Blog: The quality you don't see via PdM
Do higher levels of predictive achievement get substantially lesser amounts of attention than reactive work?
As a career manufacturing engineer, I’ve seen my fair share of different operations’ inner workings. Like any job, there were parts I loved and parts I hated, but when it was all said and done, some of my proudest life moments have been spent with my coworkers on a factory floor.
Within the operations disciplines, we are often measured and judged by our ability to react. In any company I’ve ever been, it’s usually pretty easy to pick out the “core” — those vital few folks who are the ones everyone turns to when things just aren’t going right.
These are the manufacturing engineers who, like the urban legend says, can walk up to a broken machine and place an “X” on the problem area within minutes of investigating. They…
Blog: Move beyond the process historian via IT-OT convergence
Perspective: The case for moving to predictive maintenance
5 ways oil & gas companies control costs with asset management software
Process pumps and equipment: 8 quick tips to increase uptime
Blog: Carl, Microsoft partner on IIoT machine learning case study for wastewater
"Regulating Sensor Error in Wastewater Management Systems" focuses on detection of sensor error in IIoT applications
Carl Data Solutions provides a suite of software tools called Flow Works, that are used by municipalities to help manage their wastewater infrastructure. Their tools pull data from various sensor channels that measure variables such as water flow, velocity, and depth.
These sensors sometimes malfunction or behave unexpectedly, causing skewed readings. Since forecasting models are built on top of these sensors, skewed data can negatively influence accuracy. Currently, to account for irregularities, municipalities that use Carl Data’s flow works solutions hire consultants to manually sift through all the sensor data and modify values believed to be caused by sensor error.
Due to the overhead in time and cost, Carl Data was interested in…
Light touch: Predictive maintenance for electrical systems: Part 2
Light touch: Predictive maintenance for electrical systems: Part 1
PdM words of wisdom from the experts
7 critical success factors that keep strong PdM programs on track
Video: The scale of aircraft carrier maintenance is ridiculous
How the NRC’s Nuclear Maintenance Rule shapes today's best practices
Build the right combination of predictive tools and technologies to proactively monitor your electrical systems.
The potentially catastrophic consequences of electrical system failures and hazards must be avoided at all costs. Regular predictive maintenance (PdM) on electrical systems lets maintenance teams detect and correct problems before they can shut down…
How to clean steam turbines both online and offline
Fouling of steam turbine blades and vanes is a common problem, and online cleaning is possible that doesn’t require dismantling although the results are not guaranteed.
Fouling of steam turbine blades and vanes is a common problem. A complete and thorough cleaning would require stoppage and opening up the turbine, which may mean shutting down a profitable process. Online cleaning is possible that doesn’t require dismantling although the results are not guaranteed.
This article features excerpts from a case study, “Successful Online and Offline Cleaning of Steam Turbines With and Without Disassembly” by Bladimir Gomez Supervisor of PDVSA and Barry Snider of Small Hammer Inc. at the 43rd Turbomachinery Symposium held in Houston in 2013.
At a facility, the steam turbines driving critical compressors were losing power and speed. The governor/steam valve was unable to maintain desired rpm. Unit…
Why digital photography and predictive modeling will remake the APM landscape
In this Big Picture Interview, Anne-Marie Walters explores picturing asset health.
Anne-Marie Walters, a chemical engineer, is global marketing director for Bentley Systems. In that role, she’s responsible for the global industrial process, offshore, and natural resources industries. Bentley is a leading player in the industrial…
Imation's new plan: Asset management
Allied Reliability Inc./T.F. Hudgins Inc. and GTI Predictive Technologies Inc. form strategic partnership
It's a lock: Secure your network
Sheila Kennedy says vendors are joining forces to offer more-robust industrial network security solutions.
Industrial networks are not what they used to be. These critical infrastructures now accommodate more systems, devices, and data than ever before, making security far more complex. The cloud, the internet of things (IoT), the convergence of…
Parker Hannifin acquires Clarcor for $4.3 billion
Deal enhances Parker's filtration portfolio
Parker Hannifin Corp., which makes motion-control technology, agreed to acquire filtration-products manufacturer Clarcor Inc. for about $4.3 billion, including the assumption of net debt.
Clarcor makes filters for automotive and heavy industrial applications and reported $1.5 billion in sales for the fiscal year through November 2015. The deal adds an array of industrial air and liquid filtration technologies to Parker’s filtration portfolio, according to the statement.
Read the full story at industryweek.com.
How to realize the benefits of preventive maintenance for hydraulic valves
7 steps to quash carbon buildup
Don't light my fire: Keep flammable vapors at bay
Amazon's latest idea: A flying warehouse that will deliver stuff by drone
Could an airship be more cost-efficient for drone delivery?
Amazon is exploring the use of giant airships to serve as mobile, flying warehouses that could help the online retail giant deliver more of its goods by drone.
You might already be familiar with Amazon's drone delivery service, which recently received a demo in the United Kingdom for the first time. But the idea for a fleet of large airships, disclosed in filings to the U.S. Patent and Trademark Office, expand on those ambitions dramatically.
Read the full story at chicagotribune.com.
OSHA announces Top 10 violations for 2016
Bosch & GE team up for IIoT interoperability
SAP, UPS work to attract partners to distributed manufacturing initiative
New tool helps manufacturers search for obscure parts
Invite your drives to join the motor team
The best motor and drive for the application should go together like two peas in a pod
When your industrial motor requirements move beyond a single-speed application to a variable-speed application with adjustable acceleration and deceleration, and possibly precision position or torque control, the motor and drive need to team up for a winning solution.
The motor drives connect to and provide enhanced operation to dozens of different types of motors. These include dc, ac, stepper and servo motors. There are definitions to be found online along with the advantages and disadvantages of each type of motor. However, a big thing to keep in mind is that many of the motors are designed for a specific application or their applications are limited.
Read the full story at controldesign.com.
The basics of variable-frequency drive installation
Monitor electric motor vibration, or optimize bearing lubrication?
Avoid unplanned motor downtime with the right equipment and processes
Machine learning software to transform ship maintenance
Kaeser Compressors announces 2017 Pressure & Profit conference schedule
Series features two separate learning tracks (technical and business), both offering four certified professional development hours
Kaeser Compressors is pleased to announce their Pressure & Profit Half-Day Conferences scheduled for 2017.
Pressure & Profit is an educational event to equip specifying engineers and those responsible for plant compressed air and energy management with the knowledge and tools needed to properly design and maintain industrial compressed air systems. Conference locations for the year include: Dallas, Philadelphia, Atlanta, Kansas City, Minneapolis, and Chicago.
Pressure & Profit features two separate learning tracks, both offering four (4) certified professional development hours.
The technical track, presented by Kaeser Branch Development Manager Gerald Baron, covers changes in compressed air technology.
The business track,…
Condensate management 101
Next-gen subsea compressors to reduce size, weight by 50%
Compressed-air savings to blow your mind
Compressed air controls: Don't misuse and mismanage your compressed air system
Who's afraid of the smart factory?
New technologies seen contributing to distrust of companies
A revolution is stirring in the world’s factories. Industrial robots are breaking out of their cages to work side by side with humans. Autonomous vehicles scoot around factory floors. And factories are improving their links with suppliers, exchanging data and rectifying problems, with minimal human intervention.
But almost half the 1,370 chief executives questioned in PwC’s annual Global CEO survey published this week fear that this latest industrial revolution will feed further distrust among their companies’ stakeholders — whether they be investors, employees or the wider public.
Read the full story at ft.com.
A mix of factors, not just Mexico, cause decline in U.S. manufacturing
Take a glimpse inside the Tesla plant
5 tech trends that will highlight 2017
Foxconn reportedly looking to fully automate production at factories in China
Father and son team creates liquid metal 3D printer for manufacturing
Other metal printers exist, but most use a process of laying down powered metal and melting it with a laser or electron beam
A father and son team in the START-UP NY program have invented a liquid metal printing machine that could represent a significant transformation in manufacturing.
A breakthrough idea five years ago by former University at Buffalo student Zack Vader, then 19, has created a machine that prints three-dimensional objects using liquid metal. The machine is so novel it represents a quantum leap in the ability to print three-dimensional objects in metal. Other metal printers exist, but most use a process of laying down powered metal and melting it with a laser or electron beam. In that process, some particles of the powder do not get melted, creating weakened spots.
Manufacturers are very interested in the Vader machine, with one automotive…
U.S. Army tests 3D-printed military drones
Where 3D printing will expand in 2017
Manufacturers take a page from Mother Nature
NIST: Closing tech gaps can fortify advanced manufacturing, save $100 billion
White House study: Robots, AI may take half our jobs
“Artificial Intelligence, Automation, and the Economy,” suggests the U.S. should invest in and develop AI, and policymakers need to prepare the economy for it
Artificial intelligence is coming, and policymakers need to prepare the economy for it, the White House said in a recent report.
The report, “Artificial Intelligence, Automation, and the Economy,” suggests the U.S. should invest in and develop AI, because it has “many benefits,” education and train Americans for the jobs of the future, and aid workers in the transition and empower them to share in future growth.
But the authors of the report acknowledge that there are countless unknowns, from what the effects could be, to how quickly they’ll arrive.
“Researchers’ estimates on the scale of threatened jobs over the next decade or two range from 9% to 47%,” they write, but add that the economy has always proved to be…
Forbes' 30 Under 30: The young engineers and entrepreneurs reinventing manufacturing and industry
Plant Services CMMS/EAM Software Review
Read David Berger's column, Asset Manager
After a series of stumbles in the data storage business, Imation Corp. is ready to try to move into the asset-management business with the help of Clinton Group Inc.
After a series of stumbles in the data storage business, Imation Corp. is ready to try something completely different.
In recent filings with the Securities and Exchange Commission, the Oakdale-based company described a plan to move Imation into the asset-management business with the help of Clinton Group Inc., a New York hedge fund that recently ousted the company's top executive.
Imation has been liquidating its core businesses and sold its corporate headquarters in Oakdale earlier this year, but the company still has an office in Minnesota. Imation hopes to steer as much as $1 billion in asset management work to Clinton within five years.
Since Imation has no track record in asset management, the proposal will hinge on the reputation…
Perspective: Why does the U.S. lose more manufacturing jobs than Germany?
Blog: The journey toward a digital power plant
Learn how targeted integration of data-based capabilities with deep power plant system knowledge has led to new proactive operating and maintenance strategies
The concept of the digital plant starts with data, most of which has always been there but often underutilized. For years, companies have been offering “Big Data” analytics and diagnostics to provide added value based on software and data science expertise and experience.
Targeted integration of data-based capabilities with deep power plant system knowledge and fleet-wide experience has led to new proactive operating and maintenance strategies tailored to individual plants.
For example, today’s advanced pattern recognition technologies (APR), coupled with real-time communications and expert knowledge create fleet-wide knowledge bases of normal and abnormal system behavior under a wide range of conditions, providing advancements in…
Emerson Network Power rebrands as Vertiv
Interview: Building the IIoT step by step
IIC releases new IIoT reference document focused on business strategy
Busting 3 IIoT myths
Analysis: What new metrics for IoT are emerging in the product development process?
Game on: How the IIoT is transforming asset lifecycle management: Part 1
Tesla shows what its self-driving cars see while on the road
Maximizing safety in real time
Hot topic: Decarbonizing heating
Peter Garforth explores why greater heat efficiency is needed, and why it may need to be a group effort.
The commitment by most major companies to reduce their carbon footprint is showing interesting shifts in priorities. For decades, most electricity has been generated by coal and natural gas. This produced a convenient alignment of the cost and…
Carrier's complaint wasn't wages; it was regulations, Indiana businessman says
The future of energy management
Fundamental change is taking place on the world’s energy scene. Are you ready?
How disruptive is distributed power generation?
The impact of distributed generation made waves at last month's bi-annual Combustion Turbine Operations Technical Forum (CTOTF)
Utilities and independent power producers are preparing for the coming storm — distributed generation (DG). The impact of DG was the biggest takeaway at the bi-annual Combustion Turbine Operations Technical Forum (CTOTF) that took place last month in St. Augustine, Florida.
The big theme this year was preparing for the coming storm due to disruptive technologies, in particular DG. And who better to talk about grid pattern changes than an independent system operator (ISO). Tag B. Short, Interim Director, South Region Operations, Midcontinent Independent System Operator (MISO), detailed the big shifts affecting his region’s 180,000 MWs of capacity, 1,600 generating units and 66,000 miles of transmission.
“We anticipate the retirement…
Adding a VFD? How to treat it like a VIP
Perspective: Ethane as primary fuel for gas turbines?
Learn the dos and don'ts of generator maintenance
GE Power & Water and Alstom Power combine to form GE Power
U.S. industrial production fell in November
Manufacturing output slips on decline in durable-goods production
Industrial production—measuring everything made by factories, mines and utilities—declined 0.4% in November, according to the Federal Reserve. Economists surveyed by The Wall Street Journal had expected a 0.2% drop.
Manufacturing output, the biggest component of industrial production, slipped 0.1% in November after rising in September and October. A drop in production of long-lasting durable goods, particularly motor vehicles and parts, drove the overall decline.
Read the full story on wsj.com.
Marathon sues BP, claiming shoddy maintenance at refinery
Study: Clean Power Plan could drive $442 billion in energy savings over 15 years
“Liberating” process data to enable enterprises to efficiently capitalize on the plant or shop floor information requires an overhaul of the data integration strategies
Although operations and maintenance groups generate vast quantities of data – both structured and unstructured – they can only leverage a small percentage of data to make better decisions.
For decades, much of the process data collected from real-time operational systems were “locked up” in process historians. The majority of these data was seldom used, except by engineers and maintenance and operations staffs that tend to use either basic visualization tools or somewhat more sophisticated, but usually difficult-to-use, historian tools to investigate operational situations.
But new technology approaches and technology convergence are changing this. Convergence is the gateway to optimizing plant performance through cloud-based…
Army reaches $1 billion in energy-saving projects with private sector
DMDII announces second 2016 project call for advanced manufacturing R&D projects
Steam savings for the long haul
How to monitor day-to-day cooling tower performance
List presented at 2016 NSC Congress & Expo
The Occupational Safety and Health Administration (OSHA) announced the preliminary Top 10 most frequently cited workplace safety violations for fiscal year 2016. Patrick Kapust, deputy director of OSHA's Directorate of Enforcement Programs, presented the Top 10 on the Expo floor as part of the 2016 NSC Congress & Expo, the world's largest gathering of safety professionals.
The Top 10 for FY2016 are:
1. Fall Protection, 1926.501(C) (6,929)2. Hazard Communication, 1910.1200 (5,677)3. Scaffolds, 1926.451(C) (3,906)4. Respiratory Protection, 1910.134 (3,585)5. Lockout/Tagout, 1910.147 (3,414)6. Powered Industrial Trucks, 1910.178 (2,860)7. Ladders, 1926.1053(C) (2,639)8. Machine Guarding, 1910.212 (2,451)9. Electrical Wiring, 1910.305…
Proposed ASHRAE/ACCA standard for energy audits open for public comment
HVACR contractors share chiller maintenance best practices
Johnson Controls and Tyco announce merger
Don't sweat your heating bill
In Minnesota, helping manufacturers strategize to grow revenue
Enterprise Minnesota looks to help manufacturers unlock four keys to manufacturing success
Manufacturing executives looking to boost productivity, while increasing their customer base, with the goal of growing revenue, don’t have to struggle with putting together a puzzle of multiple moving pieces.
Enterprise Minnesota, a consulting organization, sees the puzzle as containing only four pieces. And the ideal way to ensure those four pieces remain connected is through strategy. For about the past 18 months, Enterprise Minnesota has been using the image of four interlocked puzzle pieces — strategy, talent, ISO management system, and continuous improvement — to help small and medium-size manufacturers be more competitive.
Read the full story on crowrivermedia.com.
New partnership with university aims to crank up Utah's manufacturing sector
Perspective: Why U.S. manufacturing is now bigger than ever before
Blog: What EHS managers need to know about digital transformation
GM to invest $1 billion in U.S. manufacturing
Top U.S. carmaker faced pressure to follow Ford, Fiat Chrysler
General Motors Co. announced a $1 billion U.S. investment plan comprised mostly of spending on models and plants long in the works, becoming the latest automaker to answer to pressure from President-elect Donald Trump to create jobs.
The nation’s top carmaker will add or retain about 7,000 salaried and hourly workers, including almost 2,000 in domestic factories, spokesman Pat Morrissey said. The announcement was accelerated after Trump urged the company last week to follow Ford Motor Co. and Fiat Chrysler Automobiles NV and detail U.S. spending plans, said a person familiar with the matter.
Read the full story at bloomberg.com.
Fiat to invest $1 billion in Michigan, Ohio plants, create 2,000 jobs
U.S. manufacturers brace for Trump's next targets
U.S. manufacturing, construction sectors shine as year ended
Report: Businesses spend more than $1 billion each week on serious, nonfatal workplace injuries
Top five injury causes accounted for 63.8 percent of the total cost burden for U.S. businesses
According to the 2017 Liberty Mutual Workplace Safety Index, serious, nonfatal workplace injuries now amount to nearly $60 billion in direct U.S. workers’ compensation costs per year. This translates into more than $1 billion dollars a week spent by businesses on these injuries.
The Liberty Mutual Workplace Safety Index helps employers, risk managers and safety practitioners make workplaces safer by identifying critical risk areas so that businesses can better allocate safety resources.
Read the full story.
Where the industrial IoT vulnerabilities lurk in your plant
How to reduce alarm chatter
OSHA's wall of shame
How to improve the safety of your motor control centers
Implement a smart solution by integrating a low voltage motor overload relay with advanced protection and integrated arc-flash detection.
Low-voltage (LV) motor control centers (MCCs) are numerous in industrial power distribution systems. MCC are commonly a safety concern because operator and maintenance personnel have close interactions with the MCC. Also, the recognition of arc…
Avoiding electrical hazards: Stay safe, not sorry - Part 3: How context-aware technology is helping protect workers
Avoiding electrical hazards: Stay safe, not sorry - Part 2: How the IIoT is changing electrical safety
Avoiding electrical hazards: Stay safe, not sorry - Part 1: Compelled to stay safe in confined spaces
Safety on a larger scale: Honeywell integrates protective solutions offerings
CSIA upgrades Industrial Automation Exchange
Improvements make it easier for system integrators, clients to connect
Two years ago, the Control System Integrators Association (CSIA) launched the Industrial Automation Exchange, with the intention of helping industrial automation end-user clients find system integrators and their suppliers.
Now CSIA has made the site even easier to use. Today the CSIA Exchange features its own blog, largely authored by system integrator members and member partners. It has also incorporated a new library-resources section.
“As guest bloggers, control system integrators and suppliers can inform end users of trends and events across all industries and specialties,” said Jose Rivera, CSIA CEO. “They can share how-to guides and evergreen resource material helpful to automation clients. CSIA is proud of the…
What to watch for next year in automation
Did trade with China make U.S. manufacturing less innovative?
Microsoft brings desktop apps to mobile
Perspective: Harley hogging the open road to top-speed manufacturing
Obama sounds warning on automation effects in farewell speech
The way ahead for American manufacturers in 2017: 4 industry leaders weigh in
Faced with worker shortages, Montana manufacturers turn to schools
Advanced Manufacturing Center connects Toyota with Kentucky students
In Indiana, Subaru works to spark student interest in manufacturing
How one small American manufacturer pays above-average wages and makes a profit
Program gives hands-on opportunities to area high-schoolers
A local manufacturer is working to spark an interest in the younger generation for the manufacturing sector.
Since 1991, Subaru of Indiana Automotive has worked to build relationships with Hoosier students through a program called Vehicles for Learning. It provides hands-on experience in the classroom.
“We’re hoping to build not only a potential workforce of the future for SIA, but also people that will have an interest in the automotive industry and manufacturing in general,” SIA Senior Executive Vice President Tom Easterday said.
Read the full story at wlfi.com.
Survey: Manufacturing Day events boost public perception of industry
Massachusetts university prepares unemployed workers for high-tech manufacturing
A single chart everybody needs to look at before Trump's big fight over bringing back American jobs
Union boss: "It's really hard to look team members in the face and know that they're not going to be able to provide for their family in the manner that they've been accustomed to"
The day of Donald Trump's inauguration is also the last day for the midnight shift at the General Motors assembly plant in Lordstown, Ohio. About 1,200 people will lose their jobs. Trump blames GM production in Mexico. As M.L. Schultze of NPR member station WKSU reports, the reality and reaction in Lordstown is more complicated.
Read the full story at npr.org.
6 steps to project leadership success
Perspective: Don’t blame "skills gap" for lack of hiring in manufacturing
In an age of online job listings, automated résumé screenings, and increasing temporary and contract work, companies are posting more jobs than they ever expect to fill
Manufacturers posted 379,000 job openings in July, the Bureau of Labor Statistics reported Wednesday. That’s up more than 280 percent — close to quadruple — since the recession ended more than seven years ago.
When it comes to actually filling those jobs, though, the rebound has been far more gradual. Hiring is up just 36 percent since the end of the recession and has been pretty much flat over the past year. Tens of thousands of manufacturing jobs are going unfilled.
However, according to a new paper by economists Andrew Weaver and Paul Osterman, three-quarters of manufacturers that Weaver and Osterman studied weren’t having trouble finding workers at all. One possibility is that what companies mean by an “opening” has…
Study: As older workers are edged out, productivity slows
GE to invest $1.4B to acquire additive manufacturing companies Arcam and SLM
Study: One in five NY manufacturers are hiring fewer people because of Obamacare
Perspective: Why the US pines for manufacturing