Oct 2011

11 Virtual Summit on demand 35 Protective devices 45 Lean product development
PLE1110_COVER.indd 2 10/4/11 1:53 PM

No other controller can do this!
Use the technology built into the Productivity3000 programmable
controller to make your job easier. Dont pay extra or take up
valuable rack space for communications modules. With its
industry-leading seven built-in communication ports, this CPU has
phenomenal cosmic power in an itty-bitty living space!
rIug-and-Iay uss or tbernet rogramming and monitoring
uss IocaI iJO exansion ort (u to four additionaI IocaI iJO racks)
uss ort for data Iogging to removabIe drive
tbernet remote iJO exansion ort (up to 32 remote racks plus 64 AC drives)
Higb-seed tbernet ort for HMi (u to az c-more aneIs),
eer-to-eer and business system networking using ouIar
rotocoIs sucb as Modbus 1cr, sM1r for sending emaiIs
1wo seriaI orts for eriberaI device interface or controIIer
networking via Modbus R1u or custom Ascii rotocoIs
input #1 at plantengineering.hotims.com
PLE2011010_0C2.indd 2 10/7/2011 11:51:32 AM
Where Do I Go for Automation Products?
Your single source for process measurement and control products!
COPYRIGHT 2011 OMEGA ENGINEERING, INC. ALL RIGHTS RESERVED
1- 888- 55- 66342
1-888-55-OMEGA
TM
For Sales and Service, Call TOLL FREE
Dilbert United Feature Syndicate, Inc.
FREE!
Baloncici / Dreamstime.com
omegamation.com, of Course!
*PATENT PENDING
Troubleshooting and Data Logging Has Never Been Easier
Thermocouple Terminal Blocks
DIN Rail Mounting and Audit Capable
*DRTB Series
$
8 each
All Models
DRTB-RAIL-3575-1,
$
3.50, sold separately
Pre-cut DIN
rail available!
Visit
omega.com/drtb
omega.com/video
With Built-In
Connector
USA
MADE IN
PLC + HMI with Data Logging
OCS XL
Series
Starts at
$
445
Visit
omega.com/ocsxl_series
Integrated
Stepper
Drives/
Motors
STM Series
Starts at
$
375
Visit
omega.com/
stm_series
Stepper Motors
Visit omega.com/omht_series
OMHT Series
Starts at
$
55
Visit omega.com/str
STR Series
Starts at
$
270
Stepper Drives DIN Rail Fuse
Holders
ASK Series
Starts at
$
4.25
Visit
omega.com/
ask_fusehold
Visit
omega.com/
wms_protectors
WMS Series
Starts at
$
25
Supplementary
Protectors
Visit omega.com
to order your FREE copy of
Dilbert
TM
CONTROLCAT
TM
New Horizons
in Temperature, Pressure, Flow and More!

Version No. 28 Featuring 105 DILBERT Cartoons!
PLE2011010_001.indd 1 10/7/2011 11:53:48 AM
For more information, visit www.vic-press.com
Industrial Grade
Performance
SUPPLYING THE
COMPETITIVE
ADVANTAGE
FOR SCHEDULE 10S
Vic-Press
using standard off-the-shelf Schedule 10S pipe

APPLICATIONS
t Potable water
t Service air/water
t Petroleum oils
t Hydraulic fluids
t Organic fluids
t Lubricants
t Hydrocarbons
t And many more!
THE ONLY PIPE-SIZED PRESS SOLUTION
No specaLy ppe \c-Press
s
Lhe ony souLon usng off-Lhe-shef
ASTM A-3T2 Schedue T0S ppe
Aows for easer suppy chan
and nvenLory managemenL
Type 304 and Type 3T6
SURPASSING INDUSTRY STANDARDS
\c-Press
provdes pressure
performance up Lo 500 ps
AccepLed for use on ASME B3T.T,
B3T.3 and B3T.9 sysLems
In accordance wLh ANSI
0ass T50 sLandards
NSF 6T 0erLfed up Lo T80 F/82 0
for EPDM and HNBR sea maLeras
ENGINEERED FOR DEMANDING
INDUSTRIAL APPLICATIONS
Ppe wa Lhckness provdes up Lo
3 greaLer sLrengLh, 2 greaLer
durabLy and 52% greaLer fow
performance Lhan Lube
COMPLETE LINE OF FITTINGS,
VALVES AND ACCESSORIES
MosL comprehensve sLaness sLee
ne n Lhe ndusLry, from " Lo 24"
PLE2011010_002.indd 2 10/7/2011 11:55:28 AM
PLANT ENGINEERING October 2011 3
7 Online
9 Forum
23 Best Practices
60 Product Mart
62 Internet Connection
63 Advertiser Contacts
64 Comment
26
Special Report
11 Manufacturing/Automation Summit now
available online, on demand
The 2011 Virtual Manufacturing/
Automation Summit was a global event
where the discussions touched upon key
areas of importance to plant and auto-
mation personnel everywhere.
October 2011
Volume 65, No. 8
DEPARTMENTS
28 Safety rewarded
A recent study found that many workers are not wearing the necessary personal
protective equipment. Which leaves a question: Why?
28 Safety culture rewarded, enforced, honored
33 The true value of a safety system
Cover Story
PPE is personal before it is protective
PLANT ENGINEERING (ISSN 0032-082X,
Vol. 65, No. 8, GST #123397457) is pub-
lished 10x per year, monthly except in
January and July, by CFE Media, LLC, 1111
W. 22nd Street, Suite #250, Oak Brook,
IL 60523. Jim Langhenry, Group Publisher /
Co-Founder; Steve Rourke CEO/COO/Co-Founder.
PLANT ENGINEERING copyright 2011 by CFE
Media, LLC. All rights reserved. PLANT ENGINEER-
ING is a registered trademark of CFE Media, LLC
used under license. Periodicals postage paid at
Oak Brook, IL 60523 and additional mailing offices.
Circulation records are maintained at CFE Media,
LLC, 1111 W. 22nd Street, Suite #250, Oak Brook,
IL 60523. Telephone: 630/571-4070. E-mail:
customerservice@cfemedia.com. Postmaster:
send address changes to PLANT ENGINEER-
ING, 1111 W. 22nd Street, Suite #250, Oak
Brook, IL 60523. Publications Mail Agree-
ment No. 40685520. Return undeliverable
Canadian addresses to: 1111 W. 22nd
Street, Suite #250, Oak Brook, IL 60523.
Email: customerservice@cfemedia.com.
Rates for nonqualified subscriptions, including all
issues: USA, $ 145/yr; Canada, $ 180/yr (includes
7% GST, GST#123397457); Mexico, $ 172/yr;
International air delivery $318/yr. Except for special
issues where price changes are indicated, single
copies are available for $20.00 US and $25.00
foreign. Please address all subscription mail to
PLANT ENGINEERING, 1111 W. 22nd Street, Suite
#250, Oak Brook, IL 60523. Printed in the USA.
CFE Media, LLC does not assume and hereby
disclaims any liability to any person for any loss or
damage caused by errors or omissions in the mate-
rial contained herein, regardless of whether such
errors result from negligence, accident or any other
cause whatsoever.
PLE1110_TOC_V6ms.indd 3 10/4/11 1:57 PM
Dust From Thermal Spraying
Safe Change Filter Replacement
Weld Smoke Collector Laser Cutting Smoke Abrasive Blast Dust Collectors
Dust From Chop Saw Plasma Cutting Smoke Collector
Plant Engineers, the Camfil Farr APC Gold Series
is the
most rugged, reliable, easy to maintain dust collector on the
marketGUARANTEED!
The Gold Series
modular design allows for virtually unlimited customization

and our exclusive stocking program assures that your Gold Series is delivered
when you need it. Call us about NFPA and ATEX Explosive Dust compliance
issues.
Paper Scrap Handling Systems
Large Agriculture Installations
Food Processing Dust
Looks Like a Safe Because Its
TM
800-479-6801
Follow. Connect. Watch. Learn.
www.camfilfarrapc.com
870-933-8048
International Calls:
PLE2011010_004.indd 4 10/7/2011 12:01:01 PM
Electrical Solutions
35 Make the right choice
on protective devices
Choosing the correct protective device
for a low-voltage distribution system
requires system performance analysis.
Mechanical Solutions
39 Automated orbital welding
systems streamline
in-process inspections
Passing in-process inspections for orbital
welding projects is critical, as a failure can
lead to costly rework, project delays, and
system downtime.
Maintenance Solutions
45 Lean product development
provides manufacturing value
Relentless focus on customer value reduces
time to market.
Automation Solutions
55 An iPhone as your next HMI
Consumer-grade smartphones and tablet computers
are fast becoming commonplace extensions of industrial
networks, permitting process monitoring, and even
(gasp!) process control.
9 Forum
Molnar: We need an innovation policy
Implementing inventory management policies and procedures
The pitch on CMMS: More capacity, profits
PlantEngineering.com
1111 W. 22nd St. Suite 250, Oak Brook, IL 60523
Ph 630-571-4070, Fax 630-214-4504
CONTENT SPECI ALI STS/EDI TORI AL
BOB VAVRA, Content Manager
630-571-4070, x2212, BVavra@CFEMedia.com
AMANDA MCLEMAN, Managing Editor
630-571-4070, x2209, AMcLeman@CFEMedia.com
MARK HOSKE, Content Manager
630-571-4070, x2214, MHoske@CFEMedia.com
PETER WELANDER, Content Manager
630-571-4070, x2213, PWelander@CFEMedia.com
AMARA ROZGUS, Content Manager
630-571-4070, x2211, ARozgus@CFEMedia.com
PATRICK LYNCH, Project Manager/POY
630-571-4070, x2210, PLynch@CFEMedia.com
PUBLI CATI ON SERVI CES
JIM LANGHENRY, Co-Founder and Publisher, CFE Media
630-571-4070, x2203; Jlanghenry@CFEMedia.com
STEVE ROURKE, Co-Founder, CFE Media
630-571-4070, x2204, SRourke@CFEMedia.com
TRUDY KELLY, Executive Assistant
630-571-4070, x2205, TKelly@CFEMedia.com
ELENA MOELLER-YOUNGER, Marketing Manager
630-571-4070, x2215; EMYounger@CFEMedia.com
MICHAEL SMITH, Creative Director
MSmith@CFEMedia.com
PAUL BROUCH, Web Production Manager
630-571-4070, x2208, PBrouch@CFEMedia.com
MICHAEL ROTZ, Print Production Manager
717-766-0211, Fax: 717-506-7238
mike.rotz@frycomm.com
JEFF ADEE, Direct Mail List Services
630-288-8323; jadee@mardevdm2.com
RICK ELLIS, Audience Management Director
Phone: 303-246-1250; REllis@CFEMedia.com
LETTERS TO THE EDITOR
Please e-mail your opinions to
BVavra@CFEMedia.com or fax us at 630-214-4504.
Letters should include name, company, and address,
and may be edited for space and clarity.
INFORMATION
For a 2011 Media Kit or Editorial Calendar,
email Trudy Kelly at TKelly@CFEMedia.com.
REPRINTS
For custom reprints, electronic usage or content licensing,
contact: The YGS Group
Phone: 800-290-5460 x100
email: Plantengineering@theygsgroup.com
PUBLI CATI ON SALES
Tom Corcoran, West, TX, OKTCorcoran@CFEMedia.com
1111 W. 22nd St. Suite 250, Tel. 215-275-6420
Oak Brook, IL 60523 Fax. 484-631-0598
Karen Cira, Southeast KCira@CFEMedia.com
879 Autumn Rain Lane Tel. 704-523-5466
Charlotte, NC 28209 Fax 630-214-4504
Kerry Gottlieb, N. Central KGottlieb@CFEMedia.com
1111 W. 22nd ST. Suite 250, Tel. 312-965-8954
Oak Brook, IL 60523 Fax 630-214-4504
Richard A. Groth Jr. NJ/ E. PA RGroth@CFEMedia.com
12 Pine Street Tel. 774-277-7266
Franklin, MA 02038 Fax 508-590-0432
Stuart Smith, International stuart.smith@ssm.co.uk SSM
Global Media Ltd. Tel. +44 208 464 5577
Fax +44 208 464 5588 fax
PLE1110_TOC_V6ms.indd 5 10/4/11 1:57 PM
Performance You Can Count On
The Ingersoll Rand R-Series 75-100 hp compressors combine proven
components with innovative technology to deliver continuous, reliable
performance with features like:
&Total Air System (TAS) to provide clean, dry air in a single package
&PAC protection to monitor key parameters that maximize uptime
& V-Shield technology for extended compressor life
Ingersoll Rand...reliability you can count on.
www.ingersollrandproducts.com
PLE2011010_006.indd 6 10/7/2011 12:04:15 PM
Plant Engineerings In Depth articles
appear at www.PlantEngineering.com.
These Q&A sessions give key industry leaders and influ-
encers a chance to have their views and opinions on key
issues reach Plant Engineerings global audience online.
As President Obama outlined his new jobs initiative
in September, Plant Engineering discussed the proposal
with U.S. Rep. Don Manzullo (R-16th, IL). The discus-
sion covered the need for jobs creation
in the manufacturing section and the role
Congress and manufacturers needed
to play to develop a strong manufacturing
workforce.
Among the comments from that discus-
sion:
PE: What additional proposals or ini-
tiatives would you like to see a final bill
contain?
Manzullo: I would like to see President
Obama seriously and specifically address
the overregulation of many industries in the
United States. I agree with the President that
every rule should meet the common sense test. Regula-
tions should protect people from environmental and health
hazards and unsafe workplace practices. But overregulation
will continue to result in jobs, companies, and potentially
entire industries relocating overseas.
I reject his characterizations that Republican concerns
about regulations will lead to a race to the bottom. For
example, the Department of Health and Human Services
has labeled styrene as a human carcinogen that causes
cancer even though most other scientific studies disagree.
Styrene is a basic ingredient in products such as plastic,
fiberglass, and composites. Unless changed, this designa-
tion by HHS could result in thousands of jobs in the plas-
tics and composites industries relocating abroad without
protecting human health.
Additionally, I have long believed that a robust export
agenda is a key part of our path to national recovery. The
Milken Institute estimates that export control moderniza-
tion could generate 340,000 jobs over the next 10 years. I
was disappointed the President did not specifically mention
export control reform, as he did in his 2010 State of the
Union address. He also did not mention extending some
of the basic small business tax cuts that are scheduled to
expire, such as bonus depreciation of equipment purchases
that helps our manufacturers.
PE: The issue of the Skills Gap for
American manufacturing has been the
single biggest issue our readers face as
they try to improve their manufacturing
operations. What can and should Congress
do in terms of job retraining programs
to help move workers into these needed
skilled jobs?
Manzullo: I completely agree we have
a problematic manufacturing skills gap in
this country. I have heard from numerous
manufacturers in northern Illinois who can-
not find trained workers to fill open posi-
tions, even in an area with double digit
unemployment. But the Presidents Fiscal Commission
has correctly identified that the government funds more
than 44 job training programs across nine different federal
agencies. This overlap of services leads to confusion and
unnecessary bureaucratic overhead that could be better used
to train individuals. We need to streamline these job training
programs so they help unemployed Americans get retrained
into jobs that actually exist.
I also commend community colleges across the coun-
try, particularly those who have specialized programs in
manufacturing.
PE: What is the responsibility of manufacturers them-
selves to help improve their business position? What can
and should they be doing to help themselves?
Manzullo: First, manufacturers must make sure their
companies meet all the applicable global manufacturing
standards. You cannot compete in this global economy if you
do not have a world-class operation. This includes having an
up-to-date, informative website and a live person answering
your phone. In addition, manufacturers should be looking
for customers all around the world. The United States only
has 4% of the worlds consumers. There are many resources
available to help you find and succeed in overseas markets
(www.export.gov). Currently, many manufacturers are able
to weather the downturn in the U.S. economy because they
have laid the groundwork in exporting abroad.
Read the full interview with Rep. Manzullo at
www.PlantEngineering.com.
www.PlantEngineering.com
This months poll:
How is the proper use of PPE in your plant managed?
Your responses at PlantEngineering.com:
62% Full compliance enforced
18% Full compliance expected
8% Compliance left to manager
7% Compliance left to employee
2% No compliance
Check out this months poll at PlantEngineering.com
An online conversation with Congress
U.S Rep. Don Manzullo (R-16th, IL)
PLE1110_ONLINE_V4ms.indd 7 10/4/11 1:58 PM
1
Cut installation cost
Easy conveyor routing
at any angle (over, under
or around obstructions,
through small holes
in walls or ceilings)
conforms to process
layouts, drastically
cutting installation
costs, while consuming
minimal floor space.
2
Slash initial cost
Flexicon conveyors
cost far less than
drag chain conveyors,
bucket elevators,
pneumatic conveying
systems and other
conveyors of equivalent
capacity, both initially
and in operation.
3
Save on maintenance
Rugged inner screw is
the only moving part
contacting material
(no internal bearings)
yielding ultra-high
reliability with little
maintenance cost
or downtime.
4
Use less energy
Low horsepower motors,
simple gear reducers
and ultra-efficient
operation significantly
cut energy cost per
volume of material
conveyed.
See the full range of fast-payback equipment at flexicon.com: Flexible Screw Conveyors, Pneumatic Conveying Systems, Bulk Bag Unloaders, Bulk Bag Conditioners,
Bulk Bag Fillers, Bag Dump Stations, Drum/Box/Container Dumpers, Weigh Batching and Blending Systems, and Automated Plant-Wide Bulk Handling Systems
2010 Flexicon Corporation. Flexicon Corporation has registrations and pending applications for the trademark FLEXICON throughout the world.
5
Convey at multiple
locations
Available mounted
on mobile bases
with casters, Flexicon
conveyors with hoppers,
dust collectors and other
accessories can operate
at multiple locations,
eliminating the need
for dedicated conveyors.
6
Save on sanitary
construction
Other conveyors
can command
high premiums for
food, 3-A dairy and
pharmaceutical models,
but Flexicon conveyors
can meet sanitary
requirements at
comparatively low cost.
7
End costly
contamination
Enclosed tube prevents
dust and spillage,
eliminating cost and
quality concerns
associated with
contamination of
your product and
plant environment.
8
Reduce cleaning costs
Removable end cap
allows reversing of
screw for evacuation
of material, in-place
flushing of crevice-
free interior, or quick
removal of screw for
sanitizingall with
minimal labor or
downtime.
9
Convey disparate
materials
Handle sub-micron
powders to large pellets
including non-free-flow-
ing products that pack,
cake, seize, fluidize,
abrade or smear, with
no separation of blends,
often eliminating the
need for multiple units.
Cut Your Cost 9 Ways with
One Ultra-Economical Conveyor
See why thousands
of engineers like you
have purchased more
Flexicon conveyors
than all competitive
designs combined.
visit flexicon.com
USA
sales@flexicon.com
1 888 FLEXICON
UK
AUSTRALIA
SOUTH AFRICA
+44 (0)1227 374710
+61 (0)7 3879 4180
+27 (0)41 453 1871
Z
-
0
5
6
8
PLE2011010_008.indd 8 10/7/2011 12:10:56 PM
Hannover Fairs Inter-
national is launching
its latest business-to-
busi ness i ndust ri al
technology show in the
U.S. next year in con-
junction with IMTS at Chicagos McCor-
mick Place from Sept. 10-15, 2012. CFE
Media, which includes Plant Engineering
and Control Engineering magazines and
their associated Website and electronic
products, will co-sponsor
the event and present a
two-day global automa-
tion forum.
Mai n i ndust ry sec-
tors include automotive,
aerospace, energy, infra-
structure, food and bever-
age, machine tool, mate-
rial handling, medical,
mechanical and fluid power
transmission. Exhibitors,
who have already secured
booth space, include B&R
Automation, Beckhoff
Automation, Harting North
America, IXXAT Automa-
tion, and Lanbao Sensor of
China.
Technologies for improving manufac-
turing processes will be on display and
will feature key applications of process
and production automation plus energy-
related applications. IANA 2012 prom-
ises to attract high profile domestic and
international buyers offering an excel-
lent platform for networking with their
global peer.
Hannover Fairs portfolio of industrial
automation events are well established
industry gatherings in Europe and the
BRIC countries. Hannover Fairs will
promote IANA during all of its industrial
shows, including Hannover Messe, the
worlds leading showcase for industrial
technology held annually in Hannover,
Germany, as well as its other shows
geared towards target industries for auto-
mation vendors:
Access to industrial automation solu-
tion providers at IANA will significantly
increase return on investment for the
more than 80,000 attendees, said Larry
Turner, Hannover Fairs CEO. We have
already secured commitments for more
than a third of IANAs exhibitor space
and are still a year away from the event.
CFE Media will lead the two-day
executive level IANA Global Automa-
tion and Manufacturing Summit. Key-
note topics range from enterprise asset
management to process optimization,
energy management, and sustainability
manufacturing. Case studies of plants
that have automated for profitability,
improved performance of existing assets,
and reduced maintenance costs will be
presented. Educational events and topics
covering a broad array of interests will
include an international focus. The event
also features plant tours to major manu-
facturing facilities in Chicago.
We have partnered with Hannover
Fairs on a number of projects in the past,
most notably Global Plant Engineering,
said CFE Media publisher Jim Langhen-
ry. We are excited about the IANA event
for 2012 and look forward to connecting
the key leaders in industrial automation
and manufacturing together with IANA
attendees. Our goal is to identify the key
ideas that can help manufacturers oper-
ate smarter, safer, and more productive
facilities.
Other conference tracks will include
presentations on motion control in auto-
mation and hydraulics and pneumatics in
automation. The goal of these tracks is
to help engineers tasked with improving
performance, productivity, life efficiency,
and the green efficiency of manufactur-
ing equipment and industrial automation
systems.
The International Society of Automa-
tion will offer automation stan-
dards education via a one-day
course. Topics of Measurement
and Control Fundamentals,
Grounding and Noise Reduc-
tion for Control Equipment,
Introduction to and Practical
Applications of SCADA Sys-
tems, Industrial Wireless Sys-
tems, Improving Manufacturing
through Automation and Safety
Instrumented Systems are just
some of the highlights.
To secure further growth in
the industrial automation sec-
tor during this challenging eco-
nomic climate, the U.S. needs
to ensure that productivity is
broadly based, said Turner. IANAs
keynote themes, training, and educational
tracks have been formatted to offer best-
in-class solutions for all IANA visitors.
First-time IANA exhibitors can either
purchase raw space by ordering their
required services through the IMTS online
E-Kit or purchase turnkey booth packages
in 10-ft by 10-ft increments. IANA offers
dedicated display areas and pavilions.
NFPAs IFPE Fluid Power Zone, a pavilion
for companies exhibiting technologies in
the fluid power transmission, hydraulics
and pneumatics and mechanical transmis-
sion space will be present. NFPA members
will receive a 10% discount to exhibit
in the pavilion.
For more information on exhibiting
or sponsoring IANA, please contact,
Aryan Zandieh of Hannover Fairs USA at
(312) 924-1688 or azandieh@hfusa.com.
FORUM
Industrial automation show debuts in 2012
CFE Media, Hannover Messe partner on IANA event at next years IMTS Show
PLE1110_FORUM_V8ms.indd 9 10/4/11 1:59 PM
PLE2011010_010.indd 10 10/7/2011 12:13:31 PM
FORUM
A
maintenance manager from Canada. A reliability
superintendent from Spain. The chief executive of
Integrated Telecom from Pakistan. An electrical
engineer from Argentina.
They came from 37 countries, from manufacturing facili-
ties large and small, and from every level of the organiza-
tion. They all had one common goal: To learn how to get
better at manufacturing.
Just like the live event in
Chicago in March, the 2011
Virtual Manufacturing/Auto-
mation Summit was a truly
global event, putting experts
from a variety of fields together
with manufacturing professionals from around the world in
a day-long discussion of key areas of importance to plant
and automation personnel everywhere.
The Virtual Summit is now available on demand for those
who saw the initial event and want to review the content
with others in their organization, or for those who may
have missed the live event and want to see what the rest
of the world is talking about. Go to www.PlantEngineer
ing.comor www.controleng.com to click through to review
the presentations. The 2011 Manufacturing/Automation
Virtual Summit is sponsored by IBM and Infor.
One of the great truths of global manufacturing today
is that the problems plants face are usually pretty similar
anywhere in the world. The goals are the same to produce
the highest quality products at the lowest possible overall
costs. Plant managers must navigate the availability of mate-
rials, the safe and efficient operation of the manufacturing
line, the individual needs of employees, and the constant
emphasis for cost containment
and product availability from
management.
The 2011 Virtual Summit
delivered knowledge from
some of manufacturings top
experts. Here are some high-
lights from these presentations:
How Detroit is finding its way back as a manufactur-
ing leader, presented by Dave Reiber of GM: Our design
team and our engineering team want our feedback. And
were getting results. Employees are much more involved
with the design engineering community. We actually have
a team that takes calls from dealerships as well as consum-
ers. Were trying to listen, trying to dig in deeper and help
folks. And Ive seen it work.
Arc flash and electrical safety, presented by Joe Weigel
of Schneider Electric: Maintenance is not well done in
Manufacturing/Automation Summit now available online, on demand
A virtual trade show at
your command

12 October 2011 PLANT ENGINEERING
FORUM
this country on electrical systems. Circuit breakers usually
fail in a closed position with no indication of failure. They
will supply power reliably until theres an event. Then it
doesnt know what to do. It cant operate because it hasnt
been lubricated in 20 years.
Maintenance as a profit center, presented by David
Cline of Harland Clark: The best way to create change
is to engage the people with whom youre trying to create
change. If you do it for them, theyll fight you along the way
and youll never sustain the results. Its a leadership issue.
Automation integration,
presented by Augie DiGiovanni
of Emerson Process Manage-
ment: Proactive is when you
engineer maintenance out of a
certain process. For example,
when taking vibration readings
on a piece of rotating equipment, you notice the bearings
need to be replaced every three months. Most engineers
understand that bearings are designed to last longer than
three months. Replacing it with the right sized bearing
solved your reliability issue just by proactively engineering
a change in the equipment.
Global strategies for manufacturers, presented by Mary
Bunzel of IBM: People want to be excellent in their work
naturally. If they dont have a tool or direction, they
evolve it on their own. While that information might be
quite excellent in isolation, it is isolated. And the rest of
the organization is not able to benefit from that. One of
the ways that I see manufacturing evolving on a global
perspective is through the joint effort of multi-cultures,
multi-sites, coming together, picking really smart people to
come together into governance so they can set the strategy
for global approach to maintenance and operations.
The Virtual Summit also featured keynote speeches from
U.S. Rep. Don Manzullo (R-16th, IL) and Doug Woods,
president and CEO of the Association for Manufacturing
Technology.
The Summit takes on some
of manufacturings biggest
challenges and delivers must-
have how-to information on
the key issues they face daily,
CFE Media publisher Jim
Langhenry said. Manufactur-
ing needs a new way to approach its issues. The Virtual
Summit platform makes the event not just live, but totally
interactive. Attendees can ask questions, visit virtual show
booths, review vendor information and request a visit from
a company representative everything youd expect to be
able to do at a live trade show. And since its free to the
attendees, its both informative and cost-effective.
To register for the Virtual Summit, or to review your
previous visit. Go to www.PlantEngineering.com or www.
controleng.com and click on the Virtual Summit tab
under Events.

Asset management that pinpoints wasted energy:
good for business and good for the globe.
Reduce energy usage and costs, maximize asset potential, optimize PP&E, all
while minimizing environmental impact.
Thats what you get fromInfor EAM software. A solution that helps you drive your asset management
plans, decisions, and actions to reduce energy. More than 10,000 organizations worldwide are using
Infor EAM to save money and increase profts, and you can too.
Visit us online at http://go.infor.com/energy-mgmt/ for more information you need to extend the life of
your companys assets while you cut costs and go green.
Copyright 2011Infor. All rightsreserved. www.infor.com.
Attain Complete Visibility
PLE2011010_013.indd 13 10/7/2011 12:15:23 PM
Enclosures
from XS to 3XL
Mike Molnar noted that
in his first week in Washing-
ton, D.C. as the new chief
manufacturing officer for
the National Institute of
Standards and Technology
(NIST), the area suffered an
earthquake and a hurricane.
Comparatively speaking,
his appearance as the keynote speaker
at the first imX conference in Las Vegas
was a breeze.
It helped he was speaking to an audience
eager to help manufacturing grow. A lot
of people dont understand the importance
of manufacturing. You do, Molnar told
the audience at the Las Vegas Convention
Center. In my family, there was no more
noble thing than being in manufacturing.
Im a manufacturing guy.
Molnar noted that they myths of U.S.
manufacturingthat the U.S. is no longer
a manufacturing leader and that manu-
facturing still is a dark and dangerous
jobare not supported by any facts. But
he did challenge manufacturers to do a
better job of embracing the modern reali-
ties of manufacturing.
The concern isnt about who is No. 1.
The concern is about advanced manufac-
turing, about growing jobs
in the U.S. Manufacturing
these days is global.
Ot her nat i ons ar e
involved with an industrial
policy, he added. We need
an innovation policy. That
feeling was reflected in a
recent report to President
Obama, which said the U.S.
is losing manufacturing
leadership in the production of high-
tech products, including those resulting
from U.S. innovation and inventions, and
in manufacturing-related R&D.
The federal Advanced Manufacturing
Partnership has four basic goals:
Improve tax policies
Support research and development
Strengthen the existing and emerg-
ing workforce
Create partnerships with industry
and education.
According to the U.S. Dept. of Com-
merce, the Advanced Manufacturing Part-
nership brings industry, universities, and
the federal government together to invest
in emerging technologies, and demon-
strates the presidents commitment to
building domestic manufacturing capa-
bilities to create the new products, new
industries, and new jobs of the future.
A healthy domestic manufacturing
industry is vital to our nations economic
recovery, said Peter Borden, president
of imX partner the American Machine
Tool Distributors Association. Our
leaders in Washington know it, and the
industry knows it. At imX, were com-
ing together to determine how to work
collaboratively to strengthen a manufac-
turing base that will continue creating
jobs for American workers and provide a
solid foundation for sustained economic
growth.
The inaugural imX event, co-spon-
sored by eight leading machine tool,
CNC, and robotics companies, focused
on delivering knowledge and solutions
to the attendees in Las Vegas. In contrast
to the biannual IMTS Show in Chicago,
which centers on tools, machines, and
technology, the imX event was decidedly
lower tech. Its also envisioned as a bien-
nial event in the off-year from IMTS.
Manufacturers and attendees were
generally pleased with the format. The
eight Learning Labs, each conducted
adjacent to the booth of one of the major
sponsors, were focused on presenting
specific strategies and solutions as
opposed to product introductions.
For example, Ollie Senechal of Sand-
vik Coromant used his presentation on
FORUM
Molnar: We need an innovation policy
NIST chief manufacturing officer talks about industry collaboration at imX event
By Bob Vavra, Content Manager
Mike Molnar
FORUM.indd 14 10/7/2011 12:27:11 PM
www.rittal-thesystem.com
Sept. 12, 2011 to discuss the issue of clos-
ing the gap between the cost of manufac-
turing and the price of the product. He
noted five challenges facing manufactur-
ers today:
Accelerated cost pressures
Global competition
Reduced lead times
Use of complex designs and/or exotic
materials
Greater environmental awareness.
As customers look at new machine tool
applications or systems, Senechal echoed
the service theme of the event to suggest
suppliers can provide greater value than
simply a good product at the lowest pos-
sible price. Get the machine tool dealers
involved early on in the buying process,
he said. That can help you shorten the
time to production, which will result in
a quicker return on investment.
Also at the top of the weeks agenda
was a discussion of closing the Skills
Gap. The Society for Manufactur-
ing Engineers rolled out its Mission
Critical: Workforce 2021 initiative
at the show. The theme of that dis-
cussion, was to develop strategies
to attract, train, and retain a new
generation of manufacturing work-
ers with the skills necessary to keep
manufacturing competitive in the
U.S.
The inaugural imX Conference in Las Vegas brought together cutting-edge technology and innovative Learning Labs.
FORUM.indd 15 10/7/2011 12:27:24 PM
FORUM
and the issues faced during program implementa-
tion. The company needed a materials inventory
management system that provided appropriate
control and integrated with a new computerized
maintenance management system (CMMS). Key
questions for this company were:
1. Are current inventory arrangements appropri-
ate to the types and value of the inventory?
2. What actions, if any, should they take to
improve the management and governance of the
inventory investment?
An initial review evaluated the companys capability,
accountability, and systems, and identified how and where
they needed to improve in order to achieve their goals. The
process involved both qualitative and quantitative analyses to
ensure that all aspects of inventory management were covered.
This review identified a number of challenges and issues that
the company needed to address:
1. No reliable records of the quantity, quality, or location of
spares held. At each location the supervisors and maintenance
teams knew where items were but there was no record of the
actual quantity or quality of the items.
2. No tracking of usage. Parts purchased for a project were
routinely used in other areas and vice-versa. As long as the
parts were used in the general cost areas for which they were
purchased there was no perceived need for further allocation
of costs. As a result their cost data was unreliable.
3. No standards for storage. There was no formal recognition
of environmental effects or even the need for operating a first-
in-first-out (FIFO) approach for items with a limited shelf life.
4. No identification of critical items. All parts were treated
equally, irrespective of the impact of non-availability on oper-
ating results.
5. Poor control of repairable spares. Items that werent needed
were repaired and sometimes items sent out for repair were not
collected in a timely manner, resulting in operational losses.
6. The imminent implementation of a new CMMS meant
that they needed a consistent approach for tracking of costs
and parts usage.
Development and implementation
Following the initial inventory review, we decided to apply
a four-stage process to manage the policy and procedure devel-
opment and the subsequent implementation (see Figure 1).
Ironically the key was to be clear about each stage so that the
company did not go about trying to implement major structural
changes too early. Sometimes companies can mistake action for
progress and we needed to ensure that approaches developed
were both pragmatic and robust before starting to centralize
major items and rationalizing inventory holdings. Plus, with
a large number of sites to manage we needed to avoid the
The catalyst for action was a corporate take-
over and the subsequent need to publish public
accounts. For years the companies involved had
largely ignored their spare parts management
approach, as long as there were no major stockouts
no one was interested. However, as a combined
entity they needed to ensure, and report, appropri-
ate management and governance of their inventory
investment across a network of 25 locations.
In order to move them along the path towards
achieving smart inventory solutions, they needed to develop and
implement a full range of policies and procedures, including:
Corporate level policy, requiring board-level approval
Operational procedures for use on a daily basis
Stocking policies
Storeroom organization guidelines
Storage guidelines.
This case study shows the process applied to establish the
policies and procedures for materials and inventory management
Book excerpt: Implementing inventory
management policies and procedures
By Phillip Slater
Donaldson Company, Inc.
Compressed Air &
Process Filtration
800-543-3634
2011 Donaldson Company, Inc. All Rights Reserved.
compressedair@donaldson.com
donaldson.com
Q
u
a
l ity
M
anagement
S
y
s
t e
m
ISO
9001:2008
Registered Member of
Cost effective
High performance
Greater efficiency
Ease of use
Versatile
FOR CLEAN COMPRESSED AIR
THINK DONALDSON
J
o
in
U
s
!
P
R
O
C
E
S
S

E
X
P
O
B
O
O
T
H

#
1
6
1
5

N
o
v
. 1
-
4
, C
h
ic
a
g
o
FORUM.indd 16 10/11/2011 6:18:32 PM
MORE in-stock products with FREE shipping*
MORE #1 rated tech support thats FREE
MORE free manuals and software
MORE savings without sacrificing quality
ns
st
1-800-633-0405 | www.AutomationDirect.com
#1 Value in Automation
* See inside for details
O
v
e
r 1
0
,0
0
0
in
d
u
s
tria
l c
o
n
tro
l
p
ro
d
u
c
ts
in
s
to
c
k

a
n
d
re
a
d
y
to
s
h
ip
bit.ly/infoadc
You need quality products
at a great price from a solid supplier. . .
. . . Since 1994 our prices have been
typically 50% less than more traditional suppliers.
Since our industry-changing catalog first hit the mailboxes in 1994,
weve been offering a better value on industrial controls by running
our business efficiently and passing the savings on to our customers.
In 1999, we made it easier to research and purchase by becoming
the first automation supplier with a 24/7 online store.
Weve made the commitment to offer the best products at
the best value we could deliver so you have a better choice.
In this uncertain economy, you need to
save money and save time . . . we can help.
Programmable Controllers
Field I/O
Software
HMI
Drives
Soft Starters
Motors & Gearboxes
Steppers/Servos
Motor Controls
Proximity Sensors
Photoelectric Sensors
Limit Switches
Encoders
Current Sensors
Temperature Sensors
Pilot Devices
Process
Relays/Timers
Communications
Terminal Blocks
Wiring
Power Products
Circuit Protection
Enclosures
Tools
Pneumatics
and more!
AutomationDirect
Price/Part Number
Competitor
Price/Part Number
All prices are U.S. published prices. AutomationDirect prices are as of October 2011. Hoffman
prices are taken fromwww.hoffmanonline.com 2/14/11. Allen-Bradley list prices are taken from
http://www.rockwellautomation.com/en/e-tools 2/21/11. Prices may vary by dealer. Many other
part numbers are available fromvendors. All prices subject to change without notice.
NEMA12 Enclosure, steel,
wall mount (20x 16x 8)
$243.00
N12201608
$489.30
Hoffman A-201608LP
Supplementary Protector,
Single pole, 5 AMP,
D trip curve
$8.50
WMZS1D05
$42.60
A-B 1492-SP1D050
AC Drive, 5 hp, 460V $407.00
GS2-45P0
$995.00
A-B 22B-D010N104
Proximity sensor, 18 mm,
3-wire NPN DC shielded,
with 2-meter cable
$21.75
AK1-AN-1A
$81.90
A-B 872C-DH5NN18-E2
You need it delivered
FAST and you dont
want to pay for
shipping . . .
. . . order from us, youll get it
in 2 days or less with no charge
for shipping on orders over $300**.
You insist on better service
and you want it FREE . . .
. . . our FREE technical support
has been voted #1 for eleven
years in a row.
Many industry magazine reader surveys
have placed us at the top of the list for
service. In Control Design magazine,
weve been voted #1 in multiple product
categories eleven years in a row.
The awards are nice and we appreciate
them, but a satisfied customer who comes back time and time
again is our best reward. Located just north of Atlanta, Ga, we start
every business day with that in mind.
You want training and
information to fit your schedule . . .
. . . we have FREE live Webinars and
were constantly updating our on-demand
product videos.
And for almost-FREE online videos that dive deeper into our product lines,
go to www.interconnnectingautomation.com for in-depth training libraries.
You bought the products,
you want FREE manuals . . .
. . . all our manuals, CAD drawings,
and documention are FREE downloads
available 24/7.
You paid hard earned money for our products. Why
should you have to pay more for the manuals to use
them? That doesnt make sense.
If youre evaluating a product, download the manual to
help you make a better choice - no purchase necessary.
Over 10,000
products in stock
and ready to ship
1-800-633-0405
www.AutomationDirect.com
more info www.AutomationDirect.com/price
more info www.AutomationDirect.com/service
more info www.AutomationDirect.com/support
more info www.AutomationDirect.com/videos
complete details
www.AutomationDirect.com/2day
** 2-day transit time does not apply for LTL shipping of heavy orders or drop-shipped items not in Cumming, GA ware-
house. (We cannot ship heavy items to Hawaii or Puerto Rico.) For orders under $300, you may request that your order
ship via the 2-day (transit) method; shipping charges will be added to invoice. For complete details on shipping methods
and charges, see Terms and Conditions in our catalog or on our Web site. We do not guarantee delivery times of the
carriers. AutomationDirect is not responsible for carrier delays due to weather, mechanical failures or other issues.
more info
www.aboutplcs.com
Easy for new user
Basic machine
control
Lowest cost
Advanced discrete
Basic process
control
Expandability
Ethernet
Advanced discrete
and process
Data collection
Extensive
communications
Distributed I/O
Whether youre a newcomer to PLCs, or a seasoned
veteran; whether you need simple discrete control or
need to calculate complex algorithms lightning fast,
you can find what you need among our cost-effective
programmable controller families.
2011-fall-insert-inside:Layout 1 8/25/2011 8:57 AM Page 1
You need quality products
at a great price from a solid supplier. . .
. . . Since 1994 our prices have been
typically 50% less than more traditional suppliers.
Since our industry-changing catalog first hit the mailboxes in 1994,
weve been offering a better value on industrial controls by running
our business efficiently and passing the savings on to our customers.
In 1999, we made it easier to research and purchase by becoming
the first automation supplier with a 24/7 online store.
Weve made the commitment to offer the best products at
the best value we could deliver so you have a better choice.
In this uncertain economy, you need to
save money and save time . . . we can help.
Programmable Controllers
Field I/O
Software
HMI
Drives
Soft Starters
Motors & Gearboxes
Steppers/Servos
Motor Controls
Proximity Sensors
Photoelectric Sensors
Limit Switches
Encoders
Current Sensors
Temperature Sensors
Pilot Devices
Process
Relays/Timers
Communications
Terminal Blocks
Wiring
Power Products
Circuit Protection
Enclosures
Tools
Pneumatics
and more!
AutomationDirect
Price/Part Number
Competitor
Price/Part Number
All prices are U.S. published prices. AutomationDirect prices are as of October 2011. Hoffman
prices are taken fromwww.hoffmanonline.com 2/14/11. Allen-Bradley list prices are taken from
http://www.rockwellautomation.com/en/e-tools 2/21/11. Prices may vary by dealer. Many other
part numbers are available fromvendors. All prices subject to change without notice.
NEMA12 Enclosure, steel,
wall mount (20x 16x 8)
$243.00
N12201608
$489.30
Hoffman A-201608LP
Supplementary Protector,
Single pole, 5 AMP,
D trip curve
$8.50
WMZS1D05
$42.60
A-B 1492-SP1D050
AC Drive, 5 hp, 460V $407.00
GS2-45P0
$995.00
A-B 22B-D010N104
Proximity sensor, 18 mm,
3-wire NPN DC shielded,
with 2-meter cable
$21.75
AK1-AN-1A
$81.90
A-B 872C-DH5NN18-E2
You need it delivered
FAST and you dont
want to pay for
shipping . . .
. . . order from us, youll get it
in 2 days or less with no charge
for shipping on orders over $300**.
You insist on better service
and you want it FREE . . .
. . . our FREE technical support
has been voted #1 for eleven
years in a row.
Many industry magazine reader surveys
have placed us at the top of the list for
service. In Control Design magazine,
weve been voted #1 in multiple product
categories eleven years in a row.
The awards are nice and we appreciate
them, but a satisfied customer who comes back time and time
again is our best reward. Located just north of Atlanta, Ga, we start
every business day with that in mind.
You want training and
information to fit your schedule . . .
. . . we have FREE live Webinars and
were constantly updating our on-demand
product videos.
And for almost-FREE online videos that dive deeper into our product lines,
go to www.interconnnectingautomation.com for in-depth training libraries.
You bought the products,
you want FREE manuals . . .
. . . all our manuals, CAD drawings,
and documention are FREE downloads
available 24/7.
You paid hard earned money for our products. Why
should you have to pay more for the manuals to use
them? That doesnt make sense.
If youre evaluating a product, download the manual to
help you make a better choice - no purchase necessary.
Over 10,000
products in stock
and ready to ship
1-800-633-0405
more info www.AutomationDirect.com/price
more info www.AutomationDirect.com/service
more info www.AutomationDirect.com/support
more info www.AutomationDirect.com/videos
complete details
www.AutomationDirect.com/2day
** 2-day transit time does not apply for LTL shipping of heavy orders or drop-shipped items not in Cumming, GA ware-
house. (We cannot ship heavy items to Hawaii or Puerto Rico.) For orders under $300, you may request that your order
ship via the 2-day (transit) method; shipping charges will be added to invoice. For complete details on shipping methods
and charges, see Terms and Conditions in our catalog or on our Web site. We do not guarantee delivery times of the
carriers. AutomationDirect is not responsible for carrier delays due to weather, mechanical failures or other issues.
more info
www.aboutplcs.com
Easy for new user
Basic machine
control
Lowest cost
Advanced discrete
Basic process
control
Expandability
Ethernet
Advanced discrete
and process
Data collection
Extensive
communications
Distributed I/O
Whether youre a newcomer to PLCs, or a seasoned
veteran; whether you need simple discrete control or
need to calculate complex algorithms lightning fast,
you can find what you need among our cost-effective
programmable controller families.
2011-fall-insert-inside:Layout 1 8/25/2011 8:57 AM Page 1
Programmable
Controllers
Universal Field I/O Software Operator Interface AC Drives
Motors and
Worm Gearboxes
Motor Controls Pneumatics Process
Relays & Timers Sensors
Pushbuttons,
Switches and Lights
Terminal Blocks
and Wiring
I/O and
Communications
Wiring
Communications Power Products Enclosures
Motion Control
Circuit Protection Tools
Comments from our current customers:
Products are a good value for a fair price.
We've used a wide selection of what's offered.
Online ordering is easy. Supplies are delivered quickly.
Every year the product line is expanded. Currently
trying the pneumatic fittings with great success.
Ken, Holly MI
AutomationDirect is the best vendor of automation
products that I have ever used and second best is
not even close. I make regular decisions to purchase
automation products from AutomationDirect based
solely on the quality of the Web site and the availability
of knowledgeable technical support staff.
There is that super low price thing, as well :)
Steve, Charbonneau OR
This company is by far the easiest to
order from and the quickest to ship than
any other online supplier that I know of. Quality of most
items are as good or better than the brand "X" boys.
Thanks for the great site.
Todd, Hood River OR
I have been in the machine design trade for 15 years
and never found a company like this one. The support
you receive when working with this company is un-
heard of. Some companies charge for tech support.
The software is friendly and all the information you
need is available online.
The company is how most should be ran.
Online comment from Affton MO
A quality product line, with FREE #1 rated technical support and quick shipping!
Call 1-800-633-0405 or visit us at: www.automationdirect.com
1-800-633-0405 | www.AutomationDirect.com
2011-fall-insert-outside:Layout 1 8/25/2011 8:55 AM Page 1
Stage 1:
Mobilize
Establish team
Establish the
ongoing rules
and measures
Conduct initial
stocktake
Create the
baseline for
KPIs
Stage 2:
Systemize
Develop policy
and procedures
Train personnel
in use
Commence
appplication
Stage 3:
Centralize
Determine
what can be
centralized
for greater
efficiency
and improved
coordination
of purchasing
and logistics
Stage 4:
Rationalize
Once the
inventory is
centralized
and there is
reliable usage
data, the
opportunity
arises to
rationalize the
quantities held
grapevine setting the agenda.
The key activities within the first two
stages of this process were:
Establish a steering committee
Review governing accounting stan-
dards and their implications
Manage internal communications on
the project progress and process
Develop stocktake processes and
documentation
Conduct a pilot stocktake, followed
by a company-wide stocktake
Visit a best practice site to review
its infrastructure and practices
Develop standards for materials stor-
age and storeroom/yard layout
Coordinate clean-up of locations
Develop and document new policies
and procedures
Approve policies and procedures at
board and executive level
Review infrastructure needs and
develop an initial budget for infrastruc-
ture improvements
Review CMMS capability and
implementation issues
Conduct awareness training for key
personnel.
The project then focused on training
personnel and implementing the relevant
policies and procedures across the geo-
graphically diverse locations. It was only
after the establishment of common and
consistent approaches to inventory stor-
age and management that the company
could then confidently move onto stages 3
and 4 where the opportunities for central-
ization and rationalization are reviewed.
As the development of policies and
procedures was critical to the programs
success we adopted the swim-lanes
approach to help simplify the presenta-
tion of procedures and clarify the respon-
sibility and sequence for each action.
The key feature of the swim-lane
approach is that each role is allocated
a lane and by reading cross the page
each individual can see what they are
required to do and where it fits within the
whole process.
Results
At the conclusion of Stage 2 the com-
pany had established the appropriate sys-
tems for management and governance of
inventory investment, including:
Materials Management Policy and
Procedures developed and implemented
Systems established for recording
and tracking materials usage
Procedures established for conduct-
ing stock takes
Standards established for labeling
and storage
Guidelines established to identify
critical and other spares types
Guidelines established for estab-
lishing stock levels and reordering of
materials
Guidelines established for improved
control of repairable spares
CMMS implementation coordinated
with materials management improvements
Full transparency of stock holdings
at all locations established
Figure 1: Four-Stage Implementation Process. Source: Phillip Slater
Statement of Ownership, Management and Circulation
1. Publication Title: PLANT ENGINEERING
2. Publication Number: 790-920
3. Filing Date: 9/23/11
4. Issue Frequency: 10x, monthly except in January and July
5. Number of Issues Published Annually: 10
6. Annual Subscription Price: USA $145 CAN $180 MEX $172 INTL $318
7. Complete Mailing Address of Known Ofce of Publication (Not printer): CFE MEDIA, LLC 1111 West 22nd St., Ste #250 Oak Brook, IL 60523
8. Complete Mailing Address of Headquarters or General Business Ofce of Publisher (Not printer): CFE MEDIA, LLC 1111 West 22nd St., Ste #250 Oak Brook, IL 60523
9. Publisher: Jim Langhenry, CFE MEDIA, LLC 1111 West 22nd St., Ste #250 Oak Brook, IL 60523
Editor-in-Chief: Bob Vavra, CFE MEDIA, LLC 1111 West 22nd St., Ste #250 Oak Brook, IL 60523
Managing Editor: Amanda McLeman, CFE MEDIA, LLC 1111 West 22nd St., Ste #250 Oak Brook, IL 60523
10. Owner: CFE MEDIA, LLC 1111 West 22nd St., Ste #250 Oak Brook, IL 60523
Jim Langhenry and Steve Rourke, CFE MEDIA, LLC 1111 West 22nd St., Ste #250 Oak Brook, IL 60523
11. Known Bondholders, Mortgagees, and Other Security Holders Owning or Holding 1 Percent or More of Total Amount of Bonds, Mortgages, or Other Securities: None
12. Does not Apply
13. Publication Title: Plant Engineering
14. Issue Date for Circulation Data Below: October 2011
15. Extent and Nature or Circulation
Average No. Copies Each Issue
During Preceding 12 Months:
Actual No. Copies of Single Issue
Published Nearest to Filing Date:
a. Total Number of Copies (Net Press Run): 50,960 50,284
b. Paid and/or Requested Circulation:
(1) Paid/Requested Outside-County Mail Subscriptions Stated on Form 3541.
(Include advertisers proof and exchange copies)
49,130 49,500
(2) Paid In-County Subscriptions Stated on Form 3541.
(Include advertisers proof and exchange copies)
(3) Sales Through Dealers and Carriers, Street Vendors, Counter Sales, and
Other Non-USPS Paid Distribution
124 11
(4) Paid Distribution by Other Classes of Mail Through the USPS
c. Total Paid and/ or Requested Circulation [Sum of 15b, (1), (2), (3), and (4)-** 50,054 49,611
d. Free or Nominal Rate Distribution (By Mail and Outside the Mail)
(1) Outside-County as Stated on Form 3541 497 418
(2) Free or Nominal Rate In-County Copies Included on PS Form 3541 0 0
(3) Free or Nominal Rate Copies Mailed at Other Classes Through the USPS 0 0
(4) Free or Nominal Rate Distribution Outside the Mail (Carriers or other means) 100 0
e. Total Nonrequested Distribution [Sum of 15d (1), (2), (3), and (4) 497 418
f. Total Distribution [Sum of 15c and 15f] 50,551 50,029
g. Copies not Distributed 409 255
h. Total [Sum of 15f and 15g] 50,960 50,284
i. Percent Paid [15c divided by 15f times 100] 98.22% 99.16 %
16. Publication of Statement of Ownership: Publication Required. Will be printed in the October 2011 issue of this publication.
17. I certify that all information furnished on this form is true and complete. I understand that anyone who furnishes false or misleading information on this form or who
omits material or information requested on the form may be subject to criminal sanctions (including nes and imprisonment) and/or civil sanctions (including civil
penalties). Jim Langhenry (signed), Publisher
CFE Media Statement of Digital Circulation
Publication Title: Plant Engineering, 12-Month Average September
Printed Circulation as reported on PS Form 3526, line 15a 50,960 50,284
Digital Circulation 21,609 20,510
Total Circulation 72,569 70,794
FORUM
More than 100 staff trained in appli-
cation of new policies and procedures.
These provided the foundation upon
which the centralization and rationaliza-
tion programs could now commence.
Three key actions underpinned the suc-
cess of this program:
1. Tackling the issues relating to peo-
ple, processes, policies, and procedures
2. Identifying and addressing internal
myths and biases
3. Formalizing the approach to manag-
ing the spare parts store room.
By working to establish a materials and
spare parts management system rather than
focusing on spare parts optimization this
organization has set itself up to achieve
long-term success with its materials
and spares parts management.
This article is an edited excerpt from
the second edition of the book Smart
Inventory Solutions by Phillip Slater,
published by Industrial Press Inc, ISBN
978-0-8311-3401-3. For more informa-
tion, visit www.PhilipSlater.com.
Issue Mitigation
Lack of buy in by middle
management.
Maintain Senior Management support and develop support at the coal face
(working around the mid level).
Continue communication with mid-level management, including demonstrating
benefits.
Establish auditable procedures and standards.
Establish personal implementation-related KPIs for key managers.
During the program, the
initial champion for materi-
als management moved on
in the organization.
Executive level buy-in used to continue the push of the program.
Local champions established at each location as people showed interest.
Little organizational under-
standing of good practice.
Visited an external good practice location to demonstrate what good practice
looked like and that it was possible to achieve in their industry.
Development of written standards, which included (where appropriate)
photos of good practice.
Establishment of an internal good practice location that was used as a role
model for other locations.
Insufficient data to estab-
lish reordering parameters.
Development of a decision making model which used known information to
establish the most appropriate calculation approach and then provided a
sensitivity analysis to model the effect of different estimates of requirements.
Need to establish order-
ing parameters for a large
number of items.
Establish a Materials Usage Review Group to identify critical items and ensure
sufficient procurement while establishing the data for automated reordering.
Lack of trust that the
new system will ensure
availability of the required
materials.
Materials Usage Review Group monitored levels while trust in the system was
established.
Issues and concerns relating to trust were proactively identified and followed up.
Inadequate storage
infrastructure
Established an infrastructure plan with the aim to gain funding approval and
establish the required infrastructure over several years.
Source: Phillip Slater
Table 1: Issues and mitigation actions
FORUM.indd 18 10/7/2011 2:48:29 PM
Protect: heat exchangers, spray nozzles,
instrumentation, pump seals, I.E. & R.O.
units, air compressors and the environment.
Remove: airborne particles, sand, gravel,
algae, pollen, silt, scale, rust, microbiological
growth, zebra mussels and other dirt
particles down to micron size.
Applications: anywhere that dirt is
a problemcooling water, process water,
reclaim water, effluent water, intake water,
waste water, wash water, potable water.
Users: U.S. government, municipalities,
big 3 automakers, steel mills, major oil
companies, commercial buildings, food,
chemical, pharmaceutical, plastics, paper,
car/ rail washes, mines, power.
Cooling
Tower
Insects
Airborne
Particles
Rust
Pollen
Algae
Leaves
Water
Filter
O
R
I
V
A
L
Spray
Nozzles
Instrumentation
Heat
Exchanger
Automatic Self-Cleaning
WATER FILTERS
213 S. Van Brunt St.,
Englewood, NJ 07631
(800) 567-9767
(201) 568-3311 5 Fax (201) 568-1916
www.orival.com 5 filters@orival.com
New Filtration Technology
Keeps Cooling Water Clean
An older, wiser maintenance con-
sultant, who mentored me many years
ago, posed a question: What does
maintenance do? My nearly automatic
response was, They fix broken things.
His answer reminded me of my elemen-
tary school teachers retort: Wellthat
is correct, but give me more. As I con-
tinued to talk about how maintenance
fixes what is broken, he finally inter-
rupted me and said, Yes, thats true.
But the main thing they do is increase
an organizations capacity.
Those words have stuck with me
ever since. The maintenance team
should not simply be considered a
cost center. What is the opposite of
reducing downtime? Simpleincreas-
ing uptime! A strong maintenance plan
and well-oiled team keep operations
running smoothly, using less spare
parts, less overtime labor, and fewer
resources such as electricity and water.
And that helps preserve costs and
increase profitability.
Sales isnt the only profit-making
department in the organization. The
ma i nt e na nc e
team, typically
r el egat ed t o
the basement,
is keeping pro-
duct i on r un-
ning efficient-
ly, increasing
capacity, and positively affecting prof-
itability. Yet they are often the unsung
and under-appreciated members of the
organization.
At the core of maintenance opera-
tional success is a well-conceived plan,
a well-trained team, and a computer-
ized maintenance management system
(CMMS). Without a CMMS driving the
schedule for performing critical tasks
in advance of potential equipment fail-
ures, the goal of increasing the organi-
zations capacity will not be achieved.
CMMS helps differentiate strong
performing assets from weaker ones
to show where
to earmark pre-
cious people and
dollar resources
in an intelligent
manner, there-
by i ncr easi ng
u p t i me a n d
decreasing downtime expenses. This
allows management to make smart
repair-versus-replace decisions with
proven vendors; the staff gains credit
for work well done; and PM schedules
get adjusted to avoid future issues.
An added benefi t i s i mproved
cash flow resulting from not getting
surprises that an expensive piece
By Paul Lachance, Smartware Group
The pitch on CMMS: More capacity, profits
A strong maintenance plan and
well-oiled team keep operations
running smoothly, using less
parts, labor, and resources.
FORUM.indd 19 10/7/2011 2:50:48 PM
1/4, 1/2 & 1 Ton Air Chain Hoists
are now available for Quick Shipment
with 4 brands to choose from.
Scan this QR Code with your smartphone for more information.
Call (800) 888.0985 or (716) 689.5400 U www.cmworks.com
FORUM
of equipment suddenly needs to be
replaced but was not in the budget.
Also, since CMMS captures activ-
ity related to asset repairs and keeps a
running history, it prevents duplicate
repairs and unnecessary costs. CMMS
is very useful for looking at cost pro-
gressions in maintenance for planning
capital budgets. It tells maintenance
whether it is more costly to continue
repairing an asset or to replace it.
CMMS benefits the bottom line.
You have likely heard this sce-
nario over and over again: Its a
hot day and the temperature in your
office is too high. The problem is
related to the HVAC in your office
area. Employees wonder, When will
maintenance get here and fix this?
Or maybe a production line is
down, delaying an important order,
which incurs overtime and parts
costs. Since the default perception
of maintenance is that a technician
gets called when trouble strikes, it
is natural to associate maintenance
Hazardous Duty
Enclosure Protection
800-441-7475 hazloc.org The Originator of Vortex Tube Products
Keep your electrical panels
cool, clean and protected
with the low-cost alternative
to air conditioners.
It is simple to install, has no
moving parts and is extremely
reliable. No electricity required.
FORUM.indd 20 10/7/2011 2:55:25 PM
without sacrice
COMPLIANCE
SAFETY
without compromise
We can all agree, safer is betterespecially when safer virtually eliminates
the threat of an arc fash incident. With IR Windows from Fluke, NFPA 70 E
compliance is easier because you dont have to open panels or power
down to inspect equipment.
Fluke IR Windows exclusive
t CLIRVU
gives your eyes and your camera a clear, unobstructed view

t AutoGround
provides effortless compliance with grounding standards

For more information
www.fuke.com/nocompromise 1-800-760-4523
2011 Fluke Corporation. 5/2011 Ad 4057341A
800.221.3298 U fax 216.241.3480 U www.clevelandvibrator.com U Made in the USA
Manufacturing Quality Industrial Vibrators and Vibratory Equipment since 1923
Chemical Food Pharmaceutical Plastics Powders Construction Laboratory Textiles Metals Ceramics
Air Piston Vibrators U Turbine Vibrators U Rotary Electric Vibrators U Ball Vibrators U Electromagnetic Vibrators U Vibratory Tables
Vibratory Feeders U Vibratory Screeners U Ultrasonic Screeners U Vibratory Conveyors U Tailored On Demand
Made tough with a continuous duty motor design for maximum force outputs,
our low maintenance vibrator lines answer a diverse range of material handling
needs. Select from air or electric powered models for use with screeners, bins,
hoppers, conveyors, packing tables, parts tracks, feeders and more.
Air Piston (Pneumatic) Vibrators
tSupport capacities from 10 lbs (4.5 kg) to 100+ tons (90 MT)
tMetallic impact line features lightweight, one-piece models with tough,
ductile housings and coating options for specialized applications
Rotary Electric Vibrators
tLarge stock of 50+ motors, single and 3-phase
tAdjustable force outputs: 30 to 40,000+ lbs
Miniature Pneumatic Vibrators
tMore effective than competitive models 3x larger
tMost compactgreat for small parts tracks and feeders
Get the quality, service and reliability you expect from
88 years of engineering and manufacturing experience.
ENGINEERED FOR PERFORMANCE
and repair with problems the staff likely didnt create.
Even with preventative maintenance, it sometimes forc-
es equipment to be taken offline, preventing the flow of
productionand that too generates negative perceptions
upstairs, which puts the burden on maintenance staffers
to prove their value. It is the maintenance directors job
to explain to management: We are not just fixing broken
thingswe are increasing our organizations capacity and
saving significantly on asset management!
Solid reporting and analysis will help create a smooth-
running operation. Again, CMMS reduces emergencies and
the maintenance team blends into the background. This is
good news as it typically means a reduction in downtime
and an increase in uptime.
But you need to let upper management know why a
CMMS is needed. CMMS at the core of your maintenance
operations will improve your teams ability to help the
organization lower costs and increase profitability. It will
also kick out the reports to prove it, should inquiring
minds in upper management want to know.
Lachance is president and chief technology officer for Smart-
ware Group, which produces Bigfoot CMMS. Lachance has
been developing and perfecting the companys CMMS solution
for the maintenance professional for 18 years. Contact him at
paul.lachance@bigfootcmms.com.
FORUM.indd 21 10/7/2011 3:10:34 PM
Keeping your production on track
Copyright 2011 Atlas Copco Compressors LLC. All rights reserved.
Hi, I'm Daniel and Ive been a service technician working with Atlas Copco products for
over 26 years. Ive seen technology race ahead over that time, but the one thing always
setting the pace is our commitment to keep your productivity on track.
The key behind Atlas Copcos service offering is that its fully customizable, with a
selection of plans and programs that put you in the drivers seat. We understand how
important compressed air is within your workplace and keeping your production fine
tuned is our number one priority. Looking after your processes and applications is part
of every Atlas Copco employees mission and this goes far beyond the compressor room.
Inspecting your piping system for leaks, assessing pressure drops, and checking
condensate drains is all in a days work for our service teams.
Our driving force is to continue to bring sustainable productivity through safer, cleaner,
more energy-efficient and cost-effective compressed air technology. Simply log onto
www.atlascopco.us/danielusa or call 866-688-9611 to learn more about us, our products,
and how we have earned and will continue to earn our reputation.
PLE2011010_022.indd 22 10/7/2011 3:17:54 PM

BEST PRACTI CES

A
few years back, as an energy man-
ager in a huge aero-structures
fabrication plant in the Midwest,
I learned a valuable lesson about
energy conservation projects from the
guys in the maintenance department.
As a major subcontractor to the
Department of Defense, our facility was
producing structural assemblies for mili-
tary aircraft. The site operations
contained 50 buildings with over
8,000 employees working on a
24/7 schedule to meet the stringent
production schedules demanded by
program managers and prime con-
tractors.
Basic manufacturing processes
include machining, forming, heat
treatment, subassembly compo-
nents, fabrication, painting, final
assembly, and full operational test-
ing of each completed structure for
the various military aircraft mod-
els and two commercial contract
passenger planes as well. Total
energy costs at the site averaged
over $450,000 per month.
Part of the DoD contractor certi-
fication process requires having a formal
energy conservation program in effect and
using energy management systems (EMS).
The energy program also required quar-
terly progress reviews with DoD officials.
The plant had an early generation IBM
EMS that was hard-wired to most of the
major equipment on-site. We were able
to monitor and control operation of many
utility systems and some larger process
systems to optimize energy usage. Energy
awareness and conservation measures
were fully expected. Progress was being
made.
Huge structural components (after
machining and forming) required chemical
cleaning, acid etching, and rinsing prior
to military specification painting and dry-
ing. Those processes were significantly
energy-intensive. Analysis of those vari-
ous process energy systems had been
given a priority, and we were analyzing
the equipment with most potential.
Energy project opportunity identified
The ventilation systems for those spe-
cific chemical cleaning processes included
numerous 100 hp supply and exhaust fans
to maintain process conditions and control
fumes abatement. Energy costs were being
delineated, especially the heating load to
maintain ambient plant conditions dur-
ing winter months. Those fans had been
designed to operate continuously, with
manual control only.
Most of those processes generally oper-
ated on a two-shift/six-day schedule. The
fans ran from 6 a.m. on Mondays to mid-
night on Saturdays.
We decided to implement time-of-day
energy-saving control measures on eight
of those 100 hp fans (four supply and four
exhaust) during the third shift. Electrical
power savings were significant ($350 per
day). I was quite pleased with the idea and
our programming capability, which could
be controlled from my office remote ter-
minal or from the IBM mainframe in the
maintenance electrical shop. Over $9,000
per month of cost savings was immedi-
ately apparent on the No. 2 electric meter
supplying that area of the plant.
Prior review of our plan with process
engineering and the safety department
had been conducted, and subsequent air
quality testing confirmed that indoor air
quality was not being adversely affected.
The ventilation system appeared to have
been very conservatively designed.
In addition to the direct power
savings, we had estimated build-
ing heating and cooling energy sav-
ings of approximately $4,000 per
month during the 8-month heating
and cooling seasons.
The next quarterly energy review
meeting with the site leader and the
DoD officials received compli-
ments and praise.
Subsequent issue addressed
About three months later, I was
in my office on a Monday morn-
ing working on another project.
In walked the mechanical main-
tenance supervisor and an HVAC
technician. They dropped a large set
of worn V-belts in the middle of the office
floor. There were six D-size belts, each
about 10 ft long. The supervisor then asked
me how much money we were saving by
turning the chemical process ventilation
fans off and on every day.
I quickly indicated about $9,000 per
month. The guys were a little surprised
at this amount, but the supervisor then pro-
ceeded to explain that belt failures, ventila-
tion system complaints, and maintenance
labor had gotten out of control over the
past few weeks. He further explained that
a new set of matched belts cost about $900
plus 10 man-hours of mechanical time to
replace the worn belts and perform a nec-
essary realignment.
We had neglected to consider that the
1,800 rpm induction motors on these large
fans caused significant motor sheave
Recuce energy costs with
time-of-day energy load shed
By Gary Wamsley, PE, CEM, JoGar Energy & Utility Services Inc.
slip and belt wear during every start. The
maintenance team had changed four sets
of belts in the past month. That was work
that maintenance certainly did not need.
After offering some coffee and remov-
ing a little bit of egg from my face, I
agreed to set up a brainstorming session
with a couple of the plant engineering
and maintenance guys for later in the
week. The rather obvious solution was to
add soft-starters on the motors, which
took about 2 months to get approved and
installed (they cost about $1,800 for each
motor).
The new starters worked just fine.
Everyone was happy, and I had gained
some valuable experience. Moreover,
the motors were happier too, not being
instantly started daily under heavy load.
I also committed myself to conducting a
more thorough risk analysis on future
unique projects.
Summary
Variable speed drives (VSDs) are a fair-
ly standard option on many larger HVAC
and process ventilation fan systems. Since
there are now several excellent VSD sup-
pliers, the costs have become very rea-
sonable and VSD reliability is excellent.
If your facility has motor driven fans,
pumps, rotary air compressors, machine
drives, and so on (40 hp and larger) that
stop and start frequently, a drive motor
soft-starting feature can significantly
reduce your ongoing maintenance work
in addition to generating good energy
savings.
One caution: If your process condi-
tions are critical (i.e., precise pressure,
flow, and/or temperature control, etc.),
be sure to specify high-quality VSDs.
More economical VSD units can pro-
duce motor speed variability (regulation
control overshoot) during every process
setpoint change. I recall installing VSDs
on FD fan motors for three 75,000 PPH
oil-fired steam boilers back in the late
1990s.
Every time the steam load changed,
the boilers produced that gray haze out
the stack. We had to go back and install
a better quality VSD unit. Review this
issue thoroughly with the VSD
suppliers.
Wamsley is a mechanical engineer with
more than 40 years of plant operational
experience. He is president of JoGar
Energy & Utility Services, Inc. located
in Alpharetta, Ga. JoGar Energy Services
offers on-site energy reviews, boiler effi-
ciency testing services, technical assess-
ments of specific utility systems, and train-
ing seminars. Wamsley can be reached at
(678) 977-1508.

BEST PRACTI CES

In addition to the direct power
savings, we had estimated
building energy savings of
approximately $4,000 per
month during the 8-month
heating and cooling seasons.
SGR
BEARING PROTECTION RING
Save your
motors with
Your motors may be at risk!
Now, with the AEGIS
Shaft Voltage Test

Kit, you can measure voltages on the shafts
of your motors to quickly and easily see if
they are at risk of bearing damage.
The AEGIS
SGR protects motor bearings

from damaging shaft currents, extending
motor life and reducing downtime.
U
Channels harmful currents safely to ground
U
Maintenance-free, lasts for life of motor
U
Easy to install standard sizes
and universal mounting kit simplify
installation on any size or shape motor
1-866-738-1857 | sales @ est-aegis.com
www.est-aegis.com
VFD-Induced Bearing
Currents Kill Motors!
For a free in-plant motor shaft voltage test, fill out the
form on our website: www.est-aegis.com/freetest.htm
BESTPRACTICES.indd 24 10/7/2011 3:21:55 PM
1
1
H
S
T
3
7
5
6
Lowering operating costs is
what the Hyster Fortis
line
does best. Each Fortis lift truck
can be customized to ft your
application so you get the
powertrain, hydraulic controls
and cooling system you need.
And when you purchase a Fortis
lift truck, know that each one
comes with the Hyster legacy
of building tough lift trucks.
Lower costs. Better ROI.
Tougher trucks. Bring it.
YOU HAVE TO LOWER OPERATING COSTS.
THEN YOU HAVE TO LOWER THEM AGAIN.
WITHOUT SACRIFICING PRODUCTIVITY.
#1 IN TOUGH APPS WORLD-CLASS SERVICE FULL PRODUCT LINE INDUSTRIAL GRADE PARTS
PURPOSE-BUILT RETURN ON INVESTMENT PROVEN HERITAGE STRONG DEALER NETWORK
hyster.com
2011 Copyright Hyster Company. Hyster and are registered trademarks of Hyster Company.
PLE2011010_025.indd 25 10/7/2011 3:24:38 PM
COVERSTORY
S
afety is an absolute right and
absolute expectation of every
worker, and the vast majority of
workplaces ascribe to some struc-
tured safety program. Whether it
is part of a formal Lean safety
effort or a continuing emphasis on safety,
most manufacturers build safety into the
structure of their organization.
The reasons are both altruistic and econom-
ic: The safety of workers is protected by law,
but it also is a common-sense way to build
a loyal workforce. Workers who feel their
company cares about their personal safety
consider the company a good place to work.
The economic reality of an unsafe work-
place is well documented. A single safe-
ty-related event on a plant floor can be
expensive, and a serious injury can cut into
workmans compensation costs and drive
a once-profitable business to the brink of
disaster.
Still, at the end of the day, worker safety is
a personal issue. Yet a recent study indicates
that it may be the line workers who must take
that personal safety message more to heart.
PPE compliance
A study released this summer by Kimber-
ly-Clark Professional indicates that almost
9 in 10 safety professionals have observed
workers not wearing necessary personal
protective equipment when it was required.
Almost 3 in 10 observed this practice on a
continuing basis.
This high rate of noncompliance with
PPE protocols presents a serious threat to
worker health and safety, said Gina Tsi-
ropoulos, manufacturing segment marketing
manager for Kimberly-Clark Professional.
While the reasons for noncompliance are
varied, the threat to workers is clear-cut.
Without the proper use of PPE, they are at
risk of serious injury or even death.
OSHA regulations on the use of PPE are
clear, and the standards on PPE, lockout/
tagout, and arc flash safety are well docu-
mented and continually communicated.
Yet injuries and fatalities continue in the
workplace.
In 2010, OSHA reported more than 4,500
fatalities in the workplace. That number was
virtually unchanged from 2009, but it still
means 12 people per day die in workplace-
related injuries in the United States.
OSHA enforcement tends to punish
employers for unsafe working conditions.
Employers who fail to maintain a safe work-
place environment have faced some stag-
gering fines:
$917,000 in proposed fines for 50 safety
violations against a Boston-area manufac-
turer after an explosion injured four workers
in March 2011
$1.94 million in proposed fines against
an Alabama lumber mill for safety and health
violations in a plant that had previously been
cited 77 times by OSHA in the past 4 years.
The plant management had not instituted
A recent study found that many workers are
not wearing the necessary personal protective
equipment. Which leaves a question: Why?
By Bob Vavra
Content Manager
PPE is personal
before it is protective
Photo courtesy: Kimberly-Clark Professional
PLE1110_CVRSTRY_V10ms.indd 26 10/4/11 2:28 PM
lockout/tagout on machinery being cleaned.
OSHA also has cited dozens of manufac-
turers for various workplace safety violations
around the country that resulted in numerous
injuries and even fatalities. Fines for those
violations are still pending final investiga-
tion.
But the first line of defense against an
unsafe workplace is the worker, and the
Kimberly-Clark Professional study indi-
cates more work is needed to get workers
to understand and comply with existing PPE
rulesboth those covered by OSHA and
those covered by company policy.
Getting their attention
Complacency is the enemy, said Deanna
Thornton, Global Safety Director of Market-
ing, Kimberly-Clark Professional. Weve
seen that people are most attentive after
someone is injured. Workers get comfort-
able and pay less attention over time. When
this happens, they make choices that are
sometimes unsafelike not wearing PPE.
Keeping workers engaged long-term is a
challenge that safety managers battle every
day.
Thornton said the choice of PPE is a per-
sonal one but is affected by a number of
external factors. Safety programs are more
effective when the employees understand the
risks and choose to protect themselves, she
said. Although it is the responsibility of the
safety manager to educate workers as well
as enforce safety procedures, the ultimate
decision every day to make the safe choice
lies with the worker.
Other important factors in encourag-
ing PPE compliance are comfort, fit, and
style. Employees want PPE that fits well,
is comfortable and also stylish, she added.
Additionally, PPE with a wider range of
options to fit a variety of body types can also
drive higher levels of compliance.
Companies such as Kimberly-Clark have
tried to respond to the call for style and com-
fort in safety apparel. Some safety manufac-
turers have licensing deals with major sports
organizations that allow team logos or other
branded materials to appear on PPE equip-
ment such as gloves and hard hats. Other
licenses with major retail brands, such as
Harley-Davidson, can make the PPE about
form as well as function. And if all of that
drives compliance, employers consider it a
small cost to pay.
That issue also has caught the attention
of safety product
manufacturers. We
always start with
customer needs in
our devel opment
process. Addition-
al l y, we capt ur e
customer feedback
throughout devel-
opment and al so
test PPE products in
real work environ-
ments to get con-
structive feedback
on how product s
act ual l y perform
in the workplace,
Th o r n t o n s a i d .
For example, we
learned that weld-
ers want ed aut o-
darkening filters to
be intuitive and they
wanted to be able to
adjust the controls
with their gloves
on. Working with
welders across the
nation, we launched
J a c ks on Sa f e t y
Tr ue s i ght ADF,
an innovative new
product that deliv-
ers on this need.
One of the more
surprising aspects
of PPE compliance
r eveal ed i n t he
study is that its not
the bulky electrical
suits required by arc
flash rules or the
use of gloves in the
plant that is the greatest area of noncompli-
ance. Eye protection was cited as the single
most challenging area of noncompliance by
workers, despite the fact that almost 60% of
all eye injuries occurred when the worker
was not wearing proper eye protection.
Comfort is an important component
behind noncompliance with PPE rules,
according to the Kimberly-Clark Profes-
sional study. Workers cited both the physical
comfort of the product and that it made them
too hot as reasons for not using the PPE, the
A single safety-related event on the
floor can be expensive, and a serious
injury can cut into workmans compen-
sation costs, driving a once-profitable
business to the brink of disaster.
continued on page 32
Photo courtesy: Kimberly-Clark Professional
COVERSTORY
I
am very pleased to talk to you about
something we are very proud of at my
company: the strong culture we have built
around safety, health, and environmental
leadership, and why it all matters. I can
tell you from an employee engagement
and business standpoint, it has made a sig-
nificant difference in our company.
Eight years ago, we committed to dramat-
ic improvements in our safety performance.
We realized that even though we were below
industry averages in our safety measures, we
were having too many injuries. And if we did
not decrease our injury rates, we would prob-
ably soon have a death or serious injury. We
knew we could be better.
Eight years later, I am pleased to say that we
have one of the safest workforces in the world,
and we are driving a culture of safety at work
and at home, as well as driving more aware-
ness and action in healthy lifestyles for our
employees and their families. We have clearly
taken a relatively solid company and elevated
it to the next level. Keeping our employees
and their families safe and healthy at work and
at home has become definitive of our culture.
It is part of our DNA.
Why it matters
I am convinced safety, health, and environ-
mental leadership matters at our company and
would at yours as well.
Why? It really comes down to people. Like
many of your companies I am sure, safety is
at the heart of what we do as a business. We
work in an inherently dangerous business
energy management. Our people know that if
we cannot complete the job safely, we will not
do the job. They also know that we all play a
role in ensuring that our employees come to
work and leave work without injury.
We measure our safety performance by track-
ing cases that require medical attention beyond
first-aid, lost-time accidents, and lost-time
days. This has resulted in 75% improvements
in all of our measurements since 2003.
More importantly, compared to our starting
point eight years ago, this means an avoid-
ance of over 500 injuries per year. That is
500 people a year who are safer than when we
began, 500 people who go home safely to their
families every night. It goes beyond proving
care. It is a responsibility, an obligation, and
something that we take very seriously.
There is no question that a companys safety,
health, and environmental performance are
also a cornerstone for business success. We
see our strong focus in these areas as one of
the key drivers of employee engagement. It is
also bringing substantial business benefits in
terms of reduced costs and improved quality,
production, and productivity. Our performance
has generated more than $10 million a year
in direct savings, which we call our safety
dividend. We reinvest it in ongoing improve-
ment programs and healthy lifestyles initia-
By Chris Curtis
Schneider Electric North America
When Schneider Electric received the National Safety Councils
Green Cross for Safety Medal this year, it became the first
company to receive the councils two most prestigious awards
Schneider Electric also earned the Robert W. Campbell Award
in 2009. What kind of safety program delivers this kind of safety
recognition? One that isnt a program at all; safety is a part of
Schneider Electrics culture today.
A safety culture
that is rewarded,
enforced, honored
National Safety Council President and CEO Janet
Froetscher presented the Green Cross for Safety
Medal to Schneider Electrics Chris Curtis, Presi-
dent and CEO, North America, and Jeff Drees,
U.S. Country President. Photo courtesy: Schnei-
der Electric
Here today. Here tomorrow.
The RittalXpress stocking program ensures next day shipping for more than 2,200 of our most popular
Industrial and IT enclosures, accessories and climate control products. Visit www.rittal-corp.com/rittalxpress for
a complete selection of in-stock products.
www.rittal-thesystem.com
PLE2011010_029.indd 29 10/7/2011 3:26:45 PM
COVERSTORY
tives like free health assessments, personal
fitness subsidies, on-site fitness centers, and
other programs that encourage people to be
safe, healthy, and community-minded.
Lessons learned
There is a lot of work behind our safety
results and maintaining and improving this
level. It doesnt just happen. Here are some
of our keys to success:
1. Ensure leadership commitment.
A safety culture starts with leadership com-
mitment. You have to have strong sponsorship
and commitment at the top of the organization.
Everyone from our top management on down
in our organization is accountable and aware
of our safety programs, our results, and what
is going on. If we have an injury or event, it
is a system failureeveryone is notified and
held accountable.
Our safety performance is also part of
how we manage our talent, and measure and
reward performance. One question we ask our
managers: If someone working for you gets
hurt, do you feel you failed on the job? The
answer needs to be yes. We also have an
annual performance award for all employees
based on the company hitting certain key per-
formance measures20% of that annual per-
formance award is based on safety measures.
2. Focus on your most critical areas first.
When we started our program, we focused
on several key areas to reduce our hazards
in the workplace. These were hazards where
we had the highest risk of a serious accident.
The four most visible for us were:
Forbid any repair work on energized
live equipment;
Ensure all machine hazards are guarded;
Mandatory to wear personal protection
equipment; and
Absolute commitment that if the job can-
not be performed safely, it should not be per-
formed at all.
3. Increase safety training and audits.
When we started, we made safety training
mandatory for all employeesa very visible
way for us to show we were serious and com-
mitted. This continues today. All employees are
required to take certain courses depending on
their jobplant or office employee. We have
also expanded our program to include more off-
the-job training. An example of this is our Saf-
eStart program, which focuses on how things
like rushing, stress, and complacency lead to
increased risks of injury, no matter where you
are, at work, at home, or at play.
We also increased our number of safety
audits at our customer job sites in our Power
Service Organization, from 225 in 2003 to over
450 last year. The purpose of these audits is
not finger pointing, it is continuous improve-
ment, sharing best practices, and ensuring that
we are not only protecting our employees,
but also our customers. Our 26,000 people in
North America also do a fabulous job of let-
ting us know where things can be improved.
Conditions change, plants and offices change,
people change. It is an ongoing effort.
4. Drive awareness at all levels.
Creating a safety culture requires continual
communication and reinforcement at every
level. From all-employee meetings to daily
production supervisor meetings on the fac-
tory floor, every communication starts with
a message on safety.
All of our locations track days without an
accident. We take the time to celebrate locally
our key milestone days90 days, 6 months, 1
year, 2 years. For the bigger ones we always have
senior management involved in the celebration.
We also have been active in organizations,
like the National Safety Council, and receive
numerous awards for individual plants as well
as the excellent company recognition I men-
tioned earlier. Internal and external recogni-
tion of people and teams is key to ongoing
progress and improvements.
Advice to others
Just like other investments, safety, health,
and environmental performance must be mea-
sured, reported, evaluated, and continuously
improved. But to create a safety culture, you
must make it personal and visible. Set goals
and communicate regularly on your progress.
Recognize and reward success.
Most importantly, it comes down to people
and our obligation to them as leaders. We are
successful because safety is not just a pro-
gram for us, it is a way of life. Safety, health,
and the environment is not a priority that
can be traded off. It is an absolute each day.
It is a leadership imperative and a journey
that never endsto do all that is necessary
to ensure our people come to work and
leave work without injury.
Curtis is president and CEO of Schneider
Electric North America.
Keeping our employees
and their families safe
and health at work and
at home has become
definitive of our culture.
It is part of our DNA.
Using anything other than Sullair replacement parts is
like forcing a square peg into a round hole.
Sullair compressed air systems consist of highly
engineered components, carefully matched for
capacity and pressure and are designed for total
system integration to achieve maximum performance
and energy efficiency.
Maintaining the system
The dependability of a Sullair system relies on proper
maintenance and quality parts. In fact, all Sullair
service parts are designed for Sullair equipment and
are built to exacting standards.
Sullair components must be routinely inspected and
maintained to ensure that youll always get the
productivity your Sullair system was designed to
deliver at the lowest total life-cycle cost.
Lubricant technology leadership
Sullair pioneered the lubricated rotary screw
compressor and today leads in the development of
long-life and biodegradable lubricants that eliminate
environmental pollution, improve economics, and
maximize performance.
Sullairs name inside and out
When replacement parts are needed, use only those
from Sullair. Why? Because they are good enough to
earn the Sullair name. Remember, installing anything
other than a Sullair part in your compressed air
system is like forcing a square peg into a round
hole. Is it worth the risk?
TM
www.sullair.com
Sullair Corporation is a subsidiary of Hamilton Sundstrand Corporation. Hamilton Sundstrand is a subsidiary of United Technologies Corp. (NYSE: UTX)
PLE2011010_031.indd 31 10/7/2011 3:31:07 PM
Calculating the true cost of workplace injuries
T
he issue of workplace injuries and the use of PPE
are both personal, human issues. The cost of these
injuries can have an equally devastating effect on a
business, and an online calculator brings the total costs of
these injuries into clear view.
As part of its Safety Pays program, OSHA and The
National Council on Compensation Insurance, Inc. have
created an injury cost calculator that takes into account
both the direct and indirect costs of a workplace injury.
The NCCI has studied and analyzed data from around
the country and plugged its copyrighted data into the
OSHA calculator. While a disclaimer on the Safety Pays
website notes that the data is only a predictive tool and not
an actual calculator for specific cases, it does provide an
interesting way to get a general overview of the full cost of
a wide range of workplace injuries.
While the actual cost of an injury is often covered by
health insurance and workers; compensation insurance,
the Safety Pays website adds this note: Indirect costs are
usually uninsured and therefore, unrecoverable. An abbre-
viated listing of indirect cost drivers includes:
Any wages paid to injured workers for absences not
covered by workers compensation
The wage costs related to time lost though work stop-
page
Administrative time spent by supervisors following
accidents
Employee training and replacement costs
Lost productivity related to new employee learning
curves and accommodation of injured employees, and
Replacement costs of damaged material, machinery,
and property.
Visit the Safety Pays program at http://1.usa.gov
/fP2g0Q.
study found. Yet 69% of
the study respondents
said the reason behind
noncompl i ance wi t h
PPE was that they didnt
think the PPE was neces-
sary for the task.
When safety manag-
ers were asked how they
intended to improve PPE
compliance, 61% said
t hey woul d i mprove
training and education,
and 48% would do more
monitoring of employee
compliance.
Manufacturing a
safety culture
As a manufacturer of
safety products, Kimber-
ly-Clark must also walk
the walk on the subject
of safety. We have a
multifaceted approach
that includes a culture
of safety, comprehen-
sive training, and engi-
neering processes and
controls at our manu-
facturing sites, said
Thornton. We allow
employees to be engaged in the PPE selection
process, and we offer a wide range of options.
The company also recognizes that employ-
ee safety is a 24/7 process. A workplace
injury can have an economic impact on a
family, but an injury to an employee at home
can have an equally devastating result. And
whether an employee is injured on the job
or at home, the manufacturer still loses a
worker. Thats why many companies have
extended workplace safety training to the
home environment.
We have a corporate-wide campaign
called Whos Counting on You? It reminds
employees that while working or at an activ-
ity outside of work, its essential to return
home safely for the people who depend on
them, said Thornton. We also encourage
our employees to wear PPE when mowing the
lawn or performing other household chores.
We are always looking for ways to improve
our safety culture, and it starts with employee
engagement.
The best programs and the best equipment
will not put protective glasses, gloves, and
hearing protection on a worker. The Kim-
berly-Clark Professional study proves a
fundamental issue about PPE: Before it is
protective, it is personal.
We change the conversation so that
empl oyees make t he choi ce t o pro-
tect themselves, Thornton said. We
move away from enforcement t o
personal accountability.
The safety of workers is protected by law, but it is
also a common-sense way to build a loyal workforce.
Workers who feel their company cares about their
personal safety consider the company a good place
to work.
COVERSTORY
continued from page 27
P
h
o
t
o

c
o
u
r
t
e
s
y
:

K
i
m
b
e
r
l
y
-
C
l
a
r
k

P
r
o
f
e
s
s
i
o
n
a
l
Eaton.com/Top10
2.
3.
1.
Clean,
uninterrupted
power
Safety first
Accurate
power control
At Eaton, we are working
hard to keep it that way.
With unparalleled knowledge of electrical
power management across industries,
every day the experts at Eaton deliver
customized, integrated solutions to solve
your most critical challenges.
Delivering innovation to
improve electrical safety
where you live, work and play.
Providing the highest quality
backup power protection.
Advancing energy efficiency,
reducing costs and improving
system reliability.
To help prevent the 90,000 residential
electrical fires that occur in North
America each year, Eaton pioneered
affordable circuit interrupter technology
and helped incorporate it into electrical
codes. In a plant, an arc flash event
can generate temperatures that are
four times that of the sun. In 2007,
Eaton introduced the FlashGard
Motor Control Centeran industry

firstwith features engineered to help
prevent injuries from electric shock,
arc flash burns and arc blasts.
Eaton leads the way with over 40
arc flash prevention solutions and
engineering services teams that provide
training and arc flash hazard analysis.
To deliver the highest quality backup
power protection for your home
computer, network, server and
data center, Eaton is applying the
knowledge that developed the first
AC power inverter and commercial
UPS combining battery charges and
inverters.
To keep clean, uninterrupted power
flowing, Eaton delivers the industrys
most efficient UPSthe Eaton 9395
boasts a 99% efficiency rating and
the highest reliability on the market.
It is the first power-quality product to
receive SMaRT
Gold certification.
Eaton is building on the expertise that
enabled development of the first
automatic motor starter and three-
phase, oil-insulated contactor to deliver
motor control that lowers total cost of
ownership and enables processes to
run more efficiently.
Bringing the first automatic motor
starter to market made Eaton the
natural choice to provide the control
equipment used to build the Panama
Canal a century ago. Today, Eaton
is providing the sophisticated
equipment and expertise for major
Panama Canal upgrades.
A day without power is practically unthinkable.
For 100 years, Eaton has pioneered
industry-leading technologies to
become a clear leader in electrical
power managementintegrating the
competencies and equities of some
of the worlds most respected names.
The result is a brand you can trust to
meet every power management need.
Every day, Eaton recommits itself to
ensuring that reliable, efficient and safe
power is available when its needed most.
EATON CORPORATION 100 Years of Electrical Innovation
2.
3.
1.
Clean,
uninterrupted
power
Safety first
Accurate
power control
At Eaton, we are working
hard to keep it that way.
With unparalleled knowledge of electrical
power management across industries,
every day the experts at Eaton deliver
customized, integrated solutions to solve
your most critical challenges.
Delivering innovation to
improve electrical safety
where you live, work and play.
Providing the highest quality
backup power protection.
Advancing energy efficiency,
reducing costs and improving
system reliability.
To help prevent the 90,000 residential
electrical fires that occur in North
America each year, Eaton pioneered
affordable circuit interrupter technology
and helped incorporate it into electrical
codes. In a plant, an arc flash event
can generate temperatures that are
four times that of the sun. In 2007,
Eaton introduced the FlashGard
Motor Control Centeran industry

firstwith features engineered to help
prevent injuries from electric shock,
arc flash burns and arc blasts.
Eaton leads the way with over 40
arc flash prevention solutions and
engineering services teams that provide
training and arc flash hazard analysis.
To deliver the highest quality backup
power protection for your home
computer, network, server and
data center, Eaton is applying the
knowledge that developed the first
AC power inverter and commercial
UPS combining battery charges and
inverters.
To keep clean, uninterrupted power
flowing, Eaton delivers the industrys
most efficient UPSthe Eaton 9395
boasts a 99% efficiency rating and
the highest reliability on the market.
It is the first power-quality product to
receive SMaRT
Gold certification.
Eaton is building on the expertise that
enabled development of the first
automatic motor starter and three-
phase, oil-insulated contactor to deliver
motor control that lowers total cost of
ownership and enables processes to
run more efficiently.
Bringing the first automatic motor
starter to market made Eaton the
natural choice to provide the control
equipment used to build the Panama
Canal a century ago. Today, Eaton
is providing the sophisticated
equipment and expertise for major
Panama Canal upgrades.
A day without power is practically unthinkable.
For 100 years, Eaton has pioneered
industry-leading technologies to
become a clear leader in electrical
power managementintegrating the
competencies and equities of some
of the worlds most respected names.
The result is a brand you can trust to
meet every power management need.
Every day, Eaton recommits itself to
ensuring that reliable, efficient and safe
power is available when its needed most.
7.
6.
4.
Powering
electric
vehicles
Sustainable
by design
Protection
you can
count on
Pioneering circuit protection
for global applications.
Reducing energy
consumption to use
resources more effectively.
Fueling energy efficiency for a
cleaner, healthier environment.
Eaton is applying the expertise used
to develop the first molded case circuit
breaker in 1923 to protect the circuits
that maintain the electrical safety
of our homes, offices buildings and
complex industrial and commercial
processes.
For instance, the Series NRX
low voltage power circuit breaker

delivers the performance of a power
circuit breaker in the compact size
of a molded case breaker. Depend
on Eaton circuit breakers to deliver
protection you can count on.
In 1920, most people thought green
was just a color. Even then, Eaton
saw opportunities for efficiency. The
result? A $1 million plant in Cleveland
designed to conserve heat and
maximize natural light.
Today, sustainability is integral to
Eatons culture and guides every
action takena commitment that
extends far beyond its own facilities.
The Department of Energy recognized
Eaton for meeting the highest
standards in managing energy-saving
performance projects. Today, Eaton is
a certified energy services company
(ESCO).
5.
Groundbreaking
vacuum
technology
Reliably switching high
stress currents in industrial
and utility applications.
Eaton is leveraging the engineering
expertise that pioneered the use
of vacuum tubes to control heavy
currents nearly 80 years ago by
continuing to offer vacuum interrupters
and circuit breakers with long
mechanical and maintenance-free lives.
Chances are, if you are using vacuum
interrupting technology, you may
already be relying on industry-leading
Eaton solutions.
Back in 1976, Eaton started studying
the viability of alternative power
sources and became involved in the
development of power systems for
electric cars.
Today, Eaton is the only company to
offer hybrid-electric and two hybrid
hydraulic system technologies for
commercial vehicles, as well as an
electric vehicle charging infrastructure
for commercial and residential use.
In Canada, Eaton is partnering with
utilities to bring electric vehicle
technology to the forefront. And, Eaton
is already supplying and supporting
vehicle charging stations across the
United States.
7.
6.
4.
Powering
electric
vehicles
Sustainable
by design
Protection
you can
count on
Pioneering circuit protection
for global applications.
Reducing energy
consumption to use
resources more effectively.
Fueling energy efficiency for a
cleaner, healthier environment.
Eaton is applying the expertise used
to develop the first molded case circuit
breaker in 1923 to protect the circuits
that maintain the electrical safety
of our homes, offices buildings and
complex industrial and commercial
processes.
For instance, the Series NRX
low voltage power circuit breaker

delivers the performance of a power
circuit breaker in the compact size
of a molded case breaker. Depend
on Eaton circuit breakers to deliver
protection you can count on.
In 1920, most people thought green
was just a color. Even then, Eaton
saw opportunities for efficiency. The
result? A $1 million plant in Cleveland
designed to conserve heat and
maximize natural light.
Today, sustainability is integral to
Eatons culture and guides every
action takena commitment that
extends far beyond its own facilities.
The Department of Energy recognized
Eaton for meeting the highest
standards in managing energy-saving
performance projects. Today, Eaton is
a certified energy services company
(ESCO).
5.
Groundbreaking
vacuum
technology
Reliably switching high
stress currents in industrial
and utility applications.
Eaton is leveraging the engineering
expertise that pioneered the use
of vacuum tubes to control heavy
currents nearly 80 years ago by
continuing to offer vacuum interrupters
and circuit breakers with long
mechanical and maintenance-free lives.
Chances are, if you are using vacuum
interrupting technology, you may
already be relying on industry-leading
Eaton solutions.
Back in 1976, Eaton started studying
the viability of alternative power
sources and became involved in the
development of power systems for
electric cars.
Today, Eaton is the only company to
offer hybrid-electric and two hybrid
hydraulic system technologies for
commercial vehicles, as well as an
electric vehicle charging infrastructure
for commercial and residential use.
In Canada, Eaton is partnering with
utilities to bring electric vehicle
technology to the forefront. And, Eaton
is already supplying and supporting
vehicle charging stations across the
United States.
10.
8.
Optimizing
data centers
Lean
connectivity
Renewable
energy
Transforming the way
OEMs build machinery.
Improving the operation
and energy efficiency
of data centers.
Powering a
brighter tomorrow.
With a powerful operator interface
platform and the game-changing
SmartWire-DT
solutionthe
first networking control system to
connect power componentsEaton
is delivering the next generation
of connectivity to enable remote
intelligence, simplify wiring and
reduce commissioning and testing.
Taking things even further, Eaton is
also integrating electrical and hydraulic
systems to deliver a total solution to
provide more accurate speed control
and more reliable performance for full
control of machine axis movement.
Data centers manage the information
that keeps business running. Eaton is
applying the expertise that developed
a patented heat containment system
to optimize airflow and improve the
overall operation and energy efficiency
of data centers.
Over the last decade, there has been
an initiative to increase data center
capacity, which often taxes equipment
cooling systems. Eatons robust
enclosure and airflow management
portfolio, industry-leading UPS
and power distribution solutions
meet the challenges of data center
energy efficiency.
Our collective energy appetite is rapidly
increasing as nations modernize and
economies evolve. Electrical energy
consumption is projected to double by
2030. Eatons core competencies in
electrical power distribution and control
equipment are bringing wind, solar and
smart grid solutions to life today.
Soon, Eaton will deliver a turnkey
3.2 megawatt solar power system
the largest in the statefor the
New Mexico VA Health Care System.
Eaton was chosen for its electrical
power management expertise, a
robust service organization and solar
power system design and installation
competencies.
Imagine the potential of the next 100 years.
Visit Eaton.com/Top10
Commercial l Industrial l Residential l Utility l Alternative Energy l IT and Data Centers l OEM l Public Sector l Institutional
9.
10.
8.
Optimizing
data centers
Lean
connectivity
Renewable
energy
Transforming the way
OEMs build machinery.
Improving the operation
and energy efficiency
of data centers.
Powering a
brighter tomorrow.
With a powerful operator interface
platform and the game-changing
SmartWire-DT
solutionthe
first networking control system to
connect power componentsEaton
is delivering the next generation
of connectivity to enable remote
intelligence, simplify wiring and
reduce commissioning and testing.
Taking things even further, Eaton is
also integrating electrical and hydraulic
systems to deliver a total solution to
provide more accurate speed control
and more reliable performance for full
control of machine axis movement.
Data centers manage the information
that keeps business running. Eaton is
applying the expertise that developed
a patented heat containment system
to optimize airflow and improve the
overall operation and energy efficiency
of data centers.
Over the last decade, there has been
an initiative to increase data center
capacity, which often taxes equipment
cooling systems. Eatons robust
enclosure and airflow management
portfolio, industry-leading UPS
and power distribution solutions
meet the challenges of data center
energy efficiency.
Our collective energy appetite is rapidly
increasing as nations modernize and
economies evolve. Electrical energy
consumption is projected to double by
2030. Eatons core competencies in
electrical power distribution and control
equipment are bringing wind, solar and
smart grid solutions to life today.
Soon, Eaton will deliver a turnkey
3.2 megawatt solar power system
the largest in the statefor the
New Mexico VA Health Care System.
Eaton was chosen for its electrical
power management expertise, a
robust service organization and solar
power system design and installation
competencies.
Imagine the potential of the next 100 years.
Visit Eaton.com/Top10
Commercial l Industrial l Residential l Utility l Alternative Energy l IT and Data Centers l OEM l Public Sector l Institutional
9.
Eaton Corporation
Electrical Sector
1111 Superior Ave.
Cleveland, OH 44114
United States
877-ETN-CARE (877-386-2273)
Eaton.com
2011 Eaton Corporation
All Rights Reserved
Printed in USA
Canadian Operations
5050 Mainway
Burlington, ON L7L 5Z1
Canada
1-800-268-3578
EatonCanada.ca
Trademarks are the
property of their
respective owners
Eaton.com/Top10
I
n the past 3 years, I
have noticed a substan-
tial increase (more than
700%) in the number of
calls and e-mails I have
received from colleagues
and friends who are
involved in various manu-
facturing operations.
The reason for the
increase appeared
simple: a request for
help related to safety
issues or compliance with
OSHA regulations in their
segments. I continue to
experience resistance
when explaining the basic
fundamentals of safety
to operation managers,
most of whom appear to
be committed only to throughput.
It is easily discernable that the majority of those who
exhibit this lack of knowledge do not understand the
long-term benefits of a serious and committed plant,
equipment, and resource safety system. I deliberately
do not use the words safety program here as the word
program is best used to describe something that has a
beginning and an end.
Safety system is an apt description for a never-
ending operational process.
So why all the recent fuss? In May 2011 of this year,
OSHA announced a new initiative that will target the
various metals industries, most of which are located in
the Great Lakes Basin. This includes Wisconsin, Illinois,
Michigan, Pennsylvania, New York, Indiana, and Ohio.
The astonishing thing about the calls and e-mails I
have received is the mind-set of the friends and col-
leagues I have communicated with concerning compli-
ance. Of the 317 emails and 281 phone calls I have
received in the past three years, only six colleagues
have expressed concern with upgrading their safety sys-
tems to improve operating safety standards, as opposed
to the majority asking, How can we become at least
minimally compliant?
In almost every case where safety systems have
been correctly installed,
an improvement in
throughput has been
realized. So why is there
so much resistance to
properly installing safety
systems?
Because the overall
perception from manage-
ment and employees alike
is that its a hassle and it
means they must learn
a new and/or improved
method of producing
goods.
The immediate reac-
tion is, Sheesh, well this
will waste an incredible
amount of time, resources,
and finances.
So lets examine the
true actual cost of not having a properly maintained
safety system in place.
Consider whether any of the following are applicable
and if any show an increase or decrease within your
operations.
LTIs (lost time incidents)
RIs (recordable incidents)
Medical insurance claims
Workers compensation claims
Increase in employee absenteeism.
If you are experiencing any one of the above listed
items, I will wager you have issues with all of the other
items. And if you want the full scope of the effect these
have on your operations and bottom line, get together
with your human resources, medical, engineering, and
operations staff and start comparing notes and costs.
Once you start the process of actually mining the
data, it is easy to demonstrate the true cost associated
with not having a well-rounded safety system in place.
Once you have assimilated all of the costs and add
these costs into the costing/profit margins of your opera-
tions, I can assure you that you will have the undivided
attention of those who actually count the beans.
Dyer is Engineering Manager at NorthCoast Engi-
neering Services Group LLC. dyerjerry@gmail.com
Gather the data to look at the true
value of a safety system
By Jerry Dyer, NorthCoast Engineering Services Group LLC
A single pump failure can disrupt your plant for
days bringing production to a halt and impacting
your bottom line.
Replacing your silicon-carbide components with CeraComp dramatically
reduces your risk of pump failures! This new ceramic-matrix composite
offers the chemical and thermal resistance you require with the increased
toughness and fracture resistance youve been looking for. CeraComps
superior material properties deliver increased reliability and MTBR (mean
time between repair), eliminating catastrophic failure and keeping your
plant running efficiently.
Contact Greene, Tweed today to learn more about this exciting new material!
Greene, Tweed & Co.
|
PetroChem & Power
|
Tel: +1.281.765.4500
|
www.gtweed.com
06/11-GT AD-US-PP-008
45678
CeraComp Components
Wouldnt it be great
if everything was
FRACTURE RESISTANT?
PLE2011010_034.indd 34 10/7/2011 3:32:57 PM
ELECTRICALSOLUTIONS
P
ower system engineers are faced with
a wide array of protective devices
from which to choose. Circuit break-
ers or fuses? Current-limiting or not?
Would ground-fault protection be an appro-
priate choice even if not required by code?
Regardless of the situation, every decision
affects some aspect of system performance.
What is a designer of a low-voltage distribu-
tion system to do? Modern protective devices
do a decent job of protecting a branch circuit.
Differences relate to less frequently occurring
corner cases. Examples might include:
1. Breaker manufacturers questioning the
quality of circuit protection if the incorrect fuse
is installed. How often is this really going to
occur? I think we can all assume that supply
chain buys the correct replacement and that the
service professionals installing the replacement
fuses know and use the correct type and size.
2. Fuse manufacturers claiming better arc
flash performance than circuit breakers on
bolted fault. An arc flash does, after all, require
an arc. If a circuit has no arcing connections
(as a system with bolted fault current would
not have), then measuring arc flash incident
energy at that current has little meaning. The
equation used in IEEE-1584 describes testing
where the arcing fault currents were as little
as 10% of the available bolted fault current. In
low-voltage systems, real fault currents are a
fraction of bolted values.
Focus your efforts
So if these are the corner cases, where should
power system engineers focus their efforts?
According to IEEE 493-2007 (Gold Book)
Table 10-32, well over 90% of electrical faults
are arcing faults that involve ground. This tells
us at least two things:
Arcs include impedance. IEEE-1584
testing calculated that arcing impedance was
related to many factors, but for low-voltage
systems, arcing current was typically in the
range of 80% down to as low as 10% of bolted
fault current.
By David Loucks, PE
Eaton Corp.
Make the
right choice on
protective devices
Choosing the correct protective device for a low-voltage distribution
system requires system performance analysis.
Figure 1 (above): A remote
racking system uses the
rotation of a shaft for the
insertion and removal of the
breaker. Personnel can be
25 feet or more away from
the switchgear door during
the racking process. Photo
courtesy: Eaton Corp.
PLE1110_ELECSOL_V4ms.indd 35 10/4/11 2:29 PM
A ground detection system might provide
improved fault clearing performance.
These two factors strongly suggest that
applying ground-fault protection to circuit
protective devices would provide improved
selectivity. This is because ground-fault
current pickup settings can be more sensitive
than phase settingsso sensitive that a fault
current below full load current could be cleared
instantaneously.
By themselves, fuses cannot provide ground-
fault protection except for relatively high-
level ground faults. To provide ground-fault
discrimination in a fused system, a system
must be installed that detects ground faults
and sends a trip signal to the disconnecting
element.
The IEEE Gold Book states that you are 2.5
to 70 times more likely to have a ground fault
in a system than a phase-to-phase fault. Thus,
the protection against ground faults is a priority,
yet it is impossible to predict the actual fault
current of a ground fault because you cannot
predict its path with absolute certainty. You
have to prepare for the maximum load, although
it is very rare that you would be faced with a
100,000-amp fault.
Furthermore, because you are up to 70 times
more likely to have ground faults, the cur-
rent will most often be less than 10,000 amp,
maybe much less. If you follow this toward
an assumption that a system must operate
quickly at 10,000 amp and less, fuses simply
have a more difficult time clearing those faults
quickly.
Since the fuse curve is very steep, when the
fault current increases, energy let through is
decreased. The problem is that the process
works in reverse. If you decrease the fault
current, the increase of energy let through
increases dramatically.
While perhaps not intuitive, a fault of less
than 10% of your maximum current level can
cause higher arc flash incident energy than a
fault at full bolted fault levels. This is because
as current decreases, time increases, as does arc
flash danger. Circuit breakers operate some-
what differently in that once current exceeds an
instantaneous value, the clearing time does
not vary much.
Therefore, as current drops below bolted
fault levels, the time remains constant. With
decreasing current and constant time, the inci-
dent energy is decreasing. Fuses dont have
a zone where they switch from time delay to
instantaneous, so for fuses the incident energy
increases as the current decreases.
Ground-fault protection
Zone selective interlocking is recommended.
While conventional selective coordination tech-
niques can insure that the protective device
closest to the fault clears first, those techniques
work by adding intentional delay to the clearing
time of the upstream device.
This goes counter to our goal of using ground
fault to clear the fault as rapidly as possible.
One solution is to interconnect up- and down-
stream protective devices in a zone selective
interlocking scheme. Should a ground occur
within a zone bounded by two ZSI-equipped
protective devices, the upstream device will
clear without any intentional delay.
Make sure the protective device is rated to
interrupt the fault current or include an auto-
matic override. If a ground is detected, the relay
must be inhibited from opening the disconnect
if the fault current exceeds the load-interrupting
rating of the switch.
Pay particular attention to GF relays that
inhibit operation at high currents. These relays,
called Class II GF relays, are typically supplied
with motor control. Since motor starters have
very low interrupting ratings, the inhibit levels
will be very low.
Currents exceeding these low levels will
be inhibited from opening the switch, and
the fuse will be required to clear that fault. In
many cases the fuse clearing time of a Class
II GF relay application can easily exceed 10
sec clearing time.
To work around that problem, some GF
relays will simply add a time delay. The pur-
pose of the time delay is to allow sufficient
time for the fuse to clear the high current fault
before opening the switch. The problem is that
technical papers have shown that during the
0.1 sec window where tripping is inhibited, a
single-phase arcing ground fault has enough
time to propagate into a 3-phase fault. At that
point the phase currents are more closely bal-
anced and the GF relay may no longer issue
a trip signal.
So be careful when calculating arc flash inci-
dent energy on low-voltage systems. Many of
the standards are focused on measuring incident
energy from 3-phase bolted fault current levels
when, according to IEEE, most faults are sin-
gle-phase arcing ground faults where fuses in
particular have problems. However, at the very
highest current levels, fuses reduce peak
current better than most circuit breakers.
Loucks is PCM Solution Manager for Eaton
Corp. and a Senior Member of IEEE.
INSIGHT
ELECTRICALSOLUTIONS
Digital I/O media
module
Digital I/O media modules
that send signals are now
available. The modules have
an auxiliary output that pro-
vides 24 Vdc with 3 W power
to control connected compo-
nents without an additional
power source. Other features
include IP20 protection class,
high shock, vibration resis-
tance, and immunity to elec-
trostatic discharges and mag-
netic fields. The digital inputs
comply with the EN 61131-
2:2007/type 3 standard.
www.Belden.com
Belden Inc.
Input #200 at plantengineering.hotims.com
Three-phase MF motor
The L-Force three-phase
MF motor with a frequency
inverter is now available. It
is available in power ranges
from 0.55 to 22 kW and has
efficiency levels from 94% to
98%. The modular system
allows for optimum design
flexibility. Combining the
motor with an 8400 series
inverter will increase the
motors efficiency during par-
tial load and reduce energy
use by up to 30%.
www.LenzeAmericas.com
Lenze Americas
PLE1110_ELECSOL_V4ms.indd 36 10/4/11 2:29 PM
Operational Excellence with OpenPlant
2011 Bentley Systems, Incorporated. Bentley, and the B Bentley logo are either registered or unregistered trademarks or service
marks of Bentley Systems, Incorporated or one of its direct or indirect wholly-owned subsidiaries. Other brands and product names are
trademarks of their respective owners.
Youre invited to join us on the 2011 OpenPlant Tour - an exclusive multi city event
to learn how OpenPlant:
s Improves partnerships between owner-operators and EPCs with change
managed distributed data
s Provides robust, multidisciplinary application integration throughout the
project lifecycle
s Leverages AutoPLANT and PDS into a modern open and distributed informa-
tion model using the ISO 15926 standard
Dont miss this opportunity to experience the latest enhancements, watch live
demonstrations and see how to leverage OpenPlant to improve your projects ROI.
October 13, 2011 New Orleans, Louisiana
October 18, 2011 Houston, Texas
October 25, 2011 Edmonton, Alberta
Register for Bentleys 2011 OpenPlant Road Show at
www.bentley.com/openplantroadshow-PE
Open Minds think
PLE2011010_037.indd 37 10/7/2011 3:36:07 PM
To learn more
about protecting
your facility from
Arc-Flash damage call
800-832-3873 or visit
www.littelfuse.com/afv
The Littelfuse PGR-8800 Arc-Flash Relay protects your personnel, equipment,
and reputation by rapidly detecting developing Arc-Flash incidents and tripping
the circuit before signicant damage occurs. The PGR-8800 can detect an Arc-Flash
in less than 1 ms, making it one of the fastest Arc-Flash relays on the market. It
detects both current and light to minimize nuisance trips and provide overcurrent
protection. With 24 photoelectric or ber-optic sensors, the PGR-8800 offers
complete coverage for your applicationno matter how challenging the space.
The PGR-8800 Arc-Flash Relay
Minimizes Equipment Damage with
Rapid Arc-Flash Detection
Scan with your mobile
device to view a short video
PLE2011010_038.indd 38 10/7/2011 3:37:55 PM
MECHANICALSOLUTIONS
T
odays orbital welding systems employ
a variety of automated features, such
as data collection, programming, and
live weld progress, which help welders
complete more accurate, high-quality welds,
and increase their likelihood of passing in-
process inspections.
Even more importantly, automation also
provides efficiencies for welders and inspec-
tors when conducting those inspections.
Automated documentation
Todays orbital welding power supplies
automatically record the majority of required
welding data for projects, removing the burden
of manual documentation from welders. The
systems capture this data electronically for
simple, error-free transfer to quality control
administrators and third-party inspectors.
Automated electronic data collection ensures
that searchable quality assurance data is avail-
able to welders and inspectors so each party
can conduct in-process inspections in an effi-
cient manner.
Welders are typically required to main-
tain comprehensive data about each weld in
a projecta cumbersome process that can
easily account for 30% of a projects total
construction labor hours when performed man-
ually. The data includes multiple parameters
associated with each weld as required by the
project and code specifications, such as ASME
B31.3 for process piping and ASME Section
8 for pressure vessels. Data may include the
welders certifications, materials used, loca-
tion of the weld according to a weld map, and
numerous other details.
Automated data collection captures all of
this data with minimal operator input, allow-
ing welders to focus on their primary job,
which is to complete accurate, high-quality
welds. To ensure complete data collection,
some orbital welding power supplies high-
light required data fields and do not permit
Automated orbital welding systems
streamline in-process inspections
By John Glessman
Swagelok Co.
Passing in-process
inspections for
orbital welding
projects is critical,
as a failure can
lead to costly
rework, project
delays, and
system downtime.
Welding power supplies
with high-speed thermal
printers enable users to
print a hard copy refer-
ence of weld details for
documentation purposes.
Photo courtesy: Swagelok Co.
PLE1110_MECHSOL_V5ms.indd 39 10/4/11 2:30 PM
welding to start until operators fill in
all open fields. In addition, welders can
provide documentation data electroni-
cally to quality control administrators
for input into spreadsheets, which virtu-
ally eliminates the potential for human
error during data transfer. Proper data
transfer yields a higher probability of
passing in-process inspections.
Electronic documentation data made
available to third-party inspectors expe-
dites their in-process inspections. As
part of quality control procedures,
inspectors may review project
data, including weld logs
and documentation pack-
ages, to confirm that the
welding company provided
all of the required informa-
tion, the examinations were
performed appropriately, and
the project is free of errors.
In an electronic format, this
data is sortable and search-
able, providing inspectors
with valuable efficiency dur-
ing their reviews.
In-process inspections
Electronic documenta-
tion records also help
inspectors locate data
faster during in-process
inspections compared to
leafing through hard copy
weld logs. If an inspector spots
an error on a specific weld during a
visual examination or physical test, he
can quickly find information about that
weld, as well as any welds performed
during the same time period or under
similar parameters, in the database.
This efficiency is especially helpful
given the varying documentation and
in-process inspection requirements set
forth by industries, applications, and
owner companies.
For example, welding projects in bio-
pharmaceutical manufacturing plants
typically require visual examination
of every weld. Welders must visually
check the outside diameter (OD) of
welds and record this information
sometimes along with a video or image
file. An inspector will use a borescope
to examine the inside diameter (ID) of
a specified percentage of welds in a
system. With welds chosen randomly
for examination, inspectors can quickly
search electronic records to locate spe-
cific welds and their corresponding data.
Inspectors can also perform nonde-
structive tests on welds, including one
or more of the following:
1. Dye Penetrant Test (PT): A dye
penetrant is applied to the OD of the
weld bead, excess penetrant is removed,
and a developer is applied. Any
remai n-
ing dye penetrant is a visual indica-
tion of a surface flaw such as porosity
or a crack.
2. Radiographic Testing (RT): X-rays
or gamma rays produce images on a film
used to detect internal discontinuities of
the weld. After the radiograph is taken,
an inspector examines the film for signs
of lack of fusion, voids, or cracks by
looking for light or dark areas, or irregu-
lar shapes and variation.
3. Ultrasonic Testing (UT): A probe
transmits an ultrasonic signal into the
weld surface, and the resulting reflection
of that signal is displayed on a monitor.
Operators watch the monitor to look for
any imperfections within the weld, such
as porosity, voids, or cracks.
Specifications often dictate what is or
is not acceptable. If a weld fails a test,
the inspector may search the electronic
database to find all welds performed dur-
ing the same period and review their
parameters. Next, he may perform
additional testing on those welds and
potentially recommend rebuilding that
portion of a system.
In some cases, welding jobs
require intermediate in-
process inspections at spe-
cific project milestones. In
these cases, data automati-
cally stored on the weld-
ing power supply may
streamline the inspection
and enable the welder to get
back to welding sooner. For
example, a particular code
case for a nuclear project
requires inspectors to exam-
ine the welding process every
four hours.
Welders may be working
on a section of tubing and liter-
ally have to stop when the 4-hour
window expires. An inspec-
tor will then verify that the
welds meet the inspection
criteria and code requirements
before the welder can resume
working. Power supply data and alarm
settings can assist with the isolation and
troubleshooting of any weld in question.
In some industries and applications,
in-process inspections may not focus
on every weld. Instead, inspectors may
check documentation data to confirm
the consistent operation of the orbital
welding power supply. Before complet-
ing actual project welds, welders will
coupon in by performing a destructive
test with a sample tubing section and
examining it against specifications. This
test becomes part of the searchable elec-
tronic weld log and serves as a baseline
for subsequent welds.
These welds may also undergo tensile
or bend testing as part of the qualifi-
cation process. If the test weld meets
quality standards, the welder can use the
established weld schedule and process
to continue welding the same materials
MECHANICALSOLUTIONS
Orbital welding power supplies employ
a variety of automated features to
help improve the quality of welds and
the likelihood that welds will pass in-
process inspections. Photo courtesy:
Swagelok Co.
1.800.433.5700
Allied Electronics, Inc 2011. Allied Electronics and the Allied Electronics logo are trademarks of Allied Electronics, Inc. An Electrocomponents Company.
THINK ALLIED
SM
Your Project Starts Here
The new 2012 Allied Catalog
helps you get the job done.
Order the Catalog today
@
/2012catalog
Uvzr |Z, \zw raJacls
d+ ar|J-c|ss Lagg|izrs
agnJzJ Cannzclars nJ
|nJaslri| ^ala+lian U[[zring
alznsivz Tzsl $ qzsarz+znl La|alians
PLE2011010_041.indd 41 10/7/2011 3:39:43 PM
INSIGHT
before couponing out after a specified time
limit or number of welds, or when an essen-
tial variable is changed. The interval between
couponing in and out presents a verified time
frame in which all welds should meet speci-
fications, provided the last weld is as sound
as the first.
Automated features
By reducing manual requirements and
instances of human error, even more auto-
mated features on todays orbital welding
power supplies improve the likelihood that
welders will create successful, high-quality
welds that will pass in-process inspections.
For example, newer orbital welding power
supplies provide complete, automated con-
trol of both purge and shield gas. Purge gas
controls help maintain proper ID pressure
at the weld joint, while shield gas controls
protect the weld bead from atmospheric con-
tamination on the OD of the weld. Utilizing
an integral mass flow controller, these sys-
tems adjust gas flow automatically based on
the weld program. Rather than an operator
manually controlling gas flow for each weld,
which introduces variability, automatic con-
trols adjust gas flow accurately throughout
the welding process for consistent, high-
quality welds.
In addition, some power supplies present
detailed live weld progress data to help opera-
tors better evaluate welds. Graphics show the
progression, performance levels, and stop/start
for each level of a weld in real-time. If the
weld deviates from the selected schedule, the
graphic will indicate points where those varia-
tions occurred so the operator can evaluate the
weld after completion.
This feature enables
welders to make effi-
cient adjustments to
improve weld quality.
Conclusion
Through in-process
i nspect i ons, bot h
welders and inspec-
tors have their eyes
on accuracy, quality, and completeness to
minimize the potential of placing systems
with flawed welds into service. By leverag-
ing automated orbital welding power sup-
ply features, welders enhance their ability
to create accurate, high-quality welds, while
also improving their efficiency in collecting
documentation data.
Ultimately, these automated features
improve the likelihood of passing in-process
inspections and creating leak-tight final
systems.
Glessman is the manager, welding system
products, for Swagelok Co., Solon, Ohio.
www.swagelok.com. He can be reached at
john.glessman@swagelok.com.
Specialty clamp
cylinders
Clamp cylinders, rotary
clamp cylinders, and air
grippers used in industrial
machinery, inspection devic-
es, and factory automation
are now available. The clamp
and rotary clamp cylinders are
compressed air types, while
the air grippers are parallel
type, open/close stroke. The
clamp cylinders are available
in tube inner diameters sizes
of 40, 50, and 63 mm. The
rotary clamp cylinders are
available in varying sizes and
tube inner diameters as well.
www.MISUMIUSA.com
MISUMI
Portable tramp oil
separator
The Hydroflow Portable
Tramp Oil Separator uses a
high-speed centrifuge built
into the portable separator.
The separator delivers clean
fluid with tramp oil levels
below 0.5% and metallic
solids in the 2- to 5-micron
range, which is essential for
metalworking shops. Features
include a stainless-steel hood
and bowl, built-in clean fluid
centripetal discharge pump,
quick disconnects on feed
and discharge, strainer and
50-micron cleanable prefilter,
and air pump with a floating
skimmer for feed.
www.Eriez.com
Eriez Manufacturing Co.
Graphical interfaces
display live weld
progress data to
help operators better
evaluate welds in real
time. Photo courtesy:
Swagelok Co.
Newer orbital welding systems feature
integral USB ports that enable opera-
tors to download documentation data
electronically, which can help minimize
human error during data transfer.
Photo courtesy: Swagelok Co.
MECHANICALSOLUTIONS
ITS
TO
YOUR
ADVANTAGE.
Using Woodhead products makes a
statement. It says that you care about
superior quality, outstanding product selec-
tion and dependable performance in harsh
or regular environments.
It demonstrates that you dont simply want
solutionsyou want the right solutions for
the maintenance and repair work that you
do. It shows that you place a high priority
on safety, reliability and performance.
WIRING DEVICES
POWER DISTRIBUTION
PORTABLE LIGHTING
TOOL SUPPORT
REELS & GRIPS
ADVANTAGE: WOODHEAD.
T HE WOODHEAD ADV ANT AGE
www. woodhead.com/pe
PLE2011010_043.indd 43 10/7/2011 3:41:24 PM
Lubriplate.com
SPECIFY THE
LUBRIPLATE
ADVANTAGE...
Lubriplate provides you with a full line
of advanced, synthetic, extended life
air compressor fuids that interchange
directly with most OEM fuids.
SynXtreme AC Series
100% Polyol Ester (POE)-Based, Maximum Performance Fluids.
For Rotary Screw, Rotary Vane and Reciprocating Air Compressors.
ECO-Friendly - Readily Biodegradable (Pw1).
Potential for Extended Drain Intervals up to +10,000 Hours.
Syn Lube Series
100% Synthetic, Polyalphaolefn (PAO)-Based Fluids.
Fully Compatible High Performance, OEM Fluid Replacement.
Provides Extended Drain Intervals up to 8,000 Hours.
Synac Series
100% Diester-Based Synthetic Air Compressor Fluids.
High Temperature Fluids, They Eliminate Varnish Buildup.
Up to 8,000 Hour Drain Intervals.
Syncool
100% Synthetic, Polyglycolester-Based Fluid.
ECO-Friendly - Readily Biodegradable (Pw1).
Superior Heat Transfer Properties.
Excellent Oxidation Resistance.
SFGO Ultra Series
Class H-1 Food Grade, 100% Synthetic,
(PAO)-Based Compressor Fluids.
NSF H-1 Registered, Meets FDA
Regulation 21 CFR 178.3570.
Lubriplate
Synthetic Lubricants
Newark, NJ 07105 / Toledo, OH 43605 / 1-800-733-4755
www.lubriplate.com / LubeXpert@lubriplate.com
Experience the Difference Quality Makes!

PLE2011010_044.indd 44 10/7/2011 3:43:01 PM
MAINTENANCESOLUTIONS
P
layworld Systems, Inc. has always
prided itself on its ability to understand
the competing needs of the customers
it serves. In the recent recession, the
companys ability to maximize customer value
enabled it to thrive when others struggled. A
family-owned, 230-employee company with
headquarters in Lewisburg, PA, Playworld
makes commercial playground equipment
for schools, new housing developments, and
parks. Its sales were closely tied to credit
markets, school board and local government
budgets, and new home construction.
But this company had some secret defenses.
In 2003, Playworld began to systematically
upgrade its operations to eliminate waste and
streamline processes using Lean manufactur-
ing. By 2005, it had cut the time to fulfill
orders from 10 weeks to 9 days, and improved
order accuracy from 85% to 97%.
By 2005, the company began to reap the
benefits of these efforts: less cash tied up in
inventory, lower costs overall, lower costs
to correct mistakes in customer orders, and
more rapid response to changes in customer
demand. It began to move Lean practices into
other areas of the business.
In the fall of 2008, the company set aggres-
sive targets to make similar improvements in
product development:
Shorten time to market from 18-plus
months to less than a year
Ensure that all products hit their cost tar-
gets and launch dates, and
Reduce the hit on the factory from expe-
dited prototypes to meet catalog deadlines.
As the impact of the recession hit, the com-
pany began to appreciate the most important
benefits of its program to reinvent itself: the
ability to deliver customer value with flexibil-
ity and speed. Playworld had the ability to do
things that its competitors simply could not do.
Despite 20% across-the-board cuts that hit
product development severely, the company
was able to get more products and the right
products to market in the fall of 2009.
Ninety percent of our products were within
5% of their target cost, and we got 50% more
By Katherine Radeka
Whittier Consulting Group
Relentless focus
on customer value
reduces time to
market.
Lean product development
provides manufacturing value
Photo courtesy: Playworld Systems, Inc.
PLE1110_MAINTSOL_V4ms.indd 45 10/4/11 2:32 PM
INSIGHT
Digital pressure gauge
The DPG409 series digital
pressure gauges are now
available. They feature a
backlit display that can read
digits from over 35 ft and
have a rugged stainless-steel
enclosure. They also have
sealed gage ranges from 100
to 5000 psi and vacuum rang-
es from 0 to -10 in H
2
O to 0 to
-15 psi. All units include setup
software can be installed via
USB.
www.Omega.com
Omega Engineering Inc.
Air/gas mass
flow meter
The ST75 Flow
Meter is designed
for line sizes from
0.25 to 2 in. in
process industry
and manufactur-
ing assembly
plant environ-
ments. The ST75
provides three
outputs: mass flow rate, total-
ized flow, and media tempera-
ture. The media temperature
compensation ensures per-
formance under variable pro-
cess and plant temperature
conditions with an accuracy
of +/- 1%. The ST75 is well
suited for low- and high-flow
applications with a
turndown range at 10:1 to
100:1.
www.FluidComponents.com
Fluid Components Intl LLC
products out to the market than we had in
previous years, said Brett Barrick, director
of product development. We invested a 20%
cut in R&D expenses into more than 200%
more tools to support new products. It was as
if we got all the tools for free.
The need to reinvent
Playworlds revamped new product devel-
opment process also contributes to the com-
panys success. In 2005, Playworld Systems
recognized that it had a problem turning ideas
into products at a price customers would pay
and within a time frame that would allow it to
meet competitive challenges. It took 18 to 24
months to develop a new piece for one of its
existing playground systems. New playground
systems took much longer.
The process for deciding which prod-
ucts would be built was based upon pretty
picturesconcept sketches the industrial
designers created to describe their ideas for
new products. Although the designers knew
enough about engineering and manufacturing
to get a sense of how standard line additions
would work, the process broke down whenever
they tried to do something new.
Anything more than the simplest product
line addition was plagued with design loop-
backs and revisited decisions that delayed
product launches from one year to the next.
It was not unusual for products that appeared
in the catalog to be unavailable until many
months into the catalog year. Some new prod-
ucts were plagued with quality problems in
the initial months after introduction due to
inadequate time for field testing.
Playworld often found that new products
were much more expensive to produce than
forecast, and that customers were not willing
to purchase new products at a price that was
profitable for the company. With all of the
investment in new tools already made, Play-
worlds sales and marketing department would
have to find ways to justify a higher price.
Results from new product development
efforts were disappointing. It took a lot of
work to deliver a product that did not deliver
the promise embedded in the pretty pictures
they saw so many months before, and prod-
ucts took a long time to develop traction with
customers.
Lean product development
Playworld decided to bring Lean thinking
into product development. It sought to rep-
licate the gains achieved in manufacturing
upstream in engineering and design. When
Playworld made its first attempts in 2007,
Lean product development was still new and
In 2005, Playworld Systems recognized that it had a problem turning
ideas into products at a price customers would pay.
The most versatile collection of watertight devices

for demanding industrial environments.
wetguard
Watertight Done Right.

Santoprene TPV exterior resists oil, acids,
alkalies, and many industrial solvents.
Corrosion-resistant blades, contacts, terminal
screws and clamps.
Patented multi-point sealing system forms an
impenetrable barrier against dirt and moisture.
Industry exclusive FD boxes available in
one-, two- and three-gang congurations.
Leviton.com/Wetguard
PLE2011010_047.indd 47 10/7/2011 3:46:02 PM
Instead of relying on individuals, the Lean product development
organization captures and shares the knowledge created.
not well understood. Like many others,
Playworld first tried to use Lean manu-
facturing tools such as value stream
mapping in product development.
These methods did not work. For
one thing, most product development
waste is invisible; it sits in hard drives
or inside the brains of overloaded engi-
neers. The most important wastes in
product development are the inability
to deliver products at a cost that reflects
true customer value, ineffective deci-
sion-making that leads to confusion,
and the lack of systems to understand
and capture the knowledge created in
the product development process.
That type of waste does not show up
on a value stream map until the conse-
quences are severe, with uncontrolled
rework loops. Although a value stream
map can identify rework loops that slow
product development, the root causes
of those rework loops are not shown by
anything captured within the map itself.
What is needed: address the reasons
why rework loops are needed in the
first place.
Doing a value stream map on a prod-
uct development process that is too
slow and costs too much is like map-
ping a manufacturing process flow
when a machine is leaking oil and creat-
ing a hazard. Most Lean manufacturing
experts would agree that the priority
should be the leaky, hazardous machine.
The team should use Lean problem-
solving methods to fix the leak perma-
nently and remove the hazard before
trying to redesign the entire process.
The typical product development
group has leaky machines all over
the place. Every unproductive meeting
steals time away from value-creating
development work. Every revisited
decision makes it harder for people
to focus. Every time an engineer has
to make a decision under pressure to
make it work, without the time to make
it work well, customer value suffers.
When its easier to reinvent some-
thing than it is to reuse something
that works, the organization misses an
opportunity to make things easier for
downstream partners, including the
end user: a parent pushing a child on
a swing.
The remedies for all of this waste are
counterintuitive: pursue more alterna-
tives than you can ultimately deliver,
spend more time learning earlier to
save time later, get the technical staff
engaged with the customers even if it
seems like they dont have time for that,
and wait to make decisions until the last
responsible moment. How do we know
that these counter-measures work?
The current state
The Lean product development com-
munity recognizes that product develop-
ment has key differences from manufac-
turing that require us to use a different
tool set, even though the principles of
Lean thinking still apply. Unlike most
of the organization, product develop-
ers have four different value streams to
optimize:
The customers value stream: how
a customer expects to use a product to
realize its expected benefits. Waste in
this value stream includes things such
as extra setup time, poor user interface
design that makes the product hard to
use, maintenance, and repairs. Play-
worlds customer value stream is com-
plex, with different people responsible
for recommending the product, config-
uring a system, paying for it, installing
it, and using it. These customers have
competing needs, and the end user the
child who goes up a climber and down
a slide has almost no role in the key
decisions that lead to the design and
purchase of a new playground structure.
The production value stream: the
value stream most familiar to Lean orga-
nizations. At Playworld, the main factory
is in the same building as everything
else. After five years of experience this
value stream is easy to see.
INSIGHT
The product design and test value stream:
the processes used to turn an idea into a prod-
uct that someone can buy. This is the process
that early Lean product development work
tried to optimize. Waste here includes things
such as excess requirements, overloaded
resources, unproductive meetings, excess
documentation, and project status reporting.
The knowledge creation value stream:
Invisible inside most organizations, it turns
out to be the key that unlocks a deeper under-
standing of the root causes for late products,
defects, and excessive cost. The knowledge
creation value stream is the flow that develops
raw ideas into mature product knowledge used
by product developers
to guide the details of
product design.
In most organiza-
tions, this flow hap-
pens through cross-
fertilization between
teams; product devel-
opers build experience
that they take from one
project to the next. The
knowledge they build
oft en comes from
their experiences of
living through painful
design loopbacks of
build-test-fix.
In a Lean product
development organi-
zation, the knowledge
creation value stream
is a set of interlocking
learning cycles that
look a lot like the plan/
do/check/act (PDCA) cycles an operator uses
to permanently fix a leaky machine.
Rather than build knowledge to improve a
process, these learning cycles build knowl-
edge the team needs to deliver good products.
Instead of relying on individuals to bring their
knowledge from team to team, the Lean prod-
uct development organization captures and
shares the knowledge created.
When Playworld looked at these four value
streams, it learned that their industrial design-
ers already had a good understanding of cus-
tomer needs but the other three value streams
suffered.
As a result, designers were not able to turn
their understanding of customer needs into
products that met those needs at a reason-
able cost. They did not have a good way to
understand how much it would cost to produce
a product until too late in the process. They
needed a deeper understanding of costs related
to the production value stream.
The product design and test value stream
contained many rework loops. Industrial
designers moved off of products once they
were sent to engineering. There were some
opportunities to make later changes, without
addressing root causes of the major problems.
Like many organizations, Playworlds knowl-
edge creation value stream entirely depended
on individuals. Associates needed to spend
more time understanding what they did not
know and putting it into a framework.
Cutting time-to-
market
Playworld Systems
leadership decided to
focus on weaknesses
in its understanding
of t he product i on
value stream as well
as its ability to make
eff ect i ve pr oduct
decisions for driving
maximum customer
val uei mpact i ng
both the knowledge
creation value stream
and the product design
and test value stream.
First, leadership put
in place an A3-driven
product definition pro-
cess that helped define
each new product idea
at increasing levels of
refinement, capturing the history of key deci-
sions. A3s are reports sized to fit an 11 x 17-in.
piece of paper. The size forces the reports
author to focus on only the most essential
information; all of the information in the
report is visible at one time.
Alongside the pretty pictures of a new
product, the industrial design team now had
places to document customer needs, revenue
forecasts, potential manufacturing issues, and
unproven technology. That documentation
keeps customer needs and target costs visible.
The resulting product definition A3 reports
drove good decision-making through the boxes
on the form and the approvals required. Play-
worlds template for the product definition A3
report created space for early input from the
key functional areas that would be required
High-speed drive fuses
The Edison JHL series 600
Vac/450 Vdc fuses combine
high-speed semiconductor
fuses and Class J branch-
circuit fuses in one package,
protecting both ac and dc
drives and controllers. The
fuses are designed for power
semiconductor devices that
utilize diodes, GTOs, SCRs,
SSRs, and electronic motor
controllers. The JHL series
are available in 1- to 600-Amp
sizes.
AutomationDirect
Industrial inspection
camera
The SeeSnake nanoReel
industrial inspection camera
is used for small-diameter
lines ranging from to 2 in.,
and has the ability to make
tight turns for specialized
applications. The camera
system allows users to push
cable distances of up to 85 ft.
For additional flexibility, the
internal drum cartridge can
be removed from the housing
assembly with interchange-
able drums for specific appli-
cations.
www.RIDGID.com
RIDGID
Playworld makes commercial
playground equipment for schools, new
housing developments, and parks.
INSIGHT
to develop the product.
This helped ensure that
manufacturing experts,
engineering, marketing,
finance, and industrial
design all delivered the
information needed to
make a good decision.
Second, Pl ayworl d
developed better ways
to forecast product cost
and then ran every poten-
tial product through the
cost forecast model. That
process helped the team
get a sense of ROI for
the product, and gave
the leadership team bet-
ter information for mak-
ing product concept decisions.
Playworld defined more products than it
needed. In a knowledge creation value stream,
pursuing multiple alternatives stimulates
learning, before committing with confidence
to a design.
The knowledge created through this process
is not lost, and product concepts that dont
make it into development can be revisited.
The products that make it through this pro-
cess have been more thoroughly vetted and
are much more likely to
be developed without
expensive design loop-
backs.
The team used visual
management techniques
to help it view the com-
panys entire portfolio
of products. They turned
one large wall into the
Product Planning Wall,
with each product repre-
sented on an A3 report.
A limited amount of
space on the wall cor-
responds to the organi-
zations development
capacity, helping to pre-
vent overload and con-
fusion about which products the group has
selected.
With industrial designers on staff, visual
models were already an important part of com-
munication at Playworld; its Lean efforts made
them ubiquitous. In addition to the portfolio,
visual planning walls track engineering tasks,
schedules, and other commitments.
Results
Playworld Systems no longer wastes design
Incremental encoders
DDS36 incremental encod-
ers have a 36 mm housing
and the DDS50s have a
50 mm housing, ideal for
applications where space is
limited. The DDS series of
encoders can be used in light
duty applications that require
reliable speed feedback with
pulses per revolution between
100 and 2,500. These encod-
ers are ideal for outdoor use
and suggested use for posi-
tioning of overhead cranes,
rail/transfer cars, and in
robotic applications.
www.SICK.com
SICK AG
AME heads to Dallas for 2011 conference
T
he Association for Manufacturing
Excellences 2011 International Excel-
lence Inside Conference will feature
a wide range of best practices through 41
workshops and 42 facility tours.
From Oct. 24 through Oct. 28 in Dallas,
manufacturing practitioners from around the
world will join to discover innovative meth-
ods and strategies to make business more
competitive.
Attendees find that workshops and tours
are the most valuable activities at the con-
ference, as they discover best practices and
solutions firsthand from industry experts,
says Cheryl Jekiel, conference chair. We
are grateful that our tour host companies
and workshop leaders open their doors and
their minds to our members.
One of the most coveted activities at AME
conferences, audited plant tours offer first-
hand observations on how strategies and
tactics are implemented on shop floors and
used daily to sustain success. These tours
provide unique perspectives that attendees
can modify for their own journey to enter-
prise excellence. Scheduled tours include,
but are not limited to:
Cowboys Stadium
Raytheon
Medtronic
Lockheed-Martin
Capital One headquarters.
In addition to audited plant tours, attend-
ees may also participate in hands-on work-
shops led by industry-leading consultants
and providers. From effective decision mak-
ing and Lean healthcare, to value stream
mapping and sustainability, attendees will
be surrounded by a variety of workshop top-
ics and industry experts.
For more information on AMEs 2011
International Excellence Inside Conference,
including the complete list of tours and
workshops, visit www.ameconference.org.
Playworld understands the competing
needs of the customers it serves.
High-bright line
mount displays
iKeys new high-bright line
of panel-mount displays are
manufactured for optimal
viewing in direct and indirect
sunlight. This brightest line
to date includes the 15.1-
in. FP15-PM-HB-1700 with
1,700 nits and the 17.1-in.
FP17-PM-HB-1000 with 1,000
nits. Both are available with
optional touch screens.
www.iKey.com
iKey, Ltd.
Event Sponsors:
Virtual Events are a powerful educational tool:
All that attendees need is internet access to attend
Virtual events eliminate travel, time, and scheduling constraints
Attendees will have real-time access to top-notch educational
Webcasts, videos, information from industry leading vendors,
and networking opportunities with all event participants
Watch videos, view Webcasts, and
download white papers covering critical
topics at the Virtual Manufacturing/
Automation Summit. You can now
access the summit 24/7 on-demand
at your convenience!
Hear from thought leaders and
experts on:
o Maintenance as a Prot Center
o GM and Ford: The Way Back for Detroit
o The Intersection of Manufacturing
and Automation
o Arc Flash Live: Electrical Safety as
a Core Principal
o Global Strategies for Manufacturers
The virtual future of manufacturing is at your ngertips!
Register and view the event today: www.cfesummit.com
PLE2011010_051.indd 51 10/7/2011 3:47:29 PM
resources on products it will have to
abandon. Good ideas get a fair amount
of investigation when its cheap and
easy to explore them, only going for-
ward when their contribution to cus-
tomer value becomes clear.
The implications of Playworlds cus-
tomer-focused Lean product develop-
ment process for the organization are
significant. In the midst of the reces-
sion, with 20% fewer resources, the
companys associates delivered more
new products, 90% within target cost
goals. It delivered those products in
time to prevent much of the expedit-
ing that plagued prior years catalog
development.
Customers who see these products at
the industrys major trade shows can
order the new products with confidence.
The products have all of the innovative
design, quality, and safety features that
Playworld has always delivered, at a
price more in line with their expecta-
tions.
It is a little too early to say what
effect this has had on sales revenue
and Playworld Systems bottom line.
There are some promising early signs.
Its products stack up remarkably well
against its competitors products at
trade shows.
Playworld saw a 29% increase in
new products for its 2011 catalog over
its 2010 catalog. At the same time, the
company reduced the number of late
projects by 29%, and only 1% of its
new products were delayed more than
60 days from the scheduled introduc-
tion date. Playworlds 2011 new prod-
uct introductions were 138% higher
than those of 2008, which was the last
year prior to its implementation of Lean
product development techniques.
Whats next?
Housing construction and municipal
budgets are still under serious pressure.
To help these customers and to open
up new markets, Playworld decided to
put everything it learned about Lean
into a low-cost line of products. This
past fall, it launched a focused program
to develop a new playground system
from the ground up that is 40% less
expensive than its standard lines with
equivalent play value.
This goal drove Playworld associates
to challenge traditional assumptions
about manufacturing and construction
methods for playground systems. It
used all of the skills it had built over
the past 2 years to:
Pursue multiple alternatives to
solve challenges in optimizing speed
and cost.
Build a simple visual planning wall
in a corner of a conference area to keep
track of major tasks, issues, investiga-
tions, and alternatives.
Leverage new knowledge and ana-
lytical methods to lower costs in their
standard product lines and found ways
to save cost on the value line.
Involve everyone early in the
product development cycledesign,
manufacturing, engineering, finance,
and marketingso they could make
robust decisions quickly.
The project teams experiences dur-
ing the past 2 years gave them unshake-
able confidence that it could meet this
challenge. It delivered the entire new
systemfrom idea to first commercial
product salein less than 6 months.
Our next challenge is to learn from
this experience to break free of the annual
cycle, said Steve Malriat, CEO. That
will help us make the most of our orga-
nizations capacity and be even more
responsive to customer needs.
Radeka is the president of Whittier
Consulting Group and co-founder of the
Lean Product & Process Development
Exchange. She is the author of The
Field Guide to Lean Product Devel-
opment, to be published in 2012 by
Productivity Press. More information
can be found at: www.leantechnology
development.com.
Reprinted with permission from
Target magazine (Third Issue 2011),
Association for Manufacturing Excel-
lence, www.ame.org. AME is a content
partner with Plant Engineering.
In the midst of the recession, with 20% fewer
resources, the company associates delivered more
new products, 90% within target cost goals.
Electronic circuit
protection
The ESX10-TC, a version of the
ESX10-T designed for SCADA applica-
tions, limits the short circuit current to 1.3
to 1.8 times rated current and disconnects
100 ms after the fault has been detected.
The ESX10-TC has the ability to remotely
reset the device from outside an enclo-
sure, which can be accomplished via a
simple push button or PLC controller.
www.E-T-A.com
E-T-A
INSIGHT
TS cameras
Teledyne DALSA Genie TS series cam-
eras combine advancements in CMOS
imaging sensor technology with a newly
optimized camera series for the GigE
Vision camera. The Genie TS series will
include VGA, 1.2, 1.4, 2, 4, 5, 8, and 12
megapixel formats, reach speeds up to
300 fps, and be available in both mono-
chrome and color versions. The Genie TS
is also engineered for Intelligent
Traffic/Transportation Systems applica-
tions.
www.TeledyneDALSA.com
Teledyne DALSA
2011 Fluke Corporation. 4060043B
NEW.
Six amazing models.
One trusted name.
The Fluke P
3
Series
Proven
Practical
Performance
P
3
The only thing that precedes Flukes
highest standards of quality is our
reputation for making the fnest
measurement tools in the world.
Fluke thermal imagers are no
exception. And, the P3 series handily
delivers on the promise to offer the
most tool for the money.
SUper|cr |nage qUa||ty
Cne-|anded, easy-tc-Use |nterface
TcrtUre tested
Find out more about these
new products from Fluke at
www.fuke.com/P3series
Thermal Imagers
Ti27
TiR27
Ti29
TiR29
Ti32
TiR32
MAINTSOL.indd 53 10/7/2011 3:56:18 PM
Other opportunities
to connect
While our print magazines
remain the touchpoint for
more than 200,000 qualied
subscribers each month, we
also recognize that there are
so many other opportunities
each day to reach busy end
users. Thats why weve
developed a wide range of
ways to connect with
our audience:
'
Webcasts
'
Videos
'
Newsletters
'
Websites
'
RSS feeds
'
An expanding global
video library
'
iPhone and Droid apps
'
Social networks
Our goal?
To give you the knowledge
you need, when you need it,
in the format you want it,
delivered to the device
youre using, with the ability
to utilize that knowledge to
do your job better.
CFE Media
1111 W. 22nd Street
Oak Brook, IL 60523
630-571-4070
www.cfemedia.com
Engineering is personal.
So is the way you use information.
CFE Media delivers a world of
knowledge to you. Personally.
Engineering is personal.
So is the way you use information.
CFE Media delivers a world of
knowledge to you. Personally.
You take pride in your profession one of
acquiring and applying design and build structures, machines,
devices, systems, materials and processes that safely realize a
solution to the needs of society.
And, to do your job better each day, you need a trusted
source of information: CFE Media Content For Engineers.
CFE Media strives to...
'
Inspire engineers to interact, respond to peers, and contribute to
content that will assist other engineers with similar challenges.
'
Develop an infrastructure that aligns, organizes and maps content
to audiences specialized needs and business opportunities.
'
Fully understand our audience and its changing needs for targeted
information and delivery channels through the use of industry
experts and leaders.
CFE Media is home to three of the
most trusted names in the business:
Consulting-Specifying Engineer provides the
latest knowledge on commercial and institutional
facility construction and management.
Visit www.csemag.com
Control Engineering delivers a wide array of
strategies and solutions to help control system
designers create a more efcient process.
Visit www.controleng.com
Plant Engineering delivers plant-oor knowledge
and expertise to help manufacturers operate smarter,
safer and more efciently.
Visit www.plantengineering.com
PLE2011010_054.indd 54 10/7/2011 3:51:09 PM
AUTOMATIONSOLUTIONS
I
t was a typical buffet breakfast at a
process industry user group meet-
ing. Your correspondent was enjoying
an unhealthy dose of high-cholesterol
selections and making small talk with other
attendees. One took out his Apple iPad and
began checking email. After a few moments,
the discussion turned to ways he used that
device, and he said, very of matter-of-factly,
that he could use it to access his plant net-
works sitting right there using a wireless Inter-
net connection and see how the process was
running. If necessary, he could log in and even
control the process via that device. He and one
other colleague had the credentials to do that.
This was not some young tech native, but a
gentleman probably in his sixth decade. The
plant in question was a full-scale paper mill.
Its possible that he had become blas about
the level of technology that it represented, but
I suspect he realized that the others of us at
the table found the whole idea fascinating and
maybe a little scary. The notion that such an
interface is practical over the Internet, wire-
lessly, and using an off-the-shelf Apple device,
stands much industrial networking conven-
tion on its head. Whats next? Controlling a
chemical plant with a Mac? That may be a
bit too much, but why shouldnt industrial
applications use this level of convenience, pro-
vided there is an appropriate level of security?
Smartphones and tablet computers, regardless
of the manufacturer, are hugely powerful and
represent a useful extension of industrial net-
works, especially Ethernet- and Web-based
communication. Apple claims there are more
than 425,000 apps available for iPhones, so
its no surprise that some extend into indus-
trial contexts. The number of offerings for
Googles Android platform is not far behind.
Many industrial system suppliers, partic-
ularly those that are a level removed from
large plant-wide control platform suppliers,
are working with these types of apps, provid-
ing extensions of plant networks in process
and discrete manufacturing. The basic concept
of this is not all that new. Earlier versions
typically used an interface to send automat-
ed voice or text messages to operators cell
phones if specific events happened. These
were particularly popular in applications such
as enabling an unmanned pumping station for
a water utility to send an automated alarm
message. Such uses go back into the 1990s
and are still available today.
However, todays applications are vastly
more sophisticated, taking advantage of the
growth of wireless networks, the growing
capabilities of portable devices, and rap-
idly expanding Ethernet networking. Once
a system is connected to the Internet, all
such barriers disappear, for better or worse.
Moreover, the mind-boggling proliferation of
An iPhone
as your next HMI
Consumer-grade smartphones and tablet
computers are fast becoming commonplace
extensions of industrial networks,
permitting process monitoring, and even
(gasp!) process control.
By Peter Welander
Control Engineering
PLE1110_AUTOSOL_V5ms.indd 55 10/4/11 2:33 PM
800.290.5460 x100 I PlantEngineering@theYGSgroup.com
The YGS Group is the authorized provider of custom
reprint products fromPLANT ENGINEERING magazine.
PIace your press directIy in
the hands of your customers
and prospects with custom
reprints from PLANT ENGINEERING
magazine
Event Collateral
Media Kits
Direct Mail
Online Marketing
Recruiting Packages
Presentations
Develop greater
brand awareness
and showcase
your featured
editorial from this
industry-respected
publication.
43Welder shortage looming 52 Innovations in Ethernet 57 Predictive diagnostic
PLE2011010_056.indd 56 10/7/2011 3:58:37 PM
AUTOMATIONSOLUTIONS
applications for smartphones and tablets
seem to enable just about anything from
anywhere. As tech natives move into
manufacturing, there is an expectation
that such capabilities are available as a
matter of course.
Driving the process
Mobile access is driven by the need
for continuous ubiquitous viewing, from
management watching production to an
operator remotely adjusting a process,
says Mark Lochhaas, automation I/O
product manager for Advantech Indus-
trial Automation. Using a smartphone
to access SCADA or HMI data is simply
a type of thin client function on a small
wireless platform. Conceptually, any
device that can browse the Internet could
be used to dynamically access automa-
tion data, either real time, or historically,
perhaps from the cloud. The server must
be able to host a mobile app, and the
mobile device must have an app that is
compatible with the host.
The companies that are pressing this
development are not necessarily the
large control system architects, but
smaller companies that support network-
ing and are more willing to experiment
with new things. Most of the driving
force has come from the IT side, reflect-
ing growth of mobile applications on
that side. Within the convergence of IT
and the factory floor everything is being
connected, from individual devices to
factory floors being connected to sup-
ply chain management systems to inte-
gration with the rest of the business,
says Brian Vezza, director of machine-
to-machine (M2M) solutions at Wind
River. The combination of M2M, cloud,
and smart consumer devices is driving
powerful new business opportunities for
industrial, energy, medical, and other
markets. Within the plant environ-
ment, M2M devices enable enhanced
situational awareness where plant man-
agers, business leaders, and others can
see a much deeper understanding of
their operating environment, resources,
objects, and things. By combining infor-
mation generated from M2M devices
with other systems (e.g., the context)
and using analytics or other forms of
control and/or business logic, business
becomes more intelligent and valuable.
Designing the app
There is a great variety of functional-
ity in equipment selection. For the con-
text of this discussion, we will stay in the
area of apps that are extensions of prod-
uct platforms (as opposed to something
like a savings calculator or configuration
selector) and available for purchase off
the shelf, typically from iTunes, rather
than those that are purpose built for a
specific application. Thats not to say
they wont require some customization,
but this is done by the individual user.
Such apps are also very inexpensive,
often less than $10 or even free.
Some companies design their apps to
interface with specific types of hard-
ware, while others create systems that
are more platform agnostic. Here are two
contrasting examples as illustrations:
Opto 22 and ProSoft Technologies.
While their applications both involve
HMI functions including control, the
underlying concepts and approaches
are different.
Opto 22
Opto 22 has released its iPAC iOS
app that is designed to communicate
with its SNAP PAC system using Apple
iOS devices (iPhone, iPod Touch, and
iPad). The app goes into the control
network via the wireless network and
seeks out those devices. Once it finds
them, establishing communication is
very simple. The company says that a
user with proper security credentials
can inspect SNAP I/O points and PAC
Control strategy variables, and execute
control functions such as turning digital
output points on or off, writing values
to analog outputs, and changing control
variables and table entries. Specific I/O
points and tag names can be retrieved,
viewed, and saved to a watch list for
future reference.
For us there is no hardware inter-
face required. With the iPAC application
installed on a mobile device that runs
the iOS operating system, which basi-
cally means Apple, the first thing that
is required is a wireless network, says
Benson Hougland, vice president, Opto
22. The main reason for that is these
mobile devices dont have an Ethernet
jack, so the only way to access informa-
tion of any kind is via wireless. All of
these devices include Wi-Fi, but they
dont all include a 3G connection. The
second thing you need is access to the
control network wirelessly as well, but
the question is how many people have
their control system network accessible
from their wireless network. Theres
going to be a large share that do not.
Naturally that has to be a secure net-
work. Most people realize today that
they dont deploy wireless networks
without strong security that is part of
any wireless network hardware that you
can buy today.
This is not meant to be an HMI tool
that connects to any hardware devices.
This product was designed specifically
to communicate with Opto 22 control-
lers and brains. Its predominantly used
for commissioning, troubleshooting,
maintenance, and things like that. Its
only useful for people using Opto 22
hardware, but future products may have
additional capabilities.
Process Engineering Resources in Salt
Lake City, UT, is an Opto 22 customer
Opto 22s iPAC app is designed primarily
for commissioning and troubleshooting.
Photo courtesy: Opto 22
PLANT ENGINEERING has been helping plant engineers and
managers understand how to make their operations run
more efciently and effectively for more than 63 years.
Wherever, whenever accessibility to the news, data and
information that connects engineers, suppliers and the world
of knowledge for the manufacturing sector.
Manufacturing/Automation Summit: The best and brightest
of the engineering community comes together at the end of
March to educate engineers on the future of manufacturing.
Product of the Year, and Top Plant and Engineers Choice Award
winners are announced and honored during the two-day seminar.
Salary Survey: The annual Salary Survey results are available
in print, online, and in the January issue. The interactive
survey will not only feature numbers and data, but also
comment and insight.
PlantEngineering.com: The engineers most popular
Website for up-to-the-minute information and onsite
collection of knowledge offering important industry
information in all multi-media formats the latest top
stories, webcasts, podcasts, blogs, and videos.
Electronic Newsletters: PlantMail and Sustainable
Manufacturing give PLANT ENGINEERING subscribers a quick
way to get caught up on industry news, upcoming events
and special promotions available only to our email subscribers.
Our popular HotWire newsletters individually covering
electronics, automation and instrumentation turn the focus
on constantly evolving plant operations with the
latest information.
Webcasts: PLANT ENGINEERING brings the best and brightest
minds to your desktop for special interactive learning
opportunities. Our successful series of Webcasts now offer the
latest industry knowledge on hot topics for engineers, and provide
not only a live opportunity to interact with our experts, but the
ability to retrieve and review the knowledge from our
Website archive.
Subscribe today at
Supporting engineers In-Person
and offering High-Value Content
In-Print and Online
PLE2011010_058.indd 58 10/7/2011 3:59:48 PM
INSIGHT
AUTOMATIONSOLUTIONS
and is experimenting with
using iPAC as an extension
of its x-ray-based metallic ore
analyzers. Our biggest use
for the iPhone app is that its
going to control our sampling
system, says Dave Taylor,
systems engineer. It will be
the most valuable for our peo-
ple that are doing the instal-
lation. We can stand at the
multiplexer tank and select a
stream using the iPhone. You
can activate the I/O directly to
verify that its working, that
you have enough pressure,
and that sort of thing.
ProSoft Technology
ProSoft Technology says
its recent release of the
ProSoft i-View mobile app
provides an easy way for
users to monitor their con-
trol applications in real time
from an iPad, iPhone, or iPod
touch. Functionally, the app
enables wireless connectivity
to any PLC/PAC that operates on an Ether-
Net/IP or Modbus TCP network, via Wi-Fi or
remotely via cellular. For security, the user
must have access to both the wireless net-
work and the CPU of the processor to set it
up. During configuration, the app requires the
user to assign a matching security code both
as a password for network access and as a
security tag in the CPU of the PAC. From this
point forward when a user launches ProSoft
i-View, the security code must match that
on the CPU in order to create a connection,
preventing unauthorized users from simply
downloading the app and hacking into the
system. Where the wireless network is con-
cerned, the same considerations must be given
that would apply for any industrial application
when selecting the technology and provider.
ProSoft Technologys Industrial Hotspot
radios, for example, feature WPA2-PSK and
802.11i RADIUS security, which prevent
unauthorized access and modification to the
network, and are fully supported by a leading
team of application engineers and an array
of complementary tools, such as the ProSoft
Wireless Designer.
During setup, the user must configure the
tags within ProSoft i-View, then establish their
variance allowances. Once operational, the
app displays live PLC values
in stylized lists and graphs.
Alarms are also available,
including local notifications,
to alert maintenance teams
when a deviation from set-
points occurs, for example.
Via a cellular connection,
these engineers are able to
monitor variables in real time
and make adjustments from
virtually anywhere with cell
phone coverage.
Application use cases
are wide, says Adrienne
Lutovsky, marketing com-
munication specialist for
ProSoft . Syst em Int e-
grators have used the app
with our cellular radios to
remotely troubleshoot cus-
tomer installations. A small
packaging operation for
dairy products desired the
app to keep an eye on the
control system from home.
The latest upgrade includes
a barcode scanner, which
expands use case scenarios into areas like
quality control.
Will performance stand up?
Time will tell if network performance will
support customers expectations. Any smart-
phone user has had to deal with the frustration
of pages that take too long to load or networks
that cant deliver. While Wi-Fi and cellular
networks are improving, connectivity at some
point is going to be a disappointment. Such
experiences will determine how common these
applications become.
Even so, the possibilities are appealing. The
ease of cloud connectivity combined with smart
tablets and phones means that this information
can be available in an easy-to-use and secure
manner whenever and wherever it is needed,
says Vezza. By providing standardized M2M
device development kits and optimized devel-
opment frameworks for both hardware and soft-
ware, device manufacturers can focus on their
own value-add and differentiating functionality
instead of the underlying hardware, OS,
and core M2M software.
Welander is a content manager for
Control Engineering. Contact him at
pwelander@cfemedia.com.
ProSofts i-View is an HMI
extension that works in real
time and can be used continu-
ously. Users customize their
own screens. Photo courtesy:
ProSoft Technology
Cloud computing
solution
AssetPoints TabWare
CMMS/EAM solution is easy
to learn, easy to use, and
easy to own, so companies
are able to get up and run-
ning in days. AssetPoint offers
flexible deployment options,
including a choice between a
cloud computing solution and
on-site maintenance for com-
panies who want TabWare on
their own servers. TabWare
maximizes asset perfor-
mance, resulting in reduced
operating costs and higher
profit margins. The cloud
computing solution is a secure
SAS-70 type II audited and
secure Software as a Service
environment that consistently
provides over 99% uptime
for its users year after year,
according to AssetPoint.
AssetPoint
www.AssetPoint.com
Frequency output
current transducers
ATQ series frequency out-
put current transducers have
an open collector transistor
frequency output design,
which can serve as an input
to high-speed counter or fre-
quency PLC modules, panel
meters, or programmable
relays to monitor machine
current usage to within 1%
of range. Multiple ranges from
0-2 to 0-200 amp are avail-
able to provide resolution that
fits the needs of the particular
applications.
NK Technologies
www.NKTechnologies.com
PRODUCTMART
Enjoy your newfound
spare time.
Power System Software | Turn Days into Minutes
But be prepared to explain how you accomplished so much with
so little time and effort.
Just tell them you got a little help from EasyPower: the fastest, easiest-to-use, most
automated power system software available.
EasyPower automates everything:
One-line creation and templates Full document set drawings
NEC code design Arc flash calculations and analysis
Protective device coordination IEEE-1584 & NFPA 70E compliance
ANSI and IEC solution standards Seamless CAD output
Explore more online and download a free demo copy at www.easypower.com/demo
Reach your Audience! Place your Ad in PLANT ENGINEERINGS
Product Mart or Classieds section, call today and get results!
630-571-4070
www.plantengineering.com/newsletters
electronic newsletters
Plant Engineerings
electronic newsletters
deliver news and information on
the latest trends in manufacturing
in every corner of the plant oor.
Plant engineers and managers refer
to these sources of information
for the up-to-the-minute
news and trends that impact
their business.
PlantMail: Weekly
HotWire: Monthly
HotWire
on MES: Monthly
HotWire on
Automation: Monthly
Maintenance
Connection: Monthly
Product
Showcase: Monthly
Sustainable
Manufacturing: Monthly
Get your plant ahead of the curve.
Subscribe today by going to
www.plantengineering.com/newsletters
Input #100 at plantengineering.hotims.com Input #101 at plantengineering.hotims.com
Fall Protection
with FabEnCo
Self-Closing
Industrial
Safety Gates
American-made FabEnCo
Self-Closing Safety Gates
t unprotected openings up
to 60 inches on ladderways,
platforms and stairs. Easy-to-install FabEnCo
gates are available in aluminum and stainless
steel for special applications/environments, as
well as carbon steel. Available nishes include
galvanized and environmentally-friendly safety
yellow powder-coat. Custom gates are also
available.
www.safetygate.com/ple1
POWDER-SOLUTIONS.com
877-BFM-FLEX
BFM
IT!
Snaps In Place!
Flexible Connectors
Sanitary!
Safe! Efficient!
Tool Free!
PLE1110_PRODMART.indd 60 10/12/11 9:04 AM
PRODUCTMART PRODUCTMART
Cleveland Vibrator Company announces Sizing Guide for Air and
Electric Powered Vibrators for Hoppers, Bins and Chutes
Vibratory technology engineering and manufacturing company, Cleveland Vibrator Co. offers techni-
cal guidelines for selecting air (pneumatic) and electric powered industrial vibrators in their stream-
lined sizing guide, including air vibrator installation, force output adjustment and non-impact adjust-
ment, as well as rotary electric formulas for calculating bulk material weights and hopper volumes.
Quick reference charts reect product recommendations for air powered vibrators according to bin
capacity and skin thickness, in addition to electric vibrators according to maximum material in sloped
wall section and normal wall thickness.
Since 1923 Cleveland Vibrator Company has been designing, manufacturing and supplying vibra-
tory products and offering services to meet material handling needs. Our diverse products and knowl-
edge ranges from the precise challenges of ne powder screening to the most rugged equipment
feeder and conveyor applications. In addition to our breadth of capabilities, we differentiate ourselves
with a unique focus on quality, integrity and customer service that has made us a partner with more
than 15,000 organizations around the world throughout our 88 year history. Our comprehensive line
of industrial vibrators includes unique air-piston vibrators, rotary electric vibrators, electromagnetic
vibrators, turbine vibrators and ball vibrators used for bins, hoppers, railcars, foundry applications;
rollover and core machine vibrators and more in many sizes and varieties. Cleveland Vibrator fab-
ricated products include air and electric powered vibratory feeders, screeners, ultrasonic screeners,
conveyors and tables for light, medium, and heavy duty industrial applications.
For more information, contact Jack Steinbuch, Cleveland Vibrator Company, at (800) 221-3298,
(216) 241-7157, jsteinbuch@clevelandvibrator.com. The Cleveland Vibrator Company Web site can
be found at www.clevelandvibrator.com.
Link for Literature Guide:
http://www.clevelandvibrator.com/vibrators/sizingguide.pdf
Upload your Digital Ads to the CFE Ad Portal. Its Easy and Secure!
Sign up today... its FREE!
Log on today at http://ads.cfemedia.comand
start using this simple, fast and convenient service!
Follow the easy step-by-step instructions to submit
a new ad. Once uploaded, review your ad on screen
for compliancy, then approve for submission.
The portal also offers helpful tips for pdf creation,
plus a useful archive and status report of all ads
you have submitted.
http://ads.cfemedia.com
Industrial Vibrator Sizing Guide
TECHNI CAL REFERENCE
I. Air Vibrator Selection
A single vibrator will normally provide the necessary
force to move materials from most hoppers and bins.
The single vibrator installation requires that the force of
vibration be transmitted to full 180right and lef t of the
vibrator mounting location. However, due to the special
configurations of some hoppers, their construction or
wall thickness or the characteristics of the material itself
(sticky, lightweight, large particles, moisture, etc.),
consideration should be given to the use of multiple
smaller vibrators that are evenly arranged around the
hopper in place of one large vibrator.
The maximum number of multiples is three vibrators
mounted 120apart, or two vibrators mounted 180
apart. Greater distribution of vibration will result and
assurance that all areas will be vibrated equally. This
arrangement is of particular importance when
attempting to move material from long rectangular
shaped hoppers or from hoppers with a very shallow
taper at the discharge.
Sizing Guide for Air and Electric Powered
Vibrators for Hoppers, Bins and Chutes
A. Installation
The mounting of a vibrator on a length of channel which
is stitch welded vertically to the side of a hopper will
provide a transmission line above and below the
vibrator and will also reinforce the hopper wall as well.
The width of the channel should be to suit the base
dimensions of the vibrator. The length will also vary
with the hopper size, however, a good rule to follow is
that the channel be one-third the length of the sloping
section of the hopper.
B. Moisture Content
Moisture content of the material to be moved is also
important in the sizing of a vibrator. If the moisture
content is 6% or more, it is advisable to use the next
size vibrator or two vibrators.
C. Force Output Adjustment
All vibrators provide a range of adjustability in their
force output. Air vibrators can be adjusted with a
simpler air regulator; electric vibrators with adjustable
eccentrics; or others with SCR controls. In selecting a
vibrator, remember that it can be adjusted due to
changes in material make-up, lower hopper contents,
or vibrator over sizing.
D. Non-Impact Adjustments
There is a reduction in vibration intensity in the non-
impacting type vibrators (air-cushioned piston, rotary
electric, turbine and ball) over the impacting piston
vibrator. For piston vibrators, to achieve comparable
results, the next size non-impacting vibrator should be
used.
E. Operation Effectiveness
A short burst of vibration is normally more effective
than continuous vibration. Do not operate vibrators
against closed hopper gates or valves.
F. Noise Levels
Noise level of vibrators varies with the type. A general
ranking from loudest to quietest is a follows: impact,
ball, air-cushioned, rotary electric and turbine.
Register and view the event today:
www.cfesummit.com
The virtual future of manufacturing
is literally at your ngertips.
Watch videos, view Webcasts,
and get white papers on critical
manufacturing topics.
Access 24/7 on-demand
at your convenience.
PLE1110_PRODMART.indd 61 10/12/11 11:58 AM
alliedelec.com
Allied Electronics is a small order, high service level dis-
tributor of electronic components and electromechanical
products with over 50 sales offices across the United
States and Canada.
Allied Electronics
atlascopco.us
Atlas Copco produces and markets compressed air equip-
ment and generators, construction and mining equipment,
industrial tools, assembly systems, services and rentals.
Atlas Copco
automationdirect.com
AutomationDirect offers 6,500+ industrial automation
products through their free catalog and online store,
including PLCs, operator interfaces, sensors, and more.
AutomationDirect
baldor.com
Baldor Electric Co. designs, manufacturers, and markets
a broad line of industrial energy-efficient electric motors,
mechanical power transmission products, and more.
Baldor Electric Co.
bentley.com
Bentley is dedicated to providing architects, engineers,
constructors, and owner-operators with comprehensive
software solutions for sustaining infrastructure.
Bentley Systems Inc.
camfilfarr.com
Camfil Farr is the worlds largest and leading manufacturer
of filters and clean air solutions.
Camfil Farr
clevelandvibrator.com
The Cleveland Vibrator Co. offers one of the most com-
prehensive lines of vibrators and vibratory bulk handling
equipment available today.
Cleveland Vibrator Co.
cmworks.com
Columbus McKinnon Corp. is a designer, manufacturer,
and marketer of material handling systems and services.
Products include hoists, actuators, cranes, and more.
Columbus McKinnon Corp.
donaldson.com
Compressed air purifications solutions, compressed air
filters, dryers and process water chillers.
Donaldson Company Inc.
eaton.com
Diversified power management company and global tech-
nology leader in electrical systems for power quality, distri-
bution and control, and more.
Eaton Corp.
est-static.com
EST specializes in mitigating static charges, induced
voltages and random discharges on rotating shafts,
moving surfaces, and all types of manufacturing equip-
ment.
Electro Static Technology
flexicon.com
Flexicon Corp. designs and manufactures bulk handling
equipment and custon-engineered and integrated plant-
wide systems.
Flexicon Corp.
fluke.com
Fluke Corp. is the world leader in the manufacture, distri-
bution, and service of electronic test tools and software.
Fluke Corp.
gtweed.com
As a global technology leader, Greene, Tweed & Co.
provides the innovative solutions that enable your next
generation technology.
Greene, Tweed & Co.
hyster.com
Hyster offers a comprehensive range of warehousing
equipment, industrial lift trucks, container handlers and
reach stackers as well as quality material handling parts.
Hyster Co.
ibm.com
IBM is committed to environmental leadership in all of its
business activities, from its operations to the design of its
products and use of its technology.
IBM
infor.com
Infor offers deep industry-specific applications and suites,
engineered for speed, using ground-breaking technology.
Infor
ingersollrand.com
Ingersoll Rands diverse and innovative products range
from complete air compressor systems, tools, ARO
pumps, material handling systems and more.
Ingersoll-Rand plc
vortec.com
Vortec products use compressed air technologies to
increase equipment efficiency, improve productivity, and
deliver spot and enclosure cooling and conveying.
ITW Vortec
leviton.com
Leviton Manufacturing is North Americas leading manu-
facturer of electrical wiring devices, data center con-
nectivity solutions, and lighting energy management
systems.
Leviton Manufacturing Co.
littelfuse.com
Littelfuse is the world leader in circuit protection offering
Automotive Fuses, Automotive Circuit Protection, Fuses,
Electrical Fuses, Thyristors and more.
Littelfuse, Inc.
lubriplate.com
Lubriplate manufactures more than 200 high quality lubri-
cants, including high performance synthetic lubricants and
NSF-H1 lubricants for food processing and beverage.
Lubriplate Lubricants Co.
molex.com
Molex is a leading one-source supplier of interconnect
products. Molex is focused on the design, development
and distribution of innovative product solutions that touch
virtually every walk of life.
Molex
omega.com
Omega offers more than 100,000 state-of-the-art
products for measurement and control of temperature,
humidity, pressure, strain, force, flow, level, pH, and
more.
Omega Engineering Inc.
orival.com
Orival, Inc., is a leading manufacturer of self-cleaning
water filters, automatic water filters and strainers, for use
as industrial water filters, irrigation filters, cooling tower
filters, and more.
Orival, Inc.
rittal-corp.com
Rittal manufactures the worlds leading industrial and
IT enclosures, racks and accessories, including high-
effi ci ency, hi gh-densi ty cl i mate control and power
management systems.
Rittal Corp.
sullair.com
AirMetrix is a total system management program designed
to maximize the productivity of your compressed air sys-
tem. AirTility delivers air as needed with no capital expen-
ditures and no maintenance worries.
Sullair Corp.
tapeswitch.com
Tapeswitch designs and manufactures innovative sensing,
switching, and control products for use in machine guard-
ing, personnel protection, and other safety and control
applications.
Tapeswitch Corp.
victaulic.com
The grooved piping method dramatically reduces the
amount of installation time and reduces total installed
costs as compared to welding, threading or flanging.
Victaulic Co.
yaskawa.com
Yaskawa is the worlds largest manufacturer of ac inverter
drives, servo and motion control, and robotics automation
systems.
Yaskawa America Inc.
For more information on how to advertise in PLANT ENGINEERINGS
Internet Connection, call Jim Langhenry at 630-571-4070 x2203
O
c
to
b
e
r
2
0
1
1
P
l
a
c
e

n
e
x
t

t
o

y
o
u
r

c
o
m
p
u
t
e
r

o
r

g
o

o
n
l
i
n
e

t
o

p
l
a
n
t
e
n
g
i
n
e
e
r
i
n
g
.
c
o
m

f
o
r

h
o
t

l
i
n
k
s

t
o

t
h
e
s
e

c
o
m
p
a
n
i
e
s
.

R
e
m
o
v
e

a
t
L
i
n
e
PLE1110_INTERNET_V6ms.indd 62 10/4/11 2:33 PM
Allied Electronics 41 25
800-433-5700 www.alliedelec.com
Atlas Copco Compressors 22 17
866-688-9611 www.atlascopco.us/danielusa
AutomationDirect C-2, 16A-16D 1
800-633-0405 www.automationdirect.com
Baldor Electric Company C-4 31
800-828-4920 www.baldor.com
Bentley Systems Incorporated 37 23
800-236-8539 www.bentley.com/openplantroadshow-PE
Camfil Farr Air Pollution Control 4 4
800-479-6801 www.farrapc.com
CFE Media LLC 54
630-571-4070 www.cfemedia.com
Cleveland Vibrator Co. 21 15
800-221-3298 www.clevelandvibrator.com
Columbus Mckinnon Corp 20 14
800-888-0985 www.cmworks.com
Donaldson Co. Inc 16 10
800-365-1331 www.Donaldson.com/ToritPowerCore
Electro Static Technology Inc 24 18
866-738-1857 www.est-aegis.com
Flexicon Corp 8 6
888-353-9426 www.flexicon.com
Fluke Corp. 21, 53 16, 29
888-443-5853 www.fluke.com
Greene, Tweed & Co. 34 22
281-765-4500 www.gtweed.com
Hyster 25 19
800-HYSTER1 www.hyster.com
IBM 10 7
800-426-4968 www.ibm.com
Infor Global Solutions 13 8
678-319-8000 http://go.infor.com/energy-mgmt/
Ingersoll-Rand 6 5
704-655-4000 www.ingersollrandproducts.com
ITW Vortec 20 13
800-411-7475 www.Vortec.com
Leviton Manufacturing Co 47 28
800-323-8920 www.Leviton.com/Wetguard
Littelfuse, Inc. 38 24
800-832-3873 www.littelfuse.com/afv
Lubriplate Lubricants Co 44 27
800-733-4755 www.lubriplate.com
Molex/Woodhead 43 26
800-225-7724 www.woodhead.com/pe
Omega Engineering, Inc. 1 2
888-556-6342 www.omega.com
Orival Inc 19 12
800-567-9767 www.orival.com
Rittal Corporation 14, 15, 29 9, 20
800-477-4000 www.rittal-corp.com
Solutions For Engineers 58
630-571-4070 www.PlantEngineering.com
Sullair Industrial Products 31 21
219-879-5451 www.sullairinfo.com
Tapeswitch Corp 18 11
800-234-8273 www.tapeswitch.com
The YGS Group 56
800-290-5460 http://reprints.ygsgroup.com/m/plant_engineering
Victaulic Company 2 3
800-742-5842 www.vic-press.com
Virtual Manufacturing/
Automation Summit 51
630-571-4070 www.cfesummit.com
Yaskawa Electric America, Inc C-3 30
800-927-5292 www.yaskawa.com
PLANT ENGINEERING does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the Advertiser contacts regardless of whether such errors result from negligence, accident, or any other cause whatsoever.
Need More Info? FAX this page to: 1-800-571-7730
or mail to PLANT ENGINEERING magazine, 2000 Clearwater Drive, Oakbrook, IL 60523
Name Title
Company Address
City State Zip
Telephone Fax e-mail
Page RSC Send
Advertiser Number Number Info
Page RSC Send
Advertiser Number Number Info
CONTACTSAdvertiser Contacts for plant engineers
Request more information about products and advertisers in this issue by using the http://plantengineering.hotims.com
link and reader service number located near each. If youre reading the digital edition, the link will be live. When you contact a
company directly, please let them know you read about them in Plant Engineering.
PLE1110_CONTACTS.indd 63 10/12/11 9:03 AM
COMMENT
Think everyone is using PPE? Think again
I
t is not spelled out anywhere in the Con-
stitution, but one of the fundamental free-
doms we all enjoy is the freedom of choice.
We can choose our brand of toothpaste, our
soft drink, our car, our cell phone service
provider. We have so many choices, however,
that sometimes it is difficult to narrow it down
to an either/or proposition.
There is one area, however, where we have
a choice. We can choose to be safe at work.
That choice is protected by law. (If you are
unnerved by government interference in such
matters, it also is protected by simple human
decency.)
It is a simple choice of course we want
to be safe at work. No one wakes up each
morning and says, Cant wait to get to the
plant today so I can injure myself! Such a
statement is unthinkable.
Yet we so often continue to make the wrong
choice when it comes to workplace safety. We
do not think about safety in those harsh terms.
We shade the discussion, especially when it
comes to personal protective equipment (PPE).
The thought process with PPE is something
like, If I dont wear those gloves or that face
shield or the body suit when Im working on an
energized electrical panel, well, I know what
Im doing. Ive been doing this for years
They will talk about what a consummate
professional he was during the eulogy.
This issue came up recently when Kimberly-
Clark Professional released a study reporting
that 9 out of 10 safety professionals observed
workers not wearing required personal protec-
tive equipment on the job. Even worse, 3 out
of 10 saw these violations on more than one
occasion. I wish I could say I was surprised
to hear this, but I wasnt.
For the past three years, Plant Engineer-
ing has run the popular Arc Flash University
series, where a global audience of plant pro-
fessionals has benefitted from hearing some
of the industrys leading safety experts talk
about the changes in arc flash safety codes,
regulations, and PPE.
The discussion around PPE particularly
talks about the NFPA 70E requirements around
the levels of hazards and the PPE required at
each level. The data is clearly defined, it has
been rigorously debated and tested, and it is
clear-cut and straightforward.
And when we get to the Q&A at the end of
each Arc Flash University session, the ques-
tions from the audience are framed around the
idea of How do I wear as little PPE as pos-
sible when working on energized equipment?
If you were to choose to ski down the side
of a mountain, you would want the best equip-
ment, the tightest bindings, and the most stable
skis. If you were going to leap out of an air-
plane, which is an inherently unsafe thing to
do, youd want to ensure the parachute was
properly packed, that the pilot and plane were
sturdy, and that the drop zone was flat and
safe for landing.
When it comes to electrical safety, we are
not talking about skiing down the side of a
mountain or leaping out of an airplane. We are
talking about going to work, and coming home
from work each day hale, hearty, and able to
make the choice about whether to spend your
weekend coming down a mountain or going
up in an airplane.
Perhaps that is overly dramatic. Here is the
simple version from the folks at Kimberly-
Clark Professional: Complacency is the
enemy, said Deanna Thornton, global safety
director of marketing, Kimberly-Clark Profes-
sional. Workers get comfortable and pay less
attention over time. When this happens, they
make choices that are sometimes unsafe like
not wearing PPE. Keeping workers engaged
long term is a challenge that safety managers
battle every day.
Safety is not supposed to be a battlefield.
It is supposed to be the one area where line
workers, plant managers, and corporate execu-
tives can link arms and say, On this topic, we
agree. Unless of course you are one of those
corporate executives who make your workers
pay for their own PPE. Then you are part of
the problem, not part of the solution.
You are tempted to make the argument
that safety is about economics and profit. I
do believe safety, like maintenance, can be
a profit center for your organization instead
of a cost center. If a machine breaks, though,
we simply replace the machine. It is not that
simple with safety.
Actually, it is that simple. Before PPE is
equipment, before it even is protective, it is
personal. The PPE itself can be replaced;
the people inside cannot.
Bob Vavra
Content Manager
Workers get comfort-
able and pay less atten-
tion over timeKeeping
workers engaged long
term is a challenge that
safety managers battle
every day.
Deanna Thornton
Kimberly-Clark Professional
PLE1110_COMMENT_V5ms.indd 64 10/4/11 2:34 PM
Follow us: For More Info:
http://Ez.com/yai211
DEMAND
MORE
More quality, more exibility, more application control. Yaskawas A1000 will meet all your application
demandswith outputs ranging up to 1000HP. From simple fans and pumps to complex machine control,
A1000 can be the single drive platform for your entire facility.
Need a drive that gives you MORE? Call Yaskawa today.
PLE2011010_0C3.indd 3 10/7/2011 4:01:28 PM
Reduce Your Plants
Energy Consumption
Call in the Baldor IBE Team
In todays business climate,
virtually every manufacturing
plant is searching for ways to
reduce energy consumption and
lower operating costs. With the
change in federal minimum energy
efficiency requirements (Energy
Independence and Security Act of
2007), now is the time to survey
and replace inefficient motors. By
identifying older, inefficient motors
and PT components and replacing
them with Baldor
Reliance
Super-E
Premium Efficient motors

and Baldor
Dodge
gearing
and bearing products, you can
potentially realize huge energy
savings.
Plus, an Installed Base Evaluation
(IBE) provides the end user
the framework for a motor
management system and
overall system performance, as
well as Operational Equipment
Effectiveness (OEE) initiatives.
baldor.com
2011 Baldor Electric Company
Each IBE report includes:
Your potential energy savings
A detailed list of your current
products in service
Your expected payback/timing
Repair/replace comparisons
Inventory/spares analysis
Local rebate and incentive
program details
$ 2500
2000
$.09 $.08 $.07
POWER COST PER KWH
D
O
L
L
A
R

S
A
V
I
N
G
S

P
E
R

Y
E
A
R
1500
1000
500
$.06
Continuous
Use
80 Hrs
Per Wk
40 Hrs
Per Wk
$.10 $.11 $.12 $.13 $.14 $.15
0
Continuous
Use
80 Hrs
Per Wk
40 Hrs
Per Wk
You can expect immediate and long
term benefits from your IBE survey:
Energy savings
Improved uptime through better
system and process reliability
Simplified purchasing and
inventory management
Product availability
If youre struggling with rising energy
costs and consumption, schedule
an IBE survey today.
Its an easy call with a big
payback.
(864) 281-2100
IBETeam@Baldor.com
PLE2011010_0C4.indd 4 10/7/2011 4:02:55 PM

Oct 2011

Încărcat de

Informații document

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Oct 2011

Încărcat de

Drepturi de autor:

Formate disponibile

11 Virtual Summit on demand 35 Protective devices 45 Lean product development

PLE1110_COVER.indd 2 10/4/11 1:53 PM

in Temperature, Pressure, Flow and More!

using standard off-the-shelf Schedule 10S pipe

modular design allows for virtually unlimited customization

PLE1110_FORUM_V8ms.indd 11 10/4/11 1:59 PM

PLE1110_FORUM_V8ms.indd 12 10/4/11 2:00 PM

gives your eyes and your camera a clear, unobstructed view

provides effortless compliance with grounding standards

Shaft Voltage Test

SGR protects motor bearings

Motor Control Centeran industry

Motor Control Centeran industry

low voltage power circuit breaker

low voltage power circuit breaker

input #27 at plantengineering.hotims.com

The most versatile collection of watertight devices

Watertight Done Right.

Premium Efficient motors

S-ar putea să vă placă și