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~~~ TRENDS ~~~

Worldwide HMI Market to Reach $590 Million

Significant contributing factors and emerging technologies will influence and contribute to growth in the HMI market. These include adoption of Internet-based technology for distributed infrastructure, collaborative manufacturing architectures that will define the exchange of information from the embedded device level to enterprise tier applications, wireless HMI products, incorporation of HMI software into integrated automation solutions, and the need for interoperability across all systems and applications.

ARC Survey: Tell Us What In-Plant Training Needs

ARC would like to better understand your needs for training, specifically in support of automation support activites. We understand the difficulty plant operations have to keep their valuable support personnel up-to-date and trained. We are now soliciting feedback from end-users, suppliers, OEMs, and system integrators. Please take a few minutes to help us provide some perspective into current and future needs. If you feel you're not the right person in your company to provide this feedback, please feel free to pass this invitation on to a colleague. We'll be happy to send you a free copy of the survey results. Just enter your email address at the end. Thank you for your time. Your contribution is greatly appreciated!

Instrumentation Information as a Strategic Asset

Many manufacturers struggle with the “as-built” data that is handed over at the end of a construction project. The problem arises from what to do with it so that it will provide value throughout the life cycle of the assets it defines. Software tools have become available that can be used to create and manage such databases from design creation through the entire life cycle of the plant. The utilization of such software tools during design and engineering certainly will make E&C firms more efficient, but its impact on manufacturers goes well beyond the management of the assets themselves.

Electronic Motion Control Maximize Printing Machines

End users in the printing industry are overleveraged due to poor equipment utilization driving down operating margins. Business owners in this sector have purchased an excess of capital equipment, largely because machine operators are reluctant to run machinery at a maximum rate. As a result, end users in the industry have purchased nearly 30 percent more capacity than is utilized simply to operate in a comfort zone. Although operator training and digital control technology is available to drive advances in operational efficiency of this entire market, but operator habits are difficult to break.

Nanotechnology: a Leap in Manufacturing Efficiency

Nanotechnology, or the art and science of manipulating matter at the atomic or molecular scale, has the long term potential of revolutionizing manufacturing processes. It is a technology in its infancy, but with the potential to change everything in a manufacturing environment from sensors to controllers and even manufacturing processes themselves. In the immediate term, nanotechnology will enable significant improvements in areas such as reduced size of industrial sensors and lower power consumption by workstations and controllers.

Four Major Companies Forge ZigBee Alliance

Invensys, Mitsubishi Electric, Motorola, and Philips have formed a non-profit corporation to drive the creation and further development of the ZigBee wireless connectivity standard for a new low-cost, low power consumption wireless technology. The alliance focuses on developing interoperable, wireless appliances and devices that will provide customers with a greater choice of wireless solutions that are cost-effective, easy to use, highly reliable, and secure. The Alliance consists of over 25 total member companies and is growing. The ZigBee wireless connectivity solution will be embedded in consumer electronics, home and building automation, industrial controls, PC peripherals, medical sensor applications, toys and games.

Court Annuls EC Ruling on Schneider/Legrand

The European Court of First Instance has annulled the European Commission’s decision prohibiting the merger of Schneider and Legrand. The court also ruled against a second commission decision ordering that the two companies should be separated. The annulment of the commission's first decision results from a complex assessment. The court challenged the commission's economic analysis. It said that the commission failed to do a precise country-by-country examination of the markets affected and overestimated the combined economic power of the merger. It did accept, however, the commission’s argument that in the French market, the merger would create a dominant and anti-competitive entity. Schneider Electric’s board of directors, which noted with satisfaction the ruling of the Court of First Instance, has asked the Chairman to rapidly draw up company options based on feedback from European Commission officials. The board of directors will then decide whether it is opportune to keep Legrand.

~~~ ACQUISITIONS & PARTNERING NEWS ~~~

Entivity and Phoenix Contact Form Partnership

The partnership involves joint product development, marketing, and sales for PC-based control solutions. It brings together the strength of Entivity’s automation software and Phoenix Contact’s hardware. Together, they will develop and market bundled automation solutions containing software, PCs with embedded controllers, and I/O. Entivity will develop specific drivers and port its flagship products, Entivity VLC and Entivity Studio, to Phoenix Contact’s broad line of industrial PC and embedded controllers. Phoenix contact will provide scalable, bundled hardware and software configurations, including its windows CE-based computers.

GE Fanuc Acquires Intellution from Emerson

GE Fanuc Automation North America has signed a definitive agreement to acquire Intellution, a leading supplier of industrial automation software that has been a division of Emerson Process Management. The transaction, which is subject to government approvals and other customary conditions, is expected to close in the near future. Terms of the deal were not disclosed. Intellution provides an industry-standard software platform that collects, distributes, controls, and visually presents information from the plant floor throughout the enterprise, supplying customers with scalable solutions that deliver increased productivity and return on investment.

~~~ PRODUCT NEWS ~~~

New AspenTech Process Economic Evaluation App

Aspen Technology has a new release of Aspen Icarus, a process industry software solution for investment analysis and economic evaluation in the design and construction of manufacturing plants. Aspen Icarus 12.0 incorporates a package of improvements and industry cost updates that will enable process manufacturers to maximize the returns on their plant assets by making better-informed and more reliable investment decisions. It is used to analyze the potential cost of capital projects. The software is based on the Icarus evaluation engine that utilizes industry standards, design codes, and detailed real-world engineering and construction information. In the latest release, the database and analysis tools have been substantially updated. The new release combines a range of tools for optimal investment decision-making including "what if?" scenarios, life-cycle investment analysis, automatic expansion of process simulation models, and project management systems.

Matrikon Releases Mx Suite for Mfg. Excellence

Mx Suite shares live production information across the entire enterprise, synchronizing production to better manage planned and unplanned events on the shop floor. All stakeholders can rely on the same, actual, real-time production data to make informed and responsive decisions, driving greater profitability. It enables the improvement of cross-functional performance through total visibility and shared knowledge of operational status and unplanned events, laterally across the shop floor and vertically through all levels of the organization. MxTracker captures live production data from the shop floor and makes information available throughout the organization. It also closes the loop between planning and execution, by feeding live production data into the planning and scheduling module. MxAdvisor provides visibility into actual shop floor activity through KPI monitoring and real-time event messaging.

New IBM PowerPC Processor for Networking Apps

The new low-power, low-cost, highly integrated embedded PowerPC processor is intended for wireless local area network (LAN) access points and other networking applications. The PowerPC 405EP was designed by IBM using the company's ASIC methodology to combine the PowerPC 405 processor core and other key functions into a system-on-chip design. The chip is designed to support CPU speeds of 133, 200, and 266MHz and consumes only one Watt of power at 200MHz. In addition to wireless LAN access points, the chip also targets other edge-of-network applications such as DSL routers and cable modems. The chip features dual 10/100 ethernet connectivity as part of the base design. This can save on system costs since they do not need to add off-chip ethernet connections to their designs. The PowerPC 405EP also incorporates a PCI interface, a SDRAM controller, a 64-bit on-chip CoreConnect bus and other on-chip peripheral support. The PowerPC 405EP is based on IBM's 0.18-micron SA-27e copper process technology.

Spirax Sarco Is Not Just For Steam Products

Throughout the process industries Spirax Sarco has primarily been known as a niche supplier of industrial steam products. More important to their customers may be the company’s reputation as steam handling experts. The company has expanded its product line to include multi-variable pressure transmitters, flow meters, and computers, level controls, and control valves to provide a total solution for boiler control, condensate management, and energy recovery.

Intergraph Adds ISO Standards Library

The ISO Standards and Industrial Additions Library for Intergraph SmartPlant P&ID 3.0 is available from the Process, Power & Offshore division of Intergraph. Featuring more than 920 components, the library saves time, eliminates reference database customization, reduces standards variation, enforces consistency, and makes SmartPlant P&ID a more universal and flexible tool for engineering design in a variety of Industries. The addition of the ISO stqandards to the product’s existing ANSI, DIN, and Process Industry Practices (PIP) reference database meets customer demand. The library also helps enable faster project startup because users don’t have to select, develop, check, and import standards and symbols in a customized reference database.

New FDT Group Universal Field Device Interface

The group, a collaboration of international automation suppliers, has introduced one of the first universal field device interface solutions at the 2002 ISA Conference and Exposition. These solutions are based on the open Field Device Tool (FDT) specification. FDT builds upon and enhances existing fieldbus technology by standardizing the interface between intelligent field devices and host systems, irrespective of the device vendor or the fieldbus protocol. Using this FDT-compliant interface allows vendors to provide users with a common environment, including graphical elements, for configuring, accessing, and managing all intelligent field devices.

New Foxboro Digital Coriolis Mass Flow Meter

The Foxboro Measurement & Instrument Division of Invensys Production Management has introduced a new flow meter that continues to operate during two-phase flow. The new Foxboro CFT50 features technology to enable uninterrupted operation in batch applications starting with empty flow tube conditions. It is designed to control all aspects of the Coriolis meter for precise measurement in traditionally difficult to measure applications, overcoming a significant limitation of conventional Coriolis meters. Traditional Coriolis meters could not handle two-phase (liquid/gas) flows. Such conditions adversely affect sensor performance by causing erratic vibration of the flow tubes.

New Honeywell Pocket PC-based Toolkit for Field Devices

Honeywell Automation and Control Solutions has introduced its MC Toolkit, a single easy-to-use Pocket PC-based tool for configuration of smart field instruments. It is designed to reduce costs and enhance productivity for industrial users by handling multiple communications protocols, including Honeywell Digitally Enhanced (DE) and HART. This handheld engineering and maintenance tool not only configures smart field instruments, but also monitors, diagnoses, and manages them. It allows straightforward access to device configuration database parameters using Microsoft Pocket PC 2002 operating system technology. It automatically compares and detects any differences between the device database and its own database, thereby helping to reduce cost and ensure proper device installation •It also enables easy configuration of Lower Range Value, Upper Range Value, range, engineering units, damping, etc. Shipment of the product is scheduled to begin in March 2003.

New Honeywell Asset Management Solution

The Industry Solutions business of Honeywell Automation and Control has introduced Asset Manager PKS, a Process Knowledge Solution that increases control system effectiveness by automatically and continuously monitoring the condition of plant assets. Asset Manager PKS is embedded within Experion PKS, Honeywell’s Process Knowledge System that is used in industrial plants and mills to control, monitor, and integrate complex processes. Experion PKS enable employees with knowledge-driven applications and technologies to capture and manage information optimizing production and improving profitability throughout the organization. Asset Manager PKS continuously monitors the status, events, and operating conditions of all Experion PKS assets and field-connected devices, resulting in an efficient condition-based maintenance solution.

New AspenTech Solution for Manufacturing Polymers

Aspen Technology’s advanced process control technology for polymer manufacturers achieves significant improvements in manufacturing performance. The new product, Aspen Apollo, uses next-generation artificial intelligence. This enables manufacturers to gain significant benefits during all phases of plant operations, but particularly during the critical transitions between different product grades. These transitions are typically time-consuming, resulting in lost manufacturing capacity and generating large quantities of waste material. With its ability to consistently maintain safe and efficient operation during both steady-state and dynamic conditions, the advanced technology provides a significant step forward from earlier neural-net based solutions.

~~~ TRENDS ~~~

Worldwide Batch Control Market Is Poised for Growth

After a year of little growth, the batch control systems (BCS) market seems poised for expansion. The market for BCS in 2002 will exceed $2.4 billion. In North America and Europe, stronger pharmaceutical and food & beverage markets will lead the increased demand for sophisticated batch control systems. With recovery of Asian economies, growth in those regions will follow.

Volvo Takes Wireless to the Production Line

Many plant managers are keenly aware of the reduction in Total Cost of Ownership (TCO) that is achievable by reducing the array of wires and connectors used throughout a production operation. Flexibility and agility also increase when a manufacturing operation employs wireless sensor technology. Automaker Volvo, in partnership with ABB Robotics, has opened the door for wireless technology in many discrete production applications by proving the feasibility of using Bluetooth in an arc welding application. As a result, Volvo has embarked on a mission to identify further areas that will benefit from untethered systems.

Integration, Wireless, & Communications at ISA 2002

Anyone expecting the traditional ISA Annual Exhibition this year was in for a bit of a surprise. The current economic slump, a depressed process automation market, and the lack of a major presence by most of the leading process automation suppliers caused many visitors to stay home. There were a few bright spots for attendees looking to improve their manufacturing operations, however, namely new developments in integration and interoperability, wired and wireless communication, network security, and plant asset management. At the field device level in particular, suppliers are finally responding to manufacturer’s pleas for integration and interoperability.

Manufacturing Declines for the Second Straight Month

The manufacturing sector lost momentum again in October, according to the Institute for Supply Management (ISM). There has been very little month-over-month change in manufacturing activity; with ISM’s Purchasing Management Index (PMI) averaging 49.8 percent for the last four months. The West Coast dock lock out obvisously had an impact because ISM’s Import Index fell 6 percentage points. Order backlogs declined for the fourth consecutive month, and ISM’s Supplier Deliveries Index reflected slower deliveries for the 10th straight month. Manufacturing employment continued to decline in October with the index remaing below the breakeven point of 50 percent for the 25 consecutive month. ISM’s Prices Index was above 50 percent as manufacturers experienced higher prices for the 8th consecutive month. New Export Orders grew in October for the 10th consecutive month, while October’s Imports Index declined after 10 straight months of growth.

Strong Security Now Available For Wireless LANs

The Wireless Ethernet Compatibility Alliance (WECA), which certifies IEEE 802.11 wireless-networking products with the Wi-Fi marketing label, has ratified a new standard for wireless security. Dubbed Wi-Fi Protected Access (WPA), the technology will replace the compromised Wireless Equivalency Protocol (WEP) security technology that most existing Wi-Fi products use. Most Wi-Fi vendors will offer WPA upgrades to existing products through firmware updates. WEP was developed as IEEE 802.11i and is available for 11Mbps 802.11b and 54Mbps 802.11a products from a range of manufacturers, but intruders compromised the technology almost immediately, making it fairly easy to bypass security on many wireless networks. The new scheme, WPA, is based on several strong algorithms for encrypting network traffic, although WECA hasn't yet provided many details of how the technology works.

Dell Becomes Outsource Manufacturer for EMC

Dell, which has been using its sales force to market EMC products for the last year, will now start manufacturing EMC’s new CX200 data storage system. This is a move to take market share from Hewlett-Packard by combining EMC's data storage expertise with both Dell's sales force and Dell’s efficient assembly lines. EMC, facing extraordinary price pressure from corporate customers, expects to squeeze more savings by having some of the devices made in Dell plants. EMC controls about half of the market for high-end storage servers, but only 6 percent and 3 percent in the medium and low-end performance and price segments, which are growing faster. The CX200 "entry level" storage system is due to be available in December.

~~~ ACQUISITIONS & PARTNERING NEWS ~~~

Danaher Corp. Acquires Dover Instrument Corp.

Danaher is a leading manufacturer of motion control products and systems. Dover, a leader in high precision linear and rotary air bearing motion platforms, will be incorporate into the Danaher Motion Group, a business platform that consists of many leading brands in the North American and European markets. Over the past 30 years, Dover has successfully designed and implemented air bearing systems that operate in a multitude of high performance applications. These systems are deployed around the globe in critical manufacturing and analytical installations. Air bearing gantries, air bearing spindles, fully integrated spin stands, metrology equipment, and other custom stage designs constitute the core of the Dover product offering. Many systems are shipped complete with integrated multi-axis controls and amplifiers.

DuPont, Sarnoff & Bell Labs Team on New Displays

As part of a federally sponsored research and development initiative, DuPont -- a leader in the development and manufacturing of organic light emitting diode (OLED) displays -- and Sarnoff Corporation have agreed to develop new organic-thin film transistor (organic-TFT) technology on plastic substrates. Organic-TFTs can offer major advances in commercializing future generation flexible display devices such as full-color polymer-based active matrix OLED (AM-OLED) displays. The research initiative will be sponsored as a National Institute of Standards and Technology's (NIST) Advanced Technology Program for three years. Terms of the agreement were not disclosed. Lucent Technologies' Bell Labs, a leader in organic thin film transistors, will be subcontracted to develop a new class of organic-TFT materials and design processes. This unique technical collaboration combines DuPont's expertise in OLED display panels, flexible substrates, cost-effective printing and organic-TFT technologies, and; Sarnoff's expertise in active matrix TFT designs and video display systems.

The Siemens Phase Out Plan for Its Simatic S5 PLC

Siemens Automation and Drives (A&D) will be phasing out its successful, 20-year-old Simatic S5 PLC models starting 1 October 2003. Since 1996, Siemens has offered its customers a migration strategy to Totally Integrated Automation and Simatic S7, a more modern system with clearly improved functions. The switchover starts on 1 October 2003 with the mini PLCs Simatic S5-90U, -95U/F and -100U. They will be classified as discontinued at that point, but will be available as usual through 30 September 2004, and then as spare parts until 30 September 2013. The dates for the Simatic S5-115 controls, the medium performance range systems, are 1 October 2004, 30 September 2005, and 30 September 2014. The applicable dates for the large-scale Simatic S5-135/155 systems are 1 October 2005, 30 September 2006, and 30 September 2015. Within the scope of its spare parts guarantee, Siemens will also supply an ample quantity of critical, i.e. hard-to-obtain, components.

~~~ PRODUCT NEWS ~~~

New Honeywell Advanced Formula Manager

The Industry Solutions business of Honeywell Automation and Control Solutions has introduced Advanced Formula Manager (AFM), a calculation solution that easily transforms critical plant data from Honeywell’s Uniformance Plant History Database (PHD) into valuable process information through user-defined equations and formulas. AFM can be used in industries that include refining, oil and gas, petrochemicals, pharmaceuticals, power and chemical plants and pulp, paper, and printing mills. AFM’s equation-building capabilities increase users’ efficiency in collecting process data that can be shared across the organization in a centrally managed, flexible environment. Even users who don’t have programming experience can easily formulate equations. Combining Uniformance PHD with the AFM, calculation formulas and data can be accessed by and shared with all authorized users across the organization or distributed to other value-added systems and applications. The AFM Designer interface enables building of complex calculation libraries that can access historical and updated process data and store the calculated results in the historian database.

Elpro Releases Plant-wide Wireless Instrumentation

Elpro Technologies’ Wireless Instrumentation Backbone (WIB) provides integrated wireless connectivity for instrumentation and control signals, as well as different field communication buses. It replaces expensive signal and field bus wiring with connectivity between different bus systems. Wireless I/O and Wireless Gateway units automatically interconnect and communicate, using the unconstrained medium of wireless. The Elpro WIB uses 900MHz frequency hopping wireless technology that is designed to work as an integral part of plant instrumentation systems.

New OPUSoft Business Analysis Software

OPUSoft Software Technologies has released version 2.1 of its OPUS Web-based reporting and business analysis software, initially targets the manufacturing business sector. It allows companies to develop intra- and inter-company information portals that gather and present business intelligence across the intranet. OPUS gathers data from multiple disparate sources. These include real-time manufacturing feeds from OPC, SCADA software like Wonderware’s InTouch, Intellution’s iFIX, and Siemens WinCC; data historians such as Industrial SQL, iHistorian and OSI’s PI; plus any ODBC database, EXCEL spreadsheet, and XML data that can be generated from enterprise software systems like MES and ERP. Furthermore, OPUS enables scheduled reports to be emailed to business associates around the world, providing them with the same functionality and valuable information as Web-based reports. OPUS is not just about manufacturing data, it can be used by accounting, sales & marketing, support … and is an excellent tool for creating executive dashboards to keep everyone updated on the latest company business activities.