Taking ‘Every Reasonable REPORT on ICS: What Bringing Production Precaution’ During a Insights from Our Recent Roundtable on Industrial Back Home Means for Pandemic

MACHINE SAFETY: RESHORING: On taking ‘every reasonable REPORT ON ICS: What bringing production precaution’ during a Insights from our recent roundtable on industrial back home means for pandemic. p. 11 control systems. p. 14 automation. p. 22

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DEPARTMENTS

4 From the editor 5 Automation upfront The latest industry news, 18 deal makers, and movers and shakers 12 Centre stage Michelle Chrétien, Centre for Advanced Manufacturing and Design CONTENTS Technologies 30 The smart factory 14 The state of industrial control Research and applications Senior-level leaders at our recent roundtable on industrial to guide your digital control systems sound off on legacy equipment, device transformation lifespan and controls project planning By Kristina Urquhart COLUMNS COVER STORY 10 Industry watch The critical value of 18 Taking control purposeful work 14 11 Machine safety Building a new business during a pandemic may not have been on this panel builder’s vision board, but the team came through Eight ways for employers with a bigger order book to ‘take every reasonable By Kristina Urquhart precaution’ during a pandemic 19 New tools for training NEW PRODUCTS With technology frequently in flux, today’s workforce requires ongoing digital learning that prioritizes a proactive versus 26 Automation software reactive approach 26 Material handling By William Valedis 27 Communications & networking 10 22 Bringing production back home 27 Machine safety The pandemic is causing manufacturers to consider reshoring 28 Motors & drives initiatives. The trend is likely to drive more automation 28 Robotics By Jacob Stoller 29 Process control 24 AI at the edge Using artificial intelligence to process data on an edge device helps to create new value for OEMs ON THE COVER: THE BLACK CONTROLS CO. TEAM. (L TO R) MIKE LAKE, MATTHEW HEISZ, JON FERRIER, RICK BLACK & WADE CONRAD By Chris Catterton

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MANUFACTURING AUTOMATION · November/December 2020 AutomationMag.com 3 MA_Murr_NovDec20.indd 1 2020-10-19 11:10 AM FROM THE EDITOR BY KRISTINA URQUHART Your resource for Canada’s industrial automation news

EDITOR Charting a new course Kristina Urquhart [email protected] for investments Tel: 416-442-5600 PUBLISHER eflecting on this year is an overwhelm- The industrial automation market in Klaus B. Pirker ing exercise, to say the least. Unless Ontario, for example, will soon see gains [email protected] you’d previously spent a lot of time after a September announcement that Ford Tel: 416-510-6757 Rreading about pandemics or public of Canada and Unifor, the union representing GROUP PUBLISHER health, 2020 was a year that the vast majority of automotive workers in Canada, had inked a Paul Grossinger us didn’t see coming. three-year, $1.8-billion deal to retool the auto [email protected] We were ill prepared, and maybe we should manufacturer’s plant in Oakville for electric MEDIA DESIGNER have known better – though I’m not sure what vehicle and battery production. Graham Jeffrey could have possibly equipped us ahead of time The investment, which includes nearly [email protected] to comprehend the loss of life, the upending of $600 million in federal and provincial govern- ACCOUNT COORDINATOR our economy, the slashing of jobs, or the blow ment funding, was sorely needed – previous Debbie Smith to the way we conduct business. production contracts were wrapping up, and [email protected] Now, a pivotal U.S. election is about to the new deal is expected to retain 3,000 of the Tel: 416-442-5600 ext 3221 unfold that, no matter the outcome, will plant’s 3,400 jobs. The investment also aligns AUDIENCE DEVELOPMENT MANAGER further affect trade and international relations with the federal government’s goal to finance Urszula Grzyb both here in Canada and abroad. clean technologies in pursuit of net-zero [email protected] Through it all this year, we did what humans carbon emissions by 2050. Tel: 416-510-5180 do. We adapted, and we learned how to live At MA’s recent roundtable on industrial COO with COVID-19 in our midst. Although 2020 control systems, industry experts stressed this Scott Jamieson has been sobering, companies are busy recali- idea that investments should reflect on larger [email protected] brating for 2021. According to a recent study goals. The key to a successful controls imple- by BDC, 39 per cent of Canada’s small and mentation, said Sanjith Singh, vice-president CONTRIBUTING WRITERS mid-sized enterprises (SMEs) are getting their of industrial automation at Schneider Electric Chris Catterton, Paul Hogendoorn, Jacob Stoller, William Valedis, WSPS finances in order by cutting down on operating Canada, is to thoroughly understand what you costs, managing their cash flow and developing want to achieve from the top down. Manufacturing Automation is published seven contingency plans. Considering corporate goals such as times a year by: The study, called The Response: How Entre- sustainability, quality management or energy Annex Business Media preneurs are Adapting to the Pandemic, identifies reduction will pinpoint what results you need 111 Gordon Baker Rd., several other priorities of SMEs heading to achieve and, consequently, what you need Suite 400, Toronto, ON, M2H 3R1 into the next year, including investing in out of new technology. Ultimately, this helps Tel: 416-442-5600 Fax: 416-442-2191 technology to stay competitive (27 per cent), decision makers ensure a better, longer-last-

continuing to permit teleworking to enable ing investment. For more on investments and Printed in Canada ISSN 1480-2996 social distancing (25 per cent), selling and controls project planning from Singh and our Publication Mail Agreement #40065710 promoting goods and services online (24 per other roundtable panelists, turn to p. 14. CIRCULATION cent), and diversifying clientele (23 per cent). Days after this magazine is printed, the email: [email protected] The two top priorities – managing cash results of the election south of the border Tel: 416-510-5180 Fax: 416-510-6875 flow and investing in new technologies – may will chart a whole new course for company Mail: 111 Gordon Baker Rd., Suite 400, seem out of sync with one another, but they’ve investment across North America, and it will Toronto, ON, M2H 3R1

been constant refrains among economists and be time to prepare for how the outcome will SUBSCRIPTION RATES industry leaders over the past several months. affect operations in 2021. Canada — $43 per year Financial injections – whether via government Businesses may not have been ready for United States — $75.50 (US) per year Foreign — $86 (US) per year stimulus or a business reinvesting in itself – the pandemic, but they do know that political Students — $20.50 per year are crucial to surviving a crisis. Investments winds change every four years. And, as ever, ANNEX PRIVACY OFFICER MA drive new growth. they adapt. | email: [email protected] Tel: 800-668-2374 Occasionally, Manufacturing AUTOMATION will mail information on behalf of industry related groups whose products and services we believe may be of interest to you. If you prefer not to receive this information, please CONNECT @AutomationMag @mfgautomationmag contact our circulation department in any of the four [email protected] /company/automation-mag ways listed above. The contents of Manufacturing AUTOMATION are EDITORIAL ADVISORY BOARD © 2020 by Annex Publishing & Printing Inc. and may not be reproduced in whole or part without written consent. AL DIGGINS, Chairman of the Board, Treasurer and General Manager, Excellence in Manufacturing Consortium Annex Publishing & Printing Inc. disclaims any warranty DAVID GREEN, Technology and Business-to-Business Consultant as to the accuracy, completeness or currency of the contents of this publication and disclaims all liability in KARIN LINDNER, Founder and Owner of Karico Performance Solutions respect of the results of any action taken or not taken in DON MCCRUDDEN, Vice-President, Business Development, Festo reliance upon information in this publication. DAVID MCPHAIL, President and CEO, Memex Automation NIGEL SOUTHWAY, Business Productivity Consultant and Author on Lean Thinking BILL VALEDIS, Support Systems Developer, KINITO Support Systems

4 @AutomationMag November/December 2020 · MANUFACTURING AUTOMATION AUTOMATION UPFRONT

COVID-19 PRODUCTION existing ventilators,” says Scott for over 20 years. The pioneering says teamwork was important in Phillips, StarFish Medical CEO work of Dr. Younes, and the sup- the project’s rapid progress. Feds approve ventilator and founder. port of Cerebra Health with clin- “Our supply chain moved for production “To do that, we started with ical input and upcoming clinical quickly and diligently to discover proven technology (the original trials, is invaluable.” what supplies and services were StarFish Medical has received au- Winnipeg Ventilator designed by StarFish presented the venti- available, while our engineers thorization from Health Canada Dr. Magdy Younes), updated the lator design to expert review worked with available com- for its Winnipeg Ventilator 2.0 design to incorporate technical panels convened by NGen and ponents to create and build the to be classified as a COVID-19 advances and use non-medical ISED to positive and encouraging design,” he says. medical device. supplier components, all while feedback. “We used 106 StarFish employ- The device was approved under drawing upon a network of John Walmsley, StarFish Med- ees on the project and over 100 an interim order, which allows the companies we have worked with ical EVP strategic relationships, people at key vendors including Minister of Health to permit the exceptional importation and sale of drugs, medical devices (including ventilators), and foods for special dietary purposes that do not fully comply with Canadian requirements, but are manufactured according to comparable standards.

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StarFish Medical’s Winnipeg Ventilator 2.0. You are poised to meet your safety and quality requirements while optimizing resources and The approval allows Canadian securing process repeatability. Emergency Ventilators Inc. (CEV), as the manufacturer of record, to ship units to the Pub- Improve your plant availability, and ensure lic Health Authority of Canada quality with optimized calibration (PHAC), starting immediately. 100% • Traceable on-site and laboratory calibration of various PHAC is working with the traceability ensured with parameters company to review the devices calibration services • We are a leading manufacturer of process instrumentation that come into the National Emer- – uniquely qualified to calibrate gency Strategic Stockpile (NESS) • Our global, harmonized calibration standards provide consistent service quality so they are ready to be shipped across the country if and when they are needed. “Our goal with the Winnipeg Ventilator 2.0 is to deliver a fully featured ICU ventilator Do you want to learn more? that could save patients’ lives, www.eh.digital/3hC8yd5 be manufactured in Canada in the shortest time possible, and

PHOTO: STARFISH MEDICAL STARFISH PHOTO: not disrupt the supply chain for

MANUFACTURING AUTOMATION · November/December 2020 AutomationMag.com 5 MA_EndressHuaser_NovDec20.indd 1 2020-10-19 11:52 AM AUTOMATION UPFRONT

Dometic, Advanced Test Auto- Ford’s Windsor, Ont. plant rounds mation, Yorkville, Dorigo Sys- out the rest of the investment. tems, Powersonic Industries and The Ontario government is EM Dynamics. Having designed matching a $295 million invest- the product, we were very happy ment with the federal government to have Celestica on board to to retool the Oakville complex coordinate with our supply chain into a global hub for battery elec- and begin to bring on board their tric vehicle production. vendor network for manufacture.” “[This] announcement is a tes- tament to Canada’s attractiveness AUTOMOTIVE as a destination for clean technology, talent and infrastructure Ford, union reach deal in the automotive industry,” says worth nearly $2B for Prime Minister Justin Trudeau. vehicle production Ford’s Oakville plant directly employs over 3,000 people and Lion Electric Co. will manufacture battery electric trucks for Amazon. Ford of Canada and Unifor, the will be modernized with a flex- union representing many of the ible manufacturing system able off the production line in 2025. establish a maintenance program company’s workers, have reached to accommodate multiple battery “Any region seeking a long- for the trucks, as part of Lion’s a deal that will bring new work to electric vehicle (BEV) models. term future in auto manufac- expanding network of Experience two Canadian plants. It will also include the instal- turing must be adding value at Centers. A total of $1.95 billion will be lation of a battery-pack assembly every stage of the supply chain, The trucks will be manufac- invested in the automotive giant’s line. The Oakville Assembly particularly in the two technolo- tured at Lion’s facility in Quebec, Canadian plants, including $1.8 Complex will become one of gies shaping the next generation which has a current capacity to billion to produce five electric ve- Ford’s highest volume BEV plants of vehicles: zero-emissions and produce 2,500 electric trucks per hicles at the Oakville, Ont. plant. in North America, with the first connected and autonomous,” says year. Lion is also planning to open An engine contract slated for electric vehicles expected to roll Vic Fedeli, Ontario’s minister of a larger manufacturing facility economic development, job cre- in the U.S. to accommodate the ation and trade. growing demand for its electric The Ontario auto parts indus- vehicles in the U.S. try employs about 63,000 workers Lion’s trucks are purpose-built For Motion Feedback in for vehicles assembled in the for electric propulsion, provide for province and abroad. modularity in energy capacity, are Industrial Automation, agnostic on charging technology, INVESTMENTS are vehicle-to-grid enabled, and EPC has your solution. have a range of up to 250 miles. Lion Electric to manufacture trucks for Auto parts 9 Motion feedback for applications such as servo labeling, heavy duty Amazon manufacturers receive packaging, and material handling over $175K 9 Thru-bore, programmable, and multi-turn absolute encoders, and Quebec-based manufacturer The linear measurement solutions Lion Electric Company has a con- Two auto parts manufacturers in 9 Engineers and encoder experts available to assist tract to deliver 10 battery electric Scarborough, Ont. are receiving 9 Standard lead time: still just 4-6 days trucks to Amazon. more than $175,000 from the The first two will be delivered provincial government to help this year. Amazon plans to use improve efficiency, productivity Lion’s trucks in its middle-mile and build capacity. trucking operations, which trans- The funding is part of the ports items within the company’s Ontario Automotive Moderniza- network. tion Program (O-AMP) and will Lion Electric says the addition be matched 1:1 by the recipient of the battery electric trucks to companies, Innotech Precision Amazon’s fleet will help the retail- Inc. and Kobay Enstel Ltd. er deliver on its goal of decarbon- Innotech Precision Inc. pro- izing its transportation operations vides tooling, engineering and in support of The Climate Pledge. injection-molded components Call us today to get started. As part of the delivery, Lion for the auto industry. The com- will provide a one-time training to pany is receiving $98,582 towards Amazon and the drivers who will real-time automated monitoring 1-800-366-5412 | encoder.com operate the trucks upon delivery systems, which includes vision

of the vehicles. They will also and production data analytics. CO. LION ELECTRIC PHOTO:

6 @AutomationMag November/December 2020 · MANUFACTURING AUTOMATION

MA_Encoder20200814_MA_QuarterPage.indd Products_Sept20_CSA.indd 1 1 8/17/20202020-08-17 7:39:47 11:40 AM AM The investment will improve NEW DIGS timely manner with the quality of 25-per-cent victim fine surcharge manufacturing efficiency and service they’ve grown accustomed as required by the Provincial support sales growth. The project ABB to open new to,” the company says in a state- Offences Act. The surcharge is is expected to lead to the creation logistics facility ment. credited to a special provincial of six new jobs while helping to ABB’s sales and commercial government fund to assist victims retain 53 jobs at the company. ABB’s Motion business area is office will remain in the Vancou- of crime. Kobay Enstel Ltd. specializes making some changes in Western ver area. According to an investiga- in complex stampings, welded Canada. tion by the Ministry of Labour, seating assemblies and tube fabri- In response to growing con- SAFETY Training & Skills Development, cation. The company is receiving sumer demand, ABB will consoli- on November 23, 2018, a worker $78,410 towards custom comput- date its regional call centres and Manufacturer fined employed at the industrial plant’s er software and hardware that will warehouses in Edmonton into $40K for worker injury fabrication department was oper- support real-time data gathering a new, larger logistics operation ating an overheard crane attached and analysis of the stamping press. to house Baldor-Reliance indus- A manufacturer and supplier to a chain hoist and a Mag-Mate Kobay Enstel says the investment trial electric motors and Dodge of heavy machinery and rough lift magnet. The magnet is will improve productivity and mechanical power transmission terrain equipment has been fined high-powered magnetic device enhance competitiveness, leading products. $40,000 in Ontario provincial used to lift metal objects. to additional jobs at the company. Distribution and order hand- court after a worker suffered The worker was using the mag- O-AMP is part of the govern- ling activities will be transferred critical injuries at its industrial net to transport a chrome-plated ment’s Driving Prosperity auto in November. facility. steel bar, which weighed 233 plan, which partners with small “The move will provide our Following a guilty plea in prov- pounds. The worker was transfer- and medium-sized automotive customers with a greater variety of incial offences court in Windsor, ring the chrome bar into a drawer parts suppliers to invest in projects inventory and a larger operations Sellick Equipment Ltd. was fined to be stored. that support technology adoption. support team that will have the for the accident at its Harrow, While the bar was suspended by These projects improve processes means to deliver a wider breadth Ontario plant. the magnet, the worker reached and/or support training. of services to our customers, in a The court also imposed a underneath the chrome bar in

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order to move metal bars within representation in skilled trades the storage drawer. While doing careers in Canada. so, the chrome bar dislodged The industry-driven strategy and fell, striking the worker and has four measurable action items causing critical injuries. that are intended to generate The investigation determined awareness, trigger policy change, that the surface of the magnet recognize best practices and was not kept clear of debris. The create skilled trade workplace ministry’s inspector observed environments where women’s fragments of steel burrs and representation increases. metal shavings on the bottom of According to the Statistics Can- the magnet. ada Registered Apprenticeship Although the worker had Information System 2018 data, received on-the-job training, the when apprentice registrations in worker had not received formal the manufacturing, construction overhead crane training, nor had and transportation sectors were the worker received or reviewed analyzed, women represented 4.5 the operating manual for the Worldwide industrial robot installations are up 12 per cent over 2019. per cent of apprentice registra- magnet. The manual specifically tions. required the surface of the magnet automotive and electrical/elec- unstructured environments.” The SWiT task force estab- to be kept clean from debris. tronics, have experienced. Fonds de solidarité FTQ and lished a national target to increase The Occupational Health and “In addition to that, the con- Export Development Canada participation and retention of Safety Act (OHSA) requires an sequences from the coronavirus (EDC) led the round with par- women in skilled trades careers employer to ensure that the equip- pandemic for the global economy ticipation from Real Ventures to 15 per cent by 2030. ment, materials and protective cannot be fully assessed yet.” and a joint venture including the Another priority of the strategy devices provided by the employer company’s current employees. was to identify tactics to create are maintained in good condition. Quebec startup raises respectful workplaces. $6.5M for industrial RECRUITMENT The SwitCanada.ca web page ROBOTICS robot AI platform provides links to tools to assist CAF-FCA releases employers, unions, educators and IFR:Global industrial Omnirobotic, a Quebec-based national strategy for tradeswomen in creating healthy, robot installations up robotics automation startup, women in trades safe and inclusive workplaces. has closed a seed round of $6.5 A new report by the International million to further develop and The Canadian Apprenticeship DEAL MAKERS Federation of Robotics (IFR) indi- commercialize its AI platform Forum (CAF-FCA) is releasing cates there is a record 2.7 million for factory robots. a first-ever National Strategy for Schneider Electric industrial robots operating in This funding enables Omn- Supporting Women in Trades partners with REV factories around the world – an irobotic, which was founded (SWiT). increase of 12 per cent over 2019. in 2016, to continue building In 2019, CAF-FCA, a non-profit Schneider Electric has welcomed The World Robotics 2020 autonomous robotic capabilities that connects Canada’s appren- Calgary’s REV Engineering to its Industrial Robots report says that for high-mix production en- ticeship community through partner program in Canada as a sales of new robots remain on vironments, allowing industrial membership, led a task force Critical Power EcoXpert special- a high level, with 373,000 units robots to see, plan and execute of more than 60 skilled trades izing in power quality. shipped globally in 2019. This is high-value-added processes like stakeholders to inform a strategy The partnership will bring 12 per cent less compared to 2018, painting, welding and machining that would create more women’s IoT-enabled technology for but still the third highest sales with limited human oversight. volume ever recorded. “Our AI platform shows po- “The stock of industrial robots tential for significant productiv- operating in factories around the ity gains, along with substantial world today marks the highest energy and consumable savings level in history,” says Milton Guer- per part produced that are mean- ry, president of the International ingful to all kinds of industrial Federation of Robotics. manufacturers,” says Francois “Driven by the success story Simard, Omnirobotic co-founder of smart production and auto- and CEO. mation, this is a worldwide in- “The technology itself is crease of about 85 per cent within transformative because these five years (2014-2019). The recent manufacturers will finally be slowdown in sales by 12 per cent able to use industrial robots reflects the difficult times the for value-added tasks on Omnirobotic, a Quebec-based startup, has raised $6.5 million for its AI

two main customer industries, never-before-seen parts within technology that gives vision to industrial robots. OMNIROBOTIC (BOTTOM) NOELJINDOEL / GETTY IMAGES, (TOP) PHOTOS:

8 @AutomationMag November/December 2020 · MANUFACTURING AUTOMATION improved power availability, partnership expansion to develop MOVERS AND SHAKERS of the Ontario Tourism Education safety and operational efficiency solutions that help industrial Corporation. to customers in Western Canada. customers improve their digital The Ontario By joining as a partner, REV – a capabilities through cloud tech- Association Vecna Robotics has appointed provider of high-voltage electrical nologies. of Certified Jeff Huerta to senior vice- engineering services, solutions Microsoft and Rockwell are Engineering president of sales. Huerta’s and products for a wide range of working to deliver edge-to-cloud- Technicians and responsibilities will focus on diverse industries – will have ac- based solutions that connect in- Technologists scaling Vecna cess to Schneider Electric’s power formation between development, (OACETT) has Robotics’ sales quality portfolio. operations and maintenance Cheryl Farrow appointed a new operations to In early 2020, REV received teams through a singular, trusted chief executive meet the demand the Medium Voltage EcoXpert data environment. officer with an extensive track for its robotics Panel Builder certification from This will allow development record of executive leadership platforms and Schneider Electric, a demonstra- teams to digitally prototype, con- and team building. Cheryl orchestration tion of REV’s expertise in power figure and collaborate without Farrow brings more than Jeff Huerta software. Huerta distribution and motor control. investing in physical equipment. 20 years of experience in brings more With this certification, REV This unified information environ- not-for-profit management to than 15 years of automation uses Schneider’s technologies to ment also enables IT and OT OACETT, including governance leadership experience to the design, manufacture, test and sell teams to not only securely access transformation, amalgamation company. Prior to joining Vecna certified medium voltage (MV) and share data models across the and credentialing. Farrow’s Robotics, he was vice-president switchboards. organization, but with their eco- previous leadership roles include of North America sales at system of partners as well. CEO of the Canadian Bar Balyo. Previously, he held sales Rockwell, Microsoft Organizations can access Association, president and CEO and marketing positions with enter five-year deal Rockwell Automation solutions of the Supply Chain Management SICK, where he managed and now via the Microsoft Azure Association, executive director developed the OEM packaging Rockwell Automation and Micro- Marketplace, with more solutions of the Canadian Grocery Human sales team for the North soft have announced a five-year currently in development. Resource Council and president American market.

MANUFACTURING AUTOMATION · November/December 2020 AutomationMag.com 9 MA_Balluff_NovDec20.indd 1 2020-10-16 9:19 AM Paul Hogendoorn co-founded FreePoint Technologies with the goal INDUSTRY WATCH of giving manufacturers the benefit of information technologies that BY PAUL HOGENDOORN inform, empower and motivate their most critical asset – their people. Contact Paul at [email protected].

The critical value of purposeful work

ow do you end up building a motorcycle in your family room? (It’s actually not too Hdifficult to explain). My wife and granddaughter have kept me plenty busy the last eight months. At first, I thought they were just creating projects to keep me sane, to keep me from going stir crazy, as I wasn’t getting on airplanes, traveling to faraway places and doing what I love about work most – visiting plants and helping manufacturers make their companies stronger by connecting to their machines, and most importantly, with their people. In other words, by reconnecting meaning with work, and dignity with labour. The first project was my granddaughter’s idea. We have a run-down The author tackles a project. and dirty old pool shed that, in her mind’s eye, would make a great “she- was plumbed using 1-1/4 inch ABS, not have tangible and visible results, which shed.” It started simply, by cutting in 1-1/2 inch as has been the standard for most people have an inherent need for two windows, squaring up the frame, a few decades – and my local Big Box – especially people who are drawn to and painting it all fresh, inside and had virtually nothing to couple into the manufacturing careers. out. Then came the furniture, fridge, now separated drain, with the family Many workers lost their connection microwave, 42-inch smart LCD TV and Thanksgiving dinner only a day away. with this source of daily satisfaction, Nespresso coffee maker. To protect that With classic “just-in-time” execution, either temporarily because of short- investment, a new roof was required. we managed to get the project done and term shutdowns, or permanently be- And an air conditioner. There is a avert a bottleneck at a critical family cause of job loss. The cost of this kind of The second project was necessitated tactile and location. loss is catastrophic and immeasurable by the first; I no longer had a pool shed palpable In between those three projects financially. for the chemicals, equipment and odds sense of was one that I have been picking away The second lesson I learned is and ends associated with the pool. satisfaction at for years – something I refer to as that periods such as these offer us So, a small garden shed between our that comes “wrench therapy.” I’ve been decon- all a chance to get things done that house and the neighbour’s had to be from com- structing and reconstructing an early we would otherwise not have had a enlarged, but we quickly determined ’80s motorcycle, more for the pleasure chance to do. I have encountered many pleting tasks that it had to be replaced. To replace of wrenching than riding. It was a companies that have taken intentional it meant leveling the slope between that have garage project until the reconstructed steps to make themselves better by the houses, which meant building a tangible garden shed no longer had room for adopting new technologies; executing retaining wall, on a proper footing, with and visible the snowblower and lawn mower, due and completing projects they initiated drainage considerations. The net result results, to the pool equipment and furniture in previous years that were often is a beautiful 16-foot by six-foot secure which most moving in. Relocating the lawn and delayed; reskilling their workforce; storage area for everything that used to people have snow equipment into the garage forced reigniting the energy in their workforce be in the pool shed (which is now the an inherent me to move my motorcycle project, and by inviting suggestions and input; or by “she-shed”). need for – the only place available was the family creative out-of-the-box thinking and Then came the upstairs bathroom. especially room. (Pretty rational explanation, planning. This was a time to do all of It too started simple, but grew. What those drawn right?) those things, but not everybody did was going to be a new single sink and to manu- But through it all, I learned a them. Some chose to sit by, try to ride a paint job became a new vanity with couple of very valuable lessons that it out, and look forward for everything facturing double sinks, which meant upgrading are applicable to all manufacturers in to return to normal. the plumbing that was embedded in the careers. these disruptive COVID-19 times. The The good news is, it’s not too late walls. After a great start to the project, first lesson is that work has inherent to initiate – and complete – a few I encountered the first of several “ex- human purpose, far more than just a interesting and purposeful work pro- pected unexpected” problems. After means to earn a living. There is a tac- jects. It’s good for you, your company cutting into the main, I discovered tile and palpable sense of satisfaction and your people. So, what’s still on

that the house, built in the late 1960s, that comes from completing tasks that your project list? | MA HOGENDOORN PAUL COURTESY PHOTO:

10 @AutomationMag November/December 2020 · MANUFACTURING AUTOMATION This article was prepared by Workplace Safety & Prevention Services MACHINE SAFETY (WSPS), which has helping Ontario businesses improve health and BY WSPS safety for over 100 years. Visit wsps.ca or contact WSPS at customer- [email protected].

Eight ways for employers to ‘take every reasonable precaution’ during a pandemic

ccupational health and safety • Stagger shifts and breaks symptoms before entering the workplace, legislation says that employers • Screen employees and visitors before they and staying home when feeling ill. and supervisors should “take enter the workplace Oevery precaution reasonable in the • If masks or other personal protective 5. Document everything you do. This circumstances for the protection of a worker.” equipment (PPE) are called for, ensure they includes hazard assessments, controls, This is known as the general duty clause, but also protect against COVID-19 training, inspections, investigations, logs, what it means in this uncertain period is a ques- • Clean or dispose of used PPE safely and in checklists – so that if the need arises, you tion many employers have been asking Work- an environmentally friendly way can demonstrate due diligence – that you place Safety & Prevention Services (WSPS). have taken every precaution reasonable in WSPS Regional Community Coordinator To help workplaces control hazards, WSPS, the circumstances to protect your workers Lori Shepherd cuts through any uncertainty Ontario’s Ministry of Labour, Training, and from COVID-19. with this simple approach: “It means applying Skills Development, and other prevention the same risk management strategies to this system partners have collaborated on over 6. Review and update your COVID-19 haz- hazard as we would to any other hazard.” 100 sector-specific guidance documents. ard assessment and controls. A number To help workplaces put this into practice Each document includes a number of control of factors may prompt the need for a during wave two of the coronavirus, Lori offers options. review: the following eight suggestions. Find them at: covid19.wsps.ca/resources/ • Significant changes or improvements to sector-specific-health-safety-guidance processes or tasks 1. Identify and assess COVID-related • Challenges introduced by these changes hazards that may be present in your • Evolving information on COVID-19 and workplace. “We know the risk of contract- related hazards ing COVID-19 through close, prolonged • Changes to public health and other personal contact can be very high,” says government requirements Shepherd. “What processes, procedures and tasks could put employees at risk? 7. Reinforce everyone’s role under the How many people could be exposed to Internal Responsibility System. This the virus, and how likely are they to be- is another staple of occupational health come infected? Have any COVID-related and safety legislation. Under the system, changes implemented by your workplace everyone in the workplace – employers, introduced new hazards?” supervisors and workers – is responsible for their own safety and the safety of 2. Determine how best to control the haz- co-workers, and has specific roles and ards. Once you know the nature and extent responsibilities. of risk, it’s possible to explore control options. Apply the hierarchy of controls, start- 8. If in doubt, err on the side of caution. ing with elimination. For instance, replace 3. Develop a COVID-19 safety plan. Com- Focus on controlling hazards, not just on in-person meetings and conversations pile all of the steps necessary to protect compliance. Legislation and regulations with virtual meetings and phone calls. For workers from exposure to the coronavirus, set minimum performance requirements, hazards that can’t be eliminated, determine as well as the procedures necessary to which cannot guarantee a safe workplace. If how to control them. For instance: monitor worker exposure and their health. you focus on compliance as a minimum, and • Install transparent barriers between Include steps to take in response to a sus- not on taking every precaution reasonable, workstations pected case of COVID-19 at work. Involve you may not be managing hazards effectively. • Change the alignment of workstations so your joint health and safety committee or that workers are at least two metres (six health and safety representative early on, Helpful resources feet) apart in all directions and ideally don’t and complement internal expertise with In addition to the over 100 sector-specific face each another external expertise where needed. Once guidance documents mentioned above, WSPS • Encourage workers to maintain clean you have drafted a plan, discuss and share offers two more tools on its website. The workstations, tools and equipment; clean it with everyone at work. Hazard Assessment Template was originally and disinfect tools and other equipment created for small businesses, and can help any between shifts 4. Integrate local public health require- size workplace identify and assess hazards and • Employ signage and markings to promote ments for workplaces into your safety recommend controls. The Post-Pandemic Busi- physical distancing. (Find examples at wsps. plan. Examples include wearing a mask or ness Playbook provides information and tools ca/Information-Resources/Articles/Using- face covering, physically distancing at least to help businesses adapt to the new operating signage-to-improve-physical-distancing.aspx) two metres (six feet) apart, using proper environment. Sector-specific versions are also

PHOTO: KAMONCHAI MATTAKULPHON / GETTY IMAGES KAMONCHAI MATTAKULPHON PHOTO: • Increase ventilation hand hygiene, self-assessing for COVID-19 available. | MA

MANUFACTURING AUTOMATION · November/December 2020 AutomationMag.com 11 CENTRE STAGE

MICHELLE CHRÉTIEN, director of the Centre for Advanced Manufacturing and Design Technologies at Sheridan College, recently appeared on our podcast, Machine Language, to discuss innovation in automation and how partnerships can help

Manufacturing AUTOMATION: around new product ideas and Tell us about the Centre for really give yourself a little bit of a Advanced Manufacturing and playground to think about how Design Technologies and the to make your business grow research areas that you have or be more efficient, increase available to industry. productivity, etc. Michelle Chrétien: It’s a bit of a mouthful, so we usually refer to MA: On a broader scale, how it as CAMDT. [CAMDT is] one of does innovation impact business the applied research centres at objectives for manufacturers? Sheridan College. We’re a tech- MC: I have a whole bunch of nology hub where students and answers to that, but I think the researchers, faculty and industry one that that resonates most for can come together to learn, the times that we’re living in is explore, collaborate and innovate. that I like to think of innovation We have a number of different as a bit of insulation. A company areas across the broad spectrum with an innovative mindset, of advanced manufacturing that whose strategy includes ongoing we have expertise in, including innovation, is always better digital fabrication, which includes positioned to weather storms. I additive manufacturing. We also know in manufacturing especial- have expertise and advanced ly, it can feel difficult to justify an equipment in robotics and de-risk technology adoption. Of they’re in school means they’re investment. To this I would say, automation. And our last core course CAMDT has the expertise more likely to choose you as a number one, find a partner. There area of specialization that really [but] across the whole network, company after they graduate. are myriad ways to multiply your goes underneath all of those there’s a much broader array of Building relationships with dollar – I don’t know that we do other areas is in design. We’re expertise that you can tap into. schools can also help to address a great job in Canada of making always learning and growing By forming this network, we another one of my favourite those connections, but those and expanding as the industry were trying to create kind of a topics, which is diversity in fields opportunities are out there and I changes, [so] we’re also starting one-stop shop for SMEs looking like manufacturing. Partnering think it’s worth seeking them out. new projects in cybersecurity for for partners in innovation, and for with an academic institution The other thing I would say industrial control systems. also access to funding. and building relationships with is, think about the cost of not students and faculty at what investing. The return on your MA: Sheridan College and MA: Why is it beneficial for might seem like an early point innovation investment isn’t a CAMDT are members of the industry to partner with these can really help to address the simple calculation. You probably Southern Ontario Network types of incubators and the underrepresentation of certain wouldn’t go to your accountant for Advanced Manufacturing larger academic world to ideate populations in manufacturing and for that answer. But I do think Innovation (SONAMI). How does manufacturing concepts? broaden the talent pool. that [the] return on investment is SONAMI work with industry? MC: I feel really passionately The other reason [is] access there and it is tangible. MC: SONAMI is a network of the value of partnership – and to cutting-edge equipment It’s worth it to reach out. Find colleges and one university that one plus one usually equals and expertise with zero capital partners – you can multiply institute that work with SMEs on more than two. I have a couple investment. Across Canada, there your investment and, frankly, applied research projects. The of reasons [why] I think it’s a great are millions of feet of research everything we need is really here. goal of SONAMI is to increase the idea. One is, I talk to manufac- space and hundreds of millions of It’s in Canada. That is something capacity of the advanced manu- turers every day. And one of the dollars of specialized equipment that I think we are very fortunate facturing research and innovation things I hear most in terms of and facilities that are there. to be discovering in a time where ecosystem in southern Ontario. discussing what their barriers If you’re not reaching out in we’re all sticking a little bit closer Our network is funded by FedDev are to growth is access to talent. partnership to take advantage of to home. Ontario, and provides a really One of the top reasons to partner that, you’re really missing out excellent value to SMEs who are with an academic institution is The final thing is [that] it This a condensed transcript of our full-length interview with Michelle looking to stretch their innovation access to a pipeline of highly really is a way to multiply Chrétien on a recent episode of Machine dollar. SONAMI partners work trained, work-ready potential your innovation spend. It’s Language: The Podcast. Find all episodes with companies to explore new employees. Making connections a low-risk, low-cost way to of the podcast – and hear Michelle’s tips for partnering with schools – at products and processes, and to with programs and students while explore new technologies, kick automationmag.com/podcasts.

12 @AutomationMag November/December 2020 · MANUFACTURING AUTOMATION MACHINE LANGUAGE: THE P DCAST Engaging conversations on the latest technologies and trends in Canada’s industrial automation sector

We’ve launched a podcast! Every month, join Kristina Urquhart, editor of Manufacturing AUTOMATION magazine, as she interviews industry experts about topics related to automation and machinery, including:

• Safety integration • Robotics and sensors Brought to you by: • Motion control • Software solutions • Industry 4.0 and the IIoT • Cybersecurity and networking • Artificial intelligence • Management and innovation • And more!

For sponsorship opportunities, contact Klaus Pirker at [email protected] www.automationmag.com REPORT: INDUSTRIAL CONTROL

THE STATE OF INDUSTRIAL CONTROL

Senior-level leaders join our roundtable on automated machines and store reams of data that can be sent to edge or industrial control systems to sound off on legacy cloud services for analysis, noted Vic equipment, device lifespan and controls project Briccardi, president of RTS Consulting – Automation. Using artificial intelli- planning gence and machine learning, that data BY KRISTINA URQUHART is then used to optimize operations and drive value. “In the past, systems were very pgrades to industrial Last month, we asked several indus- much set it and forget it,” said John control systems (ICS) try experts to share their insight and Krajewski, senior director of product are one of the biggest advice on making a change to control management, monitoring and control investments a com- systems and devices such as SCADA, at AVEVA. “Now, control systems are pany can make. In- HMI, PLCs and MES at our online In- living and breathing – we’re constantly dustry 4.0 offers many dustrial Control Systems Roundtable. commissioning new things and de- Unew capabilities for ICS, but how can (You can watch the recording via auto- commissioning old things.” a manufacturer convert their control mationmag.com/industrial-control). Over the course of about two hours, systems while maintaining uptime, The advantage of modern con- our roundtable participants discussed ensuring security and minding cost? trol systems is they can connect to how COVID-19 has impacted that

14 @AutomationMag November/December 2020 · MANUFACTURING AUTOMATION The Industrial Control Systems Roundtable panelists, from left: Christian Perrier, PCI Automation; Sanjith Singh, Schneider Electric Canada; Vic Briccardi, RTS Consulting – Automation; and John Krajewski, AVEVA.

value, and how profitability, data opti- “Don’t get caught in the trap of getting a fancy mization and security factor in to any new controls project. Here’s just some new control system but using the old legacy con- of what they had to say. trol philosophy.”

Using the ICS for crisis management track and trace the finished product of control systems can only go so far The COVID-19 crisis has put more [anymore], you now need to trace until repairs get too complex and too stress on legacy ICS – particularly the supply chain – so the suppliers’ costly to do. “It raises the risk of longer those that were not yet connected suppliers – almost to the point [of] the downtime,” he said. to the internet or equipped with the component level right up until to the The availability of systems also capabilities to enable remote access. produced level.” prevents manufacturers from moving As workers moved from their usual With supply chain, production and on upgrades, shared Krajewski. For places of work early in the pandemic, logistics requiring traceability to gain example, some of his clients can only there were restrictions on what they full visibility, the industry is moving afford one to two hours of scheduled were able to access, said Krajewski. from a “smart factory” idea toward a downtime per year, and don’t want In addition, support for hardware, more holistic “smart manufacturing” to have to run two systems at once in software and service has been challen- approach. order to do an ICS changeout. ging throughout the pandemic, with “From that perspective, control “So very often you see these guys people working from home, off sick systems are really helping to connect trying to change the engines on the or reluctant to travel, said Briccardi. those dots, and connect the supplier airplane while the thing is still in Without connectivity, “users of exist- to the raw material,” said Singh. “It’s flight,” Krajewski said. “The mono- ing and legacy control really lacked or almost a farm-to-fork mentality using lithic nature of a lot of the old systems had limited visibility and control of the control system.” ICS actually led to this – to touch anything, production operations,” he said. “Total For this roundtable, I had to bring everything down. We’re access to operations, anywhere at any- Considering cost vs. value we defined industrial starting to see things become more control systems (ICS) time, is paramount to supporting the When is right time to upgrade? as the devices, segregated.” operation.” It comes down to several factors, instrumentation, This means that while one part of Sanjith Singh, vice-president, Singh said, and greatly depends on a software and a control system is down, another networks used to industrial automation at Schneider manufacturer’s desire to embrace new operate industrial part can still be running – or the Electric Canada, said that automation technologies as well as the funding processes, particu- cloud can be used to upgrade certain was a “godsend” for plants that didn’t they have available – though there are larly when it comes components on the fly. This approach to manufacturing. have enough workers onsite to main- a variety of solutions available now to is enabling more manufacturers to tain and run equipment. Plants that fit most budgets. move to a hybrid model, whereby had upgraded their PLC, HMI and But the maturity of the equipment they can bring systems that are not SCADA systems were better equipped should be of concern, as should access mission-critical fully into Industry to pivot for production of critical med- to parts. “As control systems age, there 4.0 and leave critical processes alone, ical devices and supplies needed in the is a risk of failure and fatigue at the tacking on additional connectivity fight against COVID-19. component level, which results in solutions as needed. The bottlenecking in supply chains downtime,” said Singh. “Extending the reasonable life of caused by the pandemic has high- Manufacturers are hesitant to invest assets has become a huge thread,” said lighted a bigger need for networked in new technology because they do not Krajewski. Artificial intelligence and systems, said Singh. fully understand the risk if they don’t, machine learning can help operators “As we see the demands of consum- said Christian Perrier, president of PCI learn the value of an asset “so that ers becoming greater, there’s a greater Automation. He findsleaders reluctant you can understand – do I need to need for traceability throughout the to move data outside of their current replace it, or do I need to maintain it? supply chain,” he said. “You don’t just setup. But prolonged maintenance Can I just continue to let it do its job?

MANUFACTURING AUTOMATION · November/December 2020 AutomationMag.com 15 REPORT: INDUSTRIAL CONTROL

“Very often you see these guys trying to change MQTT and others, which helps with their integration into reporting soft- the engines on the airplane while the thing is still ware, Perrier said. But they’re not the in flight,” Krajewski says. only control device from which data can be gathered. The latest tools for data analysis, Ultimately, the capital expenditure high-priority initiatives that bring which include modelling, correla- that can be preserved is gold. There maximum value, then conduct a gap tion analysis and statistical process [may be] no reason to have to buy it analysis to ensure those goals can be control, can provide ways to opti- again or rebuild it.” achieved. mize production in real time, said Briccardi pointed to a recent ex- Once an upgrade is underway, Briccardi. In order to facilitate that ample when his company worked on steer clear of old ways of thinking, analysis, control systems can move a 1960s injection molding machine. said Singh. “Don’t get caught in the the data from machines to a database Because it was not connected to the trap of getting a fancy new control for computation. Ideal performance internet, it had no metrics or KPIs system but using the old legacy targets are then fed back to the edge. to indicate its health. The client did control philosophy,” he said. “You That real-time data feedback is not want to move data to the cloud, become less efficient, because you’ve paramount to modern-day ICS, said but was willing to have analysis on spent a lot of money and your return Singh. “Clients are looking for speed. site. With a $600 PLC attached to on investment has been pushed out.” How quickly can I get data?” he said. the machine, Briccardi’s team was He suggested looking beyond the “From a manufacturer perspective, or “able to strategically pick points to project’s goals to the company’s goals. from an analyst perspective, if there’s be monitored so that we had visibility If sustainability is a corporate goal, a component failure, you want to into things like cycle time and idle then energy consumption should be know the second of the minute of the time and mold changeover time,” he a key indicator on a new ICS. Once day that it happened. So you need said. The company was able to “get you’ve mapped out what you want to real-time data transmissions.” definitive numbers on how well the achieve from a macro level, you will Speed will be further enhanced machine was performing compared know what hardware makes the most by 5G wireless networks, which are to the latest and greatest technology, sense for your application. forthcoming to the industrial sector which then allowed them to make over the next few years. With lower some strategic capex decisions on Optimizing performance latency and increased network new machines.” using data capacity, Briccardi noted that 5G A key feature of modern industrial will allow manufacturers to reliably Planning a new control systems is the streamlining of connect devices inside plants on controls project data collection so that the data can be segmented networks, allowing for As they’re considering an upgrade, contextualized and used to improve private transfer of information. some of the common things senior performance, Singh said. decision makers want to know in- In the past, manufacturers had Securing industrial clude the availability of hardware, their devices hardwired throughout control systems if there are resources to support the a plant – and this system is still in Cyber attacks are an increasing team during downtime, if data will place at most plants today. But with problem in manufacturing – and in- be able to be shared and integrated $600 wireless networks or connected dustrial control systems are a major with other parts of a plant, and if Using an inexpensive devices, data can be collected more target for criminals. The roundtable the ICS will be able to communicate PLC that cost $600, easily, and used in exciting new ways panelists unanimously agreed that with other controllers in the plant, Vic Briccardi at RTS that move beyond simple graphic their clients don’t take cybersecurity Consulting was able said Briccardi. A key part of planning to bring a 1960s representations and into preventative seriously enough. for an upgrade is creating a strategy machine online so and predictive analysis. For manufacturers without a or roadmap for the future, even if it that decisions could “One of the biggest limitations we cybersecurity plan, “once you get be made about the won’t be used for several years. equipment’s health have is our imagination,” said Krajew- locked out of your production facility, “Sometimes, direct cost-benefits and longevity. ski. For example, a PLC might not be you could go days or weeks before are not enough to make a project go,” the best place to obtain information you open it up,” said Singh. “Instead said Perrier. “Initially, your project for a certain application. “If an oper- of paying for protection, you have may not be profitable in itself, but if ator sees falling output pressure on a to pay after the fact and then spend you consider integrating it into your pump and knows the seal needs to be possibly millions of dollars because full picture, it takes on a lot more replaced – when was the last time that your production line is down. value.” information was maintained? That “We really need to start thinking To ensure the success of a new information is not in the PLCs. Do about what [this means] for our plant. controls project, Briccardi advised we have any spares in the inventory? If I were to get locked out of my plant beginning with a business goal such That information is not in the PLC.” today, what would it cost me? And is as improved financial performance Indeed, PLCs are powerful tools that cost greater or less than what it or increased productivity, as well that now incorporate office-centric would be for me to actually invest in as an expected outcome. Identify communications protocols like SQL, having a good cybersecurity plan?”

16 @AutomationMag November/December 2020 · MANUFACTURING AUTOMATION Singh advises against maintaining the status quo on a legacy ICS, What’s new in even if connected systems bring industrial control? higher risk. Roundtable participants shared the control trends that excite them moving into next year. With many cybersecurity to move forward,” Singh said. incidents kept under wraps to “Mitigate your risk. Because we protect the reputation of the af- know there is risk. Do the right Vic Briccardi, president and founder, RTS fected company, awareness isn’t things, put the cybersecurity Consulting - Automation as strong as it should be, Perrier measures in place.” Briccardi said he is excited to see where AI said. “It causes other customers That includes ensuring secure goes, because it is a boon to productivity to have a distorted picture of access to industrial control in the factory, and integral in ensuring the situation and the potential systems through encryption, maximum performance of assets with no threat,” he said. “One [attack] I authentication and restrictions waste. “I think we’re heading toward a future heard about stopped production on user activity, said Briccardi. where we’ll have conscious factories driving for three days on six job sites. Remote access works for some the supply chain,” he said. Another caused a company to employees, but it can also intro- stop functioning for maybe two duce errors in programming to three weeks, everything from if operators and engineers are John Krajewski, senior director, product customer service to production accessing control systems with- management, monitoring and control, floor.” out being present in the physical AVEVA He stressed that losses are the environment. Client attitudes on change are shifting, biggest consequence of a cyber Perrier pointed out that Krajewski said, which makes conversations attack – not only in terms of there’s an additional, rarely con- about upgrading easier. “I’m seeing a production, finances and intel- sidered element that can help to willingness to take that chance.” Mission- lectual property, but also pot- ensure security – if employees critical legacy systems can co-exist with entially human life. If an attack are well compensated, they will new AI, cloud, and machine learning on a connected machine results care more about the health and solutions – and Krajewski said he’s looking in it operating in a different or security of the company. forward to seeing how that continues to unsafe manner than its original Another way to minimize risk evolve given the demands COVID-19 has use intended, a worker could be is to work with vendors that are put on the industry. injured – or worse. specifically certified to make “[Companies] say, ‘I don’t components or provide services. know that I can balance that This is especially important at a Christian Perrier, president, PCI risk against availability’ – until it time when everyone is experi- Automation hits them. And then they realize menting with IIoT solutions that “I like the way PLCs are now talking in how important it was,” said Kra- can provide additional access languages once only seen in office software jewski. “Be honest with yourself points for cyber criminals. such as SQL, OPC and MQTT,” Perrier said. – make sure you have a clear and “Startups may not have that “This really elevates the integration level.” He documented topology of your maturity,” Krajewski said. “If also enjoys seeing how artificial intelligence system so that you understand you’re working with a startup, is being used to enhance machine vision, what the attack vectors are.” they may have some brand-new as well as the automated logistics solutions There are various areas of fancy technology, but very often that are now available for warehouses and entry for a cyber attacker to they haven’t gone through the distribution centres. compromise an ICS, and thus level of maturity where they’ve varying levels of risk, said established the security practi- Singh. He suggested contract- ces to ensure they are ready for Sanjith Singh, vice-president, industrial ing a company experienced in primetime.” automation, Schneider Electric Canada cybersecurity to provide an ob- Singh agreed. “Cheap is not “The trend I see is there’s a shift away from jective assessment of hardware, always better,” he said. “Some- buying products and turning to integrated software and systems. He also times, there is a reason why solutions,” Singh said. “People aren’t advised against maintaining something is cheaper.” looking at where they are today, they’re status quo on a legacy ICS, even Thanks to our sponsor, Schneider looking at where [they’re] going to be in if moving to connected systems Electric Canada, for their assistance three years or in five years. And I think that brings higher risk. in putting together the roundtable. thought process is developing a trend of “If we don’t do something Watch the roundtable recordings the connected world – and the connected because we are worried about and see more videos from our product inside the industrial control system.” the risk of typically what could panelists at automationmag.com/ happen, then we’re never going industrial-control. | MA

MANUFACTURING AUTOMATION · November/December 2020 AutomationMag.com 17 COVER STORY

Jon Ferrier, an electrical designer at Black Controls Co., builds panels in the founder's garage. TAKING CONTROL material and panels,” Black says. “We weren’t Building a new business during a pandemic sure what was going to happen with COVID. So it was good to get the [new space] – and good may not have been on this panel builder’s to get my house back!” vision board, but the team came through with Now, the team of five at Black Controls Company does design work and programming a bigger order book onsite at the new facility, as well as panel builds, testing and powering of components. BY KRISTINA URQUHART They specialize in a wide range of projects including automated parts assembly and testing, logistical conveyance, robotic assembly, mold hen programmer Rick equipment builder uses palletizing robots and machine tending, custom control cabinet Black decided to start conveyor systems so its client can transfer the assembly and wiring, machine wiring and his own industrial product into the sterilization bunker. electrical installations. controls company last Black Controls Company developed and The firm is vendor-neutral and works with any year, he did it for all wired the conveyor’s control system using PLCs, system based on specific customer applications, the usual reasons: to VFDs, servos and HMIs by Siemens, cabinets by but has experience with products from a number Wget back to hands-on builds after working Rittal, remote I/O and cabling by Murrelektron- of companies including Siemens, Allen-Bradley, in management, to make more use of his ik, sensing by IFM, material handling robots by Beckhoff, Omron, Mitsubishi, Fanuc, Yaskawa technical knowledge, to fill a need in the Fanuc, and field cabling by Lapp. Motoman, Kuka, Keyence and Cognex. industry, and to work for himself. “The product [runs] in batches and its Black got his start in the automation in- Black figured he would start small and then location is tracked through the system,” says dustry after completing a three-year electrical go from there. So in July 2019, he founded Black. “The conveyors are controlled by VFDs, technologist program at Georgian College. Black Controls Company out of his home in and the sterilization treatment is done on a He landed a co-op placement at Innovative Barrie, Ontario and began designing controls servo-driven conveyor. The servo allows very Automation, a large Barrie-based automation systems. By September, he was building two precise speed control. The speed in the treat- solutions provider and systems integrator. custom control panels in his garage for his first ment area is critical because it determines how Black spent at total of 12 years at Innovative client. Business steadily increased – a month much dose the product receives. Not enough wiring, programming and developing ma- later, he was able to hire an additional full-time dose and the product is not sterile, and too chines, and eventually led the programming staff member and part-time help, and, by the much dose will damage the product.” group. It was there he noted an eternal need for end of the year, the small team was working on Since wiring and programming the handling outside contractors to help execute projects. “I a shutdown project with a local integrator at an systems and building six dual bay cabinets for saw what [contractors’] responsibilities were automotive plant. that client, Black Controls Company has taken from a customer standpoint, and I decided that What Black didn’t anticipate was that mere on a number of additional jobs, expanding in it was something I wanted to pursue,” Black months later, his fledgling company would face May 2020 to a 2,500-square-foot office and says. His new team members at Black Controls a massive global pandemic, challenging his assembly space where Black now employs four are all former colleagues. newly established customer base and supply full-time staff plus a part-time bookkeeper. As they look to 2021, the team plans to chain. Luckily, Black says that while work for But back in March, as supply chains around concentrate on the material handling, pack- some industries such as automotive dried up the world were getting squeezed due to the aging and automotive sectors. “We are also during the early days of the crisis and it be- pandemic, Black’s client was concerned with excited about the recent investments made came harder to meet new customers, a strong acquiring enough raw material for upcoming in automotive battery manufacturing here in pre-COVID relationship with a company projects. So he started stocking up on product Ontario and are optimistic this will lead to that builds equipment for sterilizing medical and storing it in his house. some opportunities for us,” says Black. devices helped to buoy his business. “We ended up ordering a bunch of VFDs and “Our growth so far is in part a reflection Since exposure to the radiation used to other hardware and they were all in my living of the tremendous talent that we have on sterilize the devices is unsafe for humans, the room. The basement of my house was full of our team.” | MA

18 @AutomationMag November/December 2020 · MANUFACTURING AUTOMATION TRAINING NEW TOOLS FOR TRAINING With technology frequently in flux, today’s workforce requires ongoing digital learning that prioritizes a proactive versus reactive approach BY WILLIAM VALEDIS

igh-impact events, such as accidents or major breakdowns, temporarily elevate training and information management needs – but react- Hing to these events through one-time The current training approach is misunderstanding or miscalculations training is not ideal. usually misaligned with specific em- about costs over benefits of training. The long-term cost when we do not ployee and organizational needs and It is time to rethink how critical infor- address the root cause of issues im- values, and typically results in employ- mation is distributed and adapt to the pacts every business. Think of current ee frustration and higher operational new reality – that the workforce must training philosophies like an iceberg: costs. Implementing any training as be continually updated and trained in we react quickly to what we see on the a one-time event also diminishes the our new world. To do so, we must move surface and don’t evaluate what lies life cycle value of the investment, since from instructor-led training to blended, beneath in terms of business impact. knowledge fades away or disappears digitized ongoing learning. There are serious questions to be after the project is complete, or due to answered when determining whether employee turnover. Training myths the return on our investment has had New employees often don’t have ac- Myth: One week of training is adequate any impact or not. Was the training 10 cess to a formal onboarding processes, Reality: One week of training to last a content developed in concert with a A machine’s typical leading to a lack of accurate informa- machine’s lifecycle – typically 10 years current employee skills matrix? Did the lifecycle may be 10 tion about specific areas concerning – is inadequate, since we know every years, but operators training meet the needs of our employ- are often provided a employee health and safety, as well as organization experiences employee ees? How was the training balanced to week or less of company policies and procedures. Some turnover. Repeating OEM training our needs in terms of lecture/practical? one-time training, organizations have adopted ISO stan- is also costly since many OEMs are with no guidance as Did the training result in measurable the machine dards on how certain procedures are focused on selling their products and improvements in operation or mainten- becomes more to be followed, but little is done in the training is one of those “optional” items ance efficiencies?H ave MTTR and DT complex to repair. areas of maintenance troubleshooting, the customer may or may not buy. decreased? Does the training require operator functions and safety, which follow-up? would benefit from push notifications Myth: Available training will meet our Proactively planning for employee on critical information. needs training and critical information Training materials in manufacturing Reality: Without understanding cur- management has heretofore been a facilities range from being loosely organ- rent employee skill levels, it would be simple exercise of picking items from ized and outdated to inaccurate or totally guessing at best to try to hit the training a menu of readily available training unavailable despite being deemed critic- needs target. In many organizations,

PHOTO: TRILOKS I E+ / GETTY IMAGES TRILOKS PHOTO: offerings or products. al to the operation. Perhaps there is fear, skills matrixes do not even exist, so

MANUFACTURING AUTOMATION · November/December 2020 AutomationMag.com 19 Steps to control costs

1. Working from a skills level list helps to identify the current skill level. This first step is crucial in establishing a baseline. 2. Not everyone needs every training course or information type to carry out their job responsibilities. Electricians, for example, may need technology training that is relevant to the areas in which they are assigned. Putting all electricians through all the PLC courses that are installed in your plant may not Digitized training should be front-loaded before a project begins, with annual sessions thereafter to be such a great idea. Putting all provide refreshers or to update new content. employees through safety policy training, on the other hand, is evaluating needs is not possible. can easily be searched and used im- appropriate. Available training works in several mediately. 3. Packaging costs vary from paper scenarios. For example, organization production to mobile/online, XYZ just installed a new-generation Information management myths with the latter resulting in higher PLC model 1000 and not a single Myth: We have a document library development costs. The added technician has ever worked with this Reality: The information in these benefit of mobile/online content new model. An OEM class that intro- libraries is often outdated. Paper infor- packaging is that it provides duces the model 1000 PLC would be mation cannot be searched and stored valuable data as to where each a good choice here. But would this information is not always available employee stands in terms of OEM model 1000 PLC course address when/where it is needed. Updates are learning their specific assigned all training needs? No. manual and time consuming. material, difficulties in learning Understanding the current skill certain content and sharing level is important to set a baseline level Myth: Digitizing information is expensive feedback on important issues of expertise. Knowing what is required Reality: If we calculate the number of that impact productivity. Course after the project is complete helps us to employees times the amount of time reassignments, cross-training $8K- measure the skills gap. OEM training spent looking for required information needs and more can be handled or “off-the-shelf” training is primarily over the project lifecycle, this exercise with data and reports. 16K focused on product features, and not will be convincing enough that digitiz- Mobile/online 4. Development of courseware content development specific needs. Third-party training ing and automating the distribution of or information packages must costs can range is designed to address the designer’s information is cost effective. I once wit- not be developed in isolation. between $8,000- objectives, which may or may not be nessed an operator who was unable to $16,000 per hour of Development must include key content delivery your objectives. locate a machine parameter backup file. management stakeholders during – but keep in mind For liability reasons, large OEMs A support engineer contacted the OEM development and reviews, to how much material will not customize training content to only to find out the OEM had gone out can be delivered in ensure the content meets the one hour. your needs unless a specific waiver of of business. The parameter file then had employee and organizations future liability documents is signed, which to be re-created while the machine was objectives. One hour of mobile/ is rare. out of production for two days. online-ready learning/information Another time, a worker performed content takes about 100 hours to Myth: Classroom training meets our a task without the latest version of the produce. Mobile/online content needs task’s safety procedure. The information development costs can range Reality: During the last decade, we never made it to the operations binder between $8,000-$16,000 per hour have witnessed tremendous acceler- box, where all the safety procedures of content delivery – but keep in ation in areas of learning using tech- were kept. When the worker performed mind how much material can be nology, but not many organizations the task, they sustained what was thank- delivered in one hour. are using that technology. Traditional fully a recoverable injury. 5. Paper-based content can be classroom training should be supple- handled via presentations in mented or replaced with an enduring The cost of reacting to needs a classroom and this involves learning approach. Today, people are Processing power, big data, cloud, AI, instructor and facility costs, as well accustomed to a social/collaborative IoT, mobility, robotics, PLC, drives, as the cost of the employee’s time. and personalized learning environ- CNC, vision – all of these technological ment that is available when/where advances and others will continue to it is needed. Relevant content about put pressure on training and keeping

maintenance, operations and training the workforce informed with critical SYSTEMS INC. KINITO PHOTO:

20 @AutomationMag November/December 2020 · MANUFACTURING AUTOMATION It is time to rethink how critical information is Creating distributed and adapt to the new reality – that training content the workforce must be continually updated and Here are some ideas to help plan training trained in our new world. and critical information sharing. Operational information information in an automated process. manager’s office, he asked me to report • Develop guides on how to operate To compete in an interconnected back the name of the “incompetent machines, or how to perform tasks global market, Canadian companies shift person that was not capable of • Provide information critical to oper- are looking to fill a huge void of skilled fixing the problem.” ational procedures and safety workers in many disciplines – and After getting the plant up and run- • Use a blended mobile/online method this is a huge problem when the talent ning, I asked the electrical group how that survives the process, machine or pool is constantly draining due to much training they had received on the project lifecycle retirement, not enough young people PLC and installed network – and the • Push updates immediately after entering the industry, and loss of answer was zero. The amount of time changes workers by way of emigration. Based taken to fix the network problem is on my working experience all over the inversely proportional to the amount of Maintenance information world, technical training in Canada is time invested in training – so in this case • Upload application backups for PLC/ not always taken seriously compared with zero training, the time required to DCS and other critical devices on to other developed countries. fix the problem is, in theory, infinite. secure server Today, organizations rely on a variety The front-line workers keeping • Develop guides on how to perform of technologies to handle sales, infra- the manufacturing processes and certain maintenance tasks structure, HR, procurement, manufac- machines running must be literate • Provide information critical to mainten- ture, distribution and customer service. in specific technologies. We must be ance procedures and safety As technology dependence and the skills selective as to what training and/or in- gap are increasing, our knowledge base formation is critical for each function- Safety procedures – our greatest asset – is shrinking. But al group. We need to understand that • Develop guides for how to perform it is also unrealistic to expect workers to learning is ongoing, not a single event. tasks safely become competent in every technology The cost of training and information • Deploy safety policy and procedures in we install in plants, particularly when it sharing can be initially a single event, a secure cloud space comes to maintenance. but the tools used during the initial Some time ago, I arrived at a paper phase must be available throughout Disaster recovery mill that was down, losing production the intended lifecycle. | MA • Create plans and backups for a catas- due to a PLC network problem. I was trophic event to address loss of valuable asked to see the plant manager before William Valedis is director, support systems software, critical recipe data, product I investigated the problem, which development, at KINITO Systems Inc. and a parameter lists, drawings, etc. member of Manufacturing AUTOMATION’s was unusual. When I got to the plant editorial advisory board.

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MANUFACTURING AUTOMATION · November/December 2020 AutomationMag.com 21 OPERATIONS

BRINGING PRODUCTION BACK HOME

executive director at the Schulich Pandemic shortages have amplified concerns Education Centre, York University, “but we all get a bit lazy, and we don’t about over-dependence on offshore do it unless we’re forced to do it. So providers, causing more manufacturers to this is forcing us to go through all those risk factors.” consider bringing production back to North Mitigating offshoring’s inherent America. The trend is likely to drive more risks doesn’t come cheap. For example, companies that depend on automation offshoring often face long lead times, BY JACOB STOLLER requiring them to maintain and manage large amounts of “just-in- case” inventory. The associated costs of that – financing, storage, transport, erhaps one of the most more people have realized that supply management, shrinkage – add up to far-reaching conse- chains are too long, too complicated, some significant numbers that many quences of the COVID-19 and too unreliable,” says Harry managers are unaware of. pandemic will be that Moser, founder and president of the Moser has done the math and exposed it has accelerated the U.S.-based not for profit Reshoring a significant gap between the purchased conversation about the Initiative. cost of an offshored product and the real Pviability of the supply chains we de- “COVID-19 has revealed vulner- cost, which he calls Total Cost of Owner- pend on. In May, a McKinsey Global abilities in today’s supply chains ship (TCO). “Procurement often ignores Institute survey of supply chain exec- that have required organizations to the impact of offshoring on inventory, utives found that a stunning 92 per rethink their end-to-end processes stocking out, travel, late night phone cent plan to take steps to make their to accelerate risk management and 92% calls, IP risk, warranty, etc,” writes supply chains more resilient. resiliency,” says Takshay Aggarwal, A recent McKinsey Moser on the website reshorenow.org. “We estimate that 16 to 26 per IBM’s global leader digital supply study indicated 92 “Most companies make sourcing deci- per cent of supply cent of exports, worth $2.9 trillion to chain, citing a recent IBM survey of chain executives plan sions based solely on price, oftentimes $4.6 trillion in 2018, could be in play 3,500 C-suite executives. to make their supply resulting in a 20 to 30 per cent miscalcu- – whether that involves reverting to Pandemic-related fears may be the chains more resilient. lation of actual offshoring costs.” domestic production, nearshoring, tipping point amongst existing wor- The site includes a free online or new rounds of offshoring to new ries about tsunamis, hurricanes, pol- calculator for estimating the TCO of locations,” conclude the authors. itical instability and potential trade a given product. Users input infor- Offshoring, once seen as a panacea wars. “Business schools endlessly tell mation based on 30 factors, and the for North American manufacturers, organizations that leadership is about app computes a forecast of the TCO is rapidly losing its lustre. “Compared running contingencies on risk factors over five years. While Canadian sta-

with six months or a year ago, many for the future,” says Alan Middleton, tistics are not currently available, the BERNARD / GETTY IMAGES CHRISTOPHER PHOTO:

22 @AutomationMag November/December 2020 · MANUFACTURING AUTOMATION “You can lose by not automating,” Moser says. “But chips and components, but we’re doing the material handling.” you can’t win by automating alone, because every- A typical business case for body else is going to also automate as much as they acquiring robots, Campbell says, is to charge a higher selling price need to.” based on quick delivery. numbers are useful for Canadian a great history on commercial accessible for smaller companies manufacturers, some of whom application,” he says. due to significantly lower costs, Looking ahead have worked with Moser. The scalability and user-friendly oper- According to Middleton, the site also includes, based on U.S. Meeting the technology ating environments that no long- reshoring question needs to be government data, a service to challenges er require specialized personnel pursued with a long-term view. provide details on U.S. compan- Automation is likely to play a such as robotics engineers. “It’s not just now,” says Middle- ies that are currently importing significant role in reshoring ef- “Today, we’ve got case after ton, “but it’s getting people to from overseas, and what they are forts. The most obvious reason is case where line operators and really look at the path of tech- spending. Canadian companies the existing labour shortage. Ac- production coordinators are nology. So you’re not just looking could benefit from the service to cording to a 2019 report released doing all the robot programming at what’s the labour factor now sell more product, Moser notes. by Canadian Manufacturers & and setup,” says Joe Campbell, relative to what the technology Large manufacturers are the Exporters (CME), 85 per cent of senior manager of applications factor is, but at the realistic least likely to bring back produc- manufacturers are having diffi- development for Universal impact on design, development tion now in their own factories culty filling vacant positions. Robots North America. “These and manufacture.” offshore, Moser has found, “Labour and skill shortages smaller companies have never Canadian companies typically particularly if they are also using in the manufacturing sector been able to deploy automation don’t have the clout or access that capacity to service local are alarming. They are holding in any significant way in the past.” to capital of U.S. companies, overseas markets. back the entire sector and, by The other key is having the Middleton says, but still have “The enthusiasm also gets extension, Canada’s economic flexibility that smaller manu- some significant strengths that greater the further you go down growth,” says Dennis Darby, facturers need. Campbell says can be leveraged. the supply chain,” says Moser. president and CEO of CME in many of his customers deploy “We have good talent and a “It’s the contract manufacturers a press release about the report. collaborative robots on carts number of good companies in – mold makers, foundries and The other factor is that the and move them around to vari- areas such as IT, artificial intelli- machine shops – that will benefit economic advantage enjoyed by ous processes where they might gence and robotics,” he says, “so the most from reshoring.” countries like China and India take on the repetitive tasks such where the story can be positive While such companies don’t is no longer just about cheap as loading and unloading a ma- is on technology and material make headlines, they are a signifi- labour. “At the moment, the chine tool. Because they operate support to traditional areas cant contributor to the economy. Chinese, the South Koreans, and side-by-side with workers, they such as mining and agriculture. “The majority of employment is the Germans are automating a lot can be quickly integrated into a They have technology needs and still with small, medium-sized faster than we are,” says Moser. new work process. equipment needs as well, so why companies,” says Middleton. “You can lose by not automating, The manufacture of auto - can’t there be massive improve- Many, however, have relied on but you can’t win by automating motive electronic modules is ments in where they get their a favourable currency exchange alone, because everybody else is one area where Campbell is see- equipment from?” | MA rate with the U.S., and have not going to also automate as much ing a lot of activity. “Quite a lot been as innovative as they could as they need to.” of what we do is load and unload Jacob Stoller is a journalist and author be. “Canada has a great history Fortunately, many of the testers,” says Campbell. “We’re who writes about Lean, information of patents applied for, but not newer technologies have become not populating the board with technology and finance.

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MANUFACTURING AUTOMATION · November/December 2020 AutomationMag.com 23 TECHNOLOGY

AI AT THE EDGE Using artificial intelligence to process data on an edge device helps to create new value for OEMs BY CHRIS CATTERTON

ne of the key bene- limited insight into the health and define the inputs and outputs more fits of artificial performance of their smart equipment/ specifically. For example, for pipeline intelligence (AI) is devices once they are deployed into the monitoring, pressure, volume, and the valuable insight field, causing them to miss out on some flow rates may be important factors that it delivers to the critical information that could help not to measure. For industrial equipment, broader Internet of only avoid unexpected downtime and such as robotic arms in a manufactur- OThings (IoT) strategy. And in no indus- catastrophic failures, but also deliver ing line, cycle rates and temperatures try is this actionable and insightful data better products to market. Second, may be most significant. And in con- more valuable than in manufacturing. when OEMs do gain visibility and ac- sumer goods, such as a dishwasher or Without AI, manufacturers have IoT cess to the data their solutions are pro- washing machine, vibration and energy The Internet of limited visibility into the health and Things (IoT) refers to ducing, the cost of sending that volume usage may be the key factors to meas- behaviour of their assets (i.e., equip- physical devices that of data to the cloud for processing and ure. The device manager can take the use sensors, ment and devices), and that could have hardware and an storage can be exorbitant. AI-enabled platform and feed it into a significant impact on performance, cost internet connection machine learning engine and monitor and security. For AI to reach its poten- to collect and share Driving intelligence to the the impact on outputs. tial, each part of the asset value chain data. device OEM This process not only brings visibility needs to be able to gain insight into Regardless of whether AI-enabled into the health of a specific device, but device behaviour while connectivity IoT solutions are part of an industrial also allows the device OEM to gain costs are controlled. or consumer implementation, great insights that help health and perform- Original equipment manufacturers benefit can be derived if they are added. ance of its entire portfolio. Take house- (OEMs) face two key challenges with When device manufacturers embed hold appliances, for example. An OEM IoT deployments. First, they have AI into their devices, they are able to may want the data output to go to their

24 @AutomationMag November/December 2020 · MANUFACTURING AUTOMATION When OEMs do gain visibility and access to the data their solutions are producing, the cost of sending that volume of data to the cloud for processing and storage can be exorbitant.

industry, where AI-powered edge are in normal range where no action solutions can predict vehicle health is needed. Many IoT implementations based on similar situations with use cellular or, in some cases, satellite other vehicles. The vehicle manufac- networks for data transmission to the turer can be proactive with service cloud, and there is cost associated with announcements, alerting customers every byte of data transmitted. that their part may fail and should be When readings are in normal range, serviced to mitigate it. moving all data – good, bad and mar- This data could also be used to invoke ginal – to the cloud is expensive, and warranties, for example, if instructions in most instances not necessary. What state that a device is for indoor use, but businesses really want to be alerted humidity and conductivity are regis- to are unusual readings that indicate tering at exceptionally high levels, that impending signs of failure, so they could indicate that the device may have can take action before catastrophic been placed outside. operational downtime occurs. Many OEMs manufacture more Technology is emerging that lets all than one type of product, and machine data to be trained, collected and pro- learning technology is emerging that cessed at the network edge, with only allows this level of intelligence and out-of-range data being transmitted to insight to be trained, delivering value the cloud. This helps create significant back to the OEM without reinventing cost savings from both a data transmis- the wheel. The OEM simply needs to sion standpoint as well as a storage select what data should be gathered as one, as select data can now be parsed input and output. and stored for deeper analysis. This rapidly accelerates time to A side effect of transmitting all data market to bring embedded AI to de- to the cloud is power consumption. vices, because no new training model Most IoT devices work on batteries is needed for each device – it’s just a and whenever IoT devices connect matter of connecting to the platform. to the network and transmit, battery While different types of devices have consumption comes into play. By different data inputs, the machine reducing the amount of time devices IT systems to run further analysis on learning platform is agnostic to those connect to the network because only their machines. They can use this data data inputs. The device simply goes select data is transmitted, overall to gain intelligence on how a single through the training phase to learn battery life is improved. machine, all machines in a specific normal asset behaviour, and when- model number, or even machines in ever that behaviour deviates from Driving new efficiencies a geographic location are performing. the norm, it triggers an action, such AI-based IoT solutions are driving new Being able to aggregate this data as an alert. efficiencies across a number of indus- through AI-powered solutions allows The outcomes of an OEM using edge tries, and its value to manufacturing OEMs to better understand why things AI-enabled IoT include increased hard- is being proven through a variety of go wrong and determine what factors ware/asset reliability and productivity, use cases. Key to this is controlling led to the issue. For example, was the and greater visibility into device per- costs, and emerging technologies can problem contained to a particular formance, enabling product develop- help analyze data at the network edge, facility? Or to a particular line where ment to plan future improvements. avoiding high cloud transmission costs. parts were made? Are parts failing With new visibility provided by AI more frequently? What additional Controlling costs solutions, OEMs can access the data metrics should be measured? Further- One of the biggest expenses of using being collected by IoT devices, glean more, these OEMs can then bring a ser- an IoT solution is the cost of connec- short-term insights, and also create an vitization model into play by offering a tivity to transport raw data to the cloud environment for longer-term analysis maintenance service for an asset that for processing. Most AI solutions don’t and overall value. | MA is showing signs of failure, prior to the take into account the impact on costs asset failing. when data is sent to the cloud. Most Chris Catterton is the director of solution Translate this to the automotive of that data is reporting readings that engineering at ONE Tech.

MANUFACTURING AUTOMATION · November/December 2020 AutomationMag.com 25 NEW PRODUCTS

AUTOMATION SOFTWARE

capabilities to their products. 3D simulation software and Non-circular grinding is used transferred to the targeted in a wide variety of automated machine. manufacturing applications, num.com such as the production of camshafts, crankshafts, cams and eccentric shafts. NUM has now added non-circular grinding functionality to its NUMgrind cylindrical grinding software, which forms an application-specific element of the company’s Flexium+ CNC platform. It is Control engineering fully compatible with other software Flexium software, from release Controls engineers can 4.1.20.00 onwards. NUMgrind design machines and process is specifically designed to applications faster using the simplify the creation of G code latest release of the Studio Digitized workforce programs for CNC grinding 5000 Logix Designer software. management solutions machines through the use of Rockwell Automation has Honeywell has released a a graphical human machine updated the software with modular software solution interface (HMI), conversational- productivity enhancements to help industrial companies style “fill-in-the-blanks” type and new capabilities that can enforce compliance with key dialogues or a combination of speed up projects for process health and safety requirements, the two. Unlike conventional applications specifically. including body temperature CAD/CAM workstation tools Productivity enhancements in checks and automated entry for generating CNC machine version 33 of the Studio 5000 management processes. Software for non- tool control programs, Logix Designer software include: The solution facilitates site circular capabilities in NUMgrind is intended auto-generated diagnostics for monitoring compliance CNC grinding for use in the production supported devices that reduce in accordance with social New software from NUM environment. Application- programming time and give users distancing policies and enables provides manufacturers of dependent projects, and access to detailed diagnostic contact tracing and monitoring CNC cylindrical grinding the corresponding ISO part information, preservation of of worker safety. It also includes machines with a means of programs, can be created, online controller tag values remote collaboration capabilities adding non-circular grinding tested with NUM’s Flexium when making offline changes to empower company operations with a reduced workforce. As part of a broader plant and MATERIAL HANDLING personnel safety portfolio, the Honeywell Digitized Workforce Management – Business Lifting magnet for fast release them with the push of design securely holds the load Continuity and Response cycle times a button. Pickup and release in the event power is lost. Nine solution combines software and Industrial Magnetics recently functions can be performed different models with working hardware technology to support announced the availability by using the wireless remote load limits of 660 to 10,580 lbs return-to-work and transition of the FXE line of remote- control or direct activation are available. to operations. The system can controlled lifting magnets in from the magnet’s on-board magnetics.com support Honeywell thermal North America. Combining the control buttons. All labels and cameras that can be used with safety of a permanent magnet controls are located on top of systems compliant with NDAA for load handling with the the magnet, which gives the 2019, Section 889 to check for controlled-release capability operator easier access and elevated body temperatures of an electromagnet, the FXE visibility, allows the magnet and provide input to the access uses virtually no energy and to fit into tight spots, control system. This can enable does not require a battery and limits the operators to restrict entryway backup system. They’re ideal risk of damage access if an elevated temperature for lifting applications that to the controls. is detected, helping to automate require fast cycle times, without A built-in load the preliminary screening the operator having to touch sensor prevents process and reducing manual the load. The FXEs allow the the load from being tasks. operator to pick up ferrous released until it’s at rest and honeywell.com metal sheets or parts and safely the fail-safe permanent magnet

26 @AutomationMag November/December 2020 · MANUFACTURING AUTOMATION COMMUNICATIONS & NETWORKING and conducting sequential or open collector interfaces. be individually configured up to downloads, and extended tag Based on internal pull-up four IP addresses with a common properties that allow engineers resistors, no external wiring MAC address or set up as group to leverage contextual data is required for open collector combinations. These ports to create more descriptive analysis. Additional 24 V digital support MODBUS TCP/UDP and powerful HMI elements. inputs can save, lock and set the and Ethernet/IP as well as other When paired with the new counter value. A wide range of protocols such as EtherCAT Allen-Bradley ControlLogix additional integrated functions, and Sparkplug with additional and CompactLogix process EtherCAT I/O series such as rotary axis functionality, licenses. Other features of the controllers from Rockwell for incremental signal workpiece measurement and 750-8210 controller include Automation, the latest version analysis standstill monitoring enable data high-speed Cortex A8 1 GHz of Studio 5000 Logix Designer Beckhoff Automation has pre-processing directly in the processor, 512 MB ram with 4 can also accelerate process introduced new EL51xx I/O terminals. The measurement GB internal flash memory, and projects in key ways: HART EtherCAT terminals with built-in of period, frequency and speed the SD card slot, which extends integration allows engineers to incremental signal analysis with a resolution of 10 ns is also the memory up to 32 GB. The connect HART devices just like functionality. These four I/Os available. device is Linux-based and can they do EtherNet/IP devices, and feature eXtreme Fast Control beckhoff.com run applications with Docker pre-built task models reduce (XFC) technology and enable Containers and integrated the amount of time spent on analysis of incremental signals in Controllers with firewall. This controller supports project creation and layout and the controller. The new EtherCAT configurable Ethernet MQTT protocol and can be can improve consistency across terminals acquire incremental ports configured to connect to cloud projects. signals with high frequencies up WAGO has released the 750- services such as AWS, rockwellautomation.com to five MHz and feature many 8210 PLC, expanding its line of Azure, IBM Cloud and parameterization options and PFC200 Generation 2 controllers. more. Programming integrated functions that enable The 750-8210 includes and configuration optimum adaptation to control four configurable can be done with tasks. Each terminal offers an Ethernet ports, an either WAGO’s integrated sensor supply, which is SD card slot and e!Cockpit software parameterizable to five, 12 or 24 is IIoT-ready. Each or Codesys 2.3 based V. Users can connect encoders of the four 10/100 WAGO IO-Pro Software. with differential RS422, 5 V TTL Ethernet ports can wago.com

Remote power MACHINE SAFETY monitoring software Eaton has launched the newest corresponding key (actuator). protection and product/machine version of its Visual Power It can be set power-to-lock safety. The new Contrinex Manager (VPM) software, VPM or power-to-unlock. A tool- 14-mm and 30-mm beam Essential. The new offering operated safety release is on the resolution extended-protection, delivers the comprehensive front of the switch enclosure, slim-profile safety light curtains remote power monitoring and inside the enclosure, an eliminate blind spots (the height capabilities IT and data centre optional escape release enables of the light curtain is the height professionals rely on in VPM, but immediate opening in case of of the protected area). These in a self-installable, subscription- emergency. new slim light curtains can based license ideal for small to itcproducts.com also be wirelessly configured medium business applications. Safety door interlock through Bluetooth. The 14-mm Supporting up to 1,000 monitored switches resolution light curtains provide devices, VPM Essential provides ITC Electrical is stocking SLC finger-safe protection and a host of features, including a switches for the electro- 30-mm resolution curtains offer fully HTML5 web interface, auto mechanical locking of doors, hand-safe protection. Protection discovery, mass firmware upgrade covers, protection grilles, etc. heights are 170 mm to 1,290 and node-settings configuration The switches offer remote mm (6.7 to 50.8 in) for the 14- tools, monitoring of third-party monitoring access status and mm resolution curtains and 170 devices and multi-tenant user offer optional emergency to 1610 mm (6.7 to 63.4 in) for access control. Among Eaton’s opening from inside or outside Slim-profile safety light the 30-mm curtains. Operating two levels of VPM licenses, VPM the enclosure. SLC switches curtains ranges are 0.25 to 5 m (0.82 to Essential provides additional feature a tough thermoplastic AutomationDirect has added 16.4 ft). All of the safety light simplifications, including a body and a metal head, new Contrinex slim-profile curtains have Type 4 and Cat 4 modified home page, device designed to accept entry safety light curtains to its safety PL e safety ratings and are IP65 dashboards and set-up wizard. from four sides and the top products lineup. The curtains rated. eaton.com (user-configurable) of the are to be used for human automationdirect.com

MANUFACTURING AUTOMATION · November/December 2020 AutomationMag.com 27 NEW PRODUCTS

ROBOTICS

High-payload application-focused technology adopters are in the process of palletizing robot comprises fully connected, evaluating the platform, and Yaskawa Motoman has released plug-and-play hardware and 30-plus ecosystem players are the 500-kg-payload PL500 software with pre-selected developing necessary hardware robot, ideal for a variety of functions for rapid and and software to enable various palletizing applications, simple deployment with robotics applications, including unitized loads and other UR10. The palletizing ADLINK and Panasonic. The logistical tasks application can be set up platform’s Qualcomm QRB5165 for end-of-line in three steps on the visual processor, or distribution robot control device, with customized automation. automatic trajectory planning for robotics The PL500 and collision detection, and applications, features no need for a PC or external offers a extremely fast programming. The solution is artificial intelligence to help computing axis speeds and also compatible with third-party develop power-efficient robots architecture coupled with the acceleration for safety systems such as safety and drones. The Qualcomm fifth-generation Qualcomm maximum production interlocks, light curtains and area Robotics RB5 platform is AI Engine delivering 15 Tera throughput. It offers a large scanners. comprised of an extensive Operations Per Second (TOPS) work envelope and a high robotiq.com set of hardware, software and of AI performance for running payload to efficiently load/ development tools to create complex AI and deep learning unload pallets, and handles full Platform for robot high-compute, low-power workloads. The platform also layers or a variety of product development robots and drones for a includes support for 4G and including boxes, bags, bottles Qualcomm Technologies variety of sectors, including 5G connectivity speeds via a and cases. The PL500 features has unveiled a new robotics industrial, enterprise and companion module. a 3,159 mm horizontal reach, platform that uses 5G and defense. More than 20 early qualcomm.com 3,024 mm vertical reach and ±0.5 mm repeatability. Its T-axis features a 60-mm pass-through MOTORS & DRIVES to facilitate connections to the end-of-arm tool, as well under load. Their low inertia industrial applications. The as a high moment of inertia to makes them an exceptional portfolio includes a new motion ensure unbalanced loads are option for applications requiring controller that connects directly handled effectively. Parallel-link fast stopping, starting and into the PACSystems RX3i construction also provides acceleration. Upon request, programmable logic controller strength, rigidity and stabilization Portescap can also provide backplane for high-speed, of high moment and inertia options for customization high-precision performance loads, while heavy-duty bearings including gearboxes, encoders, with synchronized motion for provide smooth arm rotation. A coil variations and mechanical up to 40 coordinated axes, single cable is all that is needed interface modifications. enabling end users to scale to connect the manipulator to Brushless DC motor Portescap is globally ISO up their motion systems. The the controller. The PL500 robot with integrated driver 9001:2008 certified and its complete PACMotion portfolio can be floor-mounted, and Portescap introduces the production site in India is also includes motion controller, brakes are included on all axes. newest addition to its Ultra ISO 14001:2004 and OHSAS servo motors, servo drives The robot is controlled by the EC mini brushless DC motor 18001:2007 certified. and motion configuration high-performance YRC1000 platform – the 16 ECP brushless portescap.com software for applications in controller that is built to a global motor with a new integrated packaging, printing, material standard and does not require driver. These new 16-mm handling, semiconductors, a transformer for input voltages diameter motor versions are food and beverage, and general ranging from 380AC to 480VAC. available in two lengths (36 mm manufacturing. Emerson’s motoman.com and 52 mm). The integrated technology enables precise, motor drive solutions are a jerk-free positioning, preventing Robotic palletizing for good fit for applications such material slippage and production lower throughput as respiratory and ventilation losses and improving machine Robotiq has introduced a new devices, miniature pumps, efficiency. On-the-fly electronic robotic palletizing solution for medical hand tools, clinical Servo motion control reconfiguration allows users to lower throughput applications diagnostics, valve actuation as package implement rapid changeovers that require frequent changes well as many others. Portescap Emerson has released the without stopping production of task and box or pallet size. brushless motors are an ideal PACMotion servo motion to deliver shorter production The new system is designed for choice for geared applications control portfolio to offer runs and increased machine applications of up to 13 boxes because of their minimal speed an integrated automation utilization. per minute. In addition, this drop and low motor heating solution for high-performance emerson.com

28 @AutomationMag November/December 2020 · MANUFACTURING AUTOMATION PROCESS CONTROL

Conveyor Sanitary RTDs and and transmitters with sanitary Pneumatic Manifold has communications transmitter probes connection probes have a one- several capabilities for linear The AutomationDirect process year warranty and are cURus, CE and 1/4 actuators, including control temperature sensor approved. speed control, safety pressure lineup now includes RTD automationdirect.com relief and fail-safe capabilities. versions of the M12 connection The pre-assembled manifold transmitters, transmitter versions Pneumatic manifold for configuration eliminates of the RTDs without process valve actuators potential leak points and comes connection, and sanitary 3-A Cowan Dynamics has with an optional pre-installed versions of RTDs and transmitter announced advancements to ASCO solenoid valve. Actuator probes. ProSense Pt100 RTD its C-PAC Module Pneumatic technicians can select any ROEQ has launched GuardCom, sensors and transmitters with Manifold and the launch of the solenoid valve brand with the a communication solution that sanitary connection probes corresponding appropriate area enables Mobile Industrial Robots offer a clean-in-place tri-clamp C-PAC online classification (MiR) equipped with ROEQ’s process connection ideal for store. The for complete top rollers to communicate applications where corrosion C-PAC (Cowan’s compatibility. The directly with conveyor stations and product contamination are Pneumatic online store gives to initiate the transfer of factors. Temperature measuring Actuator Control) valve automation goods between mobile robots ranges for ProSense Pt100 is an out-of-the- centres and and conveyors. The solution type RTD probes with sanitary box solution that technicians the consists of two products: connections are available from the company ability to configure GuardCom installed on the -58 to 400 degrees F. ProSense says can save the C-PAC module stationary conveyor station, and XTP series temperature up to 90 per with over 35 GuardCom Connect, installed transmitters combine a precision cent in assembly variations for on the autonomous mobile Pt100 or Pt1000 RTD sensing time and to automate valve their application. The C-PAC robot. Multiple GuardCom element and transmitter actuators without using piping pneumatic manifold can be Connects can work with the electronics in a single stainless- to connect various automation ordered in three sizes. same GuardCom and vice versa. steel body. Available in three components. The C-PAC cowandynamics.com GuardCom is compatible with preconfigured measuring all stationary conveyor stations, ranges, XTP series transmitters replacing third-party wireless are ready to use out-of-the- ADVERTISER INDEX devices. Once the mobile robot box or use the free XT-SOFT has arrived at the conveyor, software to program transmitters AutomationDirect 2 Encoder Products GuardCom signals to the station with a custom measuring range. Balluff Canada Inc. 9 Company 6 that the robot is in place and ProSense Pt100 RTD sensors Black Controls Endress+Hauser 5 ready to receive or deliver the Company Inc. 23 Machine Language: packages, and the same signal is Careers in Automation 21 The Podcast 13 sent to the robot letting it know Carlo Gavazzi Murr Canada 3 that the stationary conveyor is (Canada) Inc. 7 SEW Eurodrive 31 ready. Once the transfer task is WAGO Canada, Inc. 32 completed, both units receive a signal that it is safe for the robot TO ADVERTISE to leave. Contact Klaus B. Pirker • [email protected] roeq.com

MA’s Technology Handbooks are a series of digital magazines that focus on a single product category within Canada’s manufacturing industry. Posted on MA’s website as an interactive flip-style magazine, our Technology Handbooks provide specific market and product information, as well as trends within that specific product category, to machine builders, component manufacturers, end-users and system integrators.

For more information, contact Klaus Pirker at [email protected] or (416) 510-6757.

MANUFACTURING AUTOMATION · November/December 2020 AutomationMag.com 29 MA_HandbookAd_March.indd 1 2018-02-21 2:40 PM THE SMART FACTORY

SMART INNOVATIONS MA rounds up research reports and industrial automation applications to help manufacturers make smart decisions on the path to digital transformation

The KINETIC Reflex is a discrete smart wearable worn on the belts or waistbands of industrial workers. It automatically detects unsafe work postures and provides users with real-time feedback to reduce injuries and create better work habits. The technology was recently updated with proximity alert features to enable workers to Protect programming languages from attacks practice proper social distancing and to help keep them safe during In a new research report, global cybersecurity firm Trend Trend Micro Research has worked closely with the this pandemic. With this feature, Micro highlights design flaws in legacy programming Robotic Operating System Industrial Consortium (ROS- workers are notified of potential languages that could lead to vulnerable automation Industrial) to establish recommendations to reduce the risk via a gentle vibration if they are programs. Vulnerabilities can allow attackers to hijack exploitability of the identified issues. too close to one another. KINETIC industrial robots and automation machines to disrupt The task programs that rely on these languages and features a software analytics production lines or steal intellectual property. govern the automatic movements of industrial robots can platform that enables management “Once OT systems are network-connected, applying be written in a more secure manner to mitigate Industry 4.0 to conduct contact tracing and patches and updates is nearly impossible, which makes risk. The essential checklist for writing secure task programs produce detailed reports on secure development upfront absolutely critical,” says Bill includes the following: each interaction. If a worker tests Malik, vice-president of infrastructure strategies for Trend • Treat industrial machines as computers and task positive for the virus, management Micro, in a statement. “Today, the software backbone of programs as powerful code export a list of everyone who could industrial automation depends on legacy technologies that • Authenticate every communication have potentially been exposed, as too often contain latent vulnerabilities, like Urgent/11 and • Implement access control policies well as the duration of the contact. Ripple20, or varieties of Y2K-like architectural defects.” • Always perform input validation Legacy proprietary programming languages such as • Always perform output sanitization RAPID, KRL, AS, PDL2, and PacScript were designed without • Implement proper error handling without exposing Mobile robots make an active attacker model in mind. Developed decades ago, details a move they are now essential to critical automation tasks on the • Put proper configuration and deployment procedures factory floor, but can’t themselves be fixed easily. in place

Source: Unveiling the Hidden Risks of Industrial Automation Programming, Trend Micro, 2020

COVID-19 impacts operations According to a recent survey conducted between April and August 2020 by IBM’s Institute for Business Value of over 3,800 C-suite executives across 20 countries and 22 industries, COVID-19 has prioritized operational capabilities over Mobile for logistics (such as those external growth. Among the top objectives were cost management (87%), enterprise agility (87%), cash flow and liquidity from MiR, pictured), will grow management (86%), cybersecurity (76%) and IT resiliency (75%). Other findings included: ten-fold by 2024. In a new market report, Interact Analysis predicts mobile robots will have a ten-fold investment increase 59% 60% 64% in the logistics sector by 2024. The Fifty-nine per cent of respondents Sixty per cent of organizations Sixty-four per cent of firm expects COVID-19 to be a said that COVID-19 accelerated their have accelerated their process organizations have shifted to more significant driver in long-term mobile digital transformation. automation plans as a result of the cloud-based business activities in robot growth, and that sales of coronavirus crisis. response to the pandemic. autonomous mobile robots (AMRs) will quickly overtake automated Source: COVID-19 and the Future of Business, IBM, 2020 guided vehicle (AGV) revenues.

Have a research report or smart automation application to share? Send to [email protected] and you could be featured in Manufacturing AUTOMATION! PHOTO: BARANOZDEMIR / +E / GETTY IMAGES / +E GETTY IMAGES BARANOZDEMIR PHOTO:

30 @AutomationMag November/December 2020 · MANUFACTURING AUTOMATION

SECURITY BUILT-IN

MOVE SECURELY INTO THE CLOUD

DIRECT FIELD TO CLOUD CONNECTION

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