November 2016 Newsletter-(2) · 1 The Winery Engineering Association proudly acknowledges the...

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TheWineryEngineeringAssociationproudlyacknowledgesthesupportofits

PatronSponsor & FoundingSponsor

Timehasflownonceagainandwearealllookingdownthebarrelatthatincomingdeadline,notChristmas,butVintage.BynowIhopeallmembershaveallthepre-vintageworksunderwayoratleastplanned,andforthosewhoaresuperorganised,complete.Projectsarewellunderwaywiththescrambletosecuretradespersons,techniciansandmaterialstocompletetheworks.Generallyspeaking,itseemsevidentthattheindustryismorebuoyantthanintherecentpastandwiththatwelookoptimisticallytowardsthefuture.FromthistheWEAwillbecomeevenmorerelevantwithrespecttonetworking,providingopportunitiesforbothsuppliersandwineries,andalsoincreasingthefellowshipwithintheindustry,andwiththatincreasemembershipandparticipationwithintheWEA(anditsnewsletter).Onthatnote,IwishallourmembersandreadersasafeandhappyChristmasperiod,getwhatrestyoucan,andcomebackrechargedfortheonslaughtofvintage.

www.wea.org.au

WineLines November 2016 Issue

Newsletter of the Winery Engineering Association

President

Ben McDonald Treasury Wine Estates

Ben.McDonald@tweglobal.com

Treasurer

Peter Stone Best Bottlers

PeterS@bestbottlers.com.au

Secretary Ray Pender

Australian Vintage Limited rpender@australianvintage.com.au

Postal Address

PO Box 433 BURONGA NSW 2739

Phone

03 5022 5100

Facsimile 03 5022 5135

Conference Organizer Trevor Leighton

PO Box 432 Buronga

NSW 2739 Ph. 03 5024 8611 Fx. 03 5024 8925 Mb. 0417 597 956

tleighto@bigpond.net.au

Speaker Coordinator & WineLines Editor

David Clark Ph. 03 5358 2059 Mb. 0412 518 685 djc2@bigpond.com

InThisIssue• PresidentsReport–BenMcDonald• WEA2016McLarenValeConferenceReview• WEAMembership• AFullProfessionalRepaintatNoUpfrontCost–ProgrammedProperty

ServicesArticle• NotallVariableSpeedDrive(VSD)CompressorsareCreatedEqual–Atlas

CopcoNZArticle• WhentheWaterisasGoodastheWine–ContinentalWaterArticle• MajorEnergySavingswithClimateWizardSupercool–SeeleyInternational

ProductPromotion• MakeSmartSoftwareYourSecretWeapon–RockwellAutomationArticle

WEAPresidentsReport

2TheWEAislookingforwardto2017andwhatwecandoforourmembers.Watchthisspaceformoreinfoonupcomingevents,conferenceandgeneraltechnicalinformation.Finally,Iwouldliketothankallcommitteemembers,new,continuingandrecentlyretiredfortheirsupportoverthepast12months.MerryChristmas,andasalways,Cheers,Ben.BenMcDonald–WEAPresident

WineEng 2016 TheNationalConferenceandExhibitionoftheWEA

InnovationforSmarterSolutionsSeptember2016sawtherunningofyetanothersuccessfulWineryEngineeringAssociationNationalConferenceandExhibitionthatranovertwodaysandwasheldattheSerafinowineryinMcLarenVale. Pre-ConferenceEventAhalfdaypre-conferenceworkshopwasheldattheSerafinowineryduringtheafternoonofTuesday6thSeptemberbeingthedaypriortothe2016WEAMcLarenValeconference.InthisworkshopAlexFarrenFounderandCEOofCalifornianbasedcompanyBlueMorphpresentedindetailtheprocessandequipmentthathiscompanyalongwithassociateTomBeardEngineeringhavedevelopedinrecentyearstoenabletheUVCsanitisationofwinerytanksofallsizes.AlexexplainedanddemonstratedviaanalyticalresultsofsuchtrialscarriedbyanindependentcertifiedauthorityhowthistechnologyhasgonethroughexhaustivefieldtestingintheUSAwithincredibleresultsbeingachieved

-2016McLarenValeConferenceReview-ZealandConference-

3whenbeingdirectlycomparedwithtraditionaltankcleaningmethodsandthattheuseofthistechnologyinthewineindustryhasthepotentialtosavewineriesofallsizessignificantcostsassociatedwithcurrentwater,chemicalandenergyuseplusreducedloadingonexistingwastewatertreatmentsystems.

The workshop concluded with ademonstrationofaBlueMorphunitbeingplacedintoatanktoshowtheeaseofusingtheequipment.

Althoughparticipantnumberswerelimitedtherewasagooddealofinteractivediscussionthattookplaceandthoseinattendancefoundtheworkshopcontentextremelyinformativeandenlighteningtothepointwheretrialsarebeingplannedbyacoupleofthewinecompaniesbeingrepresentedattheworkshop.

UVCDemoin9KLTank UVCDemonstrationUnit

ConferenceThisyear’sAustralianWEAConferenceandExhibitionranoverWednesday7th&Thursday8thSeptemberandinturnwasattendedbydelegatesrepresentingallareasofwinemakingproduction.Withthethemetitleofthisyear’sconferencebeingtitled‘InnovationforSmarterSolutions’delegateswereabletoattendacomprehensiveprogramoftechnicalpapersoverthetwodaysoftheconferencewhichcommencedwithawelcomeaddressbyWEApresidentBenMcDonaldandkeynoteaddressfromMr.JohnIde–WineryOperationsManagerforYalumbaFamilyVignerons,inhisaddressJohnfocusedonhowinnovationandinventionhasshapedthewineindustryinAustraliafromitsverybeginning,theinformativeaddressgivenbyJohnincludedareviewofpastandpresenttechnologies,theireffectonboththequalityandproductionefficiencyaspectsofwinemaking,andwhatwecanseeforthefuture.Hethenposedthequestionisthereanydifference

betweeninnovationandinvention?anddoesthisreallymattertousanyway?Theaddressthenconcludedwithlookingathowwecanfosterinnovationandinventioninourdailylivestolookatproblemsandopportunitieswithacreativeaswellaslogicalapproachandarriveat“outofthebox”solutionstoaddvaluethroughthesupplychain.JohnIdepresentingthe2016keynoteaddressThekeynoteaddressfromJohnsetthescenefortheconferenceandwasfollowedbyanumberoftechnicalpresentationsdeliveredondayoneoftheconference

coveringtheapplicationofGeographicInformationSystems(GIS)inboththeVineyard&Winery,

4InnovationinViticulturalMachineryandGrapeSorting,UVTankSanitisation,TitaniumFiltrationandBarrelStorageCoolingviaEvaporativeAirConditioning.

DaveGerner–TWE–GISPresentation AlexFarren–BlueMorph–UVPresentationProceedingsfordayonethenconcludedwithaneducationaltastingconductedbyMattHoldstock–SeniorOenologistwiththeAWRIlookingatShirazwineproducedinthevariousgrapegrowingareasofAustraliawiththeobjectiveofthetastingbeingtogivetheparticipantsanunderstandingofthedifferentcharacteristicsthateachregionimpartsintothisgrapevarietyduetodifferingterroir.Thiseducationaltastingwaswellattendedwithallparticipantsappreciatingtheopportunitytobeabletobroadentheirknowledgeregardingthispopularvariety.

MattHoldstock–AWRIconductingtheShirazeducationaltasting

DaytwooftheconferencecomprisedoftenpresentationswiththemorningsessioncoveringSolarPowerProcurementStrategiesforWineries,SmartSolutionsforOptimisingPowerQuality&PowerFactor

5Correction,InnovativeIoTMonitoringforPredictiveFaultFinding,Innovation,TrendsandthefutureofSynthetic&NaturalRefrigerants.FollowinglunchtheafternoonsessionscommencedwiththefirstcomprisingofthreepresentationsfromtheAWRIcoveringRapidExtractionTechniquesforRedWineProduction,UsingIn-LineSensorstoMonitorSugarLevelsDuringFermentation,Closures–OurChangingUnderstanding.ThefinalsessionoftheconferencealsocomprisedofthreepresentationscoveringMassSerialisationThroughthe“InternetofThings”(IoT),MachineSafetyMaturingintheTechnologyAge,Real,ResilientLeadership,allofthesepresentationsdrewahighdegreeofinterestfromthedelegatesandinturnwereafittingwaytoconcludetheconferenceproceedingsforanotheryear.ExhibitionAllexhibitorboothsweretakenupbyabroadrangeofsuppliersfrombothAustraliaandoverseaswhichinturngaveexhibitorsanddelegatesagreatopportunitytodiscussnewproductsandservices,developmentplansandassociatedequipmentrequirementsforthefutureaswellasgeneralnetworking.Allexhibitswerewellattendedduringtheteaandlunchbreaksaswellasbeforeandaftertheconferenceproceedingseachday.

RockwellAutomationStand JMAEngineeringStandConferenceDinnerAsalways,theconferencedinnerwaswellattendedandenjoyedbyoneandallwithgreatfoodandwinebeingtheorderoftheday.FormalitieswerekeptshortfortheeveningandfollowingashortaddressbyWEAPresidentBenMcDonaldashortandinterestingpresentationwasgivenbyMr.RossCurtis,DonorRelationsManageroftheRoyalFlyingDoctorService(RFDS)CentralOperationsinwhichhetalkedabouttheworkoftheRFDSwhohavebeenbeneficiariesofourconferencedinnerraffleproceedsforagoodnumberofyears.Entertainmentforthenightwasconductedbyanextremelyaccomplishedhypnotistwhogatheredseveralvolunteersfromtheaudiencewhointurnbecamestaractsmuchtotheamusementofallinattendance.TheRFDSpresentationwasextremelyrelevanttothenight’sproceedingsasthenextitemonthenight’sagendawasthetraditionalWEAdinnerrafflewhichhasbeenconductedeachyearsince2003,thetotalproceedsofwhichgototheRoyalFlyingDoctorService.Thisyearanearrecordamountof$6,640wasraisedwhichnowbringsthetotalamountraisedanddonatedtotheRFDSbytheWEAsince2003to$57,789.AllraffleprizesovertheyearshavebeengenerouslydonatedbyexhibitorsandsupportersoftheWEAforwhichweareextremelygratefulaswithoutsuchsupportwewouldbeunabletoassisttheRFDSinprovidingtheirgreatservicetotheoutbackandbeyond.Finally,wearemuchindebtedtothetwoMC’sforthenightbeingJoMarshallfromProgrammedPropertyServicesandGregSchultzfromRockwellAutomationbothofwhomdidanoutstandingjobincludingJo’stirelesseffortinmakingtherafflesuchasuccessasshehasdoneforanumberofyears.

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AnotherSuccessfulWEAConferenceDinner

JustareminderforthoseofyouwhohavenotrenewedyourWEAmembershipthatrenewalfallsdueeachyearonApril1st.Membershiprenewalsarenowalsohandledseparatelyfromtheconferenceregistrations.ThischangewillensurethatyourmembershipdoesnotlapseandthatinturnyouarekeptfullyinformedofallWEAeventswellinadvanceofthemtakingplace.AsaWEAmember,youwillalsohaveaccesstothemembersonlysectionofourwebsitethereforeallowingyoutoaccesspresentationmaterialsfrompreviousWEAconferences.IfyouknowofanycolleagueswhoyoubelievewouldbenefitbybecomingamemberoftheWEA,applicationformembershipcanbemadebyeithergoingtoourwebsitewww.wea.org.auorcontactingTrevorLeightonon0417597956/trevorleighton@wea.org.auTheannualcostofbeingamemberiscurrentlyonly$65whichnotonlyentitlesmemberstoreceivethenewsletterandotherupdatesbutalsoentitlesthemtoreducedregistrationfeestoourconferenceswhichinitselfcanresultinsavingsofaround$45/year

ProgrammedPropertyServicesArticle

-WEAMembership-

-FullProfessionalRepaintatNoUpfrontCosts–YesYouCan-

7On-goingpaintingmaintenancekeepsyourfacilitylookingwell-presented.Costandaffordability,however,canpreventthisfrombeingimplemented.Yet,thereareverygoodfundingandmaintenanceoptionsavailabletohelpyouavoidupfrontcosts,evenwhengettingspecialiststoprofessionallypaintyourbuilding.Whenconsideringarepaint,bethisinteriororexterior,lookforalong-termpaintingmaintenancesolutionthatletsyoucompleteasmuchworkyou’dlikeupfront,whileallowingyoutoamortisethecostoftheseworksovertheagreedmaintenanceperiodsoyoudon’tincurimmediatecosts.

Instead,youtailorrepaymentstosuityourbudget,buildingthistoalignwithanon-goingpreventativemaintenancecomponent.Themaintenanceservicewillensureyourbuildingstayswell-presented,andbecauseyouareabletohavecostsforboththerepaintandmaintenancebrokendownintosmallerpaymentsovertime,you’llbettermanageyourbudgetandcashflow.Thisisusefulwhenyouhavemultiplemaintenancerequirementstocommittosimultaneously,andalsoletsyousustainmaintenanceforlongerperiods.Plus,nolongerdoyouneedtoputoffimportantmaintenancetasks.Surfacepreparation,buildingrepairworksaswell

asfixingbrokendownpaintonwindowsanddoorsareallpartandparcelofgoodpaintingmaintenance.Thisdeliverslasting,qualityresultsabletoextendassetlifespanandstaveoffexpensivereplacementcosts.

Inthisway,yourbuildingconsistentlylooksgood,andyoudon’thavetowaituntilcracked,peelingpaintworkpromptsyoutoact.Often,delayingrepairsuntilsuchastagecouldendupmorecostly.Remedyingtheappearanceofabuildinguntilafteritstartstodeterioratewillquitelikelyincurextensivepreparationandcostlysubstratereplacementcostspriortorepainting.

Thisisparticularlytruewherethecostofrepairandreplacementincreasesovertime,andwhentheoverallcostofaproactivemaintenanceprogrammepresentsacomparativelycheaperoption.Especiallyifyoutakeintoconsiderationtheabilitytoreduceancillaryintangiblecostssuchasextendeddowntimeandlossoffacilityuseduetomajorreactiveworks,orlossofgoodwillandimageduetoalacklusterappearance.

ExampleofthebenefitsofongoingMaintenancePaintingvs.AdHocbasedonlevelofappearanceover6years.

Meanwhile,toretainthat‘asnew’look,annualpressurewashingaspartoftheserviceremovesdirtandgrime.Wheresurfacesaresoiledbytimeandweather,thesewillberepainted.

8EngagingspecialistsinpaintingandmaintenancelikeProgrammedalsogivesyouaccesstouniqueexpertise,suchasabseilpaintingteamswhocanpainthigh,difficulttoaccessareassafely.Youwon’thavetohideyourbuilding’sfaçade’sbehindscaffoldsduringarepaint.Allassociatedrisksarealsomanagedonyourbehalf.

Don’twaituntilyouhaveafadedanddatedbuilding.SpeaktotheexpertsatProgrammedtodayandseehowamaintenanceprogrammecanbetailoredtomoderniseyourproperty’sappearanceandkeepitingoodcondition–withouttheupfrontcost

-Programmed’sDiversityJourney– ArticleprovidedbyMartinCrabb–SeniorBusinessDevelopmentManager–ProgrammedPropertyServices

NoUpfrontCosts–YesYouCan-

-NotallVariableSpeedDrive(VSD)CompressorsareCreated-Equal-

9AtlasCopcoArticleHowdoVSDcompressorswork?VSDcompressorsaredesignedtoeliminatethetimethatacompressorspendsinanunloadedor“idle”statewhendemanddrops.Incontrasttoafixedspeedcompressorthatwillloadandunload,aVSDcompressorwillcontinuouslymeasureoutletpressureandregulateitsspeedtomatchyourdemand.Typically,afixedspeedcompressorwillunloadwhentheupperpressurelimitisreached,duringthisprocess-theinletvalvecloseswhilstthemotorcontinuestoturn,hencestoppingtheproductionofcompressedair.Theselossescanbegintomountasthedemandvariesinthefactory,theresultisalargepowerbillthatservicesunproductivetimeonyourcompressor.WithaVSDcompressor,thisissueiseliminatedasthecompressedairoutputisregulated-insteadofhavingtounload,aVSDcompressorcanslowdowntypicallytowithin12-13%ofmaximumoutput(AtlasCopcoVSD+range).CriticalfactorstolookforwhenchoosingaVSDcompressorNotallVSDcompressorsarecreatedequally.ThereareanumberoffactorsthatshouldbeconsideredwhenlookingtopurchaseaVSDcompressorforyourplant-priceisnottheonlyfactor.VSDcompressorsaresophisticatedpiecesofequipmentwhichcombinethelatestmechanicalandelectronictechnologiestoachieveoptimalperformanceandthusenergysavings.Themotoristheheartofacompressor,VSDratedmotorsshouldbeusedtoachievethehighestlevelofperformance.

• Itisimportanttonotethatafixedspeed

compressorcannotbecomeaVSDcompressorbysimplyattachingafrequencyconvertertotheunittovaryspeed.Thiswillworktosomeextent,howevertherewillbegreatlimitations.

• AsmotorRPMisreduced,motorcoolingbecomescritical,afixedspeedcompressoristypicallycooledbyafanattachedtothemotorshaft,andthiswillinturncauseissueswhentheRPMdropsandcoolingcapacityisreduced.

• CheckforminimumFADoutputfigures,thelowertheminimumFADforanequivalentmotorsize,

thebettertheperformance.

• Doesthecompressorunload?“Real”VSDratedmotorscanstartupundersystempressureanddonotrequireadepressurisedsystemtostartthemotorafterstopping.

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• Howisthemotorcooled?Isthemotorcooledbyafancoupledtothemotorshaft,ordoesithaveanindependentcoolingsystemthatoptimisesthecoolingloaddependingonmotorRPM?

• Whatmechanismisusedforthecompressors’drivetrain?Lossescanbeminimisedbyusingeitherdirectdriveorgeardrivesystems,beltdriveisnotrecommendedforVSDcompressors.Maintenancerequirementsarealsokepttoaminimumasdirectandgeardriveunitsaretypicallymaintenancefree.

BearinmindbeforesigningonthedottedlineCompressorsaretheproducersofoneofyourmostvitalutilitiesinthefactory.Thereareavarietyofoptions,configurationsandbrandstochoosefrom.Buyinganewcompressorshouldbeaprocesswherelongtermrunningcostsoutweightheoutrightinvestment.Buildquality,advancementintechnology,andcompatibilityoftechnologiesshouldallbeconsidered.WhatshouldIdobeforeIdecide?

• Consultyourlocalsalesengineer• Performacompressedairenergyauditonyoursystemtomeasurecurrentcompressedairand

energyconsumption• RequestasimulationoftheVSDcompressortopredictenergysavings• Compareoptionsandlookforvalueaddingfeatures• Makeaninformeddecisionbasedonfactspresented

-WEA Membership-

-WhentheWaterisasGoodastheWine-

11ContinentalWaterArticle

ADrinkingWaterSystemforLevantineHillEstateWhenKrongoldConstructionswereengagedtoconstructanewCellarDoorandRestaurantfacilityforLevantineHillEstate,intheColdstreamHills,oneoftheconsiderationswastheprovisionofwaterfordrinkingandotherassociatedpurposeswhichmatchedthequalityoffoodandwineonofferintherestaurantwhichwouldoperateunderthehighlyesteemedEzardBannerasE@LevantineHill.Thewatershouldbeclear,colourless,odourlessandtasteless,befreefromtoxicsubstances,pathogensandexcessiveamountsofsubstancesinsolutionnotnormallydetectablebytheunaidedsenses.ItshouldcomplywiththerequirementsoftheVictorianDepartmentofHealthGuidelinesforPrivateDrinkingWaterSuppliesatCommercial&CommunityFacilities(2009)andtherecommendationoftheAustralianDrinkingWaterGuidelines(ADWG).Ineffect,itshouldbetheverybestdrinkingwateravailable.LevantineHillhasarainwaterharvestingsysteminplacehoweverthisisusedforirrigationoftheextensivegroundsandsupplyofthefirefightingsystem.Theonlyotherreliablesourceofwaterwasadamonthepropertyfedbyrainwater,surfacerun-offandtoppedfromthenearbyYarraRiverwhenrequired.ContinentalWaterSystemswereaskedtolookattheproblemandprovideasolution.Ananalysisofthewaterfromthedamshowedthat,inadditiontothenormallyexpectedcontaminantswhichincludedmicro-organisms,sedimentsandorganicmatter,whichwoulddiscolourthewater,ironandmanganese,werepresentinrelativelyhighquantitiesandthiswouldneedtobeaddressedasapriority.SteveJeffs,fromContinentalWaterinMelbourne,proposedasystemcenteredona20,000litresperdayUltrafiltrationsystemwhichwouldbehousedinacontainersitednearthedam.

12Inthefinalsystem,waterwaspumpedfromthedamandpassedthroughapretreatmentfiltrationsystem,whichremovediron,manganeseandsediment,andthenthroughtheUltrafiltrationprocesswhichremovessuspendedparticlesdownto0.2micron.Fromtherethewaterundergoesasanitisationprocess,toremoveanybacteria,andispumpeduptothe280,000litreholdingtankintheCellarDoorcarpark.Fromtheholdingtank,beforethewaterreachesitsendusepoint,itisthenpassedthroughultravioletlightsanitisationand,finally,throughacarbonfiltertoremoveanyminortasteorodourthatmaystillbeevident.

TheacclaimedE@LevantineHillSallyanneBartlett,DirectorandScientistatWaterQPlusPtyLtdinMaidenGully,wasengagedtoassessthesystematcommissioningstage.Sheundertookareviewofdatafromacomprehensivesuiteofbothsourcewatersamplesandsamplescollectedatvariouslocationsthroughoutthewatertreatmentplant,includingthefinaltreatedwater.Sallyannefoundthatthecapabilityandperformanceoftheplantwasmorethanadequatetomanage/controlthewaterqualityrisksposedandtoconfidentlyproduceareliable,safedrinkingwaterproduct.Toensurethisqualityismaintained,aDrinkingWaterQualityManagementPlanhasbeenimplementedandaseriesofmonitoringdevices–includinganORPmonitorontheozonesanitisationsystem,anintensitymonitorontheUltravioletsanitisationsystemandpressuremonitoringoftheUltrafiltrationsystemarealllinkedtoeitheraudibleorvisualalarmslocatedinhightrafficareasthroughoutthefacility.Theresultingwaterissweet,pureandfullycompliantwiththeAustralianDrinkingWaterGuidelines.

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SeeleyInternationalProductPromotionWithinstalledsystemsalreadyreducingwineenergycoolingcostsbyupto80%comparedtorefrigeratedsystems,ClimateWizard’sSupercoolIndirect/DirectEvaporativeCooling(IDEC)configuration,isclearlyworking.Energy-mindedwineriesintheBarossa,AdelaideHillsandMcLarenValehaveinstalledClimateWizardwithexceptionalbenefits.Fromapuredollarcost,ClimateWizardsIDECtechnologyhaslowerpowerrequirementsandlowoperatingcosts,fromamodestcapitalinvestment.Asastand-alonesystem,oradaptedintoexistingbarrelandtankstoragecooling,ClimateWizardSupercooladdsasmallamountofmoisturesotheamountofangels’shareisminimisedplus,theneedforextrahumidificationequipmentisnegated,with100%fresh,outsideaircoolingthespaceandwine.Withagrowingproliferationoforganicandeco-sustainablewineries,theneedforconsistent,costeffectiveandlowimpactenergysupplyfor‘offthegrid’vineyardsiscritical.Indeed,energyconsistencyisimportant,especiallyforwinerieswhohaveexpandedinremotelocations.Thefurtherenergyneedstotravelregionally,themoreunpredictablethepowersupply,sothebenefitsofferedbyClimateWizard’snewcoolingsystemisturningwinemakingheadswhoneedtoutiliseplantandequipmentwhichdrawsminimalpower.AnindirectcorewithanevaporativeprocessafterwardsgivesSupercooltheedge.ClimateWizardsuppliesamuchlowertemperaturethandirectevaporativecooling,whilegivingsustainablewineries,vitaltemperatureandhumiditycontrol.AboutIndirectEvaporativeCooling:Indirectevaporativecoolingreducesthetemperatureoffreshairthroughaheatexchangesurface,that’simpervioustowater.Ononesideofthesurface,evaporationproducescooltemperaturesinwaterandair,allowingheatexchangetotheincomingairontheothersidesurface.So,primaryairiscooledwithoutchangingitsmoisturecontent.InClimateWizardsystem,someairisheatexchangedtoalowertemperature,returningalongthewetchannel.Evaporationonthewetsurfacesofthewetchannelwillproducelowertemperatures.

SupercoolInstallationExamples

PeterLehmannWines BarossaValleyEstates

-MajorEnergySavingsforPremiumWinerieswithClimateWizardSupercool-

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RockwellAutomationArticleSmartsoftwaresolutionsleverageincreasedconnectivitytoanalyseanddeliveroperationalandbusinessinformationforimprovedproductivityandprofitabilityAttheheartofanycontrolandautomationsystem,isasoftwaresolutionthatwhendesignedcorrectly,providesvaluableinsightintoaplant’soperationalandbusinessobjectives.However,withsomanyvariablestoconsider,asignificantnumberofcompanieshavedifficultyidentifyingtherightsolutionfortheirparticularapplication.AccordingtoJeffPhoon,engineeringteamleaderatGlobalSolutions,RockwellAutomation,“Whilethereareanumberoffactorstoconsiderwhendesigninganewsoftwaresolutionorupdatinganexistingsystemtomeetchangingrequirements,asolutioncanbedevelopedthatwillmeetacustomer’soperationalandbusinessobjectivesbyfollowingasystematicprocess.”DevelopingasoftwaresolutionThefirststepindevelopinganeffectivesoftwaresolutionistodevelopaUserRequirementsSpecificationtoidentifyspecificcustomerrequirements.“ThisiswhereITandautomationcrossbecausetraditionallythisstepisperformedbybusinessanalystsintheITworld,butnowourengineersalsoprovidethisexpertise,”saidPhoon.

MakeSmartSoftwareYourSecretWeapon

15Thenextstageindevelopingasoftwaresolutionisdeterminingthefunctionalrequirementsofthesystem.Thisinvolvesidentifyingandanalysingthecapabilitiesthatthesystemneedstoprovide.Byadoptingacollaborativemethodology,theengineertogetherwiththeendcustomerworktogethertoidentifytheserequirements.“Intheearlystagesofsoftwaredesign,it’sdifficultforthecustomertohaveacompleteunderstandingofalltheirsystemrequirements.Byadoptingourcollaborativemethodology,wecanleverageourdomainexperiencetodeliveradetailedanalysisofthefunctionalrequirementsforaparticularapplication,”explainedPhoon.“WecanalsoconductaFIT-GAPanalysiswherewelookatthestandardfeaturesofasoftwareplatforminrelationtotherequirementsofaspecificapplicationanddetermineifanythinghastobedonetoextendthefeaturestomeetthecustomerspecification.Sometimeseventhemostcomplete‘offtheshelf’softwarepackagerequiressomelevelofcustomisation,”headded.OncetheUserRequirementsSpecificationandfunctionalrequirementshavebeendeterminedthesoftwaresolutionmovesintotheimplementationstage.Thisinvolvesdetaileddesignanddevelopingthesolutionfortesting.TheUserAcceptanceTestingphaseprovidestheopportunityfortheendusertoverifythatthesolutionmeetsthefunctionalrequirements.Oncecomplete,operatortrainingcanbeconductedandthenthesoftwaresolutioncan‘golive’.Adoptingbestpracticeinthesoftwaredevelopmentlifecyclereducesriskandallowsenduserstogetabetterhandleonprojectcosts.Phoonemphasisesthat,“Poorplanningestimatescanleadtoprojectfailurebutwithproperplanningandexecution,softwaresolutionscanbedevelopedeffectivelyontimeandwithinbudget.”AvoiddrowningindataInthebigdataera,accesstoinformationismoreimportantthaneverasglobalcompetitivepressuresmount.Asaresultofadvancesinconnectivityandaccesstooperationalinformationfromcontrolsystems,theamountofdatathatiseasilyaccessiblehasincreasedexponentially.However,theassumptionthatmoredataisbetterdataisnotnecessarilycorrect,makingidentifyingtheimportantdataakeyprioritytoprovideoperationalinsightandvalue.“Oncewehaveaclearunderstandingoftheimportantdatapoints,thenextstepiscontextualisingthisinformationsothatoperatorscanseeinformationthatisimportantfortheirrole,”explainedPhoon.“Forexample,aproductionmanagermaybeinterestedinanoverallproductionsummarydashboardwhereasaplantfloorsupervisorwouldneedmoredetailintermsofadailysummaryreportsotheycandelvealittledeeperastothereasonswhyamachinemayhaveshutdown.Wehavethetechnologyandapplicationknowledgetopresentthedatabasedonwhoislookingatitandwhattheirrolesare,”hesaid.Theultimategoalistogettherightdatatotherightpeopleinasclosetorealtimeaspossiblesotheycanmakeinformeddecisionstooptimiseproductionandimproveproductivity.MakingitmobileSmartmobiledeviceshavebecomeanessentialpartofeverydaylife.Wenowhavethetechnologytoview,analyseandrespondtooperationalinformationfromanywhereatanytime.Phoonexplainsthat,“Although

16manufacturinginformationisoftenbehindtherestoftheITworld,industrialoperationsarenowbenefitingfrombetterwaysofpresentingdatathroughwebportals,toolsandlibraries.”TheRockwellAutomationweb-basedmanufacturingbusinessintelligenceplatform,FactoryTalkVantagePoint,nowprovidesaccesstoproductioninformationonmobiledevicesaswell.Providingtherightinformationtotherightpersonattherighttimedeliversflexibilityinmanufacturingprocesses,providingthecapabilitytomakedecisionsremotely,improveefficienciesandreducedowntime.Throughtheuseofrealtimealarming,mobiledevicescanalertoperatorstoissuesthatifleftunchecked,wouldimpactonproduction.Thisallowstheoperatortoaddresstheproblembeforeitescalates,reducingdowntimeandimprovingefficiencyandreliability.“Thesoftwaredesignprocesscanalsotakeintoaccountmobilityrequirementsbyidentifyingimportantinformationforoperators,programmingalarmingasrequiredandbestpracticefordatapresentation.Thisprocessprovidesasolutionthataddressestheoperator’srequirementsandallowsthemtomakesmartbusinessdecisionsquickly,”saidPhoon.SmartsoftwarebridgesthegapTheinformation-enabledConnectedEnterprisecandelivergreaterproductivity,betterutilisationofassetsandimproveddecisionmaking.Whendesignedcorrectly,smartsoftwaresolutionscanunlockdataprovidingoperationalinsightandimprovedproductivity.“Advancedsoftwaresolutionsaredesignedtogetthemostfromhardwaresolutions.Forexample,RockwellSoftwarecanimproveoperationsandlowerthetotalcostofownershipbybridgingthegapbetweentheplantfloorandbusinessenterprisesystems,”saidPhoon.“Inspeakingwithcustomers,wefindthatidentifyingthespecificdatarequiredandthenconfiguringthesystemtomeettheseuniquerequirementsisachallengetheyneedtoaddress.Tohelpwiththis,ourlocalGlobalSolutionsteamworkswithcustomerstohelpdesignandconfigurethesoftwaretosuitspecificrequirementsandreduceimplementationtime,”heexplained.

FactoryTalkVantagePointprovidesaccesstoproductioninformationonmobiledevices

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SmartsoftwaresolutionscanunlockdataprovidingoperationalinsightandimprovedproductivityAboutRockwellAutomationRockwellAutomationAustraliaandRockwellAutomationNewZealandaresubsidiariesofRockwellAutomation,Inc.—aleadingglobalproviderofindustrialautomationandinformationsolutionsthathelpsmanufacturersachieveacompetitiveadvantageintheirbusinesses.ThecompanybringstogetherleadingglobalbrandsinindustrialautomationwhichincludeAllen-Bradley®controlsandservicesandRockwellSoftware®factorymanagementsoftware.Itsbroadproductmixincludescontrollogicsystems,sensors,human-machineinterfaces,drivecontrollers,powerdevices,andsoftware.RockwellAutomation,Inc.(NYSE:ROK),theworld’slargestcompanydedicatedtoindustrialautomationandinformation,makesitscustomersmoreproductiveandtheworldmoresustainable.HeadquarteredinMilwaukee,Wis.,RockwellAutomationemploysapproximately22,000peopleservingcustomersinmorethan80countries.Allen-Bradley,FactoryTalkVantagePoint,LISTEN.THINK.SOLVE.andRockwellSoftwarearetrademarksofRockwellAutomation,Inc.