In 2020, AVEVA, a global leader in engineering and industrial software, announced its intent to acquire OSIsoft, a forerunner in industrial data management. This strategic move served to merge two giants in the field of industrial intelligence, combining each company’s complementary abilities.

Completed in 2021, this new partnership between AVEVA and OSIsoft would have an almost immediate impact on the automation industry at-large. Control system integrators partnered with AVEVA had an opportunity to expand their expertise to support OSIsoft PI as well, adding yet another tool to our control system design belt, if you will.

Who are AVEVA and OSIsoft? And how does this acquisition affect manufacturers looking for bleeding-edge process automation solutions? Let’s take a look:

About AVEVA

AVEVA launched in 1967 under the name CADcentre. They quickly became the game-changers on the frontier of CAD applications in industrial processes. They were the first engineering firm to create a 3D computer plant model in 1976.

AVEVA has led the charge in collaborative automation system design and cloud-based applications. Today, as a global leader in industrial intelligence, AVEVA strives to innovate sustainable automation solutions. They’re renowned for:

• Basic engineering design: Conceptualizing and designing industrial facilities.
• Detailed engineering: Creating detailed plans for construction and equipment installation.
• Operations and asset management: Monitoring and optimizing production processes, ensuring asset performance and safety.

About OSIsoft

OSIsoft was founded in 1980 as Oil Systems Inc. where they initially focused on real-time data acquisition and analysis for the oil and gas industry. They developed PI System, which revolutionized the management and utilization of industrial process data.

By the early aughts, OSIsoft had expanded their PI System capabilities for other sectors like chemical and power, and launched PI Server, an internet-based platform for accessing data. A pioneer in real-time industrial data management, OSIsoft’s PI System is a powerful automation system platform that collects, contextualizes, and analyzes data from industrial assets, providing crucial insights for:

• Process optimization: Identifying inefficiencies and improving production performance.
• Predictive maintenance: Anticipating equipment failures and scheduling preventive maintenance.
• Compliance and safety: Ensuring adherence to regulations and maintaining safe operating conditions.

Acquired by AVEVA in 2021, OSIsoft operates as a distinct brand within the company.

Impact of the AVEVA’s Acquisition of OSIsoft

The recent acquisition of OSIsoft was a genius strategic move on the part of AVEVA, and according to both industrial trailblazers, was driven by 3 main factors:

• Complementary strengths: AVEVA’s engineering expertise combined with OSIsoft’s data management prowess created a comprehensive solution for managing the entire industrial lifecycle, from design to implementation.
• Market opportunity: The demand for industrial intelligence was rapidly growing, driven by factors like digital transformation initiatives and the increasing adoption of IIoT.
• Synergy potential: The combined entity aimed to achieve significant cost savings, cross-selling opportunities and accelerated innovation in the automation and control system software market.

And they were right. Adding OSIsoft PI to AVEVA’s portfolio of automation software has had a significant impact on the landscape of industrial automation applications:

• Creation of AVEVA PI System: This combined offering leverages OSIsoft’s real-time data with AVEVA’s engineering and operational software, enabling enhanced process visibility, improved decision-making, and optimized performance across the industrial value chain.
• Strengthened market position: AVEVA has emerged as a major player in the industrial intelligence market, competing with established players in automation software, like Siemens and GE Digital.
• New innovations: The merger has spurred the development of new automation solutions and services that capitalize on the combined expertise of both companies.

Automation happens in two contexts. In the industrial sector, the integration of AVEVA and OSIsoft has driven innovation in automation applications and industrial intelligence. And in the engineering sector, this merger has driven automation companies to integrate their expertise in both to offer a new brand of OSIsoft support.

E Tech Group Supports OSIsoft PI as an Endorsed AVEVA System Integrator

As an endorsed system integrator with AVEVA and a leader in North American industrial automation, E Tech Group engineers leverage these companies’ complementary technology to support OSIsoft and AVEVA-based automation systems. And because we are dedicated to providing high-value automation and IT services, we will continue to expand our expertise as these products evolve.

Even the best automation systems don’t add up to much if the HMI is inadequate. Whether it’s difficult to access industrial data analytics, equipment aren’t communicating with sensors, or the control system panel is unable to present data saliently, a poorly-conceived control system panel can render otherwise well-designed building automation system a risk to operations and reputation.

Designing and fabricating custom control panels isn’t something every automation system integrator is experienced with, and this can contribute to subpar design. E Tech Group provides clients with this often-missing piece in automation implementation: control panels tailored to your facility’s needs.

What Should a Proficient Control System Panel Do?

There are several factors to consider when drafting a new control system panel, because there are several things a well-designed system panel should be able to do:

Monitoring & Data Acquisition

Control system panels gather data from sensors and other devices to provide real-time insights into the status of industrial processes. This data is often displayed on screens or gauges, allowing operators to monitor critical parameters such as temperature, pressure, flow, and speed.

Process Control & Regulation

Control panels incorporate PLCs, which are the “brains” of the control system. PLCs receive data from sensors and interpret it based on pre-programmed instructions. They then send commands to actuators, such as valves, motors, and pumps, to regulate the behavior of industrial equipment and maintain desired process conditions.

Human-Machine Interface (HMI)

Control system panels often feature HMIs, which provide operators with a user-friendly interface for interacting with the control system. HMIs allow operators to view process data, modify parameters, and troubleshoot issues, enabling them to effectively manage industrial processes.

Safety & Alarm Systems

Control panels often incorporate safety interlocks and alarm systems to prevent hazardous situations. These systems can detect abnormal conditions, such as excessive temperatures or pressure spikes, and trigger alarms or activate safety measures to protect equipment and personnel.

Communication & Networking

Control system panels can communicate with other devices and systems through various communication protocols, such as Ethernet, Modbus, and Profibus. This networking capability allows for centralized control and data exchange, enabling integration with supervisory control and data acquisition (SCADA) systems and other enterprise-level management software.

Regulatory Framework to Apply in Panel Design

Panel design must adhere to or exceed NEC, NFPA 70, and UL 508 and the newer UL 60947-4-1 industry standards for control system panel architecture. This requires an automation integrator with a breadth of expertise in system panel frameworks across industries.

NEC (NFPA 70)

The National Electrical Code (NEC), also known as NFPA 70, is the primary electrical safety standard in the United States. It covers the design, installation and maintenance of electrical systems in all types of buildings and structures. While the NEC is not a law in itself, it is widely adopted by state and local governments as mandatory code.

The NEC includes several provisions that specifically regulate facets of the design of control system panels in Article 409:

• Panel enclosure and protection
• Component selection, rating and installation
• Wiring and cabling
• Grounding and bonding
• Overcurrent protection
• Labelling and identification
• Access and maintenance
• Hazardous location considerations
• Compliance with manufacturer’s instructions
• Compliance with state codes and regulations

The NEC/NFPA 70 offers the broadest coverage of safety regulations applicable to industrial control system panels.

NFPA 79

Also known as the “Electrical Standard for Industrial Machinery,” NFPA 79 provides comprehensive guidelines for the design, installation and maintenance of electrical equipment and systems used in industrial machinery. While NFPA 70 addresses general electrical safety requirements, NFPA 79 specifically focuses on the safety of electrical systems in industrial machinery applications.

Key regulations set forth by NFPA 79 for control system panel design draws on NFPA 70 as a foundation, and sets further requirements that apply specifically to architecture and installation of control system panels. NFPA mainly delves into the electrical work, offering guidelines on wiring gauge and installation, wire trays, conduits, and also requires all control system panels be designed to operate at 600V or less.

UL 508 & UL 60947-4-1

UL 508 was the industry standard for designing and installing a control system panel for decades, but has slowly been phased out and replaced by UL 60947 in the last few years. The UL 60947 standards are a revision meant to harmonize industry standards between the US, Canada and Europe in order to streamline global manufacturing and commerce.

However, if a control system panel was fabricated before the code switch (27 Jan, 2017) and complies only with UL 508, it is grandfathered in.

Some areas of control system equipment covered by these standards include:

• Product testing and qualification
• Industrial voltage regulation
• Control circuit design
• Guidelines for power circuit wiring
• Branch protection
• Group motor design

Environmental Aspects to Consider in Panel Design

A facility’s automation system doesn’t happen in a vacuum; there are physical parameters that need to be addressed, especially when it comes to workplace safety. Physical design aspects to factor into schematics for a new control system panel are:

Spatial Requirements for Enclosures

Where is the control system panel going to go? What kind of enclosure will be used? There needs to be enough room and outlets inside the panel enclosure so that it can be wired and worked on. Is it a cabinet enclosure? Factor in swing distance for the doors. Is it a high-temperature location? Ensure there’s proper cooling and ventilation measures taken.

Human-Machine Interaction

Operator devices might be anything from an indicator light to an intricate touchscreen display. While a more intricate HMI might allow for more complex interactions, keeping things as simple as possible is important. An HMI must be user-friendly, without blind spots, and allow full access to the control system’s operations.

A control system panel must also include a physical emergency stop device that is not a button on the HMI, per OSHA regulations.

Supply Conductors & Overcurrent Protection

The supply conductor needs to be designed so that if every single apparatus in the system were running, it could still handle the load. This requires an understanding of the sum of all those connected apparatus’ is, so a buffer can be added.

Overcurrent protection is for what happens if the system panel receives more power than it’s rated for. This device protects the electrical components of the panel from overload. The control panel can be designed to include overcurrent protection, or it can instead be a discreet device, which may make it more convenient to access.

Front Panel Construction

There must also be physical parts that protect the control system panel itself from everyday operations. Face plates should resist water, high temperatures, chemicals, cleaners, and, if applicable, extreme weather. Because front panels/plates include user guidelines, they must also be designed to remain readable for the foreseeable lifespan of the panel.

Best Practices for Implementing a Control System Panel

Just like anything in industrial automation, when it comes to designing a control panel, the devil is in the details. A thorough approach to project strategy, schematics, fabrication, and installation is absolutely vital to implementing a cutting-edge control system panel. Key practices E Tech Group automation engineers apply to these projects include:

Component Placement

Placement and organization of the interior components of the control system panel are crucial to everything from daily operations to troubleshooting to reconfigures and upgrades. Organizing circuits and components like PLCs correctly is a balance of

• ensuring temperature grade inside the panel is coolest at the bottom so heat can escape through the top, and
• making sure the way everything is laid out is clear and intuitive to the user.

Panel Size

Component spacing is important. In theory, it might seem logical to minimize the size of the panel and enclosure to use the least space possible, but in practice that is not true. A larger panel is almost always better.

Panel size will depend on the number of components, wiring, location, and what layout is ideal for safe, accessible usage of the panel. There should be a generous amount of space for the current setup; this makes troubleshooting, reconfiguring, expanding or upgrading the current control system much simpler.

Wiring Layout

Wiring should be organized and wireways should be set up so that, should every I/O terminal be in use in the future, the layout would still work. This streamlines the process of adding new pieces of equipment.

Labelling

There is no such thing as too much labelling when it comes to building a control system panel. Each item should be clearly and concisely labelled with a syntactical system that corresponds with each part’s PLC. Labelling is important for daily use, but especially for troubleshooting.

E Tech Group: Intuitive Control System Panel Fabrication & Implementation

As a North American leader in automation engineering services, one of our unique capabilities is designing and fabricating custom control panels tailored to the goals and obstacles of a specific facility.

Even within the same industry, different buildings have different parameters that affect what makes the best automation system and, in turn, the best control system panel. E Tech Group’s team works closely with yours to model and build the ideal system panel for your enterprise.

As a CSIA-certified integrator, our automation services adhere to the highest industry standards, and our deep domain expertise in regulatory compliance means you can rest assured your operations exceed compliance benchmarks. Ensure you get the most of your newly-integrated control system with a panel designed to help your company reach its goals.

All manufacturers are required to comply with regulations and standards, no matter the industry. And while automation has made it simpler and less costly to do so, a piecemeal automation system may have gaps, disparate software and obsolescence issues that risk the integrity of that compliance. And that is a risk that no company should leave unmanaged.

Manufacturing execution systems offer a solution to blind spots and flaws in a facility’s automation design. End-to-end coverage of automated processes coupled with continuous monitoring and analytics increases efficiency and ensures regulatory compliance, protecting the integrity of your operations and your reputation.

What is a Manufacturing Execution System?

A manufacturing execution system, or MES for shorthand, is used to track and manage production processes from start to finish. MES systems can be used to track inventory, schedule production, monitor quality, and collect data on performance. They can be applied in a variety of industries, including pharmaceutical automation, food and beverage production, material handling processes like palletizing, and many more.

How does an MES compare to a DCS or SCADA system?

While an MES…

• Tracks and manages the production process
• Collects inventory, production schedules, quality data, and performance data
• Outputs reports and analytics
• Is managed by production managers and supervisors

A SCADA or DCS…

• Provides real-time monitoring and control of automated processes
• Collects sensor and actuator data
• Outputs signals in real time
• Is managed by operators and engineers

MES implementation can be invaluable to a manufacturer’s quality control and future growth goals.

What’s Important in MES Design & Implementation?

Creating a client’s ideal MES solution includes the consideration of several factors, as well as careful attention to the project’s framework. An effective MES implementation needs:

• A clear understanding of the company’s goals, particularly the processes that need to be improved and the performance indicators used to measure success.
• Thorough analysis of existing automated processes by identifying each production stage, its inputs and outputs, and the relationship(s) between different stages.
• Selection of the right MES software sourced from top-tier automation vendors.
• Effective methodology from project planning to system deployment.

In tandem, three important factors guide the approach to the project:

• Data integration: An MES system needs to be able to integrate with other manufacturing systems like ERPs, CRMs and PLCs to operate effectively.
• Security: MES implementation must include ironclad security features that protect it from unauthorized access.
• Scalability: An MES system should be designed with future growth in mind.

E Tech Group helps clients cover all their bases via open communication and close collaboration. Getting an in-depth understanding of your company’s goals and keeping you in the driver’s seat throughout the course of a projects allows us to create completely customized MES solutions that work for you.

What are the Benefits of Manufacturing Execution Systems?

MES implementation offers multifaceted benefits to any size or type of industrial producer:

• Increased efficiency: MES systems can help manufacturers to streamline their production processes and reduce waste.
• Improved quality: MES systems can help manufacturers to identify and correct quality problems early on.
• Reduced operational costs: MES systems can help manufacturers to reduce their overall costs by improving efficiency and quality.
• Improved supply chain management: MES systems can also help manufacturers to reduce inventory costs and improve on-time delivery performance.
• Increased visibility: MES systems can provide manufacturers with real-time visibility into their production processes. This helps manufacturers to identify and resolve problems quickly and make better decisions about how to improve their operations.
• Improved tracking: MES systems can also help manufacturers better track and manage product traceability.
• Enhanced compliance: MES systems can help manufacturers to comply with (and exceed!) industry regulations and standards.
• Improved public perception: By improving efficiency, quality, and on-time delivery performance, MES systems can help manufacturers to improve customer satisfaction and industry reputation.
• Increased competitiveness: By reducing costs and improving efficiency and quality, MES systems can help manufacturers to become more competitive in their markets.
• Support growth: MES systems should be flexible and scalable to support the growth of a manufacturing business.

3 Cutting-Edge MES Automation Products

They key to unlocking the far-reaching benefits of a manufacturing execution system, it must be well-designed, seamlessly implemented, and utilize the best MES platforms on the market. E Tech Group partners with the best in the business, which is why our custom MES systems can be truly tailored to the best interests of an individual client.

Three advanced cutting-edge MES platforms our engineers often apply to projects are:

AVEVA Manufacturing MES Software

AVEVA Execution MES, previously Wonderware MES, is a platform meant to be implemented across multiple industrial sites, making manufacturing system integration a reality for an entity with several facilities.

AVEVA’s automation software:

• Uses fewer IT resources
• Unifies MES data
• Reduces control system software infrastructure
• Lowers enterprise integration costs
• Reduces system maintenance to a single MES
• Reduces energy costs by using assets more efficiently.

GE Proficy Manufacturing Execution System Software

GE Proficy Smart Factory MES software is a suite of in-facility and digital cloud solutions, providing important insights for businesses via data integration, IIoT, machine learning, and predictive analysis.

GE’s automation software received top scores in Gartner MES Reports for in-process quality management, data management and collection, and production equipment integration. GE Proficy Smart Factory MES implementation:

• Increases efficiency with customization
• Reduces errors and rework
• Improve analysis and compliance
• Improve asset and process performance
• Provides centralized, remote and mobile access to data analysis and configuration
• Allows companies the ability to go paperless

Siemens Opcenter Execution MES Software

Siemens Opcenter MES software is designed to increase efficiency and quality while reducing errors and costs. This line of MES systems is available in several iterations tailored for different manufacturing sectors:

• Opcenter Execution Discrete: discrete manufacturing job shops and complex assembly operations
• Opcenter Execution Process: consumer packaged goods (CPG), food and beverage (F&B) and chemical manufacturing
• Opcenter Execution Electronics: printed circuit board, mechanical assembly and box-build production
• Opcenter Execution Medical Device & Diagnostics: medical manufacturing
• Opcenter Execution Pharma: pharmaceutical production
• Opcenter Execution Semiconductor: semiconductor production operations

E Tech Group: Forward-Looking MES Design, Implementation & Support

E Tech Group, a leading North American systems integrator, serves industrial clients across the spectrum with manufacturing execution system implementation that transforms your operations by increasing efficiency, quality, control, and consistency. We have deep domain expertise that runs the gamut of automation services – from simple system upgrades to IT assessments to complete facility-wide automation system builds.

Our distinct capabilities and hundreds of engineers’ experience allows us to provide services to a host of industrial entities. Some include:

• Data Centers
• Food & Beverage/Alternative Protein
• Chemical Manufacturing
• Metals
• Material Handling
• Consumer Products

If you’re considering an MES, SCADA, DSC, or other automation upgrade, E Tech Group will help you meet and exceed your goals with a customized control system solution that fits your needs, budget and timeline.

With the e-commerce boom and the rapid rise of direct-to-consumer platforms, it is more important than ever for manufacturers to stay competitive. And to stay competitive in this market, manufacturers, packers and distributors require automation solutions that optimize use of their human resources, as well as their ability to adapt and scale.

E Tech Group, a material handling automation company, understands this ever-present need for leading-edge process control solutions, especially as they apply to parcel hubs, distribution centers and the like. But what, exactly, do those control solutions entail? And what tangible value do they offer?

What is Material Handling Automation?

The term “material handling” refers to moving materials or products within a facility or warehouse. Material handling processes are simple, but they’re repetitive, making them prone to human error. These encompass a number of processes in the manufacturing and distribution industries, including:

• Counting
• Labeling and packaging
• Loading and unloading
• Palletizing
• Recycling/disposal
• Retrieval
• Storage
• Sorting

Automation Equipment for Simple Tasks

The processes involved in handling materials within a facility do not require complex thinking, problem solving, or skilled handling. This presents an opportunity, should technology rise to the occasion, to transition handling and distribution tasks to machine labor. Some examples of the robotics equipment we employ to automate repetitive processes include:

• Automated Guided Vehicle (AGV) – self-driven vehicles/equipment that can move around a facility without human intervention
• Automated Storage & Retrieval Systems (AS/AR) – use robots to store and retrieve materials from high-rise racks and efficiently reach locations in large facilities
• Autonomous Robots – robots that can perform tasks without human intervention, such as counting, sorting, picking, etc
• Conveyors – belts that move products along a certain path
• Palletizers – automatically pack things into pallets
• Sorters – automatically separate things into different groups

Control System Software for Material Handling

The right control system design is the key to making the most of your robotics and automation hardware. Since material handling tasks are tedious and error-prone, automating and accurately configuring these mechanized systems can slash task completion times, error and procedural defects.

Material handling automation solutions include:

• AI and machine learning
• DCS
• IIoT
• Manufacturing execution system (MES)
• Motion control system (MCS)
• PLC
• SCADA
• Warehouse management system (WMS)

As an integrator with extensive domain expertise in material handling and industrial distribution, E Tech Group is adept at working closely with our clients to create custom control systems that optimize your automated processes. To accomplish this, we leverage software from the most innovative and trusted names in industrial automation, including:

• Rockwell (PlantPAx) and Allen Bradley
• AVEVA (OSIsoft)
• Emerson (DeltaV)
• GE
• Inductive Automation (Ignition)
• Siemens
• AVEVA Wonderware
• Schneider

Benefits of Automating Repetitive Tasks

There are myriad ways that choosing to upgrade your automation system to integrate new processes adds value to your operations, both ones your bottom line will see immediately and ones that will strengthen your capabilities long-term:

·      Increased efficiency

Automated material handling systems move materials more quickly and accurately than manual systems. This can lead to faster production times, throughput and reduced costs.

·      Reduced labor costs

Automated systems can free up human workers to perform complex tasks like quality control or customer service. This can help to reduce labor costs and curb the effects of the labor shortage on your company.

·      Improved safety

Automated systems can help to reduce the risk of accidents, such as those caused by lifting heavy objects or working in hazardous environments. This can help to improve workplace safety.

·      Increased flexibility

Automated systems can be easily adapted to changes in the production process. This can help to improve production flexibility and allow for scalability without a full retrofit at each new stage of growth.

·      Improved traceability

Automated systems can help to track the movement of materials throughout the supply chain. This can help to improve supply chain visibility, making it easier to locate bottlenecks or isolated process errors.

·      Increased security

Automated material handling systems contain robust security features that ensure the integrity of your network. This can lead to less network breaches and associated risks.

E Tech Group: Future-Proofing Your Workforce with Automation for Material Handling

E Tech Group works across industries to help companies automate tasks that robots and AI can how handle. One of the largest control system integrators in the US, E Tech Group serves clients across North America with material handling automation solutions, including palletizing, sorting, retrieving, counting, packaging, and more.

From distribution centers to pharmaceutical research facilities to OEM automotive factories, the value of automating simple processes can simply not be understated. Take advantage of current technology and stay poised for future advances with E Tech Group’s robust, flexible and scalable automation systems.