< PreviousLEADERSHIP IN AUTOMATION:FIRST TEAM HONOREES 202068AWJANUARY 2020LEADERSHIP IN AUTOMATIONHISTORIAN/DATA ACQUISITION SOFTWAREAvevaGE DigitalHoneywell Process SolutionsInductive AutomationOSISoftSchneider ElectricSiemens IndustryHMI HARDWAREAutomationDirectBeckho AutomationBeijer ElectronicsIDECRed Lion ControlsRockwell AutomationSchneider ElectricSiemens IndustryUnitronicsWeintekHMI SOFTWAREAutomationDirectBeckho AutomationIDECInductive Automation InduSoftRed Lion ControlsRockwell AutomationSchneider ElectricSiemens IndustryHYDRAULICS/PNEUMATICSBimba ManufacturingBosch RexrothEmersonFestoParker HannifinSMCI NDUSTRIAL PCsAdvantechB&R Industrial AutomationBeckho AutomationMoxaRockwell AutomationSiemens IndustryIOT PLATFORMSAvevaBeckho AutomationEmersonInductive AutomationOpto 22Schneider Electric Siemens IndustryMAINTENANCE/RELIABILITYAveva EmersonEndress+HauserRockwell AutomationSiemens IndustryMES/MOM SOFTWAREAspenTechAvevaEpicor SoftwareHoneywell Process SolutionsInductive AutomationRockwell AutomationSiemens Industry2001_LIA.indd 682001_LIA.indd 681/20/20 1:46 PM1/20/20 1:46 PM packexpoeast.comREGISTER NOW FOR ONLY $30March 3–5, 2020Pennsylvania Convention CenterPhiladelphia, PA USAYou Deserve Some Quality Time With Top SuppliersPACK EXPO East provides a valuable opportunity to make quality connections with top packaging suppliers, explore their latest innovations and experience technology in action.YOUR EAST COASTPACKAGING CONNECTION 400exhibitors7,000 attendeesCountless possibilitiesProduced by:Full Page Ad.indd 73Full Page Ad.indd 731/20/20 12:50 PM1/20/20 12:50 PMLEADERSHIP IN AUTOMATION:FIRST TEAM HONOREES 202070LEADERSHIP IN AUTOMATIONAWMONTH 2020MOBILE HMI/SCADAAvevaEmersonHoneywell Process SolutionsInductive AutomationOpto 22Red Lion ControlsSiemens IndustryMOTORSABBJVLLenzeMitsubishi ElectricOriental MotorSiemens IndustryYaskawa AmericaNETWORKING WIREDBeldenHilscher North AmericaMoxaMurrelektronikPanduitPhoenix ContactWagoNETWORKING WIRELESSAdvantechEmersonHMS Industrial NetworksMoxaRed Lion ControlsSiemens IndustryPLCs/PACsAutomationDirectB&R Industrial AutomationIDECMitsubishi Electric AutomationOmron Industrial AutomationOpto 22Rockwell AutomationSchneider ElectricSiemens IndustryPOWER SUPPLIESEmerson/SolaHDIDECPhoenix ContactPulsSiemens IndustryPROCESS CONTROL SOFTWAREABBAvevaEmersonRockwell AutomationSchneider ElectricSiemens IndustryROBOTICSABB RoboticsEpson RobotsFanuc RoboticsKawasaki RoboticsMitsubishi Electric AutomationUniversal RobotsYaskawa America2001_LIA.indd 702001_LIA.indd 701/20/20 1:47 PM1/20/20 1:47 PMLEADERSHIP IN AUTOMATION:FIRST TEAM HONOREES 202071AWJANUARY 2020LEADERSHIP IN AUTOMATIONSAFETY MACHINEBanner EngineeringIDECLeuze ElectronicPilz Automation Safety Rockwell Automation TelemecaniqueSickSiemens IndustrySAFETY PROCESSEmersonHoneywell Process SolutionsPilz Automation Safety Rockwell AutomationTelemecaniqueSiemens IndustrySCADAAvevaGE DigitalHoneywell Process SolutionsInductive AutomationRockwell AutomationSiemens IndustrySENSORS DISCRETEBanner Engineering IFM EfectorTelemcaniqueSick Siemens IndustrySENSORS PROCESSBallu EmersonEndress+HauserIFM EfectorTelemecaniqueSickSiemens IndustrySIMULATION/MODELINGAutodeskEmersonEplanSiemens PLMVISION SYSTEMSBanner Engineering BaumerCognexDatalogicOmron Industrial AutomationSickTeledyne Dalsa2001_LIA.indd 712001_LIA.indd 711/20/20 1:47 PM1/20/20 1:47 PM72AW JANUARY 2020INDUSTRY-SUPPLIED CONTENTIndustrial Control System Migrations: Five Considerations to Move ForwardTwo factors driving the upgrade or replacement of legacy control systems are increased component failures and lack of replacement parts due to obsolescence. When equipment fails, the risk associated with losing control of or shutting down a process can be significant—from both safety and financial perspectives.By Lee Swindler, Industry Manager, Maverick TechnologiesToday’s industrial manufacturers are faced with an increasing pressure to update or replace legacy con-trol systems to maintain a more efficient, highly functioning, and sustainable control system infrastructure.Navigating the best path towards a new, optimized auto-mation system offering is key to future success. Migration projects, however, are extremely complex and the risks can be high without proper planning and the right team of experts. Manufacturers must carefully weigh the resource demands and system options while continuing to meet customer demands for higher-quality products and to stay competitive in an ever-changing market.Before implementing a control system migration, it’s best to have a planned and disciplined approach. To help pave the way to a successful migration, take a look at the following five key considerations:2001_F5.indd 722001_F5.indd 721/20/20 1:45 PM1/20/20 1:45 PM73AW JANUARY 2020INDUSTRY-SUPPLIED CONTENT2001_F5.indd 732001_F5.indd 731/20/20 1:45 PM1/20/20 1:45 PM74AW JANUARY 2020INDUSTRY-SUPPLIED CONTENT1. Project justificationDetermining what the control system migra-tion scope should include, how much the project will cost, how long it will take are all important, but defining the potential return on investment (ROI) is key to getting man-agement buy-in. As many corporations think in terms of business goals, objectives, and strategies, it’s best if the migration benefits can be tied to desirable business outcomes. Thus, to justify a migration, first identify and document the desirable business outcomes, such as:• Make more product by increasing facility throughput;• Improve asset utilization;• Address regulatory compliance issues;• Reduce unplanned downtime;• Improve pricing through better quality control;• Reduce variable costs such as corrective maintenance services; and• Reduce fixed costs like legacy system support contracts.The key here is to apply the known ben-efits that will result from a migration to the business goals that the company is trying to achieve. The right time to develop this justi-fication is during the upfront planning phase.2. Upfront planningPerforming the right amount of engineer-ing during the front-end loading/front-end engineering design (FEL/FEED) planning stage is proven to reduce overall project cost, minimize risk, decrease scope changes after authorization, and increase the likelihood that a project meets or exceeds its financial goals. Risk greatly increases without a scope that has been defined and agreed upon by the various stakeholders. Performing an appro-priate level of upfront engineering while still allowing for some scope evolution is critical to getting your project started on the right foot. With automation migration projects, the cutover plan affects all scope areas and therefore needs to be decided up front. A good FEL effort provides the following:• I/O list;• System architecture;• Comprehensive project execution plan (PEP);• Installation and commissioning plan;• Project schedule;• Total installed cost (TIC) estimate;• Total cost of ownership (TCO) estimate; and• Analysis for platform selection.Engaging the right team early in the pro-cess with subject-matter experts who under-stand the legacy platform along with current standards and best practices is key. Be sure to include plant operations, maintenance, and engineering resources on the project team whose knowledge and feedback is critical. Utilizing a qualified third-party automation solutions provider will bring considerable expertise to the team and help utilize proven best practices that will deliver value through-out the new control system’s entire lifecycle. If you wait to engage an expert partner later 2001_F5.indd 742001_F5.indd 741/20/20 1:45 PM1/20/20 1:45 PM75AWJANUARY 2020INDUSTRY-SUPPLIED CONTENTin the project, many aspects of the scope will already be cast in less desirable ways due to decisions made up front.3. Innovate for real improvementConsidering the many limitations of a leg-acy automation system that was designed and built 20+ years ago, manufacturers must innovate—not simply replicate—the functionality of their existing legacy infra-structure. Limitations in the older technol-ogy prevent open communication to smart field devices, subsystems, and higher-level enterprise resource planning (ERP) systems. Operators are less effective using outdated human-machine interfaces (HMIs) and their response to abnormal situations is inhibited by poorly functioning legacy alarm systems. A migration is the ideal time to reevaluate your current operations and leverage new, innovative technology to develop a custom-fit offering that improves safety, operational efficiency, effectiveness, and profitability.Modern control systems contain valuable new technologies and compliance with stan-dards that offer significant opportunity to improve asset utilization and fully realize the benefits Big Data and increased connectivity provide. These new technologies have been developed to enhance operator effective-ness with high-performance graphics, reduce operational risk with proper alarm manage-ment tools, and ensure effective cyber secu-rity protection against malicious attacks on control system vulnerabilities.4. Project execution planAs with any complex project, a detailed proj-ect execution plan (PEP) is essential and should include defined roles and responsi-bilities, risk matrix, quality plan, testing plan, training plan, resource-loaded schedule, and other appropriate items before jumping into execution. A full-scale control system migra-tion needs additional planning to minimize unit downtime and determine the exact requirements for final cutover. Many ben-efits are often realized if the project team maximizes the amount of pre-outage work and associated testing prior to planned facil-ity outages or turnarounds (TARs). Disciplined testing and commissioning procedures executed by qualified resources are critical for safe and efficient startup. Shortcuts here inevitably lead to ongoing operational problems costing many times the minimal savings from reduced commission-ing time. Thus, risk identification, mitigation, and cutover planning are critical elements to incorporate early in the PEP development.5. Team collaborationCollaboration is key to getting the right team to effectively work together and avoid prob-lem areas down the road. Good teamwork can be fostered through regular communication and clearly defining roles and responsibilities, so everyone is on the same page. As with any project, you want to minimize unnecessary scope changes. Automation projects, how-ever, need to allow for an appropriate level of scope evolution as not every detail can be defined up front. Having the team recognize and respect this characteristic will help to reduce the stress on everyone involved.It is important to build relationships with all personnel involved—especially plant operations and maintenance groups. Antici-pate resistance to change and account for culture obstacles as a risk. With a strong internal team and a third-party partner with the expertise and skills required to success-fully integrate and implement automation system components and technology, manu-facturers can guide the migration to suc-cess and maximize the return from their new automation investment.2001_F5.indd 752001_F5.indd 751/20/20 1:45 PM1/20/20 1:45 PMSpecial Advertising SectionSpecial Advertising SectionCast a vote for your favoriteautomation products and servicesOne vote per category.www.automationworld.com/leadershipWelcome to LEADERSHIP IN AUTOMATION 2020Cast a Vote for Your Favorite Automation Products and Services atautomationworld.com/leadershipWelcome to Automation World’s Leadership in Automation program. This in-print and online program for the manufacturing automation community is designed to recognize the many innovative companies that supply technology, software, devices and services that keep manufacturers competitive and successful. We created Leadership in Automation to give our readers a voice in identifying the solution providers that best exemplify leadership and innovation in their respective product categories. We believe such recognition should come from the professionals who understand the daily challenges of manufacturing, and the value of an excellent supplier partner.On the following pages, you’ll see information from the suppliers who have chosen to participate in 2020 by supplying a profile of their organization. Throughout the year, you can also find these profiles online at www.automationworld.com/leadership. Use these as a reference as you search for automation partners for your next project. Also, cast your vote online for your preferred vendor (one per category, please). The results of 2019’s voting, which was conducted through an unaided recall survey, can be found beginning on page 64 in this issue.Acromag AdvantechAerotech, Inc. Allied Electronics & Automation AS-Interface Organization of North America Automation24 AutomationDirect B&R Industrial Automation Banner Engineering Baumueller-Nuermont Corp. Beamex Beckho Automation Belden Bimba Manufacturing Carlo Gavazzi Inc. Chatsworth Products CIMON CimQuest INGEAR Digi-Key Electronics DELMIAWORKS IQMS Manufacturing SoftwareDinkle Corporation USA Dorner Manufacturing Emerson EZAutomationEndress + Hauser EPLAN Software & Services LLC Fabco-Air, Inc. A member of Festo Group FAULHABER MICROMOFesto Corp. GE Digital Hammond Manufacturing HARTING North America Helukabel USA HighByte, Inc. HMS Industrial Networks Honeywell Process Solutions IDEC Corp. Inductive AutomationL-com LAPPLenze Maverick Technologies, LLC A Rockwell Automation Company Motion Index Drives Moxa Americas Inc. MTS Sensors Murrelektronik, Inc. Newark, An Avnet Company Nexans Industrial Solutions NORD Gear Corp. Opto 22 Oriental Motor USA Parker Hannifin Corp., Pneumatic Division PBC Linear Pepperl + Fuchs, Inc Pilz Automation Safety, LP Posital-Fraba, Inc. Pro-face America ProComSol Red Lion Controls Schneider Electric SICK, Inc Siemens Digital Industries SMC Corp. of America Softing, Inc Teledyne DALSATelemecanique Sensors Transtector Systems Turck Universal Robots Wago Corp.Weidmuller Winsted Corp. Yaskawa America Inc.7778798081828384858687888990919293949596979899100101102103104105106107108109110111112113114115116117118119120121122123124125126127128129130131132133134135136137138139140141142143144145146147148149COMPANYCOMPANYPAGEPAGE76AWJANUARY 2020LEADERSHIP IN AUTOMATIONLIAContents2020.indd 76LIAContents2020.indd 761/20/20 4:47 PM1/20/20 4:47 PMSee all the Leaders in Automation at www.automationworld.com/leadersAdvertisementAcromag manufactures signal conditioning and remote I/O solutions. Process instruments include signal transmitter/converters, loop isolators, signal splitters, alarm trips, and computation modules. BusWorks® remote I/O modules for Ethernet IP, Profinet, Profibus and Modbus TCP/IP and RTU interface analog and discrete I/O signals.Acromag I/O is ideal for a broad range of monitoring and control operations where controllers communicate with instrumentation on the plant floor or in the field.Signal conditioner products include process transmitters, 4-20mA signal isolators, limit alarms, panel meters, and math computation modules. These signal conditioning products isolate, amplify, filter, condition, and convert measured signals from sensors and other instruments. The enhanced signal is ready for interfacing to your PLC, DCS, display, recorder, or other process control instrumentation.Acromag’s Ethernet/IP, Modbus TCP I/O, and Profinet products offer a variety of solutions for remote I/O, distributed process control, and factory automation applications. Analog and discrete Ethernet I/O modules interface sensors and actuators to controllers with Modbus TCP/IP or Ethernet/IP CIP protocol network communication.Acromag products are built to the highest quality standards. Manufacturing is located in Wixom Michigan and is ISO9001 and AS9100 certified. Acromag products are designed to be rugged. Many are CE compliant and designed for UL/cUL Class I Division 2 Groups ABCD, ATEX / IECEx Zone 2 and temperatures from -40 to 80°C.www.acromag.comEmail: sales@acromag.comPhone: 248/295-088230765 S. Wixom Rd., Wixom, MI, 48393 • USA Acromag Test & MeasurementNetworking & ConnectivityI/O Modules77Document_2020_LIAProfiles.indd 77Document_2020_LIAProfiles.indd 771/20/20 3:47 PM1/20/20 3:47 PMNext >