71
Remote monitoring
81
Rugged flexible enclosures
89
Oil contamination
© COPYRIGHT 2012 OMEGA ENGINEERING, INC. ALL RIGHTS RESERVED ®
omega.com
®• Superior Thermal Imaging—Up to 76,800 Pixels (320 x 240)
• Improved Digital Camera—3.1 Mega Pixel Resolution
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Visit omega.com/os-vir50
Digital Infrared
Video Thermometer
OS-VIR50
$500
Because of transmission frequency regulations, these wireless products may only be used in the United States, Canada and Europe.
Compact Infrared Cameras with On-Board Visual
Camera, Wi-Fi Connectivity, P-i-P and Bright LED Light
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OS151-USB Series
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593
Visit omega.com/os151-usb
Visit omega.com/osxl-101Thermal Imager
OSXL-101
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$1990
Electrical Energy Loss Duct-Pipe LeakageMechanical & Industrial
Not for Export: USA and Canada only
PLANTENG_1112_Control Design 10/10/12 4:45 PM Page 1
input #2 at www.plantengineering.com/information
www.automationdirect.com
1-800-633-0405
Go online or call to get complete information, request your free catalog, or place an order. Motor feeder short
circuit and ground fault protection Motor disconnecting means (NEC 430.101-430.113) Motor branch-circuit short circuit protection (NEC 430.51-430.58) Motor controller (NEC 430.81-430.91) Motor overload protection (NEC 430.21-430.44) OSHA Lockout/ tagout disconnect (NEC 430.81-430.91) Control Transformer PLC I/O Contactor Coils Relays UL 1077 Supplementary Protectors
starting at $8.75 UL 248General Fuses starting at $1.75 (5-pack)
Ensure that your equipment is safeguarded at every point in the power distribution network with high-quality, cost-effective circuit protection and disconnection
devices that meet UL standards. They’ll pay for themselves in no time!
• Rated current up to 800A, max 600V • Standard and high-interrupting
capacity types
• Non-fusible and fusible rotary disconnect switches • Make/break loads up
to 800 amps
Class T, RK5, RK1 and Class J current limiting short circuit
protection up to 600A • DIN-rail mounted • Up to 40 amps • 1, 2, or 3-pole available • 10kAIC @ 277/480VAC
• DIN rail mountable
• Full line of auxiliary switches, alarm switches and padlock lockout accessories
• B trip curve 6 to 60 amps • C trip curve 0.5 to 60 amps • D trip curve 0.5 to 40 amps
• Class CC, general purpose class M (Midget) and small dimension glass and ceramic fuses • Ideal supplementary
protection up to 30 amps for
branch circuits and end of line equipment UL 489 MCCBs starting at $179 UL 98 Disconnect Switches starting at $83 UL 489 Miniature Circuit Breakers, up to 40A starting at $17.50 UL 248
Current Limiting Fuses
starting at $36 (10-pack)
Bryant Manual Motor Controllers
starting at $23.50
• Lockout / Tagout capability • 30, 40 and 60A up to 600 VAC • 2-pole and 3-pole switches • Quick make, slow break design • UL Listed as “Suitable as Motor
Disconnect” under UL 508
• 35mm DIN rail mountable or direct mountable • Loads from 16 to 125 amps • IP20 degree of protection UL 508 Load Switches starting at $25.50 UL 98 and UL 508 Compact Fusible Disconnect Switches starting at $18.00
• Up to 30A, utilizing Class CC or Midget fuses
• 1, 2 and 3-pole models • Open fuse indication • Lockout/Tagout capability
1211-PlantEngineering-LoadProtection-MAG:load-protection 10/19/2012 1:48 PM Page 1
input #1 at www.plantengineering.com/information
NEVER SETTLE FOR
GOOD ENOUGH.
Learn more
aboutDonaldson Torit solutions
DonaldsonTorit.com
800.365.1331
© 2012 Donaldson Company, Inc.
Clean air is essential for keeping your employees and your equipment productive. Don’t risk downtime and damage to your most important assets with a sub-optimal dust collector or fi lters. Our broadest-in-the-industry product selection, unmatched customer support and a history of industry-leading innovation assures Donaldson Torit always delivers
EXACTLY WHAT YOU NEED.™
input #3 at www.plantengineering.com/information
www.plantengineering.com PLANTENGINEERING November 2012 • 3
What’s INside
What’s INside
6
Interactive
9
In Focus
23
In Practice
93
Product Mart
94
Internet Connection
95
Advertiser Contacts
96
In Conclusion
November 2012
Volume 66, No. 976
Enhancing systems
2012 Product of the Year Finalists
The next wave of innovation
PLANT ENGINEERING (ISSN 0032-082X, Vol. 66, No. 9, GST #123397457) is published 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 2012 by CFE Media, LLC. All rights reserved. PLANT ENGINEERING is a registered trademark of CFE Media, LLC used under license. Periodicals postage paid at Oak Brook, IL 60523 and addi-tional mailing offices. Circulation records are main-tained at CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Telephone: 630-571-4070 x2220. E-mail: customerservice@ cfemedia.com. Postmaster: send address changes to PLANT ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Publications Mail Agreement No. 40685520. Return undeliverable Canadian addresses to: 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Email: customerservice@ cfemedia.com. Rates for nonqualified
subscrip-tions, 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 material contained herein, regard-less of whether such errors result from negligence, accident or any other cause whatsoever.
What’s INside
30 Automation & Controls
36 Apps for Engineers
37 Compressed Air
38 Electric Motors & Drives
40 Electrical Controls 41 Energy Management 42 Environmental Health 43 Fluid Handling 44 HVAC 45 Lighting
47 Maintenance Tools & Equipment
49 Material Handling Systems
51 Power Transmission
53 Productivity Training Software
54 Safety
There are more than 100 finalists in 15 categories vying for your
approval in this year’s Product of the Year voting.
Analyze power quality and
calculate energy loss.
Poor power quality. It affects how your facility operates. It affects your bottom line. Fortunately, there’s the new Fluke 435 Series II Power Quality and Energy Analyzer. It features the most advanced waveform and power effi ciency functions available and calculates the cost of wasted energy. So don’t settle for half the job–do the whole job with Fluke.
Learn more: fl uke.com/pqandenergy.
4130712A_EN_Plant_Engineering.indd 1 10/8/12 12:27 PM
input #4 at www.plantengineering.com/information
CONTENT SPECIALISTS/EDITORIAL
BOB VAVRA, Content Manager
630-571-4070, x2212, [email protected] AMANDA MCLEMAN, Project Manager
630-571-4070, x2209, [email protected] MARK HOSKE, Content Manager
630-571-4070, x2214, [email protected] PETER WELANDER, Content Manager
630-571-4070, x2213, [email protected] AMARA ROZGUS, Content Manager
630-571-4070, x2211, [email protected] CHRIS VAVRA,Content Specialist
630-571-4070, x2219, [email protected] BRITTANY MERCHUT, Content Specialist
630-571-4070, x2220, [email protected]
PUBLICATION SERVICES
JIM LANGHENRY, Co-Founder and Publisher, CFE Media
630-571-4070, x2203; [email protected] STEVE ROURKE,Co-Founder, CFE Media
630-571-4070, x2204, [email protected] TRUDY KELLY,Executive Assistant
630-571-4070, x2205, [email protected] ELENA MOELLER-YOUNGER, Marketing Manager 630-571-4070, x2215; [email protected] MICHAEL SMITH, Creative Director
630-779-8910, [email protected] PAUL BROUCH, Web Production Manager 630-571-4070, x2208, [email protected] MICHAEL ROTZ, Print Production Manager 717-766-0211, Fax: 717-506-7238 [email protected]
KARIE BURT, Account Director, mardevdm2
212-584-9374; [email protected] RICK ELLIS, Audience Management Director Phone: 303-246-1250; [email protected] LETTERS TO THE EDITOR
Please e-mail your opinions to
[email protected] 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 2012 Media Kit or Editorial Calendar, e-mail Trudy Kelly at [email protected]. REPRINTS
For custom reprints or electronic usage, contact: Wright’s Media – Nick Iademarco
Phone: 877-652-5295 ext. 102 Email: [email protected]
PUBLICATION SALES
Tom Corcoran, West, TX, OK [email protected] 1111 W. 22nd St. Suite 250, Tel. 215-275-6420 Oak Brook, IL 60523 Fax. 484-631-0598 Karen Cira, Southeast [email protected] 879 Autumn Rain Lane Tel. 704-523-5466 Charlotte, NC 28209 Fax 630-214-4504 Patrick Lynch, AL, FL [email protected] 1111 W. 22nd St. Suite 250, Tel. 630-571-4070 x2210 Oak Brook, IL 60523 Fax. 630-214-4504 Kerry Gottlieb, N. Central [email protected]
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 [email protected]
12 Pine Street Tel. 774-277-7266 Franklin, MA 02038 Fax 508-590-0432 Stuart Smith, International [email protected] SSM
Global Media Ltd. Tel. +44 208 464 5577 Fax +44 208 464 5588 fax
Automation Solutions
71 Remote monitoring
technologies lower costs,
improve operations
The latest remote communication technologies allow experts
to monitor and control multiple plants from any location.
76 Using sensors to enhance systems
Recognize the limitations, then plan for redundancy.
Maintenance Solutions
81 Smaller, more flexible
enclosures still
need to be rugged
Cabinets allow for safe and accesible
storage, but can generate dangerous heat.
Mechanical Solutions
89 Particulates, liquids,
oxidation contribute
to oil contamination
Oil discoloration should be addressed
with high importance for optimal
operation performance.
9 In Focus
Get Skills to Work formed to address skills gap, veterans training
Georgia Tech study: Sales, Lean, skilled worker help needed
Data center management more than cooling
Hope is not an effective safety strategy
Measuring quality through software
Fine turning your preventative maintenance schedule
CONTENT SPECIALISTS/EDITORIAL
BOB VAVRA, Content Manager
630-571-4070, x2212, [email protected]
AMANDA MCLEMAN, Project Manager
630-571-4070, x2209, [email protected]
MARK HOSKE, Content Manager
630-571-4070, x2214, [email protected]
PETER WELANDER, Content Manager
630-571-4070, x2213, [email protected]
AMARA ROZGUS, Content Manager
630-571-4070, x2211, [email protected]
CHRIS VAVRA, Content Specialist
630-571-4070, x2219, [email protected]
BRITTANY MERCHUT, Content Specialist
630-571-4070, x2220, [email protected]
PUBLICATION SERVICES
JIM LANGHENRY, Co-Founder and Publisher, CFE Media
630-571-4070, x2203; [email protected]
STEVE ROURKE, Co-Founder, CFE Media
630-571-4070, x2204, [email protected]
TRUDY KELLY, Executive Assistant
630-571-4070, x2205, [email protected]
ELENA MOELLER-YOUNGER, Marketing Manager
630-571-4070, x2215; [email protected]
MICHAEL SMITH, Creative Director
630-779-8910, [email protected]
PAUL BROUCH, Web Production Manager
630-571-4070, x2208, [email protected]
MICHAEL ROTZ, Print Production Manager
717-766-0211, Fax: 717-506-7238 [email protected]
KARIE BURT, Account Director, mardevdm2
212-584-9374; [email protected]
RICK ELLIS, Audience Management Directornagement Directornagement
Phone: 303-246-1250; [email protected]
LETTERS TO THE EDITOR
Please e-mail your opinions to
[email protected] 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 2012 Media Kit or Editorial Calendar, e-mail Trudy Kelly at [email protected].
REPRINTS
For custom reprints or electronic usage, contact: Wright’s Media – Nick Iademarco
Phone: 877-652-5295 ext. 102 Email: [email protected]
PUBLICATION SALES
Tom Corcoran, West, TX, OK [email protected]
1111 W. 22nd St. Suite 250, Tel. 215-275-6420 Oak Brook, IL 60523 Fax. 484-631-0598
Karen Cira, Southeast [email protected] 879 Autumn Rain Lane Tel. 704-523-5466 Charlotte, NC 28209 Fax 630-214-4504
Patrick Lynch, AL, FL [email protected] 1111 W. 22nd St. Suite 250, Tel. 630-571-4070 x2210 Oak Brook, IL 60523 Fax. 630-214-4504
Kerry Gottlieb, N. Central [email protected] 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 [email protected]
12 Pine Street Tel. 774-277-7266 Franklin, MA 02038 Fax 508-590-0432
Stuart Smith, International International International [email protected] SSM
Global Media Ltd. Tel. +44 208 464 5577 Fax +44 208 464 5588 fax
PlantEngineering.com
1111 W. 22nd St. Suite 250, Oak Brook, IL 60523 Ph 630-571-4070, Fax 630-214-4504CONTENT SPECIALISTS/EDITORIAL
BOB VAVRA,Content Manager
630-571-4070 x2212, [email protected] AMANDA MCLEMAN,Project Manager 630-571-4070 x2209, [email protected] MARK HOSKE,Content Manager
630-571-4070 x2214, [email protected] PETER WELANDER,Content Manager 630-571-4070 x2213, [email protected]
AMARA ROZGUS,Content Manager 630-571-4070 x2211, [email protected]
CHRIS VAVRA,Content Specialist [email protected]
BRITTANY MERCHUT,Content Specialist 630-571-4070 x2220, [email protected] BEN TAYLOR, Content Specialist
630-571-4070 x2219, [email protected]
PUBLICATION SERVICES
JIM LANGHENRY,Co-Founder & Publisher, CFE Media 630-571-4070 x2203, [email protected] STEVE ROURKE,Co-Founder, CFE Media 630-571-4070 x2204, [email protected]
TRUDY KELLY,Executive Assistant 630-571-4070 x2205, [email protected] ELENA MOELLER-YOUNGER,Marketing Manager 630-571-4070 x2215, [email protected] MICHAEL SMITH,Creative Director
630-779-8910, [email protected] PAUL BROUCH, Web Production Manager 630-571-4070 x2208, [email protected] MICHAEL ROTZ, Print Production Manager 717-766-0211, Fax: 717-506-7238 [email protected]
MARIA BARTELL, Account Director, Infogroup Targeting Solutions 847-378-2275, [email protected]
RICK ELLIS, Audience Management Director 303-246-1250, [email protected] LETTERS TO THE EDITOR Please e-mail your opinions to
[email protected] 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 Media Kit or Editorial Calendar, e-mail Trudy Kelly at [email protected]. REPRINTS
For custom reprints or electronic usage, contact: Wright’s Media – Nick Iademarco
Phone: 877-652-5295 x102 Email: [email protected]
PUBLICATION SALES
Tom Corcoran, West, TX, OK [email protected] 1111 W. 22nd St., Suite 250, Tel. 215-275-6420 Oak Brook, IL 60523 Fax 484-631-0598 Karen Cira, Southeast [email protected] 879 Autumn Rain Ln. Tel. 704-523-5466 Charlotte, NC 28209 Fax 630-214-4504 Patrick Lynch, AL, FL [email protected] 1111 W. 22nd St., Suite 250, Tel. 630-571-4070 x2210 Oak Brook, IL 60523 Fax 630-214-4504 Kerry Gottlieb, N. Central [email protected] 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 [email protected] 12 Pine St. Tel. 774-277-7266 Franklin, MA 02038 Fax 508-590-0432 Stuart Smith, International [email protected] SSM Global Media Ltd. Tel. +44 208 464 5577
Fax +44 208 464 5588
PLANTENGINEERING November 2012 • 5
WHITE PAPER
Effectively manage
your fleet system
A new white paper from Hyster talks about the most effective ways to man-age your lift truck fleet systems.
When lift truck fleets are not properly maintained or utilized efficiently, downtime increases, productivity is reduced and you may end up spend-ing money when you should be makspend-ing money. The challenge of prop-erly maintaining your fleet can be resolved through an effective fleet management program.
Fleet management programs help navigate hidden opportunities to reduce your materials handling spending. As you are confronted with difficult economic hurdles, the need to shed cost for sustainability is a must if you are to emerge from these economic times leaner, stronger and poised to take advantage of economic recovery.
Visit www.plantengineering.com/media-library/white-papers to view the white paper.
VIDEO
Energy management trends
in manufacturing
CFE Media content manager Amara Rozgus sat down for an exclusive one-on-one interview with Jeff Drees, North Ameri-can president for Schneider Electric, to discuss trends in manufacturing, including the increasing use of energy man-agement and energy audits to identify and reduce the cost of energy to a plant.
Scan the QR code above with your
Smartphone or visit www.plantengineering.com/videos
W
HAT
2
C
LICK
2
Here are this month’s online highlights at www.plantengineering.com. Type the keyword into our exclusive search engine and find full details on each article:
Keyword: SME student assessment: The Society of Manufacturing Engineers (SME) has been granted $292,000 from the U.S. Dept. of Energy to partner SME Student Chapters with existing Industrial Assessment Centers at universities nation-wide.
Keyword: Compressed dew points: Sampling is needed when direct measure-ment of the air is undesirable or is simply not feasible. This may be due to a high pro-cess temperature, the need to protect the sensor from water spikes, the added conve-nience of installing and removing the instru-ment from a pressurized process without shutting down the line, or wanting to make the measurement in a more convenient location. This paper shares tips on how to get a representative sample of the process gas and avoid potential sources of error caused by incorrect sampling practices.
Keyword: Industrial wireless market: New research study from Frost & Sullivan projects massive growth for the wireless industrial automation market. While rev-enues are expected to more than double over the next four years, implementation of wireless technology still is lagging. Analysts attribute this to a lack of understanding about the full potential of wireless.
Keyword: AME Hall of Fame: The Association of Manufacturing Excellence named four 2012 Hall of Fame inductees at its annual conference. The honor recognizes individuals who have distinguished them-selves in the manufacturing community in a manner that is consistent with AME’s mis-sion to inspire a commitment to enterprise excellence through shared learning and access to best practices.
6 • November 2012 PLANTENGINEERING www.plantengineering.com
IN
TERACTIVE
www.PlantEngineering.com
Smartphone or visit www.plantengineering.com/videos
2012
2012
PRODUCT OF THE YEAR
Cast your vote
As a qualified subscriber to Plant Engineering, you are eligible to vote for the best products in this year’s Product of the Year program. Voting is open until Jan. 15, 2013, and the winners will be announced at the 2013 Awards in Manufacturing Event on March 18, as well as in the April 2013 issue of Plant Engineering.
Turn to page 29 or visit www.plantengineering.com/POY to read about this year’s finalists and cast your vote.
Machin
ing
without
Cool
ant!
Machin
ing
without
Cool
ant!
Increase tool life and machining rates!
The Cold Gun increases tool life, tolerances and production
rates by eliminating heat build up. It produces 20°F air
from ordinary compressed air. The Cold Gun is ideal for dry
machining or to replace messy mist systems. It eliminates
the costly coolant purchase and disposal.
• Low cost, portable, quiet
• Won't freeze up during continuous use • No health problems from airborne coolant • Improves surface fi nish
• No moving parts - maintenance free
High Power Cold Gun
Twice the cooling power of standard Cold Guns.
High Power Cold Gun
Twice the cooling power of standard Cold Guns.
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Replace messy mist systems & improve
dry machining with clean, cold air!
Extend CNC Tool Life
The Model 5315 Cold Gun cools a two fl ute 3/8" carbide cutter on a CNC, increasing tool life by 50%. Ideal for diamond tooling.
Milling & Drilling
Fly cutters up to 460mm in diameter have been cooled with the Cold Gun. Dissipating heat with cold air extends tool life, increases speeds and feeds, and improves fi nishes.
Chill Roll
Cooling a roll with 20°F (-7°C) air keeps the material on the surface from bunching up, jamming or tearing. The metal surface transfers the cold temperature to the product.
Tool Grinding
Cold air eliminates heat cracking of carbide and tool edge burning during grinding and sharpening operations. Increased tool life between regrinds is the result.
Manufacturing Intelligent Compressed Air® Products Since 1983
11510 Goldcoast Drive • Cincinnati, Ohio • 45249-1621 • (800) 903-9247 fax: (513) 671-3363 • E-mail: [email protected] • www.exair.com
@EXAIR www.exair.com/79/49979.htm
Watch The
Video!
input #5 at www.plantengineering.com/information PLE121101-MAG_Ads.indd 7 11/7/2012 3:27:15 PMFILLER FOR PALLET JACK BAG REMOVAL
Low profile version of patented TWIN-CENTERPOST™ filler allows removal of filled bags using a pallet jack, eliminating the need for a forklift or roller conveyor. Low cost standard models offered with many performance options.
BULK BAG FILLER USES PLANT SCALE
Full length forklifting tubes allow positioning of this TWIN-CENTERPOST™ filler model on a plant scale as needed, allowing you to fill by weight without investing in load cells and automated controls.
FILLERS WITH AUTOMATED FEEDING SYSTEMS
Every Flexicon filler is offered with pneumatic (shown) or mechanical (bottom right) feeding/weighing systems, as well as inlet adapters
to interface with optional overhead storage vessels.
COMBINATION
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features a fill head that lowers and pivots down for safe, easy bag spout connections at floor level, and a swing-arm-mounted chute for automated filling and indexing of drums.
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Fill head lowers, pivots and stops in a vertically-oriented position, allowing operator to safely and quickly connect empty bags at floor level and resume automated filling and spout-cinching operations.
CANTILEVERED REAR-POST FILLER
Offered with performance options including: powered fill head height adjustment, pneumatically retractable bag hooks, inflatable bag spout seal, dust containment vent, roller conveyor, and vibratory bag densification/deaeration system.
BASIC FILLER FOR TIGHTEST BUDGETS
A lighter-duty version of the economical TWIN-CENTERPOST™ filler, the BASIC FILLER reduces cost further still, yet has an inflatable bag spout seal and feed chute dust vent as standard, and a limited list of performance options.
PATENTED
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Two heavy-gauge, on-center posts boost strength and access to bag hooks while reducing cost. Standard manual fill head height adjustment, and feed chute vent for displaced dust. Numerous performance options. First filler to receive USDA acceptance.
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©2011 Flexicon Corporation. Flexicon Corporation has registrations and pending applications for the trademark FLEXICON throughout the world.
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CHILE UK AUSTRALIA SOUTH AFRICA +56 2 415 1286 +44 (0)1227 374710 +61 (0)7 3879 4180 +27 (0)41 453 1871 Z-1227 FillOneBulk_Y-1063 12/14/11 12:11 PM Page 1 input #6 at www.plantengineering.com/information PLE121101-MAG_Ads.indd 8 11/6/2012 2:52:54 PMA
new survey finds that veterans returning from military service believe their skills will translate well into the private sector, but don’t believe the private sector feels the same way.GE and the Institute for Veterans and Military Families at Syracuse University released the results of their “Voice of Veterans” survey to coincide with the announcement of the coalition between GE, Alcoa, Boeing, and Lockheed Martin. The four companies, working with the Manufacturing Insti-tute, have developed the Get Skills to Work program to help train and deploy returning veterans for manufacturing jobs.
The survey found that 76% of U.S. veterans and active duty military preparing to transition to civilian life are confi-dent they can be successful in their private-sector careers. But 66% said they believe the skills they gained in military service are undervalued by private sector employers.
More than 1,000 veterans and active duty personnel under the age of 45 took part in the survey. They said they want the same kind of training they received in the military, and believe their background and existing skills will trans-late well into private sector employment.
“What stands out in this data is that veterans are moti-vated to make a difference beyond their military careers. Given their contributions, we must pay attention to the
unique challenges and opportunities they face as they navi-gate the transition to civilian life,” said Mike Haynie, founder and executive director, IVMF. “There is a lot we can do to match the desire to work in dynamic, rewarding industries with training that creates a pathway for success.”
“The U.S. manufacturing industry is growing, and we stand ready to provide our military veterans with the train-ing, education, and mentorship they are seeking to build long-term, well-paying careers that make a positive differ-ence in the world,” said Frank Taylor, chief security officer of GE. “The skills earned in the U.S. armed forces translate to today’s sophisticated, highly technical manufacturing industry, and we are confident that working together with America’s heroes, we are poised to drive American com-petitiveness.”
The Get Skills to Work coalition’s goal is to bolster the tal-ent pipeline, enhance American competitiveness, and give our nation’s veterans the skills and tools they need to com-pete for the jobs of the future. Coalition partners include The Manufacturing Institute, GE, Boeing, Lockheed Martin, Alcoa Inc., LinkedIn, Futures Inc., Atlantic Council, the Gary Sinise Foundation and Techshop.
For more information about the Get Skills to Work coali-tion, visit www.getskillstowork.org.
Study: Returning vets say they have the skills to help manufacturing
Four major American manufactur-ers recently announced the creation of a coalition to fund and encourage military veterans to get the training needed to fill the manufacturing jobs shortage.
The Get Skills to Work coalition will focus on accelerating skills train-ing for U.S. veterans; helptrain-ing veterans and employers translate military skills to advanced manufacturing jobs; and empowering employers with tools to recruit, onboard, and mentor veterans. It will be managed by the Manufacturing Institute and supported through financial and in-kind commitments from GE, Alcoa Inc., Boeing, and Lockheed Martin.
“These initial investments will help 15,000 veterans translate military expe-rience to corresponding advanced man-ufacturing opportunities and gain the
technical skills needed to quali-fy for careers in this growing sector,” the group said.
“A strong manu-facturing industry is central to the long-term health and success of our economy,” said Jeff Immelt, chairman and CEO of GE. “But as technology advances, skill sets must be upgraded to ensure companies have the talent to continue to fuel innovation. Today, many veter-ans are out of work, despite the nation’s growing industrial sector and increased demand for skilled workers. Through this initiative, we have an opportunity to help veterans with extraordinary leadership capabilities better compete for good pay-ing jobs with a long-term future.”
Reportedly 600,000 high-tech manufacturing jobs remain open in the U.S., and more than 82% of manu-facturers report they cannot find people to fill their skilled production jobs. Meanwhile, one million veterans are expected to exit the armed forces over the next four years and will be transitioning to civil-ian careers.
The coalition commissioned an online survey of more than 1,000 veterans and active duty military members preparing to transition to the private sector. The sur-vey found that while 76% of respondents are confident they will be as successful in their careers as they were in the mili-tary, one-third do not feel equipped to
www.plantengineering.com PLANTENGINEERING November 2012 • 9
Get Skills to Work formed to address
skills gap, veterans training
IN
F
OCUS
overcome the challenges of the transition to civilian life; the percentage rises to nearly 48% when surveying active duty military who are scheduled to transition in two years or less.
“Veterans offer the technical, lead-ership, and critical thinking skills that advanced manufacturing demands,” said Paula Davis, president of the Alcoa Foundation. “Forming the Get Skills to Work coalition and coordinating with nonprofits to train, recruit, and develop veterans is an exciting model that has the potential to change lives and produce a significant competitive advantage for U.S. manufacturers.”
“We believe the Get Skills to Work initiative could have a major impact on the hiring of veterans nationwide,” said Rick Stephens, Boeing’s senior vice president of human resources and administration, and a U.S. Marine Corps veteran. “Using many of the same tac-tics and tools, such as a website for transitioning veterans that includes a military-to-civilian skills translator, we have hired and trained nearly 3,000 veterans in the past 21 months for jobs at Boeing. It’s a proven approach for matching the skills of those who have served our country to the hiring needs of American businesses. We’re honored to be part of Get Skills to Work, and look forward to integrating our efforts with the coalition.”
“America’s veterans want and deserve the opportunity to contribute to our soci-ety and provide for their families,” said Bob Stevens, Lockheed Martin Chairman and CEO.
The program will consist of three ele-ments:
n Accelerating skills training To help prepare veterans whose mili-tary service experience doesn’t immedi-ately qualify them for available manufac-turing jobs, coalition partners will work with local community and technical colleges to establish the Manufacturing Institute’s Right Skills Now program, which fast-tracks industry-recognized certifications and offers training in core manufacturing technical skill areas. Part-ners will engage their regional supply base to ensure the certifications being offered meet the immediate skill needs of local employers, and will work with the U.S. Depts. of Defense and Veterans Affairs, as well as local military transi-tion offices and bases, to recruit veteran participants.
n Translating military experience
into civilian opportunities
Many veterans and employers have dif-ficulty recognizing and translating the skills gained through military training and experience into civilian workforce skill sets. The Manufacturing Institute, working with Futures Inc., has created a digital badge system to help translate
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Mark Huber (from left) of Alcoa Inc., Gabriele P.M. Tyler, Deputy Director of Transition Strategic Outreach for the U.S. Army, and actor and veterans activist Gary Sinese discuss the formation of the Get Skills to Work coalition. Courtesy: GE
Among the findings of the “Voice of Veterans” study conducted by GE and the Institute for Veterans and Military Families at Syracuse University:
n 76% of young veterans are
confident they can be successful in their careers, despite the many challenges faced when transition-ing to civilian life, and this confi-dence level increases with age.
n 66% feel their skills are
under-valued. Unparalleled work ethic, leadership, teamwork, discipline, and dedication are translatable skills they have to offer the civilian workforce.
n 70% believe the skills they
earned in the military align with a job in the manufacturing industry.
n 79% are motivated to find
educational opportunities to help them find and advance their civilian career.
n Work/school balance (48%) and
financial burdens (35%) pose barri-ers to their pursuit of education.
n 76% want a civilian career that
makes a positive difference in the world.
n 78% seek a career that fills
them with a sense of pride.
n 62% believe companies have a
responsibility to provide veterans with opportunities to enter and suc-ceed in the civilian job market.
applicable Military Occupational Spe-cialty (MOS) codes, the U.S. military’s system for identifying jobs, to civilian positions in advanced manufacturing.
n Empowering employers
GE and the Institute for Veterans and Military Families at Syracuse University (IVMF) will develop and deploy a toolkit for employers focused on creating mean-ingful, lasting career opportunities for veterans in the advanced manufactur-ing sector. The toolkit will be available to employers participating in the U.S. Chamber of Commerce’s Hiring Our Heroes initiative and the 100,000 Jobs Mission, as well as the broader business community. PE
For more information visit www. getskillstowork.org.
10 • November 2012 plantengineering www.plantengineering.com
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12 • November 2012 plantengineering The 2012 edition of the Georgia Manufacturing Survey,
conducted by Georgia Tech University, points to four areas of concern for manufacturers in that state. Topping the list is a need for more help in sales and marketing, with 36% of manufacturers citing this as a significant need.
Manufacturers also want more help with the Lean manufac-turing operation, cited by 32% of manufacturers, and worker skills, with 24% needing more technical workers and 16% needing more workers with basic skills. Energy cost manage-ment is cited by 21% of manufacturers as an area of concern. That percentage has doubled since 1999.
The study also noted a significant increase in re-shoring of jobs to the state. According to a press release issued by Georgia Tech, nearly 16% of the companies responding to the survey said work had been transferred to them from outside Georgia, compared to slightly more than 14% that lost work to out-of-state facilities.
“We have finally seen a crossing of the lines so that more companies are benefiting from in-sourcing than are los-ing to outsourclos-ing,” said Jan Youtie, director of policy research services in the Enterprise Innovation Institute at
Georgia Tech. “It’s not a huge difference at this point, but it is a positive and consistent trend for the manufacturing community.”
Plant Engineering spoke with Youtie about the implications
for manufacturers in Georgia and elsewhere.
PE: What are Georgia manufacturers able to offer right now that seems to be attracting manufactur-ing investment? Is this occurrmanufactur-ing in specific sectors or across the board?
Youtie: Science-based manufacturers (those in medical device, chemicals, and petroleum industries) and large manufacturers are more apt to be engaged in in-sourcing.
PE: The study also focuses on the relationship between technology and employment. Has the skills gap emerged as a problem for Georgia manufacturers, and how are they addressing the issue?
Youtie: This survey highlighted a reemergence of manufactur-ers’ concerns about technical skills, but we continue to see that investment in training is relatively low ($100 per respondent on average).
PE: What are the barriers to sustainability? Is it more profitable today to run a sustainable plant?
Youtie: Although we do not ask about the barriers to sus-tainable manufacturing, we do see that the vast majority of manufacturers are engaged in some aspects of sustainable manufacturing, such as eliminating waste materials sent to landfills, and more than half have a goal to eliminate air or water pollution. Both of those areas appear to have their 2010 plans implemented by 2012. Other areas such as using renewable energy to run the plant still are not very common at all (set by only 7% of manufacturers in 2012), however, although the percentage with this goal has risen slightly from 2010 to 2012. PE
Georgia Tech study:
Sales, Lean, skilled worker help needed
While Georgia manufacturers still cite marketing and sales their biggest area that they need help with, the need for more technical skills, energy management and basic worker skills all rose in 2012 from 2010, the last time the study was con-ducted. Source: Georgia Manufacturing Study, Georgia Tech
Manufacturing Problems/Needs
Problems/needs 2012 2010 Change
Marketing and sales 36.0% 39.1% -3.1% Manufacturing
process/Lean 31.6% 31.6% 0% Technical skills 23.5% 18.8% 4.7% Energy costs management 21.4% 18.9% 2.5% Basic skills 16.4% 13.9% 2.5%
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Myth: Building my own data center is expensive, inefficient, and time-consuming—but worth it to meet my specific IT needs.
Due to advances in data center technol-ogy, modular and containerized data cen-ters are now often a better alternative to customized data centers. For data center managers looking to increase their ROI, modular or containerized data
centers are not only faster to deploy, but they’re also signifi-cantly more affordable and can offer better operational, effi-ciency, and processing benefits.
The most obvious benefit to
modular data centers is a drastic reduc-tion in installareduc-tion time. Tradireduc-tional data centers take months or even years for construction, compared to just 10 to 16 weeks for a modular data center. This is in part because they’re already verified for compliance in safety, energy efficiency, compatibility, and security.
Cost savings is another major benefit. Not only will the upfront cost of instal-lation be drastically lower than that for a traditional data center, but mainte-nance and operating expenses are also reduced over time. A modular approach can deliver capital expenditure cost sav-ings anywhere from 10% to 20%, and operating expenditure cost savings from 20% to 35%.
Because of their manufacturing process and predictability, modular facilities also have a lower risk of operational human error. Systems have factory-verified operation and are tuned for maximum energy efficiency. Product defects are limited and software is preprogrammed, allowing technicians to spend less time troubleshooting and more time devoted to other critical IT issues.
Myth: Sustainability in my data cen-ter is unattainable within my budget constraints.
Sustainability isn’t just for big bud-gets. Using the right equation of afford-able, widely available services and
technologies to manage a data center’s energy supply and demand, businesses of all sizes can meet and exceed green and sustainability goals—without breaking the bank. Below are a few examples.
Energy procurement: To ensure the most reliable and affordable clean energy is being sourced, data centers now have the option to work with outside sustainability service providers. These providers can help data centers with the full-time job of energy planning, monitoring, and reporting. These partners can also help reduce complexities involving price volatility, and control costs.
Energy use: Just as we’re reminded to consume energy intelligently in our homes, data centers also need to be mindful of how and when they’re consuming energy. Some methods to reduce energy usage include:
Natural cooling: Instead of an expensive HVAC system, use a free resource to cool your racks: outside air. While this is clearly best for data centers located in colder climates, it’s an ideal way to slash cooling costs and reduce energy use.
Air containment strategies: Data centers routinely mix hot and cold air, limiting how effectively a system oper-ates, as well as its overall capacity. An air containment system can be imple-mented by placing air tiles in the cold aisle, installing supply vents in the cold aisle and return vents in the hot aisle, and physically dividing the hot and cold aisles with a curtain or hard enclosure. This can return up to 25% in savings.
And as the connecting element in a smart data center equation, demand response helps data centers get the most value out of their utility budget. By tak-ing advantage of their utility’s demand response programs, businesses have the ability to determine when to best con-sume electricity, in conjunction with low rates. Plus, companies can also sell back unused energy (gleaned from efficiency and smart sourcing) to their utility at peak times, generating entirely new streams of revenue.
Myth: Updating cooling is the only way to lower data center energy costs.
There are many other tactics to be considered for lowering data center energy costs. Though cooling is a tre-mendous energy consumer, there are equally important areas you should be paying attention to if you want to slash your energy bills as much as possible, including air containment, higher voltage power distribution, more efficient UPS, redundancy requirements, and power architecture. Also consider:
Power equipment efficiency: Data centers often fail to account for the heat produced by critical devices within a data center, such as UPS, transformers, transfer switches, and wiring. By cooling the heat generated by these devices, data centers maintain optimal conditions but also consume far more energy.
Data centers should consider switching to more energy-efficient equipment, such as high-efficiency UPS, which have up to 70% less loss than legacy UPS at typical loads, servers, and CRAC/CRAH units, which can be programmed to reduce or cease demand fighting entirely.
Centralized management system: Advancements in data center infrastruc-ture management (DCIM) software now allow data center managers to easily integrate and prioritize all IT equipment and functions into one application. This centralized point of control allows data center managers to holistically monitor temperatures, operations, security, and power utilization.
While cooling should not be over-looked, data centers would do well to look at energy usage holistically. By implementing a variety of tactics, data centers can slash energy bills in a way that works best for the organization. PE
Kevin Brown is Vice President, Data Center Global Solution Offer for Schnei-der Electric’s IT Business.
14 • November 2012 PLANTENGINEERING www.plantengineering.com
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Data center management more than cooling
5
Fifth
in a seriesGO TO:
www.PlantEngineering.com Keywords: “Dubunking the Myths” to fi nd Parts 1 through 4 of this series.I
NDUSTRIALE
FFICIENCY:D
EBUNKING THE MYTHSBy Kevin Brown, Schneider Electric
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input #11 at www.plantengineering.com/information It basic nature that businessesdon’t want incidents to occur. And, at the same time employ-ees don’t want to be hurt. Busi-nesses generally, some only when confronted, don’t wish
for exposure to unneeded regulation, un-scheduled machine downtime, employee injuries, costly liabilities or the cost bur-dens associated with these issues. Yet, these are some of the negative results a business can expect as consequences of avoiding the required risk assessments for their machinery operations.
Some of the potential liabilities of exposure (avoidable consequences) might be:
Timing: Too many businesses still avoid the issue of compliance to the risk assessment requirement which extends to existing, new or modified equipment. The sooner the better to meet
compli-ance requirements and avoid citations.
Misapplied devices: Quite often safety devices are provid-ed but are miss-appliprovid-ed because a hazard level was not properly assessed. For example, a Cat 4 hazard could require a control reliable solution involving a Cat 4 safety rated switch with redundant contacts. A miss-applied device in this example could include; a single standard interlock switch, safety rated devices below Cat 4, or an application which is not control reliable.
Foreseeable misuse: A properly con-ducted machine guarding risk assessment will typically uncover misuse situations like; equipment malfunction, unauthor-ized process material, operating tooling beyond its useful life, unexpected loss of power, and reach over, under, around, or through guarding.
Misapplied procedure: Lockout/
Tagout (LOTO) is frequently misun-derstood and/or not always followed as prescribed by OSHA. LOTO incidents are preventable via frequent training, documenting procedures, not permitting shortcuts, and by establishing employee penalties for non compliance.
Unidentified modes: All modes of operation and their related tasks need to be identified in order to reveal their related hazards. Unidentified modes include; setup, cleanup and preventive maintenance.
The advice of industry experts is to not become aware of the importance of risk assessments only after a serious incident and the resulting OSHA citation, or the legal engagement, or the sever financial expenses which fall directly to your bot-tom line. “Hope” is not an effective strat-egy – proactive engaged machine safety leadership is! PE
Read J.B. Titus’ blog, Machine Safety, at www.plantengineering.com/blogs.
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Hope is not an effective safety strategy
By J.B. Titus
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LNS Research has released its Enterprise Quality Management Software Selection Guide, which looks at 18 major vendors in the spaces and offers comparisons on performance and applicability to individual industries. Matthew Lit-tlefield, president and principle ana-lyst at LNS Research, discussed with CFE Media the value of measuring quality with software, and how the acceptance of such tools is growing throughout the plant.
Plant Engineering: In evaluating the top vendors for Enterprise Quality Management Software, what crite-ria would you say is most critical for an effective system for end users?
Littlefield: There are a number of factors that determine how well suited a particular vendor is for a particular client. First and foremost I think comes industry experience, some vendors have experience in life sciences, others have experi-ence in discrete manufacturing like automotive or aerospace and defense, still others have started to develop experience in consumer products or food and beverage. The drivers and needs are very different in all these industries and very few vendors have expertise across all these industries.
Second, I would say existing IT infrastructure, some com-panies are heavily invested in ERP, others have a large PLM footprint, still others have disparate systems at the enterprise level, again different vendors have different strengths in this regard. Finally I would recommend looking at the technology itself. Originally EQMS vendors were very form based, over time many have updated their technology to be work-flow based that has a more solid data model and ability to inter-operate with other systems through web-services.
Finally, is the vendor continuing to invest in areas like BI, Mobility, and an enhanced user-experience. Some companies are and others are still behind the curve.
PE: Why is software the best measuring tool for qual-ity? What industries might benefit the most from such a system? Conversely, which industries are not a good fit for EQMS?
Littlefield: Software is an important tool for a number of reasons but I think one that stands out the most is our changing business environment. Companies are continuing to expand globally, products are continuing to increase in complex-ity, regulations continue to expand, and consumer demands continue to increase.
Companies that don’t specifically invest in a platform to manage how quality impacts the entire value chain and how Enterprise Quality Management Software Selection Guide, which looks at 18 major vendors in the spaces and offers comparisons on performance and applicability to individual industries. Matthew Lit-tlefield, president and principle ana-lyst at LNS Research, discussed with CFE Media the value of measuring quality with software, and how the acceptance of such tools is growing throughout the plant.
18 • November 2012 PLANTENGINEERING
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plantengineering November 2012 • 19 quality addresses all these market drivers will be at a distinct competitive disadvantage.
From an industry perspective, industries that have high risk products, high risk processes, a deep impact on con-sumers, or a restrictive regulatory environment are all can-didates for EQMS, including life sciences, consumer prod-ucts, discrete manufacturing, and process manufacturing.
PE: You mentioned the education process is critical in a successful deployment of EQMS. How far into the orga-nization does this training need to go?
Littlefield: For a quality culture to take hold, it truly has to go to the operator level. Continuous improvement, non-conformance management, compliance, and more all have to be managed at the most granular level possible. We are now seeing some companies that have 10,000-plus users on EQMS systems.
PE: What are the leading causes of failure for EQMS, or any operating system for that matter?
Littlefield: Very rarely is the technology to blame itself, although that could be the case with some vendors that have not kept based with investments in their products. Most likely that failure comes from executive leadership not promoting and believing in a quality culture. If executives do not walk the walk it can be very challenging to have the right culture and technology adoption flow through the organizations
PE: What’s the potential ROI for a successful imple-mentation?
Littlefield: ROI is tough to measure in the EQMS world and many companies don’t. Although there are two ways we are starting to see companies measure ROI. First is around the Cost of Quality and second is around risk reduction. Both are viable ways for measuring business success and companies that invest in EQMS can often see major improvements in these metrics, often providing an ROI in less than 1 year.
PE: Why might this be a good time for manufacturers looking to upgrade their quality management process?
Littlefield: We have seen companies be most successful with EQMS in two major ways. One if there is a major quality issue or compliance issue at your company, adopting software maybe a very prudent step for correction.
Second, if your company is focused on a new (or improv-ing an old) operational excellence initiative, EQMS can help in the success of these initiatives and building quality into operational excellence. PE
“
For a quality culture to take hold, it truly has
to go to the operator level. Continuous
improve-ment, non-conformance manageimprove-ment,
compli-ance, and more all have to be managed at the
most granular level possible.
”
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20 • November 2012 plantengineering What comes first: corrective or
pre-ventive maintenance? Well, the industrial engineers would say “PM,” of course. But the reality of busy schedules and a
reduced labor force often set in and best laid plans slip.
Example: Company X has older,
inef-ficient ventilation in one of its produc-tion facilities. The HVAC breaks down frequently, is expensive to run, and finally
management agrees to replace it with a brand new, more energy efficient sys-tem. Since the conversion, air quality and temperature have never been better, and the cost savings is tangible.
During installation, the manufacturer strongly advises Company X to follow a recommended maintenance plan. The maintenance supervisor asks her admin-istrator to make sure the PM calendar is set up in the CMMS. The team is so happy to not be dealing with the older, often malfunctioning system they won-der, “Why bother doing anything; the system is brand new!”
PMs are dutifully set up and the auto-mated reminders/PM work orders churn out every month. The challenge begins when the technician assigned tries to balance PM work orders on a combina-tion of assets, including a shiny, new ventilation system and other antiquated, poorly-running systems that should be replaced.
The reality is that technicians will likely continue to “MacGyver” older systems to keep them running and the new system will be ignored since it is humming along nicely. There are just not enough hours in the day. Reality forces us to make compromises.
Sometimes these choices have to be made. If all of a sudden the CMMS issues an actual corrective maintenance work order for this system, it indicates that the team has to get back to a more frequent schedule, but it may not need to be as frequent as the manufacturer’s recom-mendations.
A good CMMS system can deliver the information users need to better fine-tune their PM schedules. If a less-rigorous PM schedule gets the maintenance team slapped with a corrective work order, it’s time to adjust. Sometimes it is the other way around. If the CMMS system tells the maintenance manager ‘all is well’ with an asset, that may be a signal to shift resources to other equipment in greater need. PE
Paul Lachance is president and chief technology officer for Smartware Group, which produces Bigfoot CMMS. Contact Paul at paul.lachance@bigfootcmms. com.
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Fine tuning your preventive maintenance schedule
By Paul Lachance, Smartware Group
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