The document provides an overview of new products, services, and enhancements from Rockwell Automation related to maintenance. Some highlights include:
- New Ethernet Diagnostic Module and XM vibration modules to monitor equipment health.
- Enhancements to intelligent motor control solutions to simplify maintenance.
- RSMACC change management software adding verification for Rockwell Automation drives.
- Acquisition of GEPA to expand connectivity to third-party devices.
- New training courses and workstations on topics like RSLogix 5000 motion and EtherNet/IP.
Whitepaper: The Next Evolution of Yokogawa CENTUMYokogawa
In 2014 Yokogawa is adding significant new capabilities to CENTUM VP. Now the New CENTUM VP becomes the platform for delivering four new innovations; Hyper-intuitive
Operation, Total Automation Management, Intelligent Plant Conductor, and Sustainable Plant Operation. Each innovation addresses pain points felt by today’s plant owner-operators as they strive for greater operational
integrity. Yokogawa has emphasized its objective to especially leverage two enabling technologies in this development program; field digital technology and dynamic process simulation.
Repairs and maintenance of aircraft systems at Warner Robins
Air Logistics Center was tethered to an unreliable proprietary
control system prone to running the wrong recipes. The result:
irreparable damage to expensive airplane parts. Working with
PREMIER System Integrators, the organization implemented
a new solution with tightly integrated FactoryTalk® Batch,
Historian, VantagePoint® and ThinManager® software. The
new system has improved reliability and flexibility, boosting
utilization by 50 percent and saving tens of thousands of dollars
in under 60 days.
Whitepaper: The Next Evolution of Yokogawa CENTUMYokogawa
In 2014 Yokogawa is adding significant new capabilities to CENTUM VP. Now the New CENTUM VP becomes the platform for delivering four new innovations; Hyper-intuitive
Operation, Total Automation Management, Intelligent Plant Conductor, and Sustainable Plant Operation. Each innovation addresses pain points felt by today’s plant owner-operators as they strive for greater operational
integrity. Yokogawa has emphasized its objective to especially leverage two enabling technologies in this development program; field digital technology and dynamic process simulation.
Repairs and maintenance of aircraft systems at Warner Robins
Air Logistics Center was tethered to an unreliable proprietary
control system prone to running the wrong recipes. The result:
irreparable damage to expensive airplane parts. Working with
PREMIER System Integrators, the organization implemented
a new solution with tightly integrated FactoryTalk® Batch,
Historian, VantagePoint® and ThinManager® software. The
new system has improved reliability and flexibility, boosting
utilization by 50 percent and saving tens of thousands of dollars
in under 60 days.
Electric Control Valve Actuators for Industrial Process ApplicationsCTi Controltech
The Rotork CVA line of electric process control actuators offers a highly accurate and responsive method of automating control valves, without the complexity and cost of a pneumatic supply. With an increased focus on production costs and efficiency, accurate control of product through the pipeline is paramount. With resolution figures better than 0.1% and the ability to eliminate position overshoot, the Rotork CVA models help to maximize product quality and plant capacity.
Lenze makes many things easy for you.
With our motivated and committed approach, we work
together with you to create the best possible solution
and set your ideas in motion - whether you are looking
to optimise an existing machine or develop a new one.
We always strive to make things easy and seek perfection
therein. This is anchored in our thinking, in our
services and in every detail of our products. It's as easy
as that!
For more information, please contact your local Lenze office, or call me anytime on +44 1234 753216
Open Process Automation: Status of the O-PAS™ Standard, Conformance Certifica...Yokogawa1
Today, end users in the energy and chemical industries must work with and integrate multiple proprietary systems in almost every process plant or facility. These systems include manufacturing execution systems (MES), distributed control systems (DCS), human-machine interfaces (HMI), programmable logic controllers (PLC) and inputs/outputs (I/O). These multiple proprietary systems, and the integration thereof, result in elevated capital costs on new projects and high total cost of ownership through the asset lifecycle, especially in the operation and maintenance of such systems. The Open Process Automation™ Forum (OPAF) is an international forum of end users, system integrators, suppliers, academia, and standards organizations who are working together to develop the specifications for open process control systems. OPAF’s goal is to enable more open and modular systems that supports integration of best-in-class components. This architecture will provide both configuration and application portability across components from different suppliers, thereby reducing system capital cost and total cost of ownership. The vision is a standards-based, open, secure and interoperable process control architecture that reduces the cost of control system upgrades and replacements, as well as removes barriers to technology insertion, with adaptable cybersecurity designed in. This keynote presentation will outline the Open Process Automation initiative, standard and status of industry prototyping, as well as share evidence of commercialization.
Since 2007 there has been a choice of harmonised standards
to use for Functional Safety in the machinery sector.
The choices are:
ISO standard EN ISO 13849
IEC standard EN 62061
source TUV-SUD
www.regeltechnieken.org
www.ie-net.be/reg
We deal in manufacturing, supplying and exporting of Control Panels Automation Systems that are used in various applications across a range of industries. Our range includes PLC Panels, Power Factor Control Panels, Motor Control Centers, AMF Panels, Process Panel Meters, Touch Screens and HMI Panels, AC Drives, Power Distribution Boards, Mimic Control Desks etc.
The T2750 PAC hardware provides high-performance control with cost-effective redundancy options in a versatile modular system. Powerful instruments, the control units, and the I/O system form the basis of a complete distributed control and recording environment. This environment is capable of continuous analog, logic, sequential control, batch management, secure data recording at point of measurement, and setpoint programming.
Chapter 7 of the famous saga "the DO-254 for Dummies" from James BEZAMAT director of DMAP
subject : IP and verification process
More : dmap.fr
contact : contact@dmap.fr
Utilizing DeltaV Advanced Control Innovations to Improve Control PerformanceEmerson Exchange
Many functions of the DeltaV system are unique in the process industry. In this presentation we explore and discuss innovative features of the DeltaV PID and embedded Advanced Control products that can be applied to improve control performance. In particular, PID options are addressed that enhance cascade and override applications and allow effective single loop control using a sampled or wireless measurement. Application examples are used to illustrate how MPC can be easily added and commissioned online with no changes in the existing control strategy. Also, continuous data analytics is used an example that illustrates how future tools will enable improvements to be made in plant operations.
Biến tần Rockwell - tài liệu tổng quan biến tần PowerFlexLong Trump
Biến tần Rockwell - Tổng quan biến tần PowerFlex
Tài liệu cho cho chúng ta cái nhìn tổng thể về họ biến tần Power Flex của Rockwell Automation.
Để được tư vấn kỹ hơn về biến tần Rockwell các bạn liên hệ:
Công ty TNHH Công Nghệ Milo
http://www.milotech.vn
Email: sales.milotech@gmail.com
Tags: biến tần Rockwell, tổng quan biến tần rockwell, tài liệu biến tần rockwell, cataloge biến tần rockwell,
This presentation provides an overview of the book Control Loop Foundation. The book authors gave this presentation as a short course at Emerson Exchange 2010.
Nuestra empresa tiene como misión ofrecer tecnología para la colaboración en reuniones, formación o educación, sin importar que las personas estén en la misma sala o en cualquier punto del mundo, haciendo de las visiones compartidas la base del cambio.
Electric Control Valve Actuators for Industrial Process ApplicationsCTi Controltech
The Rotork CVA line of electric process control actuators offers a highly accurate and responsive method of automating control valves, without the complexity and cost of a pneumatic supply. With an increased focus on production costs and efficiency, accurate control of product through the pipeline is paramount. With resolution figures better than 0.1% and the ability to eliminate position overshoot, the Rotork CVA models help to maximize product quality and plant capacity.
Lenze makes many things easy for you.
With our motivated and committed approach, we work
together with you to create the best possible solution
and set your ideas in motion - whether you are looking
to optimise an existing machine or develop a new one.
We always strive to make things easy and seek perfection
therein. This is anchored in our thinking, in our
services and in every detail of our products. It's as easy
as that!
For more information, please contact your local Lenze office, or call me anytime on +44 1234 753216
Open Process Automation: Status of the O-PAS™ Standard, Conformance Certifica...Yokogawa1
Today, end users in the energy and chemical industries must work with and integrate multiple proprietary systems in almost every process plant or facility. These systems include manufacturing execution systems (MES), distributed control systems (DCS), human-machine interfaces (HMI), programmable logic controllers (PLC) and inputs/outputs (I/O). These multiple proprietary systems, and the integration thereof, result in elevated capital costs on new projects and high total cost of ownership through the asset lifecycle, especially in the operation and maintenance of such systems. The Open Process Automation™ Forum (OPAF) is an international forum of end users, system integrators, suppliers, academia, and standards organizations who are working together to develop the specifications for open process control systems. OPAF’s goal is to enable more open and modular systems that supports integration of best-in-class components. This architecture will provide both configuration and application portability across components from different suppliers, thereby reducing system capital cost and total cost of ownership. The vision is a standards-based, open, secure and interoperable process control architecture that reduces the cost of control system upgrades and replacements, as well as removes barriers to technology insertion, with adaptable cybersecurity designed in. This keynote presentation will outline the Open Process Automation initiative, standard and status of industry prototyping, as well as share evidence of commercialization.
Since 2007 there has been a choice of harmonised standards
to use for Functional Safety in the machinery sector.
The choices are:
ISO standard EN ISO 13849
IEC standard EN 62061
source TUV-SUD
www.regeltechnieken.org
www.ie-net.be/reg
We deal in manufacturing, supplying and exporting of Control Panels Automation Systems that are used in various applications across a range of industries. Our range includes PLC Panels, Power Factor Control Panels, Motor Control Centers, AMF Panels, Process Panel Meters, Touch Screens and HMI Panels, AC Drives, Power Distribution Boards, Mimic Control Desks etc.
The T2750 PAC hardware provides high-performance control with cost-effective redundancy options in a versatile modular system. Powerful instruments, the control units, and the I/O system form the basis of a complete distributed control and recording environment. This environment is capable of continuous analog, logic, sequential control, batch management, secure data recording at point of measurement, and setpoint programming.
Chapter 7 of the famous saga "the DO-254 for Dummies" from James BEZAMAT director of DMAP
subject : IP and verification process
More : dmap.fr
contact : contact@dmap.fr
Utilizing DeltaV Advanced Control Innovations to Improve Control PerformanceEmerson Exchange
Many functions of the DeltaV system are unique in the process industry. In this presentation we explore and discuss innovative features of the DeltaV PID and embedded Advanced Control products that can be applied to improve control performance. In particular, PID options are addressed that enhance cascade and override applications and allow effective single loop control using a sampled or wireless measurement. Application examples are used to illustrate how MPC can be easily added and commissioned online with no changes in the existing control strategy. Also, continuous data analytics is used an example that illustrates how future tools will enable improvements to be made in plant operations.
Biến tần Rockwell - tài liệu tổng quan biến tần PowerFlexLong Trump
Biến tần Rockwell - Tổng quan biến tần PowerFlex
Tài liệu cho cho chúng ta cái nhìn tổng thể về họ biến tần Power Flex của Rockwell Automation.
Để được tư vấn kỹ hơn về biến tần Rockwell các bạn liên hệ:
Công ty TNHH Công Nghệ Milo
http://www.milotech.vn
Email: sales.milotech@gmail.com
Tags: biến tần Rockwell, tổng quan biến tần rockwell, tài liệu biến tần rockwell, cataloge biến tần rockwell,
This presentation provides an overview of the book Control Loop Foundation. The book authors gave this presentation as a short course at Emerson Exchange 2010.
Nuestra empresa tiene como misión ofrecer tecnología para la colaboración en reuniones, formación o educación, sin importar que las personas estén en la misma sala o en cualquier punto del mundo, haciendo de las visiones compartidas la base del cambio.
Este artículo surge en el marco de la investigación “Tránsito digital en el ámbito educativo”, que se lleva a cabo dentro del Centro de Investigaciones Educativas TEBAS-UCV. A la luz de esta línea se desarrolló un informe en el cual se plantean problemas que van de los epistémico a lo interpretativo a través de la investigación y la producción de conocimiento y su constatación en la realidad con el apoyo de entrevistas y encuestas que han acompañado esta investigación. Este artículo toma uno de sus capítulos, el cual es de carácter inédito.
Dicha línea de investigación y sus aportes al conocimiento han servido de base al desarrollo de los Programas docentes que a lo largo de estos dos últimos años vengo adelantando en el post-grado de la UNEFA Núcleo Los Teques. A partir del cual se han elaborados contenidos digitales y se han dotado herramientas teóricas y prácticas que redundan en sendos beneficios a la práctica docente en Venezuela a través del uso de las Tics.
Create - Day 1 - 17:00 - "Buy Buttons: Shortening the Path to Conversion"PerformanceIN
Shortening the path to conversion has been an increasingly common trend within large media channels. Social media has been the most notable, with ‘Buy Now’ buttons cutting out the middle ground for social shoppers.
This form of streamlining can be great for the advertiser and great for the consumer, but NMP’s head of strategy Damien Bennett will delve into the pros and cons advertisers should be aware of when approaching these methods of acquisition.
Join Bennett for a session on the next wave of e-commerce and find out how it can keep a brand relevant while generating results
Mass tourism in historic cities, the role of civil organizations in the case ...Bunt Arquitectura
Malaga is the administrative capital of the Costa del Sol, however, it has remained out of the mass tourism
until the last decade. Coinciding with the obsolescence of the port facilities, the city has found an
opportunity in cruise tourism, becoming the second largest Spanish destination in this sector. The main
attractive of Malaga is being the birthplace of one of the most revolutionary painters, Pablo Picasso;
developing a large program for museums and hotels openings, cultural events and urban projects over the
last few years in order to create an atmosphere suitable for all visitors’ tastes. On the other hand, this
process is also creating monofunctional sectors, gentrification and theming of the principal Historic Site
areas. This implies to focus on restoration plans and on projecting an image according to the one that
tourists expect to see. In this context, several civil organizations have been formed to denounce heritage
losses, social marginality and identity simplification through collaborative works that join web 2.0,
participative cartography and academic research. We present a selection of these works.
Molecular hydrogen biomed-applications-888Morris Johnson
molecular hydrogen is a very simple yet never yet commercialized regenerative medicine agent.
My patent seeks to create the economic infrastructure to support a broad range of applications based upon a solid base of evidence for efficacy as an anti-aging tool.
Choosing the right PLC can be overwhelming for most people. If you’ve been tasked with determining what control solution is needed for your next application, a control system integrator (CSI) can be an excellent resource. A CSI should be technology agnostic. Their priority should be to understand your specific technical and commercial requirements.
Choosing the right PLC can be overwhelming for most people. If you’ve been tasked with determining what control solution is needed for your next application, a control system integrator (CSI) can be an excellent resource. A CSI should be technology agnostic. Their priority should be to understand your specific technical and commercial requirements.
IPCS Chennai Branch has long been renowned for its proficiency in industrial automation training and services. The training programmes we offer are up-to-date with regards to technical advances in order to compete in the fiercely competitive fields of PLC, SCADA, DCS, HMI, VFD, Panel Design, and Electrical Controls. Our training programmes are designed to be practically oriented and geared toward both freshmen and professionals to prepare them to fulfil industry standards. The list of programmes that are specifically designed for beginners, professionals, or industry experts.
Government, international certification, job-oriented training, and 100% placements are provided by IPCS Automation Chennai, a research-oriented training institute. PLC training, automation training, corporate training, marine automation, process control automation, machine automation, industrial automation, building management system training, SCADA training, DCS training, HMI training, VFD training, CCTV & security system training, BMS training, control panels designing training, calibration training, and embedded training are all provided by the IPCS Automation Chennai authorised training facility.
VigilantPlant is Yokogawa's automation concept for safe, reliable and profitable plant operations
Our concept is for a plant to be a place where people can be watchful and attentive, while the business responds quickly and efficiently to change. Non-stop production is assured as the plant’s personnel confidently expand their capabilities.
The traditional plywood manufacturing process usually requires a large amount of manpower and produces a significant amount of waste material. Then there is the question of safety hazards associated with manually operated machines. Therefore, manufacturers are always looking for ideas that reduce dependency on manpower, improve efficiency and boost overall productivity.
Our client was no different. They approached Messung for a cost-effective solution to control their plywood processing plant.
Implementation of T-Junction Traffic Light Control System Using Simatic S7-20...IJERA Editor
A conventional traffic light control system is designed by using devices such as timers, relays and
contactors etc. The critical timing operation is required to be carried out under the existence of heavy
traffic situations. This conventional practice leads to many problems that need additional maintenance
cost and subsequent delay for a long time. With the help of a PLC, the requirement of fast automation
and effective optimization of traffic light control system can be achieved. Use of PLC helps us to
develop this process not only for traffic signal on the roads, but also on the movement of trains and
the transfer of containers in ports in maritime works. In order to provide a solution to the above
problem, this paper introduces an execution and implementation of T-junction traffic control system
using SEIMENS S7-200 PLC. Programming in PLC is written in ladder logic with the help of STEP7
MICROWIN software
We will help create design automation solutions and services with our engineering experts to improve your plant with us. For assisting services call us today - (252)237-3399.
Mitsubishi ,
Catalog Thiết Bị Điện Mitsubishi , Catalog Thiết Bị Điện
Catalog Phụ Kiện Mitsubishi , Catalog Phụ Kiện,
Catalog Mitsubishi , Catalog,
https://www.dienhathe.com,
Chi tiết các sản phẩm khác của Mitsubishi tại https://dienhathe.com
Xem thêm các Catalog khác của Mitsubishi tại https://dienhathe.info
Để nhận báo giá sản phẩm Mitsubishi vui lòng gọi: 0907.764.966
2. FEATURES
4 What’s New in Maintenance
14 Feature Article
Measuring the Success of your
Maintenance Strategy
22 Industry Solutions
Maintenance in the Brewing Industry
24 Customer Results
Controlling the Compressor: Air Liquide
32 Tech Tips
Rockwell Automation Support Specialists
Help You Optimize the Performance of
Your Automation Assets
38 Q&A
Answers to Common Maintenance-related Issues
50 eTools
56 Products, Services & Support
88 What’s Next in Maintenance
New Rockwell Automation Products, Product
Enhancements and Services related to
Maintenance that will be available soon
91 Contacting Rockwell Automation®
Services & Support
24
theSuccessof your
Sucu
Maintenance Strate
y
Measuring
FEATURE ARTICLE
22
Kevin Oswald (
kjoswald@ra.ro
Contributing edi
Laurie Rehberga
Lori Knapper, St
Georgene Berma
Jan Zuehlke, Ka
SM Editorial Final R1.indd 2SM Editorial Final R1.indd 2l R1.indd 2 7/25/06 2:01:40 PM7/7/2/25/5/0/06 2:01:401:40 PM0 PM
3. strategic
maintenance
PRODUCTS,
SERVICES &
SUPPORT
58 ASSESSMENT SERVICES
60 CONDITION MONITORING
• Condition Monitoring Systems
• Emonitor®
Software
• Condition Monitoring Services
68 ASSET MANAGEMENT
• Asset Management Services
• RSMACC™
Software
72 SUPPORT
• Remote Support Services
• OnSite Support Services
76 NETWORKS & COMMUNICATIONS
• Network & Security Services
• Remote Access Dial-in Modems
80 TRAINING SERVICES
86 REPAIR SERVICES & RENEWAL PARTS
NOTE: Service availability/features may vary by country or region.
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4. WHAT’S
IN MAINTENANCE
NEW
4
www.rockwellautomation.com/services/rmd/enetmodule
ETHERNET DIAGNOSTIC MODULE
Maximize your network uptime and overall productivity by monitoring network status
through the control system. With the Allen-Bradley®
Ethernet Diagnostic Module
(9300-8EDM), you now have real-time access to critical network data through your
Logix-based control system. The Ethernet Diagnostic Module appears as standard
I/O, seamlessly integrating into Logix programs and updating tags automatically.
This allows you to continuously monitor your network for configuration changes,
traffic overload, and unauthorized access – and proactively implement changes
to prevent a significant reduction in performance or unplanned downtime event.
www.rockwellautomation.com/services/conditionmonitoring/protection.html
XM®
160 SERIES OVERALL VIBRATION MODULES
XM®
is Allen-Bradley’s
award winning family
of distributed machine
condition monitoring
and protection devices.
With the comprehensive
XM family, discreet or networked
monitoring solutions can be quickly and cost
effectively deployed for steam, gas/hydro turbines,
motors, compressors, pumps, fans, blowers and most
other rotating machinery.
The XM 160 Series of Overall Vibration Modules
are intelligent 6-channel monitors designed to cost
effectively serve applications for real time monitoring
of overall (direct) vibration levels. Designed as a
simple but complete monitoring system in a compact,
easily installed, easily maintained package, each
module measures and reports the overall vibration
level between selected high and low pass filters, as
well as the bias (gap) voltage per channel.
The XM 160 Series includes three modules:
XM-160 Overall Vibration Module offers
an economical solution for monitoring of
accelerometers and self or externally powered
sensors. Via DeviceNet™
, the module can be easily
integrated with other XM modules, PLC controllers,
DCS systems, graphical displays (HMI) and condition
monitoring systems. For standalone applications, the
XM-160 includes comprehensive alarm logic per
channel and supports linking of up to two XM-441
Expansion Relay modules thereby providing a total
capacity of up to 8 relays.
XM-161 Overall Vibration Module offers
the same capabilities as the standard XM-160 but
also includes a 4-20mA output for each channel.
XM-162 Overall Vibration Module offers
the same capabilities as the standard XM-160
but incorporates a DC power supply suitable for
powering standard -24V eddy current (proximity)
probe drivers.
SM Editorial Final R1.indd 4SM Editorial Final R1.il Final R1.indd 4ndd 4 7/25/06 2:01:45 PM7/7/2/25/5/0/06 2:01:456 2:01:45 PM5 PM
5. WHAT’S NEWIN MAINTENANCE
55
www.rockwellautomation.com/solutions/intelligentcontrol
INTELLIGENT MOTOR CONTROL SOLUTIONS
Reduce your maintenance costs and downtime with our comprehensive
portfolio of Intelligent Motor Control products. As part of a truly Integrated
Architecture, these products can help you:
• simplify your start-up
• reduce your installed cost
• make it easier for you to access essential plant and production data
With the following enhancements, you can now realize greater
maintenance related benefits from our Intelligent Motor Control products:
Across-the-line Starting
with E1 Plus Electronic Overload Relays
The new E1 Plus offers a self-powered design, responsive phase loss detection, wide
5:1 adjustment range, and DIP switch selectable trip class for flexible application.
The optional, side-mounting DeviceNet™
module offers two discreet inputs and an
output relay for motor starter related I/O. Protection enhancing functions include:
overload warning, jam trip and warning, and underload warning.
Pre-Packaged Motor Control
with IntelliCENTER®
RR Motor Control Centers
IntelliCENTER®
Software Version 2 further enhances
your intelligent motor control experience with easy
online configuration, electronic documentation and
pre-configured screens for monitoring devices. Using
IntelliCENTER software, a typical maintenance
electrician can quickly learn to configure, monitor
and troubleshoot electronic motor controls without
first becoming a network expert.
Variable Speed Control
with PowerFlex®
x AC Drives
Regenerative Liquid-Cooled PowerFlex drives utilize integrated active converter
technology and also offer improved power quality over a wide range of industrial
power voltages. Easy to use features include:
• Simplified programming with full-featured LCD Human Interface Module (HIM),
multi-line and multi-lingual display
• Effortless configuring and tuning of the drive with S.M.A.R.T™
start and
detailed assisted start-up routines in the LCD HIM
• Straight forward programming, configuration, monitoring and troubleshooting
are easier with PC software tools, such as DriveExplorer™
, DriveTools™
SP
and RSLogix™
5000
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6. WHAT’S NEWIN MAINTENANCE
6
www.rockwellautomation.com/rockwellsoftware/assetmgmt/rsmacc/index.html
Rockwell Software Maintenance Automation Control Center (RSMACC) Change
Management software has added Verification functionality for Rockwell Automation
drives through the Verification add-on. The Verification add-on provides back-up
of Rockwell Automation drives configurations and a comparison of the current
Rockwell Automation drive configuration to the master configuration.
To use the Verification add-on, the drives must be on a network. Supported
networks include DeviceNet™
, ControlNet™
, Ethernet/IP™
, and Data Highway Plus™
(1336T Force and 1395 only).
RSMACC software offers an integrated, modular approach that lets you
proactively and centrally manage your automated production environment by:
• Securing access to the control system
• Tracking users’ actions
• Managing asset configuration files
• Providing backup and recovery of operating asset configuration files
(disaster recovery)
By providing a single point of access for gathering, analyzing, and managing control
system information across your enterprise, RSMACC gives you intimate knowledge to
make better maintenance and operational decisions.
RSMACC™
CHANGE MANAGEMENT SOFTWARE
ADDS VERIFICATION FUNCTIONALITY FOR
ROCKWELL AUTOMATION DRIVES
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7. WHAT’S NEWIN MAINTENANCE
7
www.rockwellautomation.com/rockwellsoftware/news/
Rockwell Automation recently acquired GEPA mbH, a leading European provider
of change management software for industrial automation, process control and
industrial information technology. The acquisition of GEPA complements the
company’s strategy for expanding the asset management offerings within its
FactoryTalk®
integrated production and performance suite.
Headquartered in Landau, Germany, GEPA has been providing its VersionWorks®
for Automation software application to a primarily European customer base
for nearly a decade. A modular change management software program,
VersionWorks helps manufacturers schedule automatic program backups from
controllers and other industrial devices, document change processes required
for regulatory compliance, and recover data quickly and more cost-effectively
following a disaster.
In late 2005, Rockwell Automation announced plans to create an integrated
suite of plant-wide information software - Rockwell Software FactoryTalk - through
both development and acquisition. GEPA VersionWorks complements Rockwell
Software RSMACC™
change management software, and includes change
management and version control functionality for Siemens, Beckhoff, Schneider,
Wonderware, Citect, ABB, Fanuc and Kuka robotics, among others. In future
releases, VersionWorks and RSMACC will merge into a single product called
FactoryTalk AssetCentre as part of the FactoryTalk suite.
By leveraging GEPA’s intimate third-party knowledge base, Rockwell Automation
will begin to extend its connectivity to third-party devices throughout the
FactoryTalk suite resulting in better plant asset utilization.
ROCKWELL AUTOMATION ACQUIRES
CHANGE MANAGEMENT SOFTWARE COMPANY
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8. www.rockwellautomation.com/services/training/workstations.html
WHAT’S NEWIN MAINTENANCE
88
www.rockwellautomation.com/rockwellsoftware/assetmgmt/security/index.html
Today’s manufacturing environment demands that you be
flexible and quick to act. The demands are high, but at
what cost to your plant security?
FactoryTalk®
Security Software provides centralized
authentication and access control by verifying the identity
of each user who attempts to access the automation
system, and then by either granting or denying each user’s
request to perform actions on resources within the system.
A “securable resource” is any object in an automation
system to which a security setting can be applied, such
as the automation system itself, applications, areas within
applications, networks and devices, and system-wide
policies. Each resource is associated with a set of actions
that can be performed on it, such as “read,” “write,”
“go online,” “delete,” and so on.
For each resource, a security setting identifies which users
(or groups of users) are granted or denied permission to
perform particular actions on this resource from specific
computers (or groups of computers).
FACTORYTALK®
KK SECURITY SOFTWARE*
INTEGRATED ARCHITECTURE WORKSTATION
Providing hands-on experience for training or pre-deployment testing allows you to
simulate real-life plant issues in a no risk environment. Built from the same proven
Rockwell Automation technologies you use every day, our Integrated Architecture
workstation will help you develop and build a solid foundation of Integrated
Architecture and automation system knowledge. The Integrated Architecture workstation
will allow you to establish communications, program a basic RSLogix™
5000 project
and configure drives, motion, and visualization applications. NetLinx-enabled networks,
DeviceNet™
, ControlNet™
, and EtherNet/IP™
will be included for distributed control.
* formerly RSAssetSecurity™
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9. www.rockwellautomation.com/services/repair/
www.rockwellautomation.com/services/phone/
WHAT’S NEWIN MAINTENANCE
9
REPAIRTRAK
SM
PROGRAM
RepairTrakSM
is a unique repair program which provides the
tools to improve the reliability and availability of your electronic
manufacturing equipment - starting with the right spare parts when
you need them!
The foundation of RepairTrak is Rockwell Automation’s
comprehensive Remanufacturing Service. But RepairTrak is much
more. It also includes a 3-Year Warranty on remanufactured
equipment and a variety of tools to help you better understand
your equipment usage, what caused it to fail and even locate the
status of your repair(s) currently in the remanufacturing loop. Your
local distributor will pick up your failed or malfunctioning items
through our BoardRunner™
service to begin the repair process.
Expanded access to our online repair
management Web site
• Access plant specific reports
• Determine repair status in the
remanufacturing loop
• Track shipments back to
your facility
• Request/access remanufacturing
& repair prices
World class remanufacturing services
• Original component replacement
• Product updates/revisions/
engineering change records
• Testing to Rockwell Automation
design specifications
Plant specific pareto analysis &
probable cause & warranty reports
• Better understand plant
usage patterns
• Uncover corrective
engineering opportunities
• Understand reasons for circuit
board failures
• Review parts replaced in
the manufacturing process
ENTERPRISE TECHCONNECT
SM
SUPPORT
Enterprise TechConnectSM
provides the features of TechConnect Support in a single
agreement covering all of your sites. Benefits of the single agreement include:
• Simple contract administration – one agreement to purchase, one universal
authorization number, and one expiration date for easy renewal
• Consistent support coverage across all sites
• Universal access to the most current software updates for all sites
• Support activity reports to help manage your operations, software
licensing and training requirements
• Multi-year pricing options
Complete RepairTrak features include:
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10. WHAT’S NEWIN MAINTENANCE
10
www.rockwellautomation.com/services/training/rstlx5kmot.html
RSLOGIX™
5000 MOTION SELF-PACED TRAINING COURSE
This interactive, self-paced training course teaches the core tasks required
to effectively program motion control applications. The course is available
in both computer-based and web-based delivery formats and is part of a
series of self-paced training courses on using RSLogix™
5000 software.
In this course, you will learn how to configure servo modules, program
motion instructions, and test and tune axes through step-by-step
demonstrations. Through the demonstrations, you will learn about the various settings and options
in the software and see how to perform the required tasks for motion applications.
The course includes a variety of knowledge and learning tools including animations, background
information, interactive simulations and links to other reference materials. These tools, combined with
the step-by-step demonstrations, provide the knowledge and skills required to perform each task.
You have the opportunity to practice software tasks through interactive simulations. The simulations guide
you through the required steps and give immediate feedback on your performance to reinforce learning.
www.rockwellautomation.com/services/training/workstations.html
ETHERNET/IP™
TRAINING WORKSTATION
This self contained EtherNet/IP™
network allows you to control analog and
digital I/O from a variety of platforms while monitoring the health of the
network using EtherNet/IP modules’ built-in web-enabled technologies. The
workstation can be used to extend your network design and configuration
skills, enhance your network troubleshooting skills, and reinforce other
network skills developed during a training class. It is a hands-on resource to get you up-to-speed on
EtherNet/IP technology or maintain on-the-job skills in a no risk environment. You can develop and
test new projects in advance of actual implementation, helping you get the most benefit from your
investments in technology and employees.
This workstation can be used in conjunction with the following products:
• EtherNet/IP Network Procedures Guide
• EtherNet/IP Networks Documentation Reference Guide CD-ROM
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11. WHAT’S NEWIN MAINTENANCE
11
www.rockwellautomation.com/services/training/schedules.html
INTRODUCTION TO AUTOMATION AND INTEGRATED
ARCHITECTURE INSTRUCTOR-LED TRAINING COURSE
This two-day, introductory course develops and builds a solid
foundation in Integrated Architecture and automation system
knowledge. It will give you a broad understanding of automation
products and serves as an excellent first step when beginning any
automation training.
Your classroom experience includes hands-on instruction using a
variety of automation equipment including Rockwell Automation
software to perform basic system configuration tasks. While
performing these tasks, you will gain an understanding of how
controllers, drives, motors, networks, and HMI products function
together within Integrated Architecture.
Course Agenda:
• Identifying Components of
Integrated Architecture
• Establishing Communications
in an Integrated System
• Identifying Programming Languages
in an Integrated System
• Programming a Basic RSLogix™
5000
Project for an Integrated System
• Programming with Tag-Based
Addressing in an Integrated System
• Understanding Logix5000™
Multi-Discipline Control
• Understanding NetLinx-Enabled Networks
• Understanding the Visualization
Development Environment of an
Integrated System
• Understanding HMI Direct Tag
Referencing in an Integrated System
To view course dates and locations, go to: www.rockwellautomation.com/services/training/schedules.html
TRAINING VOUCHERS
Do you have diverse employee development needs but a limited training budget?
Our Training Voucher Account maximizes your training budget by allowing you to
prepurchase vouchers for Rockwell Automation training courses and products at
a discounted cost (up to 20%). You can redeem the vouchers at the time that best
meets the individual needs and schedule of each employee.
The vouchers can be redeemed at any time within one year for instructor-led
courses, self-paced training, job aids, and workstations. A convenient online
account management tool and monthly statement help you track your
voucher usage.
www.rockwellautomation.com/services/training/savingsprogram.html
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12. WHAT’S NEWIN MAINTENANCE
12
www.rockwellautomation.com/services/onsite/conversion.html
HMI CONVERSION SERVICES
With HMI Conversion Services from Rockwell Automation, you can
leverage our automation expertise to help you successfully migrate
from PanelView™
to PanelView™
Plus operator terminals. With these
services, you can realize the following benefits:
• Improved process availability and production capacity
• Improved manufacturing quality
• Decreased long term costs and unplanned downtime
HMI Conversion Services begin with a review of your organization’s
goals, objectives, specific site requirements, existing HMI inventory and
hardware and software programming. A service scope of supply for
the project will be developed, and a fixed price proposal is submitted
for your approval.
Upon acceptance, Rockwell Automation will be with you every step of
the way throughout the conversion project – from project leadership to
start-up and acceptance.
Project Leadership
A Rockwell Automation project leader will be assigned to be your
primary contact and coordinate/schedule all project activities.
On-site Assessment
Using standardized checklists and processes, our primary engineer
will confirm project scope, validate project risks, review testing and
acceptance criteria, and gather the required information and software
to convert existing screens and software code.
Conversion Engineering
Utilizing applications designed to convert existing screens and code,
our engineers will complete and test the screen conversion process
and any required PLC code changes necessary for a like conversion.
Start-up and Acceptance
Prior to site installation, all software will be loaded on the new
terminals and a functional test will be performed. Following installation,
our engineer will work closely with you to perform an operational test
for each machine. This test will validate the conversion and ensure
operational compliance. Complete documentation will be provided
upon acceptance of the project.
>>>
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13. www.rockwellautomation.com/services/rmd
WHAT’S NEWIN MAINTENANCE
13
www.rockwellautomation.com/services/
ONLINE MAINTENANCE
REPORTING AND ANALYSIS
Turning condition monitoring data into actionable predictive
maintenance is key to a successful Condition-based Maintenance
(CbM) program. However, collecting and analyzing data can
often be a difficult and time-consuming task.
With the new online maintenance reporting and analysis tool
from Rockwell Automation, you can easily sort, filter and summarize condition monitoring
data to maximize the benefits from your CbM program. Functions include:
• Sort at the corporation, regional, business or plant level
• Filter by collection dates, equipment, equipment type, problem severity or current
maintenance status
• Report/trend potential problems and view recommended/executed corrective action for each
• Edit program data to ensure the reported information has maximum benefit within
the specific maintenance process
• Calculate cost savings of proactive maintenance versus run to failure methods to help
determine the return on your CbM program investment
The online maintenance reporting and analysis tool is also flexible, working as an automated
gateway with existing Computerized Maintenance Management Systems.
TEAMSUPPORT™ 360 SERVICES
TeamSupport™
360 Services provide continuous remote
monitoring and 24x7 proactive technical support to help
you improve Overall Equipment Effectiveness and optimize
human performance. TeamSupport 360 helps provide a
competitive advantage to manufactures by:
• Reducing scheduled and unscheduled downtime
• Improving machine performance
• Reducing startup and changeover times
• Driving operational consistency
• Guiding operators and technicians through troubleshooting
• Providing accurate, real-time performance data to make
informed business and automation decisions
At the heart of every TeamSupport 360 program is a core team of experienced Rockwell Automation engineers that have
reviewed your specific application(s) and have your most recent system documentation on hand. Our engineers will act as
an extension of your maintenance and engineering organization by providing real-time monitoring and analysis of your
production data via a secure, high-speed web-enabled connection to your automation network(s). Combining engineering
experience with software-based diagnostic tools, our team will proactively respond to critical alarms and will immediately
contact your plant personnel to suggest corrective actions. With TeamSupport 360, in the unlikely event an issue cannot
be resolved remotely, Rockwell Automation will dispatch a local field service engineer to your facility at our expense.
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14. Measuring
theSuccess
of your Maintenance Strategy
By Scott Teerlinck
Director, Commercial Marketing
Customer Support & Maintenance
Rockwell Automation
For many companies, manufacturing and production equipment often represent their single largest capital
investment. Furthermore, the maintenance of these assets can significantly impact the top and bottom line.
However, despite the financial impact of maintenance, many organizations have not established a consistent
method to measure the value of their maintenance activities. Often this results in underestimating the impact
maintenance can have on the financial performance of the firm.
Developing a methodology for measuring your production processes provides guidance for needed maintenance
activities and shows a continual impact on return on investment (ROI). After you establish metrics for maintenance
activities, you can also justify the value of current activities and support the case for new initiatives. This is especially
true when initiating a major change to your maintenance strategy, such as moving from a reactive approach to
a proactive approach to maintenance. Without tangible evidence in the form of objective performance data,
obtaining full support from management to make the change is more difficult to achieve.
F E A T U R E A R T I C L E
14
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15. T
ancehe cornerstone for any successful maintena
strategy begins with clearly defining and
ness).communicating goals (production and busi
mance,Without clearly defining the desired perfor
neratealong with the reasons for it, companies often gen
vital toa long list of metrics, yet overlook many that are v
making critical performance-enhancing decisions.
forWhile most companies collect performance data
e informationproduction assets, the challenge is to focus on the
that is most relevant. Managing with the right metrics allowthat is most relevant. Managing with the right me
companies to thoroughly understand the effect maintenance
efforts can have on overall financial performance.
Today, companies are turning to a variety of financial metrics,Today, companies are turning to a variety of fina
commonlysuch as Return On Net Assets (RONA). RONA is
a companyused by plant management to calculate how well
aintenanceleverages production assets to generate profit. Ma
on for RONA:ies impact all three variables of the equatio
.us Costs divided by Net Assets.
ccess ofmeasure the suc
ctivenessa maintenance strategy is Overall Equipment Effec
w efficiently(OEE). OEE is a statistical metric to determine how
ulateda production line or machine is running. It is calcu
ity andby multiplying a machine’s production Rate, Qual
hreeAvailability. In other words, the product of these th
towardratios is the relative value a machine contributes to
full production.full production
All companies have data and information but many do not
properly collect or analyze it to make informed decisions.
Proper analysis of the right metrics can help reduce spare
parts inventory, boost availability and maximize uptime of
production assets. Although maintenance has been proven
to impact all of the above, it is most commonly focused on
reducing downtime.
A leading semiconductor manufacturer’s
decision to migrate toward a more
predictive maintenance strategy was
directly tied to its business goals. In an
industry where a few hours of downtime can result in millions
of dollars in losses, success is measured by uptime.
In semiconductor manufacturing, every part of the facility
plays a critical role in the process. If any part of the facility
fails, such as the plant power grid, HVAC or water treatment
system, production could come to a rapid - and costly
- standstill. Using advanced condition monitoring technology,
the company designed and implemented a comprehensive
predictive maintenance program that allows it to effectively
monitor, analyze and track equipment performance -
observing operating conditions locally as well as remotely,
across multiple production sites.
The reality is
that replacing a
fan or pump motor is
a fraction of the cost of having a fabrication line down for
any amount of time. If production is down for even one or
two hours, the lost revenue would far exceed the cost of a
replacement motor, or any other ancillary component.
Since implementing the predictive maintenance program,
the company has found countless minor vibration issues and
identified several hundred major vibration problems, which
were corrected before a prolonged production shutdown
occurred. More importantly, it has realized a five-to-one return
on investment (ROI) for the condition monitoring equipment,
and the program helped the company avoid estimated lost-
production costs of more than $1.4 million in a single year.
A complete review of
maintenance operations and
the physical asset management
process can help identify
equipment and operator performance issues and outline
recommended corrective actions that can be implemented
through maintenance initiatives. For example, in critical
applications, companies may want to have redundant or
backup equipment in place to avoid production interruptions
in the event the primary piece of equipment fails or needs
to be shutdown.
This type of in-depth evaluation is important because it
gives a baseline for making improvements and validating
results. It also can help determine which maintenance
activities will have the most impact on the company’s core
business objectives and can assist in identifying key areas of
improvement, including if a different approach (predictive vs.
reactive) will be more effective.
Once you’ve identified the most critical elements impacting
production performance, you can begin to make a physical
linkage between the maintenance approach for production
assets and improved results.
Determining What to Measure
Revenue
Expenses
Assets
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16. A STRATEGIC APPROACH TO MAINTENANCE
Characteristics of a PREDICTIVE
MAINTENANCE Approach
• Maintenance actions performed
when a need is identified
• Use comparative date to assess
the probability of future events
and performance
Apply a predictive approach:
• When downtime avoidance is critical
• If product quality is affected
• When repair and replacement
costs are high
PREDICT
16
F E A T U R E A R T I C L E
To meet today’s more demanding production and business
goals, you can no longer take an a la carte approach to
maintaining production assets. Instead, it is now necessary
for you to use a strategic approach to maintenance.
Strategic maintenance includes a comprehensive plan
that identifies maintenance-related issues across every
organizational function within your company and then
specifies and implements the system architecture and
predictive, preventive and reactive maintenance methods
to meet your needs and objectives. By implementing the
right architecture and maintenance methods, you can
obtain the following benefits:
Characteristics of a REACTIVE MAINTENANCE Approach
• “Run till it breaks”
• No routine tasks are performed
• Equipment is repaired/replaced only when obvious problems occur
Apply a reactive approach:
• When length and frequency of downtime is not critical
• When product quality is unaffected by downtime events
• If repair or replacement costs are not an issue
REACT
Characteristics of a PREVENTIVE
MAINTENANCE Approach
• A time-based approach where
actions are performed on a
predetermined, periodic basis
• Anticipates and prepares for
planned downtime
Apply a preventive approach:
• When failure mode is well established
• When warranty terms require it
• When cost of repair or replacement
is relatively small
PREVENT
Return on Net Assets (RONA) and Overall Equipment Effectiveness (OEE)
are often used to measure the success of a maintenance strategy.
To assure objectives are met, the proper internal and external
resources are identified to execute the specified maintenance
activities, and the effects of the activities are continuously
measured. While many key performance indicators can be
measured, improvement in just two – Overall Equipment
Effectiveness (OEE) and Return on Net Assets (RONA)
– can validate your maintenance strategy.
Overall Equipment Effectiveness (OEE)
% Availability x
% Quality x
% Rate =
= Return on Net Assests (RONA)
Net Assest
Plant Revenue -
Costs
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17. Any established metrics should focus on the level of improvement required to
move from the current level of performance to the desired level. Defining this
difference enables companies to better determine the specific maintenance
actions, strategies and initiatives they need to undertake. To establish a
successful measurement system, managers need to know:
• The desired level of performance in quantifiable terms
• How the current performance levels are to be determined
• Specific actions that can be taken to close the gap
between the current level and desired level.
Performance measures should reflect how the maintenance department is
providing value. For instance, in the power generation industry, the expense
of downtime is calculated in cost-avoidance terms based on the profit from
generating a megawatt-hour of electricity. Depending on the plant, the profit
for a megawatt-hour varies drastically - ranging from $5 to $25 per hour.
At one 56MW power plant in California, the cost-avoidance is calculated
at $21 per megawatt hour. Therefore, downtime at this plant could cost
upwards of $11,000 an hour (or $265,000 a day).
By measuring the value of the downtime for a production department or unit, you
can often quickly determine how and where to place your maintenance efforts.
This enables you to more accurately focus your maintenance plan on the areas
that will have the most financial impact when downtime occurs. You can then
record the cost of failures while focusing efforts directly to those causes.
In some cases, depending on the size of the plant, the type and volume of
data needed to formulate the necessary metrics are not always available.
In these instances, implementing the data collection or measurement technology
can be an investment in itself. For example, you may need a software package
to collect information to help measure production rates, equipment availability
or the amount of scrap coming off the line. With the data collected, you can
then begin to build your metrics off that data.
In an industry where margins are low and parts are needed on a 24/7
basis, the correlation between equipment uptime and profitability
is abundantly clear for the semiconductor supplier referenced
earlier. To maximize equipment reliability, the company established
a comprehensive spare parts management program that has
helped it improve parts availability, increase manufacturing efficiency, reduce
downtime and minimize its spare parts inventory investment.
The parts program has been instrumental in helping the company meet its
aggressive production goals while minimizing costly downtime. Since putting
the program in place, the company has reduced its spare parts
inventory by 25%, helping save approximately $250,000
in inventory expenses. Moreover, it credits the parts program for helping the
facility boost its capacity by 250% - which helps the company significantly
increase its return on net assets.
MeasuringSuccess
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18. F E A T U R E A R T I C L E
As previously mentioned, developing a methodology for
measuring your processes provides guidance for needed
maintenance activities and can justify the value of current
activities and support the case for new initiatives. Justifying
the value of maintenance requires a significant investment in
time and energy to not only establish accurate measurement
parameters, but also to effectively communicate the value
of maintenance and its relationship to the company’s
underlying business goals. It involves shifting management’s
attitude from one that sees maintenance as a necessary
expense, to one that views it as a driver of profitability.
When using metrics to guide your project plans, it is
important to stay objective, stick to the facts and understand
the business trends that drive the need for improvements.
For example, how does your parts management program
help improve equipment uptime and reduce expenses
related to lost production and scrap?
If management does not fully understand the impact that
maintenance activities can have on the organization
and overall business performance, it is less likely they
will support new initiatives or additional expenses.
As for a management discipline, companies are
still striving to realize the full potential and benefits
of using performance metrics as a proactive tool to
implement optimal maintenance strategies throughout
their organizations. When approached with a clear
understanding of the production issues and business
goals, metrics can be a powerful way of establishing
baselines, setting targets, determining the appropriate
maintenance methods to reach those targets, and most
importantly, measuring success.
18
The emergence of advanced automation and control
technology has made it much easier to calculate and
analyze maintenance-related metrics and their benefits.
For example, maintenance software systems can track
spare parts, compile time and costs, schedule work
and analyze equipment conditions.
To be functionally and cost-effective, data gathering
capabilities should be designed into the automation
system itself whenever possible allowing metrics to be
calculated as part of normal production activity. It is also
often easier to implement and less costly to include metric
capabilities at system conception than at a later time.
However, all metrics cannot be automatically collected
and in practice, you will need a mix of both “hard”
and “soft” measures. Also keep in mind that automation
systems and software can’t guarantee good maintenance
performance or compensate for a lack of fundamental
knowledge of what to measure and why.
In some cases, companies can boost manufacturing
efficiencies through improvements in operational
processes, such as inventory tracking and equipment
repair management. An effective inventory tracking
system can help companies track overall repair rates
and identify ways to build efficiencies into the process.
For instance, if a pattern of
repairs occurs on a particular
machine over a period of time,
storeroom managers can work
with maintenance engineers to
find and repair the root source
of the equipment failure.
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19. MeasuringSuccess
About the author
Scott Teerlinck, Director of Commercial Marketing for Customer Support and
Maintenance Business, Rockwell Automation
Scott joined Rockwell Automation in 1994 as a sales engineer trainee and has held
progressive positions within the field sales organization including Global Accountfi
Team Leader for Eastman Kodak and Branch Manager of the Rochester, NY office.fi
In June 2005, Scott was named Director, Commercial Marketing for the Customer
Support and Maintenance (CSM) Business. His role includes leading commercial
marketing and business development resources that interface with Rockwell Automation
sales employees, customers, and channel partners. Scott is responsible for identifying
and implementing commercial strategies and programs to help grow market share,
improve CSM profitability, and promote customer solutions on a world wide basis.fi
He also leads CSM efforts to coordinate marketing and strategic activities between
CSM and the other Rockwell Automation and third party businesses.
Scott earned his MBA from the Rochester Institute of Technology and his bachelor’s
degree in electrical engineering from the University of Wisconsin-Madison. He is
located in Milwaukee, where he reports to Mike Laszkiewicz, Vice President,
Customer Support and Maintenance Business.
KEYMETRICS
Return on Net Assets (RONA)
This metric calculates how well a company
converts assets to sales, and therefore profits.
The simple calculation is Plant Revenue minus
Costs divided by Net Assets.
Overall Equipment Effectiveness (OEE)
OEE is a statistical metric for machine and/or
process efficiency. It is calculated by multiplying
Rate X Quality X Availability. The product is
the value a machine contributes to the
production process.
OEE >75% is pretty good, but don’t stand
still. Drive to world class: >80% for batch
processes and >85% for continuous processes
(Maintenance Technology, February 2006).
Availability This indicator quantifies ay
machine’s downtime and operating time. The
performance metric takes into account all of
the factors that cause the process to operate
at sub-optimal speed and aids in identifying
operational periods that are at risk from
equipment damage.
Uptime This performance metric captures a
percentage of scheduled uptime that is actually
available for a machine or process to operate.
Cost of Downtime Amount of downtime is
measured in hours of interrupted production,
while the cost of downtime takes into account
expenses or losses resulting from downtime,
including lost margin, unutilized direct and
indirect labor, and unabsorbed overhead.
Mean Time Between Failures (MTBF)
MTBF is the mean (or average) time expected
between failures of a given device and is
normally measured in hours. It is meant to be
applied to a large sample over a long period
of time.
Maintenance Cost per Output Unit
This metric is used to evaluate actual costs
against stated goals or against industry
standards. It is calculated by taking the total
maintenance materials and labor cost divided
by the total units produced.
To ensure long-term success, the impact of your maintenance strategy must be continuously
measured against defined production and business goals. You can choose from a wide range
of performance indicators to measure success. The definitions for some of the most common
indicators are shown below.
19
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20. 20
F E A T U R E A R T I C L E
GETTING STARTED: CREATE A MAINTENANCE MAP
sample sketch
Instructions
ᕡ Using the worksheet to the right,
draw a rough sketch of the plant floor
(see sample sketch below).
ᕢ Identify the critical areas
of the plant with:
ᕣ Identify the Key Performance
Indicators (KPIs) for each area:
Productivity:
U Uptime / Availability
Q Quality
R Production Rate
Financial:
A
ᕤ Identify the top 1-2 issues that
impact how each area is measured.
ᕥ Label your “current” AND “desired”
maintenance approach for each
area of the plant.
Pd Predictive
Pv Preventive
Re Reactive
!
Before you can accurately measure the success of your maintenance strategy, you must first determine if the
appropriate maintenance approach is being utilized in each production area. Follow the instructions below
to map your current maintenance strategy. If your current and desired approach do not match, you may
need to implement the desired approach before the right metrics can be obtained and properly analyzed.
For help mapping your process, or implementing your maintenance strategy, contact your local Rockwell
Automation sales office. Go to page 56 for detailed information on the Rockwell Automation products, services
and support that can be utilized in your strategy.
!! vPv
Re
Pd
ReRe
Pv
ReRe
Pv
ReRe
UU
QQ
RR
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21. 21
MeasuringSuccess
HART AND CALCULATE YOUR CURRENT OVERALL EQUIPMENT EFFECTIVENESS
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22. MIXING AND GRINDING
Situation A new milling machine is being
designed and installed. Since the plant is
already functioning with its existing milling
machine, the design engineers aren’t directly
impacting production, although they need
to follow a design schedule.
Life Cycle Phase Design
Primary Staff Responsibility
Engineering Manager
Proper Maintenance Approach
A non critical part of a process with little
impact on production does not require
routine or predictive maintenance as long
as problems are addressed as they occur.
A reactive approach ensures that skilled
personnel can implement changes within
acceptable time limits. Access to support,
spare parts, and knowledgebases can help
facilitate this approach.
STRATEGIC MAINTENANCE
To determine the right
combination of maintenance
methods to apply to your
automation assets, a
variety of factors should
be considered:
• Asset Type/Function
• Utilization/Capacity
• Life Cycle Phase
• Staff/Personnel
Requirements
• Impact on Quality
and Revenue
• Average Cost of
Unplanned Downtime
If your primary maintenance
method is predictive or
preventive, some elements
of a reactive approach
will still be required. A
predictive approach will
also include some elements
of a preventive approach.
The brewery shown
provides an example of how
different approaches may
be applied based on the
above factors. The situations
are hypothetical and may
not apply to your facility.
BOTTLING AND PACKAGING
Situation The filling lines are essential tofi
the plant’s operation. These are the most
complex machines in the system and must
produce around the clock. The oldest line will
be upgraded soon, so consistent production is
needed to plan for this large expense.
Life Cycle Phase Replace
Primary Staff Responsibility
Vice President of Engineering and Operations
Proper Maintenance Approach
The failure/malfunction of complex equipment
often results in a high cost of lost production
and repair. To eliminate unplanned downtime,
or resolve problems quickly should they
predictive approach
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23. FERMENTING
Situation The filtration tanks can more than handle thefi
capacity demands of the plant. These machines are not
complex but can be a bottleneck if they aren’t running.
As this part of the plant is about seven years old, failures
occasionally happen.
Life Cycle Phase Maintain
Primary Staff Responsibility
Maintenance Supervisor
Proper Maintenance Approach
This equipment has aged enough to be within the
Mean Time Between Failure (MTBF) common for
automation equipment (seven years). Because
bottlenecks could result in a high cost of lost production,
a good preventive approach is recommended.
A knowledgeable maintenance staff, supported by
domain experts and a responsive repair process, should
adequately address most issues.
BREWING
Situation More than enough lautering tanks were
installed a year ago, so only two of the three tanks
are used at a time. The OEM says there shouldn’t
be any problems with the tanks for at least 10
years if the pumps are greased regularly and the
operators rotate usage throughout the system.
Life Cycle Phase Operate
Primary Staff Responsibility
Production Supervisor
Proper Maintenance Approach
Newer equipment past its warranty can be
a problem if maintenance and rotations are
not established, but may indicate cost/budget
preventive approach cludes
IN THE BREWING INDUSTRY
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24. CUSTOMER SUCCESS STORIES FEATURING ROCKWELL AUTOMATION
24
This article originally appeared in:
Plant Services magazine
www.plantservices.com
“Integrating a predictive
maintenance program to
maintain equipment uptime
ensures customers get the
products they want, when
they want them.”
Controlling the
Compressor:
g
AIR LIQUIDEBy Mark E. Lawrence, P.E., CMRP, and George F. Hofer
Air Liquide Large Industries U.S. LP is part of Air Liquide
Group, which produces industrial and medical gases and is
headquartered in Paris. In the U.S., Air Liquide maintains more
than 125 production facilities and 700 customer installations
spread across some difficult to reach geographies. Before
2002, the U.S. company used a legacy vibration program that
was inconsistent in its application of technology and wasn’t
producing the desired results.
Late in 2002, Air Liquide partnered with Rockwell Automation
to provide vibration analysis services to 32 plants on a trial
basis. The program expanded quickly in early 2003 to include
vibration monitoring at 107 primary production facilities.
In August 2004, Air Liquide recognized the need to expand
its predictive maintenance (PdM) program to include oil
and infrared analysis, and again partnered with Rockwell
Automation. Air Liquide’s needs and aggressive long-
term strategy didn’t leave time for incremental continuous
improvement. The key program objectives included:
• Transitioning from legacy systems to
state-of-the-art information solutions
• Understanding how reliability affects
customer relationships and profitability
• Recognizing the need for uniformity of
predictive technologies
• Leveraging technology in geographically
challenging areas
• Analyzing results and setting goals
for improvement
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25. PRODUCTS AND SERVICES
C U S T O M E R
PROF I L E
25
“NOTONLYMUSTTHEREBEROBUSTMAINTENANCEPROGRAMS
TOENSUREHIGHRELIABILITY,BUTALSOAWAYTOSEEPROBLEMS
FARINADVANCESOARRANGEMENTSCANBEMADEFOR
EQUIPMENTDOWNTIMEWHENCUSTOMERDEMANDISLOW.“
Before 2000, maintenance and reliability
functions were decentralized as was the
responsibility for approximately 100
plant sites throughout the U.S. Since
that time, Air Liquide in the U.S. has
centralized these functions under a new
maintenance department and regional
reliability centers. The new department
deployed several new systems including
a maintenance management process,
a new computerized maintenance
management system (CMMS) and
preventive maintenance programs. Once
these basic systems were in place, the
department turned its attention to its
predictive maintenance programs.
Many of the sites used vibration, infrared
and oil condition monitoring, but
because no corporate standard existed
for applying predictive technologies,
individual managers had great discretion.
As a result, applications were inconsistent
and couldn’t be integrated. Similar data
was taken at different frequencies with
different tools and at different locations
for like equipment. Therefore, data and
reports varied in format and detail, and
information couldn’t be compared and
analyzed across similar equipment.
Because a company-wide CMMS didn’t
exist when these individual programs
were established, predictive findings
couldn’t be linked to traceable work
orders. Compliance of corrective actions
versus predictive findings was unknown.
Several dozen plants eventually coalesced
around a common vibration service
provider, but the program had several
problems. The contractor owned the
data it collected. While the contractor
provided some standard reports, Air
Liquide had to pay for ad hoc analysis it
could have performed itself. But, more
importantly, the contractor had only one
office in the far southeast corner of the
U.S. Given Air Liquide’s vast geography
in the U.S., more than 80% of the costs
the contractor charged were incurred for
travel to the plant sites. Air Liquide knew
there had to be a way to get greater value.
By 2001, the infrared scanning program
was probably the closest to being
national. Electrical standards had been
developed and applied, and an internal
resource was used for data collection
and report writing. While the program
was effective, it was used primarily for
electrical devices and didn’t include
any applications to identify process,
fixed equipment or rotating equipment
problems. And given Air Liquide’s
geographic dispersal and the travel
it required, having a single resource
dedicated to the program didn’t seem
viable in the long term.
Although it was implemented at
several sites, oil condition monitoring
was probably the least used of the
technologies. There seemed to be
significant potential benefits to
increasing its use.
TRANSITIONING FROM LEGACY SYSTEMS
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26. 26
“ W I N N E RS A N D LO S E RS I N O U R B U S I N ES S A R E D E T E R M I N E D
BY T H O S E W H O C A N P ROV I D E T H E M O S T R E L I A B L E P RO D U C T
AT T H E LOW ES T P O S S I B L E P R I C E… A N D O U R M A I N T E N A N C E
A N D R E L I A B I L I T Y P RO G R A M S H AV E A H U G E E FFE C T O N B OT H
S U CC ES S FAC TO RS.”
Many of Air Liquide’s products are commodities. The
company president once remarked, “Winners and losers
in our business are determined by those who can provide
the most reliable product at the lowest possible price…
and our maintenance and reliability programs have a huge
effect on both success factors.” Whether it’s nitrogen,
oxygen, hydrogen, steam or electricity, customers want
all of the product they want, when they want it, and they
don’t want to hear excuses why they can’t have it.
This places a premium on our unit availability and
equipment reliability. Not only must there be robust
maintenance programs to ensure high reliability, but also
a way to see problems far in advance so arrangements
can be made for equipment downtime when customer
demand is low. That’s why predictive maintenance
programs play such a large role in Air Liquide’s
reliability strategies, which play a significant role
in its business strategy.
Before the 1990s, Air Liquide was primarily an air
separation company that produced oxygen, liquid
argon and both liquid and gaseous nitrogen. These air
separation units could back up production to our largest
gas customers by storing large quantities of liquid nitrogen
and oxygen. We could then vaporize the liquid and
sustain several days of downtime in the event of an
interruption in service. The primary strategy for these
products was to reduce our mean time to repair (MTTR).
This meant focusing on stocking spare parts and having
resources ready to react to get a unit running again
before the “liquid ran out.”
Air Liquide also operates four large cogeneration u
nits near Houston to provide electricity and steam
to customers in the area. Because there’s no effective
way to store backup quantities of these products,
Air Liquide adopted a conservative maintenance
strategy that required significant costs and downtime
to ensure predictable uptime.
In the late 1990s, Air Liquide expanded its business
into hydrogen, a product that can’t be stored easily
in quantities needed to ride through any significant
downtime. In this business, our standard air separation
maintenance strategy didn’t apply because even small trips
caused huge problems for customers. Major breakdowns
could be costly for both Air Liquide and its customers. For
hydrogen, the conservative maintenance strategy we used
for cogeneration required too much planned downtime
to be feasible as a business strategy. The strategy had
to provide interruption-free production with optimum
downtime for planned maintenance.
In the meantime, a majority of our customers had already
embarked on their own never-ending journey to reliability
improvement. As they eliminated or improved their
internal reliability problems, the reliability of their gas,
steam and electricity suppliers gained greater visibility.
As our customers improved their reliability game, they
demanded more from suppliers. A world-class predictive
maintenance program was becoming an important
element of a critical reliability improvement strategy.
CUSTOMER RELATIONSHIPS AND PROFITABILITY
CUSTOMER SUCCESS STORIES FEATURING ROCKWELL AUTOMATION
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27. Measure
Collect
Analyze Report
Take
Action
PDM Cycle
C U S T O M E R
PROF I L E
27
UNITY OF PREDICTIVE TECHNOLOGIES
Implementing a world-class, best-practice PdM program
begins with identifying the required measurement variables
and appropriate technology for capturing reliability data.
For Air Liquide, the nature of the equipment monitored,
predominant failure modes and mean time between
failures necessitated using vibration, oil and thermographic
technologies. Failure modes, MTBF data and industry best
practices dictated a monthly interval for vibration data
collection, quarterly for oil analysis, and annually for infrared
thermography scans.
Before August 2004, the Air Liquide PdM program consisted
of a decentralized approach to vibration monitoring, oil
analysis and thermography. Neither a unified nor integrated
approach was used in managing the data. Reports and
recommendations weren’t linked to the CMMS or return
on investment data.
Improvements that started late in August 2004 have helped
Air Liquide demonstrate a truly integrated and successful
PdM program through the following steps:
• Standardized reporting process and information flow
• Centralized data storage and access through a
common Web interface
• Centralized PdM technologies, reports and analysis
• Recommendations and reporting linked to CMMS data
• An interface for live-time, closed-loop progress
measurement
Standardizing the reporting process and information flow
involved establishing a natural link between the reports
and recommendations submitted for vibration, oil and
thermography. This also included switching from oil and
thermography programs run by individual plants to a
single-source provider for the three technologies managed
at the corporate level.
Rockwell Automation provided a common platform for
integrating vibration and oil data, and partnered with
Predictive Service Corp. to provide infrared thermography.
A common reporting platform was established quickly and
used as a report-generation tool. The latter feature was an
application utility installed on each field service engineer’s
personal computer.
Because infrared thermography was provided on an annual
basis and generally only used for electrical components,
this technology was linked via the Web interface only.
Rotating equipment is added to the thermography scan
when exceptions are noted in vibration and oil.
Centralizing the data storage into a common server platform
enabled Air Liquide to leverage the CMMS database, PdM
software database and information from the interface
for reporting vibration, oil and thermographic scans.
Once in place, a Web interface formed a dynamic link
among the three data repositories, and measured
and displayed program success.
Incorporating analysis data from
each predictive technology
ensures that asset health can be
evaluated completely. Because
each technology has a different
monitoring interval, we ensured
that oil samples were taken when
field service engineers were taking
vibration data.
When lab results are reported, oil condition
data is added to the PdM database and incorporated
into the overall recommendations made regarding asset
health. Viscosity, wear particle analysis (WPA), analytical
ferrography and other diagnostics are reported along with
vibration data for complete machine condition status.
PRODUCTS AND SERVICES
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28. 28
(UNITY OF PREDICTIVE TECHNOLOGIES CON’T)
CUSTOMER SUCCESS STORIES FEATURING ROCKWELL AUTOMATION
Since January 2005, we identified more than 148 cases of
viscosity breakdown or improper lubrication. In at least
five cases, WPA revealed significant particulate counts in
conjunction with increased vibration measurements.
Follow-up samples verify that proper lubrication was restored
and machinery repairs have been made. A direct link to the
recommendation and repair action taken enables these to be
tracked and linked to PdM program performance (right).
Linking recommendations from the three PdM technologies
with the computerized maintenance management system
established the basis for measuring PdM program success.
Once completed and properly distinguished, key PdM
program performance indicators are tracked and measured
on a real-time interface. ROI data is linked directly to
individual facilities, by zone, by business class, and even
summarized as a whole for Air Liquide senior management.
A Web interface gives senior management a “status at a
glance” indicator. This requires properly classifying work
orders and entering financial data into each action taken
from PdM recommendations. Leveraging the capabilities
of our CMMS, each PdM work order entered was classified
using the following critical components:
• Work class: “PDM” denotes any work order initiated as
a direct result of a PdM program recommendation
• Activity type: Denotes predictive technology used to
identify problem using one of four tags: “Predictive, Vib,”
“Predictive, Oil,” “Predictive, IR” or “Predictive, Elec”
• Actual repair cost: Installation and repair cost of
repair required
• Estimated savings: The reliability engineer’s evaluation
of problem reported and potential cost savings averted
by avoiding catastrophic failure
• Failure class: Type of machinery affected: motor,
compressor, etc.
• Problem code: Detailed definition of problem component;
e.g., coupling failure
Developing the interface for monitoring real-time progress
of maintenance work orders and PdM recommendations
involved leveraging the existing CMMS database backbone
and the centralized database storage architecture. Partnering
with Predictive Services, Rockwell Automation designed
and developed a Web interface capable of supplying a
PdM Web management tool for tracking the closed-loop
PdM process. The interface links, tracks and reports
progress of any maintenance action initiated from the
PdM program technologies.
This tool enables senior management to track program
KPIs, maintenance activity bottlenecks and overall program
effectiveness quickly and efficiently.
Fundamentally, the PdM program’s integration and unity
established a direct link between maintenance repair
recommendation and maintenance action taken. It
permits measuring and tracking financial data, metrics
and program success to provide ROI. Unless a direct
correlation is established between maintenance action
taken and recommended repair, program success can’t be
measured fully. An overwhelming majority of PdM programs
fail because they lack this tie, and work orders and repairs are
made without regard to the PdM recommendation.
Classifying work
orders properly
is another measure
that connects
maintenance
to ROI.
High-level statistics alert system users to problem trends.
Data Analysis Reporting Tracking
Action
Vibration
ROI
Problems
Sides
Samples
MTBF
Saves
Oil Analysis
Thermography
Feedback
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29. 29
C U S T O M E R
PRO
F I L E
PRODUCTS AND SERVICES
WHERE THE EFFORT WENT
MAXIMO WORK ORDERS
Predictive, Vib 267
Predictive, Oil 114
Predictive, IR 158
Predictive, Elec 89
Total PdM W/O’s 628
Figure 6.
Screen capture of the Web interface.
LEVERAGING TECHNOLOGY
Managing maintenance activities on a national level is a challenge many large organizations
face. Geography and disparity of equipment implementation and plant design makes stocking of
spares and planning maintenance activities difficult. Many OEMs, suppliers and key contractors
have equipment in the field that will ultimately require maintenance.
Implementing a system capable of tracking manufacturer type and reliability information
simultaneously enabled Air Liquide to isolate problematic equipment manufacturers. This
information can be used in supply-management negotiations and, more importantly, designing
and engineering new plant construction. By leveraging the
Web-based technology and interface, any reliability center
manager, reliability engineer or maintenance technician can
search and sort reliability problems by manufacturer type,
equipment type or installed locations. We can do this at the
plant level, by zone, business class or summarized for Air Liquide
overall. Leveraging this data during contract negotiations can
save Air Liquide a significant amount of time, money and effort.
Linking this interface to data in the CMMS database and PdM
software database also enables better management of reported
problems. Before visiting any Air Liquide facility, a preventive
maintenance work order initiates data collection in the CMMS. Any recommended repair
or follow-up work generated as a result of the PdM visit is then classified as a PdM work
order type, linked to the PM work order and distinguished with the appropriate activity type
and problem.
Because follow-up work orders are linked to the original PM visit, reports reveal if any follow-
up work was completed. This enables better tracking of problems throughout the approval
process, enables reliability engineers to budget appropriately and empowers the PdM engineer
with the results of closing the loop.
The bidirectional gateway and exchange of data between the PdM software database and the
CMMS database is another example of leveraging technology to substantiate program success.
Figure 6 shows a direct correlation between vibration data and work completed. The dynamic
link enables up-to-date status information and the resultant cause/effect on newly acquired
PdM data.
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30. Figure 7.
CUSTOMER SUCCESS STORIES FEATURING ROCKWELL AUTOMATION
30
ANALYZING RESULTS AND SETTING GOALS
Aligning the PdM program vision statement with monthly tracking metrics (KPIs) establishes
an overall indicator of the relationship among Rockwell Automation, Air Liquide and contract
performance. KPIs are reviewed in the form of a monthly compliance report submitted
to supply management and reviewed with the senior maintenance and reliability team.
Because KPIs are reviewed monthly, PdM program success is tracked and recorded to justify
program savings and ROI data. An example of the monthly compliance data and KPIs for
Air Liquide include:
• Sites visited • Samples taken • PdM saves • Warranty claims
• Customer care issues • Program costs and payment information
Because each technology is a unique component of the overall PdM program, and work orders
can be classified as such, further detail and tracking of individual PdM saves can be measured on
a monthly and year-to-date basis. Figure 7 represents a breakdown of PdM activity by type for
the period from August 2004 through August 2005 (one year of implementation).
Also, we track and measure work order compliance to ensure the program derives actionable
repairs from the PdM program recommendations. This variable is a measure of the number of
new problems reported versus work orders initiated. Tracked by month, Figure 8 shows an
example of one reliability zone.
Future goals include tracking and monitoring turbine efficiency and machine performance
as well as refining ROI data. One capability currently being implemented is the addition of
pressure, flow and temperature measurements to the PdM program vibration routes. The PdM
software uses these variables to calculate thermal and mechanical efficiencies. Trending can
then be used to predict expander replacements based on efficiency savings.
The partnership between Rockwell Automation and Air Liquide provides benefit to both
Air Liquide and its customers. For starters, the nearly 2,000 interventions before equipment
breakdown have avoided countless unit shutdowns. This isn’t only a benefit to our customers.
It saves Air Liquide considerable costs by attacking problems while they’re still relatively small.
However, this is just the start of what can be done with better information.
AUGUST ‘04 - AUGUST ‘05 PDM DATA
30%
17%
3%
50%
Vibration
Oil
IR
IR Compliance
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31. PRODUCTS AND SERVICES
C U S T O M E R
PROF I L E
31
Mark E. Lawrence, P.E., CMRP, is Director of Maintenance and Reliability
at AirLiquide Large Industries U.S. LP in Houston, Texas. Contact him
at mark.lawrence@airliquide.com and (713) 624-8585.
George F. Hofer is Corporate Program Manager at Rockwell Automation in Houston,
Texas. Contact him at gfhofer@ra.rockwell.com and (713) 402-2288.
0
40
80
120
140
100
60
20
160
2004-08 2004-09 2004-10 2004-11 2004-12 2005-01 2005-02 2005-03 2005-04 2005-05 2005-06 2005-072004-09 2004-10 2004-11 2004-12 2005-01 2005-02 2005-03 2005-04 2005-05 2005-06
■ CANCELLED 1 2 1 1 6 34 4 0 0 0 1 02 1 1 6 34 4 0 0 0 1
■ COMP 51 78 75 51 35 123 108 145 153 106 112 11778 75 51 35 123 108 145 153 106 112
■ PAST_DUE 1 1 2 1 3 0 1 3 6 8 0 41 2 1 3 0 1 3 6 8 0
TOTAL 53 81 78 53 44 157 113 148 159 114 113 12153 81 78 53 44 157 113 148 159 114 113
COMP 96% 98% 96% 96% 80% 78% 96% 98% 96% 93% 99% 97%96% 98% 96% 96% 80% 78% 96% 98% 96% 93% 99%
Past_Due Cuma 19 6 7 5 7 6 7 4 9 15 15 1819 6 7 5 7 6 7 4 9 15 15
One can now look across common equipment and determine which
OEM provides equipment with the lowest levels of vibration. Couple
this with work order and reliability data from the CMMS, and we can
provide quantitative information about what equipment to buy to
improve MTBR.
We’re getting to the point where, armed with data and information
that gets to the root of our problems, we can call in an OEM to discuss
equipment issues. Instead of anecdotal opinions driving the discussions,
the information from our systems now allow us to focus on improving
long-term reliability.
Any engineer, specialist or expert, anywhere in the world, with access
to our Internet site, can look at data and information on any piece of
equipment in the U.S. and can help us troubleshoot problems at even
the most remote sites.
No, we haven’t completely eliminated unplanned breakdowns, but these
events are becoming fewer and fewer and have set the stage for even
better reliability for our customers and shareholders in the years ahead.
Figure 8.
“ANY ENGINEER,
SPECIALIST OR EXPERT,
ANYWHERE IN THE
WORLD, WITH ACCESS
TO OUR INTERNET SITE,
CAN LOOK AT DATA AND
INFORMATION ON ANY
PIECE OF EQUIPMENT”
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32. T
I
P
S
E C H
32
ROCKWELL AUTOMATION
SUPPORT SPECIALISTS TELL
YOU HOW TO MAINTAIN
YOUR AUTOMATION
EQUIPMENT TO OPTIMIZE
PERFORMANCE AND UPTIME
Troubleshooting an
Ethernet/IP™
System
When troubleshooting any EtherNet/IP™
system, you
must have a logical order to troubleshooting. The
order for each troubleshooting issue is dependent
on the details for that issue.This TechTip will list and
detail, in order of priority, the troubleshooting steps
for EtherNet/IP systems.
When troubleshooting Ethernet/IP systems, there are
potentially many possible troubleshooting scenarios.
In general, there are three types of problems:
• It does not work at all
Examples: an I/O node is not connected to a
switch (missing cable), cannot ping a node, all MSG
instruction to a specific Allen-Bradley®
1756-ENBT
ControlLogix®
EtherNet/IP Module fails.
• It works but is too slow
Example: A resource (PC, controller, 1756-ENBT)
in the system is overloaded.
• It works but fails intermittently
Examples: The ControlLogix controller outgoing
unconnected message buffer is being exceeded,
Noise is causing an I/O connection to be lost.
Resolving the Problem
To resolve any of the above problems, you need to
know where to look and what to examine. Check
all of the following carefully as possible sources
of the problem:
• slow PC or slow application running on the PC
• node configuration (IP address, etc.)
• congested network (lots of traffic such as broadcast)
• slow network (satellite or frame relay)
• misconfigured switch or router
• Logix controller resources
- controller processing capability
(5550, 5555, 5563)
- timeslice for communications
- cached message queue (32 max)
- unconnected outgoing buffers (40 max)
• insufficient processing capability in an
ENBT module
• duplicate IP addresses
• defective Ethernet network hardware
(e.g., cable, switch port, or ENBT module)
• web server diagnostics or RSLinx®
diagnostics
If you have addressed all the above issues and are still
experiencing problems, noise could be the cause.
The steps below will provide general information to
resolve any of the above problems.They do not detail
individual troubleshooting possibilities.
The steps can be categorized as follows:
• It does not work at all
See Intermittent/No Response, Physical Layer
• It works but is too slow
See Logix Controller System Overhead, Module
Device Capacity, I/O or Produce/Consume Tags,
Rockwell Automation Ethernet NIC, Logix Controller
outgoing unconnected message buffer, etc.
• It works but fails intermittently
See Switch configuration, I/O or Produce/Consume
Tags, Logix Controller unconnected message buffer, etc.
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33. 33
Step 1: Intermittent or No Response
You may see the following when there is intermittent
or no response:
• “Request timed out” could result from numerous
issues including target is powered down.
• “Unknown host” means the specified IP address
is bad, e.g., 255.255.255.255.
• “Destination host is not reachable” could result from
numerous issues including a bad cable.
When any of the above occur, check for the following:
• AC power not applied
• A missing or defective cable (a clue would
be that the Link light is off or intermittent)
• You did not configure the module
• You did not completely configure the target node
– including subnet mask and gateway
Example: attempting to ping a module on a
different subnet, and the subnet mask is set
incorrectly or the gateway address is incorrect.
• On some switches (e.g., Cisco 3550), port mirroring
disables pinging (on the “mirror-to” port)
If replies are intermittent, ping continuously and
record the deviation. If the jitter is more than
10ms or you skip a reply:
• Something is busy (network or NIC)
However, a busy 1756-ENBT probably won’t be
the problem. From measurements, a 1756-ENBT
running at 100% CPU Utilization replies in the range
10-16ms. If you find a heavily loaded interface, reduce
the load to 90% or less to allow for some margin.
• The network is long (satellite or Frame relay)
• Noise is corrupting packets, and they are
being dropped
Example: ping –t 130.130.130.1
This will ping continuously
If you can ping successfully, but the problem is
not solved, continue with the next steps. For
help with the Ping command, just enter Ping
from a cmd screen (DOS screen).You could also
use RSWho to test connectivity. However, ping is
simpler to use and faster.
Step 2: Bad Hardware
If communications are consistently bad, replace suspect
hardware to isolate the trouble area. Problems could
include cables, the Rockwell Automation Ethernet
interface (e.g., 1756-ENBT) and switch port.
The problem may also be old firmware or hardware.
Record hardware and firmware versions and contact
the appropriate vendor for update information.
Step 3: Switch Configuration, Autonegotiation
or Hard-configuration
The autonegotiation specification (in the 802.3
standard) allows for interpretation by developers.
The result is every vendor’s Autonegotiation
firmware has similar, but not identical, functionality.
If one node is configured for half-duplex and the
other for full-duplex, random and possibly frequent
communications will be lost.
To see the Rockwell Automation duplex/speed status,
see Rockwell Automation web server diagnostics,
Class 1 Packet Statistics. Verify that the status reported
matches the switch configuration.
Example: If your switch is configured for
Autonegotiation, the Rockwell Automation web server
page should indicate Autonegotiated speed and duplex.
If you are running out of troubleshooting ideas, hard
configure the speed and duplex on the switch ports
and also on all Rockwell Automation nodes.This will
eliminate one more variable.
With RSLogix™ version 12 software, you can hard
configure speed and duplex. RSLinx version 2.41
software (build 10) does not yet support this feature.
THE ORDER OF TROUBLESHOOTING STEPS IS IMPORTANT. START WITH STEP 1 AND
WORK YOUR WAY DOWN. SKIP ANY STEPS THAT YOU KNOW ARE NOT NECESSARY.
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Step 4: I/O or Produce/Consume Tags
(class 1 messaging)
Look at Missed Frames in the web browser diagnostics
(see detailed web server description in Step 12). This
parameter is only for I/O or produce tag messaging.
Although some applications may still run when losing
frames, you should strive for a system with zero (0)
dropped frames.
Furthermore, if you are dropping at least four
consecutive frames, you might be dropping a CIP
connection. If you are dropping connections, this will
definitely be incrementing. If you are not dropping
connections, this may be incrementing if your system is
not as stable as possible.
Viewing Missed Frames will help quantify a problem.
The yellow triangles in the RSLogix 5000 software I/O
Configuration tree will not be seen if a connection is
lost and recovered quickly. However, the Missed Frames
counter will see everything – even one missed frame.
This counter is excellent for diagnostics because of its
high resolution.
Step 5: EtherNet/IP Module Device Capacity
Use the web server to verify that CPU utilization on the
Ethernet NIC is less than 100%. If utilization is at 100%,
this may be the problem.To reduce the utilization:
• Make I/O RPI values larger (slower)
• Reduce the number of I/O connections
• Make non-critical traffic less frequent
(e.g., MSGs and HMI)
• Add another EtherNet/IP module and
divide the traffic load
Step 6: Logix Controller Outgoing
Unconnected Message Buffer
ControlLogix controllers have a limit of 10 outgoing
unconnected buffers.As of version 8, this can be
increased to 40.These are required for all messaging -
explicit and implicit to establish a connection.
If the controller tries to exceed this limit, it will fail.
For example, if you try to initiate 50 MSG instructions
simultaneously, those in excess of the buffer size will
fail. See the Rockwell Automation Knowledgebase
document G20181 for information on reading
unconnected outgoing buffers.
attribute 17 is reserve (unused)
attribuite18 is high-water mark
attribute 19 is buffers currently in use
Use RSLogix5000 version 12 software to read
the above values reliably.
Step 7: Logix Controller System Overhead
Add more time for communications by increasing the
continuous task timeslice or run the higher priority
tasks (e.g., Periodic) tasks less frequently or at a lower
priority.The default timeslice is 10%.Try increasing
it to 30-50%.
Step 8: Slow PC Application
If your application is running slow, there are two
possible reasons:
• The PC is underpowered
• The application runs slowly
(or accesses controller data inefficiently)
In either case, look at the CPU utilization in the
Windows®
Task Manager to see how close it is to 100%.
You can also stop the application and use OPC test
client (included with RSLinx software) to access all
the data you need. Configure the topic poll rate for
1ms to operate it at the same speed as the Rockwell
Automation controller(s). If you can achieve sufficient
throughput using this approach, the problem is likely
the application itself or an underpowered PC.T
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Step 9: Duplicate IP Address
If two Rockwell Automation nodes are duplicated, the
last one to be configured will “steal” the IP address.
When this happens, detection can be simple or difficult:
• Simple Detection
In the I/O tree, a 1794-AENT adapter is configured
and operating well. However, a 17560ENBT module
is then accidentally configured for the same address.
When this situation occurs, the Logix controller
declares the connection to the AENT adapter is lost.
• Difficult Detection
Messages (MSG instruction) from one ControlLogix
controller to another are occurring.Then, after a third
device is configured, the MSGs are failing. If you
ping the IP address, it will ping OK. If the 3rd device
is of the same type (e.g., 1756-ENBT) but does not
have the desired tag, even RSWho will show good
connectivity but the MSG will fail.
Work is in progress within ODVA EtherNet/IP to
examine a standard mechanism to detect and defense
against duplicate addresses.
Step 10: Network Trace
If you have yet to solve the problem, you need to
examine the network.Take a trace of the network and
analyze it for problems. If you are unable to do this,
Rockwell Automation can provide assistance through
our Network Services and Remote Support (see the
Products, Services and Support section in the back of
this publication for information).
While waiting for an analysis of the trace, you can look
at the physical layer (see below).
Step 11: Noise or Intermittent Defective Hardware
If the preceding steps do not solve the problem,
noise or bad hardware is the problem. Intermittent
communication is most likely caused by one of
the following:
• Ethernet cable placement (visually inspect for cable
placement next to 480VAC).
• Noise/grounding (physically detach an intermittent
chassis from the enclosure and see how it operates).
• Intermittent hardware (focus on a communications
problem between 2 nodes and try the following:
replace a Rockwell Automation Ethernet interface,
move the cat5 cable (from a Rockwell Automation
node) to a different switch port, replace an
Ethernet cable.
Step 12: Web Server Description
From the Rockwell Automation web server home page,
the following parameters have proven useful when
troubleshooting a system on one of the following modules:
1756-ENBT, 1788-ENBT, 1794-AENT, 1769-L35E (Other
Rockwell Automation EtherNet/IP products currently do
not use them but may in the future.)
In the Address field of Internet browser, enter the IP
address of an Ethernet interface module (e.g.,10.88.76.96).
You will see something similar to Figure 1.
Since it is probably the busiest, the Ethernet interface(s)
within the controller chassis is where you should begin
troubleshooting (as opposed to your other Rockwell
Automation Ethernet modules such as ControlLogix,
Flex I/O, etc.).
How many errors are too much? The answer to this
question is application dependent. For example, if
you have a single bad UDP checksum (caused by
electrical noise) every 100 packets, that packet will be
discarded. Some may say this not a problem because
the production line is running fine. However, to others
this is unacceptable.
Figure 1
This page is self-descriptive and useful
See figure 2.
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Step 12 Continued
Up to this time, most requests for troubleshooting involved
the I/O and produce tag. The diagnostics most useful I/O
and produce tag are marked with an asterisk (*) below.
Backplane Statistics - Identifies backplane errors.
Connection Manager Statistics - Identifies if any Rejects or
Timeouts are incrementing. Note: you can get the same info
from RSLinx by right clicking on the Ethernet module and
selecting Module Statistics and selecting Connection Manager.
Ethernet Statistics – Identifies Input/Output errors
TCP Statistics - Displays connection requests (outgoing from
the controller thru an ENBT), connection accepts (incoming
from the wire through an ENBT to a controller.These will
increment while you are online with a web browser), and
discards (bad packets that have been discarded)
UDP Statistics - This screen will increment only if other
devices are sending non-CIP UDP packets to this module.
At this time, no devices send non-CIP UDP packets to
this module.
From testing with a produced tag (RPI=10ms), the total
UDP packets and input UDP packets do increment (on the
company network) but they increment at a rate of only 1-3
every 10-30 seconds. With an RPI of 10ms, the produce tag
rate is 200 packets per second. The conclusion is that there
is no relationship between CIP packets and UDP statistics.
Without connecting Sniffer to investigate, the assumption
is that someone in the building is sending multicast to all
stations, including my ENBT module.
Also, the addition of CIP UDP checksum errors has formally
been requested.
Encapsulation Statistics - Shows cumulative and active in/
out TCP connections used for encapsulation (CIP) sessions.
The TCP statistics shown are for all TCP connections
(e.g., CIP+ HTTP+ telnet, etc.).
Enet/IP (CIP) Statistics - Active Class 1 Transports provides
the number of transports. In general, two (2) class 1
transports equate to a connection. Use this number to
verify against your calculated class 1 total.
Class 3 transport information is supplied including client
(outgoing) and server (incoming) details.
Unconnected message information is also provided.
The UCMM Worst Backlog (Client) can be used to see
the unconnected message high-water mark for messages
to legacy PLCs. If this value is 10 and you have the Logix
processor configured for a maximum of 10, you may be
trying to exceed the controller’s limit.
Class 1 (CIP) Packet Statistics
• Link Status* (including negotiation description)
• Speed*
• Duplex*
• Method for selecting duplex and speed*
(e.g.,Autonegotiation)
• CPU Utilization Percentage*
(includes processing for everything on the module)
• Current TCP connections (for all connections, class 1
and class 3, includes actual connections and ones
being built but not yet complete)
• Current incoming TCP connections
(these are for all connections, class 1 and class 3)
• Current outgoing TCP connections (for all connections,
class 1 and class 3, includes actual connections and ones
being built but not yet complete)
• Actual class 1 packets per second* (for I/O and produce
tag only, compare your calculated value to this number)
• Reserve Class 1 capacity (displays how much is unused)
• Total Missed Class 1 Packets* (for I/O and produce tag only)
Class 1 (CIP) Active Transports* - You should see only the
RPIs you configured (e.g., If all your configured RPIs are
50ms, you should see only 50ms API).
Class 3 (CIP) Active Transports - For explicit messaging,
transports are the same as connections. Examine the remote
addresses.Verify that these are correct for your system.
Examine the number of Class 3 transports.The number
of transports expected depends on what you are doing.
Examples include:
• RSLogix 5000 opens one CIP connection.
• A PanelView™
Plus can use one or more depending on
the volume of tags on scan.With 488 tags on scan (120
integers, 120 dints, 128 reals, 128 bools), a PanelView Plus
(actually RSLinx Enterprise) opened three transports.
Figure 2
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37. 37
Using the New RSView®
SE
Backup Utility to Make a Copy
of a Running HMI Server
Previously, backing up an HMI server was done
manually by running a bat file in a LocalSystem
DOS command prompt.
This method made it difficult to configure for
custom HMI project locations.As a result, it was not
conducive for automated backup processes, nor easy
to troubleshoot.A newer HMI backup utility with a
graphical user interface should be used instead of
the BAT utility.This utility is available for download
through the Rockwell Automation Knowledgebase at
http://domino.automation.rockwell.com/applications/kb/
RAKB.nsf/WebDocs/A102052574.)
The new utility has been developed to provide an easier,
more intuitive step-by-step backup process.Another
feature of this utility supports command line operation
when used with user configurable (CFG) parameter
files. For this utility to function correctly, the RSView SE
HMI server product files must be installed on the
same machine.
To install the utility, follow the steps below:
1. Uninstall (delete) any previous version of this utility
from your hard drive
2. Unzip the A102052574EXE.zip file downloaded from
the Knowledgebase to any path location on your hard
drive.This file includes all files necessary for the newer
HMI backup & restore executable.All files must be
installed to the same directory folder. Note: this version
utilizes a new component “Rockwell HMI Backup
Server.exe” that runs as a service - register this service
according to the installation instructions included
in the utility’s Help file (A102052574DOC.zip - also
downloadable from the Knowledgebase).This
Help file provides a step-by-step configuration and
usage description.
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Step 13: RSLinx Diagnostics
From RSLinx, in RSWho, you can right click, select
Module Statistics and select the tabs/links listed below.
• Link name: General (this tab is self-descriptive)
• Link name: Port Diagnostics
Most of this information can also be found in the
web server in the following places: Diagnostics
- Ethernet Statistics, Diagnostics - TCP Statistics,
Diagnostics - IP Statistics.There is often more
information in the web server but you must look in
three different places to see everything.Additionally,
RSLinx Port Diagnostics shows some values (e.g.,
alignment errors) that are not seen in the web server.
It is recommended you look at RSLinx Port Diagnostics
and note any errors.
• Link name: Connection Manager
(Same as Connection Manager in web server)
• Link name: Backplane
(Same as Backplane stats in web server)
References/Additional Resources
1. Noise
• EtherNet/IP Media Planning and Installation Manual
(Publication ENET-IN001A-EN-P)
• Industrial Automation Wiring and Grounding
Guidelines, 1770-4.1
• GMC-RM001www.ab.com/manuals/gmc/
GMC-RM001A-EN-P-JUL01.pdf
2. System Planning and Module Capacities
• EtherNet/IP Performance and Application
(Publication ENET-AP001C-EN-P)
Windows is a registered trademark of Microsoft Corporation
in the United States and other countries.
To download the above publications, go to:
www.rockwellautomation.com/literature and
search publication number or title.
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38. USTRY EXPERTS
ANSWER
YOUR QUESTIONS
38
Q How do I determine which
Rockwell Automation e-Learning
products will help me obtain the
knowledge required to maintain
my automation equipment?
A First, select the appropriate Rockwell Automation e-Learning
course based on your learning requirements.To view available
courses, go to www.rockwellautomation.com/services/training.
The next step is to determine licensing options based on the
preferred delivery method (CD or Web) and number of users
(single user or multiple users).
RSTrainer®
Software on CD
The single user license for RSTrainer software on CD provides
access to one individual at a time.A single user license can
only be installed on one local computer unless a dongle is
purchased to enable moving the software license from one
computer to another.
Enterprise server licenses are designed for multiple users
(five minimum) and offer concurrent access to the RSTrainer
software. Companies of all sizes find this network solution to
be a great way to manage and use the RSTrainer e-Learning
suite of courses.
Web-based Training
A web-based license is designed for single user access to
Rockwell Automation University Online delivered via the
Internet.This single user license provides access to one
Rockwell Automation online course for 12 months.
Course availability is 24x7x365.
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39. 39
Q What automation-related
technical certifications are
available for individuals
to achieve?
A The Controls and Networks Certified Professional designation
identifies an exclusive group of proven professionals who have
demonstrated exceptional technical competencies and expertise
in the area of Rockwell Automation controls and networks.
Individuals participating in the certification program are
required to demonstrate their skill, knowledge, and mastery of
controls and networks by successfully completing a proctored,
online knowledge-based exam and hands-on application project.
The opportunity to become a Controls and Networks Certified
Professional is open to all individuals who have experience
using Rockwell Automation controls and network technologies
in their business. Controls and networks pre-tests are available at
www.rockwellautomation.com/services/training/access.html to
help you pre-qualify yourself for either the certification online
exam or the preparatory course, Controls & Networks System-
Level Integration (not a requirement for certification).
For additional information on technical certification,
go to www.rockwellautomation.com/services/training/
certification.html.
Q How can I ensure the new skills
acquired by my staff through a
training program are effectively
transferred to the plant floor?
A There are some fundamental practices you should consider to
maximize the effectiveness of any training investment. First,
verify that your employee meets all prerequisite knowledge and
skills identified in the course description.There is nothing more
frustrating for the student and instructor than someone trying
to learn new skills when “the basics” are lacking. Students lose
confidence in their ability to keep up with the other prepared
participants and never gain strong competency in the new skill.
Second, schedule training at the right time.Timing is everything.
Try to schedule the training as close to the anticipated need for
the newly learned skills in the work environment.An individual
can have an excellent training experience, but a long delay
between training and on the job performance may degrade their
skills and confidence.
The final suggestion to maximize training effectiveness is to
carefully select the training curriculum for each staff member
that will provide the skills and knowledge most relevant to
his/her job function. Select training courses that identify the
target audience, list job tasks practiced in class, and contain
content that matches your employee’s job responsibilities.
An “information dumping” course slows down successful
performance because the employee has to determine what
task is relevant to their job, when to perform the task and in
what sequence to perform the task.
Rockwell Automation can help determine the correct training
curriculum through an Integrated Performance Assessment. For
more information on Integrated Performance Assessments, go
to www.rockwellautomation.com/services/training/integrated.
html.Two online tools are also available to help determine the
courses that will be the most beneficial. To use these tools,
go to www.rockwellautomation.com/services/training/tool.
html (course selection tool) or www.rockwellautomation.com/
services/training/techareas.html (curriculum maps).
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Q & A
Q What are some of the
maintenance benefits of an
integrated control architecture?
A An integrated control architecture can have many maintenance
benefits. Some of the primary maintenance benefits of the
Rockwell Automation Integrated Architecture include:
Improved plant reliability with XM Condition Monitoring
Our XM®
Overall Machinery Protection Modules can process
in real time the critical parameters used in assessing the
current health, and predicting the future health, of industrial
machinery – providing machinery protection where needed,
and reducing downtime.
Multidisciplined control with the Rockwell Automation Integrated
Architecture provides a single control infrastructure for the entire
range of automation applications, including discrete, motion,
process, batch, drives and safety.
No longer must you work with a multitude of different controller
types, software types, language types and communications issues.
Redundancy, batch and other functionalities are all available.
Moreover, users can reduce training and equipment stocking
costs, reduce downtime and maintenance costs and improve
production by using common architecture and equipment
across the entire plant.
Reduced Downtime with Diagnostics in Kinetix Integrated Motion.
Motion control is often used in critical high-speed machines in
production operations. Using Integrated Architecture, you can
easily monitor the health of your control system and be alerted
to potential problems before they cause production to stop.
Improved Network Integration and Information Sharing
through NetLinx Open Network.
Your ability to collect and share data in the automation
environment is a critical component to the success of
your maintenance strategy.
Many plants already have a number of networks installed
for different purposes – but with the wide range of devices,
networks and protocols, it’s difficult to get all systems to
share data. The additional programming takes time and
requires complex integration – requiring significant startup/
troubleshooting, consuming valuable computing resources
and impeding the ability to react to change quickly.
Network solutions from Rockwell Automation form a seamless,
integrated open architecture called NetLinx. It is the best
architecture for complete bridging and routing of control
information and data. NetLinx integrates all the components in
an automation system and doesn’t require any programming
to integrate multiple networks – reducing installation time and
costs, simplifying maintenance and expandability. . . lowering
your overall risk.
Continued on page 41
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