as a result of the Year 2000 (Y2K) date problem; and many companies are restarting buying processes that were deferred in 2009.

Interestingly, they find most purchase activity taking place among chemical, food and consumer packaged goods (CPGs) manufacturers, with aerospace, semiconductor and automotive manufacturers not far behind. Increased ERP software adoption among CPGs is fuelled by "the need to manage global supply chains, distribution networks and targets acquired through mergers and acquisitions activity," observes Jonathan Gross. While aerospace, semiconductor and automotive companies are "more active with upgrades, replacements and add-ons."

The report continues on with a discussion of activity in the software as a service (SaaS) market, how vendors are adjusting prices to compensate for the economy, how offshoring influences spending and whether manufacturers are implementing integrated enterprise resource planning (ERP) systems or best-of-breed applications.

To read the full report, visit 2010 Manufacturing Software State of the Industry Roundtable

High Rise Automated Alcohol Delivery System

It all started the day Bernie left.   In clearing out his cube, he found an AB PicoLogix controller he had received from a training class at some point in his career and gave it to myself and my friend Rob who was interning with us at the time (I had just gotten a full time job maybe a year prior).  We weren't sure what to do with it at the time, but it wasn't long before Rob had a stroke of brilliance.   "Why not build an automated beer bong out of it?" he exclaimed one day.  Being fresh out of college (or still in it in Rob's case), the concept of a beer bong was admittedly probably something that was taking up too much space in our collective brains.

For those not familiar with the concept, a beer bong is generally a funnel with a maybe two foot tube attached.  The concept is that by bending the tube upwards, one can load the funnel and half of the tube with a full can of beer.  The user then gets down low, puts the non-funnel end of the tube to their lips and by raising the funnel and bringing gravity to bear, can force large quantities of beer rapidly down ones throat. Is this concept and activity leading to the degradation of American society? Perhaps.  But is it an engineer's duty in life to take an existing idea and make it better? Absolutely.  And so we decided to take this immature idea to new heights, literally.

Our concept of the automated beer bong was one that grew rapidly as we started to get into it.  Originally the idea was to automate some valves so that we could lengthen the tube and perform a larger drop.  This began to manifest itself in a 3 story design that could be setup at the top of my townhouse (which is on the second floor) and the user could be on the ground outside of the basement.

As we moved into the programming phase, we decided to add more and more functionality.  I should also point out how the lack of requirements here led to some major scope creep.  First we decided that two people should be able to share in this joy simultaneously.  I mean, what's the fun of taking a 3 story beer bong when you don't have someone next to you that you can race in such an endeavor. So we created 2 tracks tied to a single start button so they would start at the same time.  We wanted the tracks to be selectable, so I could choose to race my friend or I could choose to go solo.  If I picked the later, I didn't want beer to come pouring down the tube that had no one waiting for it at the other end and spill all over the ground.  We then came up with the brilliant idea that we would want to control the amount of beer being delivered. Perhaps I'd only want a full beer or maybe I wanted to go crazy and try multiple beers.  So we decided to control the amount of beer being delivered, making it selectable between one and six beers in half beer increments.  Finally, we had to make sure that we keep the beer bong clean and functioning and to that end we needed a CIP (Clean in Place) mode that allowed the valves to stay full open so we could flush the lines with water and cleaning solution as needed.

Fabrication went quickly, although it was certainly not up to any NEC, UL or other code. In fact, in some ways it was fairly unsafe. Some of the different buttons and switches we mounted on a piece of plexiglass, but it was initially designed to be something that would be more of a wall-mount, such to say there was no back or enclosure around the terminal ends for those components.  In addition, we used those style terminal blocks that are DIN-rail mounted and open on one side (where you are supposed to use an end cap) except we had no end piece and so one side was completely exposed. In the end we threw a blanket over the whole thing and told people not to go near it (kind of like an SOP).  We did, fortunately realize one potential safety issue ahead of time and took action to improve the receiving end of the beer bong.  We recognized that the downward rush of beer was going to push a fair amount of air initially into the receiver's mouth before the beer shows up. To mitigate this we put a T-connector at the end with a one foot length of tubing sticking up to allow the air to release and to not be forced into the person's throat.

With our crude implementation complete, we set off to run some tests.  Needless to say, we were pretty excited about testing it out.  We had to dial in the beer measurement (based off of timers and average time to get a fixed amount of beer out) and adjust the length of the air relief tube at the bottom, but overall it ran pretty well out of the gate.  This was pretty fortunate since we were doing this initial testing about 30 minutes prior to the production startup which just happened to coincide with an unveiling party. In the end everyone had a good time and no one got electrocuted, although to be fair we didn't push the full design capability of delivering 5 or 6 beers at a single time.

I apologize for not having any actual pictures of the beer bong in action. For some reason, we were counseled by our lawyer-like conscious' at the time that it would be better if no photographic evidence existed, although now I wish we had it for posterity sake. It still makes for a fine story without any pictures though, so we'll make do.

So what kind of personal engineering adventures have you experienced?  Do you have any experiences where you have used automation around the house, perhaps getting a bit too involved or overly complicated?  We'd love to hear some of those stories.

The Changing Face of Manufacturing

The technical and operations workforce in most production environments is changing – it's retiring, and with that comes some obvious impacts to production.

The age of workers in the manufacturing industry in developed countries is already over 50 years old on average, and Baby Boomers – children born in the late 1940's to early 1950's, are starting to reach retirement. In the USA alone, people aged 65 and over will reach over 70 million by the time the last boomer retires in 2030. Some countries, for example Germany, have responded by increasing the age of retirement to 67.

If you think about it this way, a company can lose 1,000 years of experience if 50 of its operators, each with an average of 20 years of experience, retire.

And let's face it, isn't the automation industry the best kept secret? If most people hear the word "engineer," they immediately turn their listening switch off because they figure they won't understand it anyway. So it's no wonder it's so difficult to find automation talent. Nobody outside our world knows our occupation exists.

Martin Michael, Vice President of Avanceon, whose world headquarters are located in Exton, PA says, "in real estate, we sometimes have a buyer's market, and we sometimes have a seller's market. In manufacturing, we have gone from a buyer's market (where manufacturers could select the best) to a seller's market where manufacturers really have to sell themselves to prospective workers. Martin adds, "replacing a lost employee is already costly, and it's even more costly in this type of environment, especially for process control engineers and process operators."

So with this bleak outlook on the pipeline of engineers, could automation be a major solution? And the answer to that is yes. In order to compensate for a diminishing workforce, manufacturers will need to increase automation. This strategic plan will replace many manual processes which should be automated anyway.

Bob Zeigenfuse, President & CEO of Avanceon says, "In today's global environment whoever manufactures products better, cheaper and faster, wins. Every country in the world is competing." Bob continues, "Technology improves productivity in many ways. It reduces labor, optimizes use of raw materials, saves energy and waste, improves quality, and it saves time."
The companies that succeed in this new age will be those that understand how to combine and coordinate new thinking in the today's environment.

 

Sustainability & Growth: You can't have one without the other

What is Sustainability?

At one point in American history, the whaling industry personified American prosperity. It employed thousands of workers, fueled thousands of homes & businesses and it created fortunes for many. There was just one problem: the whale stock was depleting, hunters continued harpooning and today nearly all the whales are gone. Within a few years, an industry that had thrived for a full century collapsed entirely. This example represents how a business can make their enterprise unsustainable.

So here is that word again, sustainability. What exactly is it?

The word "sustainability" originated in the 1980s when nations had to find ways to grow their economies without destroying the environment or sacrificing the well-being of future generations.

Today, sustainability has become the buzzword for a large variety of social and environmental causes, but in the business world it stands for a very powerful idea that a sustainable corporation is one that creates profit for its shareholders while protecting the environment and improving the lives of those with whom it interact.1

Sustainable organizations work towards preserving natural resources, including water, air, and all sources of energy.

An organization built on the principles of sustainability is built to last, and the only way to succeed in today's interdependent world is to embrace sustainability.
The Sustainability "Hot Spot"

"Sustainability is not about sending a check to a charitable organization, though there is nothing wrong in doing so," says Martin Michael, Vice President, Energy Solutions at Avanceon, whose headquarters are located in Exton, PA.

Martin continues, "The sustainable company conducts its business so that benefits will naturally flow to shareholders, customers, business partners, and the communities in which it operates."

Sustainability is the overlapping of the interests shared by your financial stakeholders and that common ground shared by your nonfinancial stakeholders. This common ground is called the "Hot Spot," where the goal of profits blends with the goal of the common good.

The best-run companies around the world are trying to identify and move into their own "hot spots," and they are discovering new ways of doing business in order to get there and stay there.

Take for example, a major company that started out in "everything electrical." In years past, this organization fought the U.S. Environmental Protection Agency (EPA) to avoid responsibility for polluting our rivers.

Today, this very same company has developed a new initiative that goes beyond compliance that will ultimately benefit society and the long-term health of the organization. Their main goal is to create clean technology to help its customers reduce their environmental impacts, primarily carbon emissions. This company announced it will double its annual investment by 2010 in clean energy technologies, and they project revenues from eco-friendly products to double as well.

The overlap between winning increased market share and supporting healthier lifestyle habits is also a hot spot for a major cola company. This major company, known for sugary sodas, purchased several "healthy product" companies. Subsequently, this "healthy-product" hot spot is the fastest growing segment for the cola company.

But healthy products is not all this company is doing. They are working on other hot spots, and they are working towards the goal of cost reduction such as improvements to reduce their energy, waste, and packaging. This social responsibility has helped this major cola company grow their earnings per share and in turn make their company more sound for decades to come.

"When companies try to be viable for the long term, they manage their business based on principles that will strengthen rather than undermine the company's roots in the environment, the social fabric, and the economy," says Martin. He continues, "A business that strives to fit as much of its activities into that "hot spot" zone should have real long-term advantages over its rivals."

"Avanceon is also working towards finding that hot spot, not just for ourselves but for other organizations as well," says Bill Fenn, Director, Energy Solutions at Avanceon. Bill continues, "Take for example, our iBoiler service, a total steam management solution which provides a benchmark for performance and helps keep a plant focused on operating with efficiency in mind. We can help our customer save 10% in fuel costs as well as reduce their carbon footprint by showing them how to optimize their boilers' performance."

"A company can spend down its capital for a while, but generally not for long. A firm that works on principles of sustainability is built to last, says Martin Michael. "We have seen a huge influx of interest in our iBoiler service, "he continues. "Companies today know that a good place to start their sustainability effort is to begin looking at their boilers which are a major source of heat production and power, but consume huge quantities of fuel and electricity."

Avanceon is an Exton, PA-based solution provider to industrial and manufacturing companies worldwide. Avanceon is a CSIA Certified Member. For information on how you can get started on your sustainability plans, please call Martin Michael, Vice President, Energy Solutions at 610-458-8700

Impact of volunteering on organization culture

Together we do it better

At times investing time and money in social activities leaves a notable impact on the culture of an organization.  Getting your employees involved in philanthropic initiatives not only helps an organization fulfill its commitment towards corporate citizenship but also helps motivate its employees in general.  No one denies that it feels good to be a part of a noble cause.  The majority of people who wish to be a part of philanthropic activities, may lack the enthusiasm to take initiative on their own. But once they are presented with the opportunity, you may find that they will take up the responsibility excitedly and be filled with pride once the goal is achieved.  It’s common that people like to get engaged in such activities in the company of their friends and acquaintances, as social activities give them an opportunity to relax and unwind. In this lies a great opportunity for organizations to plan team building activities for their employees. We can expect wondrous results if an organization is able to plan interesting volunteer programs and encourage their employees to participate as teams. The volunteer programs can also be a lot of fun if planned well.  One way is to plan excursion trips for employees to underprivileged areas where they can go and council young students living in suburban areas about choosing the right education and careers options.   First Aid Training can be made mandatory for all employees and visits can be arranged to an area affected by natural disaster or let’s say to a military hospital. You could also take your employees out for a tree planting campaign or arrange charity walks on a weekend.  The activity based approach is much better than just making donations to charitable organizations as it greatly increases awareness of the cause.   At Avanceon we have tried and tested this method and it has helped us improve working relationships between various groups of employees.  One team was sent for a disaster management program.  The team came back happy and satisfied.   We were amazed to see they seemed to be more compassionate about their work commitments and the organization. 

In the end it’s all about the contributions we make.  So why not have more and more people help each other in doing good things?   When caring for the community becomes a part of an organizations cultur, everyone wins.

Beenish Rai

Marketing & Communications Associate 

Avanceon LP

email: brai@avanceon.com

Control System Integration Jobs: Hire a SWAN

Engineering is a very diverse discipline. At Avanceon we need thinkers and doers, inventors and implementers, designers and troubleshooters. Sometimes one person contains all of these skills, though more often a team comes together to complement each others' skills. The whole is greater than the parts.

When it's time to hire most of us look for the standard requirements, probably including some sort of specific experience or skill set. However, many innovative companies are now focusing more on an individual's personal attributes than where they obtained their degree or what their specific experience is

This successful practice is known as following the SWAN Model: Hiring employees that are Smart, Work Hard, Ambitious and Nice. Though hard to gauge at an interview, these qualities almost guarantee a decent worker. When hiring a non-entry-level person, the SWAN model, coupled with what they've done in the past, is a far better indicator of success than any resume.

Photo by: suvodeb

People at Avanceon share a common set of attributes: we are all SWANs! We have found that SWANs likely have what it takes both to help our clients and to be successful at our company. "SWAN" is an acronym for people who possess four qualities: Smart, Work hard, Ambitious, and Nice.

Smart

We are looking for people with keen minds who may have pursued a variety of academic interests and demonstrated achievement in their chosen fields. Once these people join Avanceon, they can turn their intellects on the problems facing our clients and develop creative, effective solutions.

Work hard

Being smart is not enough to succeed at Avanceon; you must also be willing to apply yourself every day. We look for people who have demonstrated their ability and willingness to work hard through academic/professional achievement and extracurricular involvement.

Ambitious

We look for people who set high goals for themselves and then strive to achieve those goals. Implementing our solutions allows us to validate our designs at an operational level, and it takes an ambitious individual to propose and then implement a system that could potentially change the way a company does business.

Nice

Many companies seek to hire people who are smart, hard working, and ambitious. Avanceon, however, has one additional requirement: you must be nice. Being nice is more than just a measure of one's integrity and character. We work closely both with each other and with our clients to solve problems and implement solutions. We encourage cooperation and sharing among all of our associates and one of the best ways to ensure this high level of cooperation is to hire nice people.

Stimulus Package and Saving Industrial Energy?

Trying to understand the so called "Stimulus" package and its impact on industrial business is hard to figure out around all of the hype.  I have found the government's own website at http://www.recovery.gov/ to be lacking in detail and mostly centered on selling the value of the stimulus package.

I recommend the web site for the Alliance to Save Energy at http://www.ase.org/.  I don't know if this site is always accurate but they appear to be a good source of information. 

Since energy is a big part the plan I looked around and found this article on Energy-Efficiency Home and Vehicle Tax Credits and found it very informative although it doesn't apply directly to Industrail Energy I thought it was worth sharing.

http://ase.org/content/article/detail/2654

Your thoughts and ideas on saving industrial energy are always welcome so please comment if you have something to add.

 

Industrial Energy Management

I find it interesting that the world talks about energy management all of the time, but we too often focus on the most visible items around us without really attacking the areas where it can make the biggest difference.

According to the US Department of Energy, the industrial manufacturing industry is one of the largest users of energy and subsequently also one of the largest opportunities to reduce energy waste.   Water, Air, Gas, Electric, and Steam produce the acronym WAGES.  For each letter in WAGES, the opportunity to save energy can be 10 times the savings gained by taking every SUV off the road.

Not that I am advocating that gas guzzlers are ok, but should we be putting more time and money into areas that give us the biggest return?  Stay tuned and I will elaborate more on this subject in the coming weeks.

In the mean time, visit www.eere.energy.gov/industry/ to get the unbiased information.