Plant Engineering Sep14

27 Meet the 2014 Engineering Leaders Under 40
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Facts are
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John Adams
As our second president, John Adams focused

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Its a fact: Compressed air is inherently inefficient.

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2014 Kaeser Compressors, Inc.
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ITS WHATS ON
THE INSIDE
THAT COUNTS
No matter who made your dust collector, you can count
on Donaldson Torit to have your next filter replacement.
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2014 Donaldson Company, Inc.
September 2014
Volume 68, No. 7
27 2014
Engineering
Leaders
Under 40
The 2014 Engineering Leaders Under 40 each have a story to tell about their path into manufacturing.
They have mothers and fathers, veterans and students, but they all have found manufacturing a career
worth investing their lives in. In turn, their contributions will benefit manufacturing for decades to come.
9 Plant Engineering workforce development study

In the latest study on the issue of workforce development, Plant Engineering research found that nearly
two-thirds of respondents reported a skilled workforce shortage within their facility in 2014. Of those facilities, 24% have 5% to 7% of jobs currently unfilled, and another 25% have 8% to 10% unfilled. Compared
to 2013 data, the 5% to 10% range of jobs being unfilled has increased 10 percentage points.
9 Worker development focuses on partners, employees

Smart business leaders know that to build a successful global organization, you must devote time, resources
and capital into developing high-quality products and innovative solutions. However, as the manufacturing
workforce ages and the number of skilled workers entering the industry decreases, it is equally important to
invest in programs that will discover, prepare and retain strong team members to continue this progress for
years to come. Heres how one manufacturer is addressing these issues.
PLANT ENGINEERING (ISSN 0032-082X, Vol. 68, No. 7, GST #123397457) is published 10x per year, monthly except in January and July, by CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523.
Jim Langhenry, Group Publisher /Co-Founder; Steve Rourke CEO/COO/Co-Founder. PLANT ENGINEERING copyright 2014 by CFE Media, LLC. All rights reserved. PLANT ENGINEERING is a registered trademark of CFE Media, LLC used
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www.plantengineering.com
PLANT ENGINEERING
September 2014 3
LASER & PLASMA CUTTING
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CONTENT SPECIALISTS/EDITORIAL
BOB VAVRA, Content Manager
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ALLEN MOWERS, Production Coordinator
AMowers@CFEMedia.com
41 Evaluate cleaning
strategies to improve
productivity
Equipment thats not properly
cleaned can become unreliable
and affect the reliability of the part its producing. Without
industrial cleaning to keep manufacturing equipment free of dirt
and grime, parts wear faster, breakdowns occur more often, and
efficiency and productivity suffer.
PUBLICATION SERVICES
JIM LANGHENRY, Co-Founder & Publisher
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LETTERS TO THE EDITOR
Please e-mail your opinions to BVavra@CFEMedia.com.
INFORMATION
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Mechanical Solutions
49 Welding cells
adapting to
manufacturing
changes
Creating an adaptable
weld cell goes beyond
just improving the physical space, but that is also a very important
component. Choosing flexible and modular welding equipment is
an important way that manufacturers can maximize the value and
useful life of that equipment.
Electrical Solutions
57 Reaping the rewards of

data-driven efficiency
Leading manufacturers are already
leveraging big data to slash facilitywide energy use, improve space
utilization, optimize scheduling, and
decide when new capital equipment
investments make sense based on
accumulated data.
Automation Solutions
61 Can there be a
single wireless
protocol for field
devices?
One fieldbus protocol has
emerged as the leading
solution for process applications, and our industries have benefitted.
Perhaps the same thing can happen with wireless field devices.
PLANT ENGINEERING
September 2014 5
SEPTEMBER
Trending
New Products
Maintenance
Electrical
Mechanical
Energy Management
Plant Automation
Safety
People and Training
The industrys best research
Product of the Year
Plant Engineering conducts five research

projects each year: studies on energy,
Finalists
announced
Nov. 15
safety, maintenance
and workforce
development,
andtheour
annual
Salary SurThe finalists for
2013
Plant Engineering
vey,
the of
industry
Product
the Yearstandard
awards willfor
bemanufacannounced
turing
Look
forand
theonline
Salary
Survey
in thetrends.
November
issue
on Nov.
15.
inItsyour
emailmanagers
box in the
nextformonth,
it
the plant
source
the bestfillnew
out and of
help
continue
benchmark
products
the us
year,
and their to
chance
to vote on
the the
latest
in manufacturing.
besttrends
of the best
in manufacturing.To
review
our current research, go to
www.plantengineering.com/poy
www.plantengineering.com/research.
Editorial research
VIDEO: Three types of maintenance activities

Jeff Shiver, CMRP, of People and Processes discusses maintenance activities that plant personnel need to
consider: non-intrusive, intrusive and detective. Check out these and other videos from Jeff Shiver in the Plant
Engineering video archive. To watch, scan the QR code or go to www.plantengineering.com/videos.
On a quarterly basis, Plant Engineering conducts

research studies on various industry topics.
Access the following full reports at
n Workforce
development
www.plantengineering.com/research
n Energy management
Maintenance
Workforce development
Energy Management
People and training
ONLINE: Top 5 Plant Engineering stories for August

Here are the top 5 new stories this month at www.plantengineering.com for August:
2014 Workforce Development Study: 6 key findings
Compressed air demandFind and fix leaks
Special Report: New solutions put us on the way to preventing arc
flash incident
2014 Energy Management Study: 5 energy monitoring trends
On-demand videos
Upcoming and on-demand Webcasts
Online training center
Case studies130+ all in one place
on dozens of topics
eGuides
White papers
Services available
The three laws of asset management

Go to www.plantengineering.com for the latest industry news,
product innovations and manufacturing trends.
IMTS online covers all the bases

No one could see everything at the IMTS 2014 but the
Plant Engineering team had all corners of the show floor
covered with minute-by-minute reports from the show
floor on Twitter, daily reports on LinkedIn and Facebook
as well as at www.plantengineering.com, and full reports
from the seminars and events that make this North Americas most important manufacturing show.
In October, www.plantengineering.com also will feature videos from the 2014 Global Automation and
Manufacturing Summit, where industry leaders and experts share their views on the present and
future of manufacturing.
6 September 2014
PLANT ENGINEERING
Site search engine: Search current and

past articles at
www.plantengineering.com by topic,
keyword, author or company name to
find solutions to your plant issues.
Channels, new products: Visit our
specialized microsites providing feature
news, products, applications, tutorials
and research for engineering
professionals.
e-Newsletters: Keep current with the
latest information and news with our
weekly PlantMail and topic-specific
electronic newsletters.
System Integrator Guide: Consult our
listing of more than 2,300 automation system integrators. You can find a
specific company or run a seven-way
multi-parameter search.
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IN FOCUS
2014 Workforce Development Study: 6 key findings
Two out of every three manufacturing the next three to five years.
to online recruitment and 37% offer
2. Causes: When asked about the pri- in-house training for less experienced
plants have some sort of skilled worker
shortage, and that is leaving jobs unfilled, mary cause of the workforce shortage applicants.
5. Manufacturings image: Half of
even at a time of still-high unemployment within their plants, 68% said they are having trouble finding qualified applicants respondents dont believe that manufacand strong manufacturing growth.
That is one of the key findings in the among the new workforce, and only 12% turing is portrayed as a positive career
2014 Plant Engineering Workforce cited a lack of finances to seek workers choice in the U.S. More than half agree
that introducing manufacturing at an
Development study. In June 2014, more and fill positions.
earlier education level, incorpothan 200 plant engineers and manrating apprenticeship programs,
agers within the Plant EngineerMore
Percentage of unfilled jobs
than 15%
and improved salaries, benefits,
ing audience responded to the the
9%
Less than 2%
and job security would improve
survey, which asked key questions
15%
11% to 15%
manufacturings image.
on the causes and effects of the
6%
6. Community outreach:
lack of a skilled workforce in the
2% to 4%
Eight-one percent of respondents
U.S., what manufacturing plants
8% to 10%
21%
think their manufacturing plants
25%
are doing to combat this issue,
are seen as positive lights in their
and how facilities are establishing
5% to 7%
respective communities, and more
a positive relationship with their
24%
than 40% maintain this status
communities.
by hosting or volunteering for
Plant Engineering sees the follocal events and by being active
lowing six high-level findings to be
members of their local Chamber
important factors that are impact3. Unskilled workforce: According to of Commerce.
ing the manufacturing industry today:
respondents, the younger workforce lacks
1. Workforce shortage: Nearly two- project management (62%), engineering
Access the full 2014 Workforce Develthirds of respondents indicated a work- (53%), and team-building skills (48%), opment report with additional findings
force shortage within their plants, and but they are quite proficient in computer and insight, as well as all other exclusive
within those facilities, 7% of jobs are skills (76%).
Plant Engineering research by going to
4. Actions taken: In an effort to comwww.plantengineering.com and clicking
currently unfilled, on average. 63% agree
that the shortage will only increase within bat the shortage, 50% of plants have taken on the Research tab. PE
Worker development can focus on partners and employees

Glenn Goldney
Rockwell Automation
Smart business leaders know that to

build a successful global organization, you
must devote time, resources and capital
into developing high-quality products and
innovative solutions.
However, as the manufacturing workforce ages and the number of skilled workers entering the industry decreases, it is
equally important to invest in programs
that will discover, prepare and retain
strong team members to continue this
progress for years to come.
Rockwell Automation believes that people are the foundation of its success. We
demonstrate commitment to building our
team through significant investments into
educational and development programs

for our employees.
Recruitment and retention
Core to its corporate culture, Rockwell

Automation views people as its most
critical asset. When we recruit new
employees, we seek out individuals who
will not just fill a role, but can grow with
the company over time.
To help prepare recent college graduates with the specific knowledge and
practical skills theyll need to build a
career, we invest in several distinct training programs for early career employees.
New employees, recruited globally,
can participate in one of four tracks
held at state-of-the-art facilities in North
America and Asia. Engineer in Training
(EIT) provides a six-month intensive cur-
riculum educating new employees on our

hardware and software products, and their
practical application. Sales Training is a
six-month program, which focuses on our
portfolio of products and where theyre
found in various industries.
Our Leadership Development Program
begins with the EIT core curriculum and
continues with three additional, sixmonth, rotational assignments in various organizations across the enterprise,
providing on-the-job training in real
business opportunities across several
disciplines. Lastly, our Technical Development Program expands on the EIT core
curriculum with a series of technically
focused rotational assignments in various elements of our development organization, building the next-generation of
technical architects.
PLANT ENGINEERING
September 2014 9
IN fOCUS
These programs are a strategic investment designed to help young professionals begin their careers with a foundational
knowledge of our organization and industry that sets them up for years of success.
Rockwell Automation provides ongoing
training for employees throughout their
tenure. From hands-on technical training
and new product instruction, to leadership
skills and diversity programs, Rockwell

Automation offers a variety of opportunities for individuals to continue developing their skills and building their career.
We encourage each employee to develop
a 70-20-10 strategy for career development
with his or her manager. We recommend
70% of learning should be done on the
job, 20% through mentors and peers, and
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10% through formal training. Each plays

a vital role in fostering collaboration and
preparing employees.
Supporting a customers workforce
We also invest in sharing our knowledge

and experience in this arena with our customers. In the past, potential employees
were multiskilled and readily available.
However, increasing attrition among
highly skilled manufacturing professionals is leading companies to look for a
better solution to identify potential talent
and develop leaders.
Our Global Workforce Solutions initiative gives Rockwell Automation the opportunity to create custom workforce development programs with our customers that
complement their overall business goals.
In order to create multifaceted employees, we offer a portfolio of more than 50
craft skills hands-on courses that cover
the entire manufacturing landscape
from basic math to welding, mechanical
concepts and electrical skills, over 150
automation and controls courses, and a
comprehensive portfolio of Industrial
Leadership Skills programs.
To help our customers overcome the
skills crisis, we developed the Accelerated Skills Academy (ASA), an immersive
12-week program for highly motivated
employees. By investing in this program, our customers see their employees gaining skills in three months that
would usually take five to eight years of
on-the-job learning in various positions.
Customized programs for vertical industries educate our customers employees
on skills specific to their trade.
The latest offering in our workforce
development portfolio is Managing
Industrial Networks With Cisco Networking Technologies. This is a handson, lab-based course, which helps students with the foundational skills needed
in managing and administration of networked industrial control systems.
As we look toward the future of
manufacturing, Rockwell Automation
knows that investing in our employees,
and helping our customer do the same,
is key to building strong teams that will
lead the way. PE
Glenn Goldney is global business
manager, workforce and training services, Rockwell Automation.
10 September 2014
plant engineering
IN fOCUS
In industrial settings, two-way radios still a smart choice

Michael Korch
Motorola Solutions
Consumer technology versus digital radios. Which one makes

the most sense for manufacturing and industrial communications?
Interestingly, Motorola Solutions recent survey of the state of
plant communications reveals that two-way radios and cell phones
remain in a dead heat as the primary means of communications
in plants nationwide. Yet critical differences between the two are
worth careful consideration before making technology investments.
Its challenging to evaluate which communications solutions
will meet your current needs and also scale to accommodate future
demands. Determining the ideal fit of technology to business goals,
worker, and function is a very important part of the equation and
ultimately impacts your total cost of operation. As you evaluate
new device investments, consider the communications capabilities
you cant afford to do without.
Its very important to arm workers with the right tools for the
job to ensure its done correctly, efficiently, and safely. While
everyone wants the latest and greatest capabilities that consumer
devices deliver, they also want technology that helps them work
efficiently and is durable enough to withstand harsh environments.
As failure rates for smartphones exceed 20%, failure rates for
rugged devices, such as two-way radios, continue to plummet.
They are designed to handle shocks, slips, vibration, and drops.
In contrast, consumer technology is designed to meet mass demand,
and will never provide the security features or durability to

stand up to the rigors of continuous use. And shoehorning those
into your operation will end up costing you more money in the
long runup to 51% more.
Reliable voice communications
Private voice technology has enjoyed many advancements

over the last decade, all designed to make conversations more
reliable and user friendly while providing the specific communications coverage required by the users. The voice quality
of consumer devices has evolved as well, but will never deliver
the features that are most appropriate for an enterprise setting largely because they are intended for manufacturing and
industrial communications. Their unreliability and coverage
limitations also can prove problematic.
Digital two-way radios are designed to be fully customizable providing you control over what your workers can access
or, more importantly, cannot access in order to keep focused
on the job. In addition, supervisory control features in digital
radio systems ensure that critical messages will be heard, even
when workers are busy on noncritical calls.
What are some of the features that matter most? Voice quality has to be loud enough to hear and be heard in any environmenteven hands-freewith ambient noise from wind,
machines, trucks, or the road filtered out. The ability to connect and reliably extend push-to-talk capabilities inside the
four walls and across your PBX outside the four walls allows
greater worker productivity and lowers operating costs. And
only two-way digital radios can deliver it.
Built to last
Enterprise digital radios are built tough. A dropped device will

not shatter screens or interrupt workflows. Water, ice, salt,
sand, heat, blunt force impactsdigital radios are designed to
withstand it all and keep on working.
Smartphone technology is cool, but one drop on a concrete
floor and business critical work would come to a complete stop.
Enterprise-class devices are built to last longer, dont break as
often, and are easier to repair. As you would expect, increased
durability also increases costs, but for most applications the
investment pays huge dividends in the future in decreased repair
costs and reduced downtime, which directly impacts profits.
Keep business operations running
Studies from multiple leading industry analyst firms, such as

Gartner and VDC, suggest that over three years, the total cost of
a typical consumer smartphone is actually 25% to 50% higher
than the total cost of a similar enterprise-grade device. Each
device failure costs 80 minutes of productivity and over 2.5
hours of support time.
The old adage of you get what you pay for still holds
true today, and for plant communications, digital two-way
radio communications remain the smart bet. PE
Michael Koch is Entergy and utility principal at Motorola
Solutions.
12 September 2014
plant engineering
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So Mobil-branded industrial lubricants help you get the most out of your machinery. We have an exceptional product range, a
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Copyright 2014 Exxon Mobil Corporation. All rights reserved.

All trademarks used herein are trademarks or registered trademarks of Exxon Mobil Corporation or one of its subsidiaries unless otherwise noted.
IN fOCUS
Compressed air demand: find and fix leaks first
Michael Camber
Kaeser Compressors
IN
S
NO TOC
W K
Though still a small minority, more

and more industrial plants are taking
the initiative to conduct compressed

air audits to collect and analyze data
that show how their systems are operating with an eye to how they could
more reliably deliver stable air pres-
CAST STAINLESS STEEL
XCESX
EXPLOSIONPROOF
ENCLOSURES
Call for a Free

Application
Evaluation!
sure, use less energy, and in many

cases, both.
Generally, most compressed audits
collect data on the supply side of
the air system (e.g. when compressors are running, main header pressure, etc.). They may collect pressure
data from further downstream that
can indicate demand side issues,
but they usually dont directly assess
them.
Supply side audits are very helpful in
making adjustments to compressor sizing and controls to meet current or projected demand, but they assume that the
demands are productive. The reality is
that much more air is produced than is
needed. Artificial demand (unnecessary high pressure), inappropriate uses,
and leaks are the culprits.
Leaks are in effect just another user
of compressed air. Ideally, plant operators would review all compressed air
uses and reduce or eliminate inappropriate uses before conducting
audits that influence changes to the
compressed air supply. But the reality is that often its the audit that first
alerts the user of significant leakage.
The following chart from an actual
compressed air audit showed that this
plant was losing 170 cfm to leaksthis
accounted for 45% of their total 380
cfm demand.
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Air audits and leak detection go

hand-in-hand. The best preventive
adalet.com info@adalet.com TEL 216.267.9000 FAX 216.267.1681
14 September 2014
plant engineering
maintenance programs capitalize on this relationship and

make it truly cyclical:
Both approaches make
sense. If you know for a fact
that you have a high leak
load, then dont start with
an audit. Fix the leaks first.
Dealing with artificial
demand and inappropriate uses can be complex if
it requires in-depth process
analysis. Leaks, on the
other hand, are much more
straight-forward.
Leak detection should be
part of a preventive maintenance program but rarely
is. We often remind customers that leaks are very wasteful, yet
customers are for whatever reason
reluctant to fix them. Be the exceptiondont ignore them and hope
theyll go away. Fixing the leaks
will immediately add money to the
bottom line.
To sum up: evaluate and reduce

as much of your demand as possible
before evaluating and changing supply side equipment or settings. Look
for ways to eliminate unneeded high
pressure and air wasting applications.
But even if these are not feasible find-
ing and fixing leaks is the low hanging

fruit. PE
Michael Camber is the Marketing
Services Manager for Kaeser Compressors Inc. For more information, visit
www.us.kaeser.com.
Apex VS Series
Matching air demand. Minimizing energy costs.
Maximizing efficiency.
Since entering the variable speed market, Gardner Denver has helped a
multitude of organizations realize the efficiencies that are produced by a
variable speed compressor. During that time, Gardner Denver has proven
to be at the forefront of the variable speed market. Our latest offering, the
Apex VS, offers the efficiency and reliability that you demand delivered by
a service friendly, industrial design. The Apex VS is an investment in your
organizations future that will pay off for years to come.
Come see us at Pack Expo

booth #10006
www.gardnerdenver.com
2014 Gardner Denver. All rights reserved.
IN FOCUS
PMI hits three-year high

Awesome results from manufacturing as benchmark climbs to 59.0%
Bob Vavra
Content Manager, CFE Media
You can look at another high data point

for the monthly Purchasing Managers
Index (PMI) released Sept. 2 by the Institute for Supply Management as indication of the continued strength of the U.S.
manufacturing sector. Or you can take the
word of one manufacturing respondent in
the primary metals markets, who called
August, the strongest month in years.
Business is solid. Awesome!
The PMI jumped to 59.0% in August,
climbing 1.9 percentage points from
Julys healthy 57.1% figure. It was the
highest the index has reached since
a 59.1% reading in March 2011. The
growth was driven from another healthy
climb in the New Orders Index, which
rose 3.3 percentage points to 66.7%.
The August PMI is led by the highest recorded New Orders Index since
April 2004 when it registered 67.1%,

said Bradley Holcomb, chairman of the
Institute for Supply Managements Manufacturing Business Survey Committee.
At the same time, comments from the
panel reflect a positive outlook mixed
with caution over global geopolitical
unrest.
Other PMI-related indices also rose in
August. The Production Index was up 3.3
percentage points to 64.5%, the Employment Index was roughly unchanged at
a strong 58.1%, and the Raw Material
Index reversed a one-month decline with
an increase of 3.5 percentage points to
52.0%. Any figure about 50% indicates
growth for the sector.
Survey respondents were almost universally positive. Among the comments:
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manufacturing. Packaging materials
prices are staying in check, minimum
wage is up a bit, but manageable.

(Food, Beverage & Tobacco Products)
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good, our business is up. (Fabricated
Metal Products)
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World issues taking a toll on business.
Consumers are cutting back on spending. (Transportation Equipment)
2YHUDOOEXVLQHVVLVLPSURYLQJ2UGHU
backlog is increasing. Quotes are
increasing. Much more positive outlook in our sector. (Electrical Equipment, Appliances & Components)
'HPDQGLQWKH8QLWHG6WDWHVLVFRQsistent and geopolitics remain a concern. (Chemical Products)
%XVLQHVVLVVWURQJ/DERULVEHFRPLQJ
a difficult issue. (Furniture & Related
Products)
'HPDQGLVVWURQJ1XPEHUVDUHXS
over last year. (Machinery) PE
See how remote racking, switching protects workers

and equipment CBSARCSAFE.COM/VIDEOS
CBS ArcSafes remote racking and remote switching solutions reduce

arc-ash dangers and technician fatigue during dangerous operations.
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trip charge close. The vibration data created by the breaker
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for equipment management, trending, and further analysis
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APPS FOR ENGINEERS
Featured apps
CFE Medias Apps for Engineers is an interactive directory of more than 240
engineering-related applications for Android and iOS operating systems, created
by various companies. The app helps users do their jobs better and save time,
providing a pre-sort of relevant mobile engineering applications loaded with
various calculators, catalogs, file viewers, measurement tools, and more.
www.plantengineering.com/appsforengineers
FLIB
Android: 4.0+
Cost: Free
Company: Ten Days One App
Website: www.tendaysoneapp.com
Flib is a unit conversion app that learns as you use it. With multiple converters to choose
from Flib also auto arrange the 12 most used on its main screen for convenience.
Convert Everything Converter

Android: 2.2+
Cost: Free
Company: Fluffy Delusions
Website: http://fluffydelusions.blogspot.com
Convert Everything provides the ability to convert and calculate units ranging from
Angular Acceleration to magnetic flux density.
Convertible: Ultimate Unit Converter Convert the normal and the not-so-normal
iOS: 7.0+
Cost: $1.99
Company: Efecto Pty Ltd
Website: http://convertibleapp.com
Convertible is a conversion application, unique due to the way it visualizes the data it
processes. Capable of converting length, area, energy, torque and many others.
Converter+
iOS: 6.0+
Cost: Free
Company: xNeat
Website: www.xneat.com
Converter+ is a simple, elegant unit conversion app focused on a simple, usable and
beautiful experience.
PLANT ENGINEERING
September 2014 17
A DV E R T I S E M E N T
Greenheck Offers Complete Line of Industrial Dampers

Greenheck industrial dampers are heavy-duty, flanged-style frame
dampers with various blade styles and pressure classes designed
to control airflow and provide shut-off in HVAC and industrial
process control systems. Built under an ISO9001-2008 Quality
Assurance Program, Greenheck industrial dampers also include
options for balancing and isolating higher pressures and
temperatures. Ideal for manufacturing, nuclear,
tunnel, bio lab, and power generation applications,
Greenhecks complete line of industrial dampers
includes control, backdraft and pressure relief,
UL rated smoke, tunnel transit, blast, tornado,
and bubble tight dampers.
Bubble Tight
Dampers
Greenheck Model HBTR-151

(10 in. wg) and HBTR-451
(30 in. wg) bubble tight
dampers are designed for
isolation protection for zero
leakage. Each damper is
manufactured to stringent
guidelines and is tested in
accordance with AMCA
500D and ASME N509 prior
to being shipped. Various actuator options are available as well as
construction options of high grade painted finishes or type 304 or
316 stainless steel.
Innovative Product Development
Greenheck, the worldwide leader in manufacturing and

distributing air movement and control equipment, maintains
on-site laboratories to test products against the latest industry
performance requirements issued by AMCA, ANSI, ASHRAE,
UL and others.
On-site testing also allows the company to continuously develop
reliable new products and to enhance performance of existing
products by adding important new features. As a result,
Greenheck has established itself as an innovative industry leader
manufacturing more than 980 reliable, energy efficient air
movement and control products, including the most UL certified
dampers and the largest selection of AMCA licensed dampers in
the industry.
Specifications Made Easy
To make specifying Greenheck

products easy, Greenhecks Computer Aided Product Selection (CAPS)
software provides all of the relevant
and accurate information needed by
specifiers including product selections,
sizing, fan curves, configuration details
and payback analysis plus AutoCAD
and configurable 3-D Revit drawings
for Building Information Modeling
(BIM). Available for download from
www.greenheck.com, CAPS is
third-party certified and includes
performance certifications like AMCA,
UL, AHRI, NFPA, OSHPD, Miami-Dade
County Approved and more.
Greenheck ventilation products build
value in air with reliable performance,
safety, quick cost-saving installation,
energy efficiency and quiet operation.
GREENHECK
P.O. Box 410 | Schofield, WI 54476-0410
715-359-6171 | Fax: 715-355-2399
www.greenheck.com
info@greenheck.com
A DV E R T I S E M E N T
Protecting people, processes and equipment

MovinCool brings cool, refrigerated air to production
lines without the need to spend hundreds of thousands
on 100 or more tons of cooling. MovinCool portable
AC units help reduce the risk of heat exhaustion and
increase employee morale, leading to improved
manufacturing quality and productivity.
MovinCool, the worlds largest manufacturer of

commercial spot air conditioners, offers a wide range
of models, with capacities from 9,000 to 60,000 Btu/h.
MovinCool protects people, processes and equipment
from their hottest environments as well as provides
moisture removal.
MovinCools portable models can be quickly
wheeled into place whenever needed, with
virtually no installation required. The companys
latest compact, ceiling-mounted models allow easy
installation in tight spaces. Applications include:
IT data centers, computer rooms, server and
telecom closets
Hospitals, laboratories
Offices, schools, temporary buildings
Warehouses, factories, food-processing facilities
Outdoor sporting and other events, movie sets
Moisture removal (disasters, construction sites)
For more than thirty years, MovinCools Classic &
Classic Plus series of industrial air conditioning units
has provided effective cooling solutions for factories,
warehouses and workplaces.
MovinCool spot cooling

units prevent product
defects by eliminating
warping and condensation due to excess
heat and humidity.
Our portable AC units
reduce processing time
for most heat-related
production processes
by up to 94%.
Within the air conditioning industry, MovinCool
has a reputation for highest quality. Dealers who
specialize in spot air conditioners, and who stand to
lose significant profit if they have to replace a unit
once it is installed, consistently say they prefer
MovinCool air conditioners because of their
superior reliability.
MovinCool is a brand of DENSO, one of the worlds
largest manufacturers of automotive parts. DENSO
supplies advanced automotive technology, systems
and components, including air conditioners, to all of
the worlds major car manufacturers. In the 1980s,
DENSO pioneered the concept of workspace spot
cooling to meet its own factory needs. Since then,
MovinCool has developed spot cooling systems to
accommodate many different applications. For more
information, visit http://www.movincool.com
(800) 264-9573 | info@movincool.com | www.movincool.com
ALL FLUKE.
* All Fluke Ti9X, Ti1XX, Ti2XX, Ti3XX, Ti4XX models are enabled with Fluke Connect
2014 Fluke Cor poration. A ll trademarks are the proper ty of their respective owners. Smar t phone, w ireless ser v ice and data plan not included with purchase. First 5 GB of storage is free. Compatible w ith iPhone 4x and up r unning iOS 7 or higher, iPad (in an iPhone frame on iPad) and Gala xy S4, Nexus 5,
HTC One r unning A ndroid 4.4.x or higher. Apple and the Apple logo are trademarks of Apple Inc. reg istered in the U.S. and other countries. App Store is a
ser v ice mark of Apple Inc. Google Play is a trademark of Google Inc. 8/2014 6003423a-en
ALL WIRELESS.
All standard* with Fluke Connect.
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EquipmentLog
history
SEE IT. SAVE IT. SHARE IT.

Now more reasons to connect with Fluke.
Learn More
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Fluke Cloud
storage
Understanding Materials Handling

Applications, Solutions for the
Paper Industry
The paper industry is an intense, fast-moving
environment with little tolerance for downtime in
operations running 24 hours a day, seven days a week,
365 days a year. Because of these demands, operations
are looking for equipment that can withstand the abuse
with minimal downtime.
This white paper explores environmental impacts and
operating conditions in the paper industry and
provides an overview of materials handling equipment,
attachments and options that can enhance paper
industry productivity.
Paper is produced in several manufacturing steps

pulping, manufacturing, convertingthen distributed
and may finally be recycled. Each step of the process
involves materials handling activities, where raw
materials, paper, other paper products and waste paper
have to be moved, stored, loaded or unloaded.
usage; however,
warehouse lift trucks
are found in the paper
industrys distribution
functions, where
end products are
typically palletized
to be moved.
Because of the unique operational challenges with the
paper industry, many lift trucks may require specialized
attachments to accommodate oversized, bulky or
oddly shaped loads. The white paper emphasizes the
importance of understanding attachment types to know
how they could help productivity in a particular paper
application. For example, forks features, clamps and bin
dumpers are all attachment options, but knowing their
different applications and specifications is critical.
As demonstrated in this white paper, the paper industry
continues to be a challenging environment for materials
handling equipment. The harsh operating conditions
and round-the-clock operations demand the very best
in lift truck durability and features to ensure the best
productivity. With the right lift truck and the right
attachments and options, any paper and pulp operation
can be well equipped to successfully meet its materials
handling needsultimately benefitting the operations
bottom line.
The white paper outlines these differing applications

found in the paper products industry, including pulp and
paper mills, converting facilities and recycling plants.
Paper applications are dominated by Class IV and V trucks
due to harsh applications and rough, dirty, high-hour
Download the paper at:

http://bit.ly/1rHHYPk
andrea.simrell@jacksonmg.com
Hyster.com
Turning Air Compressors

into an Energy Source
Werner Rauer | Product Manager for Screw Compressors, Kaeser Compressors, Inc.
Michael Camber | Marketing Services Manager, Kaeser Compressors, Inc.
The rise in energy prices is an unwelcome reality in

todays manufacturing and business environment.
While the rate of price increases for natural gas,
heating oil, and other sources may vary from year
to year, the upward trajectory is clear. Energy cost
reduction strategies are vital to staying competitive.
Industrial compressed air users looking for new ways
to combat rising energy prices often overlook a
significant resource in their plant.
One important way operational efficiencies can be
increased is by harnessing heat from compressed air
systems, which are a major component of industrial
energy consumption.
Download this
whitepaper at:
www.kaeser.com/whitepapers
The heat generated by compressed air systems can

be a very good source of energy savings. In fact,
100% of the electrical energy used by an industrial
air compressor is converted into heat. 96% of this
heat can be recovered (the balance remains in the
compressed air or radiates from the compressor into
the immediate surroundings).
Kaeser Compressors, Inc.s whitepaper,
Turning Air Compressors into an Energy Source,
discusses how the heat rejected by rotary screw
compressors can be harnessed for a variety of plant
uses to yield sustainable energy savings.
Authored by industry experts Werner Rauer and
Michael Camber, it also gives key tips on when heat
recovery may or may not be an efficient way to
save money.
Email: customer.us@kaeser.com | Tel: 866-516-6888

www.us.kaeser.com
Plastic Bearings Have Staying Power

Nicole Lang | dry-tech Product Manager, igus
During the past three decades, there has been an
evolution in the advancement and use of highly
engineered plastics in bearing applications. Plastic
bearings are no longer designed like their dime-adozen, injection-molded nylon ancestors.
Today, plastic bearings cost and weigh less than
their metal counterparts, but what many design
engineers still do not realize, is that they also often
last longer in unforgiving environments.
High-performance plastic bearings are working to
shed their negative image and continue to forge
a path into almost every industry; from packaging
machines and medical devices, to automotive,
farming equipment, textile machinery, and many
more. Plastic plain bearings are an economical
replacement for needle, ball, and plain metal
pe201409_whitePpr_IGUSHlf.indd 1
bearings. However, they are often not considered

a viable choice in the engineering community
due to the common misconception that plastic is
inferior or weaker compared metal.
The truth is that composite plastic bearings can
Download the paper:
outperform their metal counterparts in countless
rotary, oscillating, and linear-motion applications. http://www.plantengineering.
In addition, plastic bearings are readily available in com/index.php?id=11721
many different styles, sizes, materials, and colors to
meet the demands of almost any application.
In this whitepaper, igus Product Manager for
iglide bearings, Nicole Lang, will discuss common
misconceptions about plastic bearings, the comparison between plastic and bronze, arguments to
use iglide plastics in place of metal, and successful
applications of plastic bearings.
Contact sales@igus.com
www.igus.com
8/5/2014 5:21:23 PM
How to Read a Psychrometric Chart

and Make a Better Measurement of Humidity
Humidity is a tough measurement.
If youre interested in making a better
measurement of humidity, the first step is
to understand the parameter.
What better way to begin to understand
the various humidity parameters and their
interrelations than to study the visual
representation in a psychrometric chart.
This paper includes an easy 8 step
framework designed to demystify the
psychrometric chart along with a detailed
psychrometric chart you can print, put on
your wall and share with your team.
pe201409_whitePpr_rotronicHlf.indd 1
Learn about the different parts of

the chart and parameters depicted on a
psychrometric chart
Learn how you can find any of the 8
parameters with only 2 measurements
Learn how you can show the effectiveness
of evaporative cooling based on
relative humidity and temperature
Choose to download the chart in SI units
or IP units or one of each
Once you have a good understanding of
the chart, youre on your way to a better
understanding of humidity with better
measurements to follow.
Download the paper:

http://content.rotronic-usa.
com/chart
www.rotronic-usa.com
Email: info@rotronic-usa.com
9/5/2014 11:17:27 AM
How is Dew Point Measured Reliably?

What is the effect of pressure on dew point? Which is the right dew
point instrument for optimized compressed air quality? What are
the benefits of integrating dew point instruments into a continuous
monitoring system?
This paper answers these questions and provides information to help
you increase the life of your compressed air system, improve process
quality and lower costs:
Principles of dew point measurement

Choosing the right dew point instrument
Installation tips
Measurement best practices
Practical considerations for installing a continuous monitoring
system... and much more
ple201409_whtPprHLF_vaisala.indd 1
Download the paper at

www.vaisala.com/CompAirCMS
www.vaisala.com/compressedair
instruments@vaisala.com
8/6/2014 4:08:00 PM
No matter what your social networking preference is,

theres a way for you to connect with Plant Engineering!
Make the connection now...
www.plantengineering.com/connect/social-media.html
socialMed_fillerHLF_ple.indd 1
1/15/2014 9:03:50 AM
YOUR 24/7
BACKUP TEAM
Compressors are the heartbeat of
your facility, pumping clean, quality
air that is vital to your production
processes, and regular maintenance
signicantly increases your
systems life expectancy.
Therefore, the health of your
compressor system is our #1
priority, and our support continues
throughout its lifetime. Whether
its providing genuine parts or a
comprehensive service plan, we
offer several service options to
meet your needs and give you
peace of mind.
www.atlascopco.us 866-688-9611
2014 HONOREES
Hassan Ahmed .............28
Kenneth Benedict ........28
Jason Donath ...............30
Greg Giles .....................30
John Glenski.................30
Jared Higgins ...............32
Thomas Hughes ...........32
Heather Johnson..........34
Thomas Keeports.........34
Atif Khan .......................34
2014 Engineering
Leaders Under 40
There is no single path to a career in manufacturing. Some kids play with LEGOs; others
find their career through a parents involvement in the industry. Others get involved in
manufacturing through the serendipity of
being in the right place at the right time in
their lives.
The 2014 Engineering Leaders Under 40
each have a story to tell about their path into
manufacturing. They are mothers or fathers,
veterans or students; they all have found manufacturing a career worth investing their lives
in. In turn, their contributions will benefit
manufacturing for decades to come.
They have come to engineering at a time
where their skills and commitment are needed
more than ever. They also come at a time when
we need many more like them. The national
consensus is that the skills gap is real, that it
is inhibiting the already-dynamic growth of
American manufacturing. Plant Engineering

research has shown for many years that the
lack of skilled workers is the top issue facing
manufacturing professionals. The 2013 Salary Survey found that 35% of manufacturers
cited the skilled worker shortage as their most
pressing issue; no other concern topped 20%.
While the paths of the 2014 Engineering
Leaders Under 40 took to a manufacturing
career are varied, the goals are all the same:
to build a long career that advances both their
personal and professional goals. At a time in
manufacturing when we need to find more
skilled workers, the stories of these young
professionals should serve as an example to
others who choose to join this profession, and
as an example to manufacturers as to how to
recruit, train, and retain the next generation
of manufacturing professionals.
Meet our 2014 Engineering Leaders Under 40:
Chris Lake .....................35

Greg Larson ..................35
Brian Pack.....................35
Peter Saladis.................36
Aron Semle ...................36
Mahesh Singh...............36
Jason Stefanski............37
Shadrach Stephens .....37
Melissa Unger ...............37
Jeff Winter .....................38
Brian Zakrajsek ............38
PLANT ENGINEERING
September 2014 27
Hassan Ahmed, 26
Utility Manager
GlaxoSmithKline
Karachi, Pakistan
Education: BS Industrial and Manufacturing Engineering, NED University of Engineering and Technology
Hassan Ahmed is a confident and hardworking person who has quickly advanced his career and dominated the utility sector
with energy-saving ideas. He started as a utility engineer-in-training shortly after graduating from NED University, and within 4
years became utility manager at GlaxoSmithKline. Energy-saving strategies implemented by Hassan over the years include: the
design, fabrication, and installation of a desiccant air dryer; reviewing HVAC design criteria and revising systems to comply with
energy standards; and installing VFD controls on air handling units and pumps for increased annual savings. Hassan is responsible for looking after all the systemssuch as generators, boilers, air compressors, HVAC, water treatment, purified water
plants, nitrogen systems, gas boosters, and heat exchangersthat deliver utilities for efficient manufacturing operations.
Hassan likes to work in a professional environment full of challenges, where he is free to implement strategies and wait for
results. He likes to communicate and socialize with people to understand their views on life and other topics, and his goal for
life is to be inspired and be an inspiration for others.
Why choose this career path? I have always had an inclination towards engines and mechanical drive systems and
machines, said Ahmed. Utility was the best option to get myself completely devoted towards mechanical machinery and to
have a career of my interest. With heat and energy applications and studies, these things just drive me to work better with
enthusiasm and more interest.
Kenneth Benedict, 36
Project Manager
Avid Solutions Inc.
Winston-Salem, N.C.
Education: AAS and BS Electrical Engineering, Virginia Polytechnic Institute and State
University
Kenneth Benedict believes in developing good relationships and earning the trust of his
fellow coworkers at Avid Solutions. He has delivered many successful engineering projects and has recently developed client relationships into partnerships. In the 9 years he
has worked at Avid, Ken is recognized as a subject matter expert and many other engineers come to him for advice and technical direction. Starting at Avid Solutions as an
automation specialist, he quickly moved into engineering sales and was then promoted
to project manager.
In his personal life, Ken works with young engineers to help develop their skills and leadership. He is also a dedicated father
who enjoys golfing and fishing in his free time.
Why choose this career path? I originally chose to get into system integration because I loved programming control systems, said Benedict. Nothing excited me more than taking something from design to implementation and seeing my code
come to life in the form of controlling a process. As I became more experienced, I found I enjoyed the other parts of being a
controls engineer, things like electrical design, process design, and developing full-blown batch systems. Most recently, as a
project manager, I have found a passion for helping customers design and implement solutions to their needs while managing
the scope, schedule, and budget of a project.
28 September 2014
plant engineering
Jason Donath, 35
Project Manager
Avid Solutions
Winston-Salem, N.C.
Education: BS Electrical Engineering, Florida State
University
In his 8 years at Avid Solutions, Jason Donath has worked
tirelessly to educate himself, becoming an internal subject
matter expert in batch and continuous distributed control
systems (DCS), while enlightening others simultaneously.
Jason is proficient in batch automation implementation per
the ISA-S88 batch control standard; control panel design per
NEC and UL specifications; process control and optimization;
PID loop tuning; DCS, HMI, and PLC programming and configuration; batch manager configuration; and checkout/startup/commissioning. On specific DeltaV projects, Jason has
various responsibilities, including module programming, I/O
configuration, sequence control programming, graphic display
configuration, and custom scripting and faceplates.
Outside of work, Jason has developed, promoted, raised
funding for, and is currently teaching a LEGO Physics class
for homeschooled children. Having two homeschooled children himself, Jason is passionate about their mentorship and
education. In addition, Jason takes his health very seriously,
is driven to push his limits outside of his profession, and is an
active CrossFit participant.
Why choose this career path? Being in the system integration field gives Jason the opportunity to feed his desire
for learning and continuous improvement. Jason constantly
seeks out ways to expand his base of knowledge as well as
depth in specific areas, such as distributed control systems
and related technologies.
Greg Giles, 39
Director, Error Proofing
and MES
RedViking
Plymouth, Mich.
Education: MS Electrical
Engineering, University of
MichiganDearborn
Greg Giles is the leader of
an engineering team at RedViking that focuses on integrating
cutting-edge solutions into off-the-shelf and custom manufacturing
execution systems (MES). As an engineering manager, Greg has
created an environment of personal and professional accountability
that enables each team member to solve problems effectively and
efficiently. He is also committed to fostering an environment of personal and professional growth for his team, encouraging training
and idea-sharing on the job, and goal-setting and achievement off
the job. He is seen as a trusted advisor on issues ranging from PLC
and device selection to software implementation, network configuration, and server and application architecture.
After work and family, Greg is avidly dedicated to mountain biking.
Greg uses his bike time to mentally work out solutions to engineering problems. He recently completed the Lumberjack 100 in less
than 8 hours, coming in 39th of over 200 competitors.
Why choose this career path? Greg is a lifelong tinkerer, starting
with building remote-control cars, then computers from parts catalogs, then radio equipment, and today entire factory assembly lines.
When choosing engineering disciplines for his college major, he
chose electrical engineering because it required one less chemistry
class than the alternatives. His father and grandfather were both
Ford engineers, and Greg started his career as a Ford engineer as
well. Today, he encourages his son and daughter to be designers
and builders, and to value math and science.
John Glenski, 32
Senior Controls Engineer
Process Plus
Cincinnati, Ohio
Education: BS Electrical Engineering, University of Dayton
John Glenski led the programming and design effort for the installation
of multiple process mixing systems, and packaging lines, across two
geographically-diverse locations in the United States. It was recognized
that an existing legacy controls system would need re-controlling for
project success. John oversaw the addition of that re-control (raw
material delivery system, additional mixing systems) seamlessly into
the project, now totaling over 5,000 I/O points. The entire design of the
system incorporated advanced Ethernet communications and networking among PLC, I/O, VFD, HMI, and the clients legacy control system,
which the rest of the facility still utilized.
30 September 2014
plant engineering
John spiritedly works to further the community around the University

of Cincinnati, including personally renovating two turn-of-the-century
dilapidated homes near the university and turning those homes into
properties that he actively rents. A husband and father of three girls
under the age of six, John strives to get his girls interested in engineering and the sciences by including them on numerous building projects
around the house, including the most recent: a full-size cedar seesaw.
Why choose this career path? Johns interest in engineering, specifically electronics, began relatively early in life. As the youngest child of
nine, he discovered many old discarded electronic devices in his parents attic, including a rotary phone. These devices were available to disassemble, and this investigation sparked his original interest. Pursuing
electrical engineering in college, the ability to control a device and have
that device directly benefit people is what drove John into the process
controls field and sustains his passion today.
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Jared Higgins, 32
Corporate Associate
Parkhill, Smith & Cooper Inc.
Lubbock, Texas
Education: BS Mechanical Engineering, Texas Tech University
Jared Higgins has a passion for energy and water conservation for buildings and the ambition to
see his ideas come to fruition. Shortly after graduating from Texas Tech, Jared began designing
HVAC systems for buildings and realized that he could make a difference through energy management and conservation. He has worked with several clients throughout the U.S. and Europe on
energy management control systems and was selected by the U.S. Dept. of Defense Education
Activity to assist in standardizing their control systems and developing an energy conservation and
commissioning guideline.
Outside of work, Jared has always been an avid river kayaker. Last year, he decided to take the
plunge and try ocean kayaking for the first time. He had always avoided it because he didnt think
he would get the same rush that comes with river rapids, but he managed to hit some high surf in California on the Monterey
peninsula and is planning to ocean kayak in St. Thomas later this year.
Why choose this career path? In 2011, Jared was struggling with deciding his future path. He was fortunate to meet chemical engineer Bill Cameron, who mentored him in the oil and gas industry and introduced him to process automation, where he
began his path in engineering. Since then, Jareds passion for energy conservation and water conservation has developed,
and he believes he is making real-world differences. With the number of net zero facilities increasing, Jared is ready to meet
challenges and opportunities head-on.
Thomas Hughes, 30
Energy Specialist
Leidos Engineering
Oklahoma City, Okla.
Education: BS Mechanical Engineering, Oklahoma State University; MS Industrial Engineering and Business Administration, University of Oklahoma
Thomas Hughes joined Leidos Engineering as a part-time intern while pursuing his first masters degree. Since then, he
quickly moved up to a leadership role, acting as an assistant project manager on a new technology around an advanced
nuclear reactor concept. From there he went on to do fundamental analysis on a variety of carbon capture concepts before
taking a key role on the Leidos Engineering geothermal project team. Over the past 3 years, Thomas has become an
expert on the leading technologies used to generate power from geothermal resources. He has also led the companys
effort to develop a coal upgrading design that economically demoisturizes low-quality/high-moisture coal and then stabilizes the coal against moisture reabsorption and spontaneous combustion tendencies.
Thomas passion for learning shows through in his community and industry activities. He is active in ASHRAE and has
served as an officer for this building technology society. He is a member of AEE and ASME.
Why choose this career path? Thomas parents both come from highly technical fields. When he was young they encouraged him to be curious and ask lots of questions, which is what got him started in science and engineering. Inspired by a
high school physics teacher, he decided to pursue a career in engineering. He always liked building things, so construction
was a good fit for him because he can create something in his head, put it on paper, and then help shape that vision into
reality. Thomas enjoys watching his vision manifest into something physical that could potentially make the world just a little
bit better.
32 September 2014
plant engineering
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Heather Johnson, 39
Thomas Keeports, 39
Division Manager
Interstates Control Systems Inc.
Sioux Center, Iowa
Electrical Controls Engineer

JST Corporation
Harrisburg, Pa.
Education: BS Computer Science,

Creighton University
Education: BS Electrical Engineering, Pennsylvania State University
Heather Johnson has advanced through

many positions at Interstates, including systems analyst, lead control systems developer, and project manager. Today, she is
division manager leading a seven-member team. Heathers situation
is unique: her entire Interstates career involves supporting a single
client, though company ownership has changed over the years.
As the clients plant personnel changed, her historical knowledge
and experience with their systems allowed her to provide continuity.
Starting out, Heathers projects were large and she worked on major
portions of code as part of a team. Her role transitioned to smaller
projects which she priced, planned, and executed on her own. As the
projects she was securing grew larger, Heather needed additional
programmers to help her execute them. While at times she misses
being in the depths of programming, she has learned to let go of the
details to develop and guide others to succeed in their careers.
In Heathers opinion, keeping a balance between work and family is
an important skill to have and to model for children. As a mother of
four children ranging in age from 5 to 14, she finds herself working
through KNex projects with them.
Why choose this career path? If a young person is interested in
programming and computers, he or she should try some classes to
test it out. Heather always thought she would be involved in a healthrelated field, but found that her passion is programming and computer
science. If programming is of interest, stick with it because things are
always changing and there are always new challenges every day,
said Johnson.
Atif Khan, 36
In his current position, Thomas Keeports leads a project to extend

Ethernet connectivity to all of the machinery in JST Corporations U.S.
assembly plant, and coordinating with colleagues at sites across the
globe who are working on similar projects. When completed, JST will
gain the ability to provide remote troubleshooting and data collection
services. Tom has introduced many new features to the assembly
machines that will cut development, conditioning, and in-plant troubleshooting time considerably. As an in-plant controls engineer for many
years, Tom was familiar with the few problem machines at JST that
were difficult to work on or keep running. Since switching to this new
machine design, Tom is very sympathetic toward the operators who
will interface with equipment that he helps build. His passion is to produce a control system and human machine interface experience that
will never be that problem machine.
A few years ago, Tom had the opportunity to create a control system for an eight-lane pinewood derby track. He designed and built
the hardware and wrote the software program, which tracked and
recorded all times in a database. The results were projected on a
large screen using a dual-screen monitor setup.
Why choose this career path? I chose this career path because of
opportunities that I had to be involved with technology at a young age,
said Keeports. When I was growing up, my uncle owned a computer
store and allowed me to come hang out whenever I wanted to. I had
the opportunity to learn about computers and to help him build and
repair them. I knew that my future career plans would involve using
computers at some level. During a college internship, I was introduced
to machine controls and fell in love with the industry. I knew that this is
what I wanted to do.
Education: BS Computer Science, Georgia Institute of Technology
A natural introvert, Atif has had to work especially hard to open up and
present his views to others. As his experience has grown over the
years, he has impressed his peers and managers with his technical
expertise and calm personality. In addition, Atif enjoys being a liaison
engineer with university students on projects sponsored by Sandvik.
He gets a kick out of listening to the out-of-box ideas generated by the
undergrad students.
Atif Khan has been involved in control system design, implementation, testing, and deployment at Sandvik Alachua ever since he was
first hired as a software engineer 5 years ago. Within 2 years he was
promoted to automation engineering manager, and together with his
team, Atif has collaborated with Sandvik Global Competency Centers
to achieve time-to-market targets that would otherwise be difficult to
accomplish. Atif continuously provides feedback to executive management with regard to automation roadmaps and how Sandvik Mining
should align itself in the marketplace.
Why choose this career path? Atif has been influenced by his father,
who was a professional civil engineer. As Atif was growing up, he was
introduced to computer consoles, such as Atari and Commodore 64,
and since learning BASIC programming language has always been
fascinated by how computers work. As a teenager, he developed programs for companies to maintain their database of inventory and got
hooked on programming. While in college, programming in LISP for an
artificial intelligence course was all the motivation that Atif needed to
pursue his career.
Automation Engineering Manager

Sandvik Mining
Alachua, Fla.
34 September 2014
plant engineering
Chris Lake, 38
Vice President of Engineering, Chief Engineer
RedViking
Plymouth, Mich.
Education: BS Mechanical Engineering, University of Michigan
Chris Lake has helped to change the world of military helicopter testing for the U.S. With the design, build, and implementation of the Transmission Test System (U.S. Patent 8,758,184), he has ensured accurate, repeatable gearbox
testing for enhanced troop safety. His designs also dramatically improve the operator work environment, creating ergonomic machine access and safe machine interactions. In his current role at RedViking, Chris manages 40 mechanical,
software, and controls engineers, as well as program and project managers, technical writers, and university interns.
Chris is widely recognized for his contributions to the world of multimodel transmission and gearbox testing, and has spoken at conferences
nationwide.
Chris met his wife, Amanda, when he was 14 years old, and they will celebrate their 15-year wedding anniversary this fall. He worked for Amandas father and started his engineering career at age 14. Chris and Amanda have a 5-year-old daughter with juvenile diabetes, and together they
have worked to raise funds for the Juvenile Diabetes Research Foundation.
Why choose this career path? Chris has always had a hands-on, problem-solving personality. He has always loved building things, and started
working with machinery at a young age. He enjoyed the experience and the challenge of engineering then, and continues to love it today.
Greg Larson, 37
Brian Pack, 35
Manufacturing Engineering Manager

Turck Inc.
Plymouth, Minn.
Sr. Electrical Engineer I

Raytheon
El Paso, Texas
Education: BS Manufacturing Engineering, St. Cloud State University
Education: BS Electrical Engineering, New Mexico State University
Through his 14 years of service at Turck, Greg Larson has displayed

a consistency of purpose to a group that experiences a lot of day-today challenges in balancing both customer and company needs. He
has been able to create a group that straddles and brings together
both manufacturing development and production activities. Greg is an
internal champion for making Turck more efficient through automating the companys internal processes. His work on the the PLS Tablet
Project and the Automated Labor Calculator has helped Turck eliminate
unnecessary and/or redundant steps, saving money and increasing
productivity.
Brian Pack served 5 years in the U.S. Marine Corps as an avionics

technician and earned several associate degrees before going to work
as a controls engineer for the Schneider Electric/Square D manufacturing plant in Lexington, Ky. Brian has continued to add to his outstanding accomplishments, earning his bachelors degree in electrical
engineering, obtaining his engineering intern license, and leading the
electrical design of a Terminal High Altitude Area Defense (THAAD)
radar trainer for Raytheon and the U.S. Army. Brian introduced new
technologies to Raytheon and the army, integrating PLC/HMI controls
for more open architecture and lower cost where traditional MIL-SPEC
type equipment ordinarily would have been used.
Greg enjoys running, biking, and hiking, among other outdoor activities.
In the past few years, he started competing in running events, including
the Tough Mudder and Warrior Dash. For Greg, these runs are about
tackling a challenge head-onwhether its jumping over fire, crawling
through mud, or clambering over barricades.
Why choose this career path? I first became interested in engineering while working for a corrugated box company that my dad worked
at, said Larson. Working with the engineers, I saw that by doing
some analysis and applying some basic science and math principles,
you can make a significant impact on processes and efficiencies. Ive
always remembered that and do my best to always look for ways to
make improvements. Im lucky to have a strong, supportive, and skilled
team at Turck who I can trust and work with to implement changes and
improve processes for our internal and external customers.
Brian attributes much of his success, academic and professional, to

the support of his wife, Angie. While they both had very humble beginnings in rural eastern Kentucky, she encouraged him during his service in the Marine Corps and his studies as a full-time student. Angie is
now a full-time student while Brian works as an engineer and aspires
to someday own his own company that offers engineering consulting
and systems integration.
Why choose this career path? It was easy, said Pack. I started
my education in the Marine Corps as an avionics technician, and soon
realized that I enjoy troubleshooting and problem solving. I worked on
the AV8B Harrier (jump jet) troubleshooting and diagnosed problems
with the various avionics systems. It turned out that I was good at it,
which encouraged me to pursue a degree in electrical engineering.
plant engineering
September 2014 35
Peter Saladis, 38
Manager, Assembly
The Raymond Corp.
Greene, N.Y.
Education: MBA, Long Island University
Peter Saladis joined the Raymond Corporation with an advanced educational background but little manufacturing experience. He began as a
manager of a portion of Raymonds largest assembly line. Soon he was creating excellent standardized work, training his staff, and utilizing weak
point management and change point management techniques. These tools helped reduce defects and warranty claims paid by 75%, while volume increased 50%. Pete was then promoted to manager of the entire line, which includes 90 workers, three supervisors, and nine team leaders.
His use of the tools and his ability to apply them is a model used throughout the entire site and enterprise.
Pete works very hard on his peer relationships and shares openly any information that can benefit his teams performance. He is assertive, professional, and leads by example. He participates in events outside of work that benefit the community.
Why choose this career path? Pete believes in American manufacturing and in our local workforce. He believes leadership and management
can make us competitive with anyone. He takes pride in helping people grow, mature, and develop into productive, respected team members.
Pete believes the Raymond Corporation focuses on customer fulfillment, with a focus on quality where people are the most important asset. Pete
and his team readily accept any challenge.
Aron Semle, 35
Product Manager, KEPServerEX
Kepware Technologies
Portland, Maine
Education: MS Computer Engineering, University of
Maine, Orono
Aron Semle began his career at Kepware as a software
engineer and quickly moved up the ranks to product
manager for the companys flagship product, KEPServerEX. During the course
of his past 6 years at Kepware, Aron has consistently demonstrated his passion
for using new technology to solve modern-day problems in data collection. Aron
serves on the OPC Foundations Board of Technical Advisors and is active in the
ongoing development of OPC standards. In addition to his board affiliation, Aron
participates in many technical events, focusing on subjects like automated drilling and cyber security where OPC connectivity is not currently part of the domain
knowledge. Through these events, Aron continues to champion OPC technology
and helps others understand its capabilities, possibilities, and limitations.
Aron competed in his first marathon last fall, the Mount Desert Island Marathon.
He finished, enjoying the physical challenge and beautiful sites of Bar Harbor,
Maine. He claims if he can do it, anyone canand like all things, you just need to
put the time in.
Why choose this career path? Product engineering provides an outlet for ongoing creative problem solving, said Semle. Every day, Im tackling new complex
problems with a team of incredibly talented peers who challenge me to think differently and approach projects from unexpected angles. No two days are the same
in my work at Kepware, and no two customer projects are alike. We are constantly
innovating, tinkering, and creating, and the product of our work is incredibly rewarding. From plant floor efficiencies to enterprise operation improvements and top-line
savings, our work has a tangible impact in which you cant help but take pride.
36 September 2014
plant engineering
Mahesh Singh, 29
Deputy Manager, Environment Health and Safety
Roulunds Braking India Pvt. Ltd.
Sonepat, Haryana
Education: BS Economics, M.K.J.K. College; MS
Industrial Safety Management, Guru Jambheshwar
University of Science and Technology
Mahesh Singh is a certified internal auditor for ISO14001 and OHSAS-18001 with nearly 8 years of experience in the manufacturing industry. Working at Roulund Braking India, Mahesh has reduced the amount
of lost-time injuries by nearly 80%. Mahesh has also
introduced the work permit and lockout and tagout systems at his facility, and he has saved Roulunds Braking
India approximately $1.5 million by incorporating LED
lighting.
In his spare time, Mahesh loves to travel and familiarize himself with other cultures. He also enjoys listening
to music, playing cricket at a district level, and playing
badminton.
Why choose this career path? Environment health
and safety are essential for an industry to be successful, said Singh. This is a profession where one can feel
internal satisfaction by contributing towards the welfare
of the society and environment. It is a profession which
enables you to act and protect the life of those working
in any industry. It is an integral factor to increase the productivity and employee satisfaction. This is very noble
profession which gives you the feel of a deep satisfaction and a moment of pride by saving lives.
Jason Stefanski, 33
Shadrach Stephens, 33
Director, Software and Controls

RedViking
Plymouth, Mich.
Maintenance Group Leader

The Dow Chemical Company
Freeport, Texas
Education: MS Electrical Engineering, University of Toledo
Education: BS Electrical Engineering, Southern University
Since Jason Stefanski started with RedViking, he has developed a team of highly skilled dynamic test systems engineers,
including software, controls, electrical design, and fluid power
engineering. This team is a critical part of the Flexible Transmission System project that was recently awarded a U.S.
patent and was recognized for outstanding innovation in engineering. As a manager, Jason identifies the unique strengths
of his team members and tasks them with projects where they
will excel, encourages engineering skill cross-training, and
models honesty with a strong work ethic. Jason designed the
energy regeneration system for a set of U.S. Dept. of Defense
helicopter transmission test systems that will reduce taxpayer
spending on energy by millions of dollars.
Shadrach Stephens has 11 years of instrumentation and controls industry experience and has achieved many accolades along the way. Most
recently, his reliability team was the recipient of the 2013 HART Plant
of the Year award, in which he led a team of 12 technicians to increase
instrument reliability by 85% in 3 years, resulting in millions of dollars in
production savings. At the beginning of his career, Shadrach was introduced to lean manufacturing principles when he partnered with other
manufacturing engineers and Japanese consultants to design and manufacture U-shaped HVAC production lines, which resulted in higher productivity and quality while using significantly less floor space.
Jason is a strong believer in teaching through demonstration,

and he and his wife work to demonstrate charitable behavior
to their children, including volunteering for the Salvation Army
and making donations to a homeless shelter. Jason also uses
his hobby, remote control helicopters, to teach his son about
electrical and mechanical engineering, as well as patience
and persistence. An engineer through and through, Jason
named his first son Diesel.
Why choose this career path? Jasons father was an electrician, and he was always interested in his dads work. Since
his high school days, hes been interested in automation and
how to program it.
Melissa Unger, 31
Materials Cost Manager
Victaulic
Easton, Pa.
Education: BS Industrial Engineering, Penn
State University
Melissa Unger began her career at Victaulic
in 2003 as a rotational engineer, and she has
rapidly advanced through the company while
undertaking various leadership roles. Over the past decade, Melissa
has progressed from plant engineering to plant superintendent to her
present position as materials cost manager. Today, Melissa works globally with all of Victaulics facilities to increase efficiency and improve
productivity. She is also very skilled in process improvement, including
finding ways to secure local efficiency gains and manufacture products
close to Victaulics customers, according to Chris Misiak, Victaulic
director of operations.
Shadrachs passion is to coach and mentor other industry professionals

and engineering students. In the last year, he attended mentoring workshops and volunteered to represent his organization at the 2014 National
Society of Black Engineers Conference to mentor and recruit promising
engineering talent. Shadrach empowers individuals and groups by providing them with the skills they need to effect positive and productive change.
Why choose this career path? The controls industry is one of the most
innovative engineering disciplines providing unique opportunities to seasoned professionals and recent graduates that are seeking challenging
problems to solve, said Stephens. With the enhanced capabilities of
smart technologies and the Internet of Things, controls professionals in
the manufacturing sector are now tapping into portals of information that
enable organizations to make data-based decisions. Ive observed that
these key business decisions require professionals that have the ability to
understand technology trends and the value they deliver, the voice of the
customer, and the effects of human behaviors.
Melissa has a strong passion for the outdoors

and being active. She enjoys fishing with her husband, riding her four-wheeler, playing baseball
with her father, playing with her dog Nikky, and
cruising around in her Ford Mustang. When she
is not outdoors, she likes spending time with family and friends or reading a good book. Melissa is
also a member of the American Foundry Society,
a U.S.-based metal casting organization.
Why choose this career path? My passion for
driving continuous improvement, thinking outside
the box, and never giving up when times get tough began at a young
age, so I knew I wanted a career that would enable me to utilize these
traits, said Unger. Industrial engineering gives me that opportunity,
and also allows me to get my hands a little dirty. It has proven to be
a great fit. Victaulic has helped shape my career path and leadership
skills by allowing me to explore various roles, empowering me to make
smart decisions that keep my career and our innovative company moving forward.
plant engineering
September 2014 37
Jeff Winter, 31
Safety Business Manager,
North America
Grantek Systems Integration
Oak Brook, Ill.
Education: BS Electrical Engineering Technology, Purdue
University
Within Jeff Winters first year at
Grantek he has driven change
in the companys organizational
structure and its culture. His
ability to bring leadership is the
combination of his personal drive for continuing education,
his passion for doing the right things for clients, his ability to
integrate future trends with customer needs, and his strength
in establishing relationships internally and externally. He is
recognized as a subject matter expert in machine safety and
a business leader by clients, coworkers, and industry groups.
Brian Zakrajsek, 32
Senior Electrical Engineer
Koch Modular Process Systems LLC
Paramus, N.J.
Education: BS Electrical & Computer
Engineering, Ohio State University
In 2011, Brian Zakrajsek joined Koch
Modular Process Systems as a senior
electrical engineer supporting the chemical industries. He currently wears many
hats, including distributed control system
and programmable logic controller (PLC)
development and integration, electrical and process control, instrumentation
selection, project management, and international commissioning tasks. Brian is a
certified professional engineer for electrical power as well as a certified automation
professional from the International Society
of Automation (ISA). Since 2005, he has
been an active member of the ISA and is a voting member for
ISA101-HMI.
38 September 2014
plant engineering
Last year, Jeff hosted an all-day Safety Peer Networking

Event, where he both created the content and recruited all 26
corporate/director-level attendees.
Global travel is Jeffs non-work passion. At least once a year
he tries to venture outside of the country. He enjoys learning
about the history, as well as, the local culture on each of his
trips. Jeffs interest in technology, engineering, and safety are
not limited to his career. He chooses his cars based on a lot of
the same criteria (with the additional criteria of horsepower).
He enjoys driving cars with state-of-the-art technology and
always finds ways to use every bit and byte the vehicle has to
offer.
Why choose this career path? Jeff has always enjoyed
meeting new people, exploring new places, and learning how
all the things around us are made. Jeff started his career as
a sales engineer where he was able to combine these interests. Through his exploration he has developed a passion in
making machinery safe, productive, and compliant. This has
lead to being able to build a more successful business practice internally and ultimately make a positive impact on the
industry of safety as a whole.
Brian is an identical twin; his brother is a

partner at a small web analytics consulting
firm in Boston. In his opinion, being a twin
is truly amazing. The bond of friendship,
competition, and shared experience he
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MAINTENANCESOLUTIONS
Figure 1: A consistent
cleaning regimen is
part of any successful maintenance program, but often can
get overlooked when
developing a maintenance strategy. All
images courtesy:
Omegasonics
Evaluate cleaning strategies

to improve productivity
Reliability, safety can increase with a clean plant environment.
Frank Pedeflous
Omegasonics
n every type of manufacturing environment and industry, industrial equipment

and parts need to be cleanedfrom
precision aerospace instruments to carburetors to equipment that manufactures
pharmaceutical productsand the degree
of cleanliness and how its achieved varies widely.
To d a y s i n d u s t r i a l e n v i r o n m e n t i s
marked by highly accurate machining
and finishing processes and precision
manufacturing methods. The result is
manufacturing tolerances, or permissible
limits in a products variation in physical
dimension or measured value, are tighter
than ever. Therefore, any contamination
or debris left behind on parts is sure to be
problematic and must be removed for the
parts to function reliably.
Reliability takes on a slightly different
meaning when talking about items that
will come in contact with the human body,

such as pills from forming machines or
medical testing or surgical instruments. In
these instances, it is imperative to remove
dirt, debris, and abrasive contaminants,
as well as molds and toxic chemicals that
can make humans sick. This is an issue
especially prominent in the pharmaceutical industry where manufacturers actually need to validate their cleaning method
per FDA requirements. All residue must
be removed from the equipment prior to
manufacturing the finished product.
In addition, if parts need to go to a
plating or coating stage, they need to be
exceptionally clean for the coating to
stick. Finished parts generally cannot go
to end users with cutting fluids on them.
Equipment thats not properly cleaned
can become unreliable and affect the reliability of the part its producing. Without
PLANT ENGINEERING
September 2014 41
mAINTENANCESOLUTIONS
Figure 2: In some industries, a clean plant operation is important. For those in the food and pharmaceutical industries, it is
regulated, putting a stronger emphasis on such practices.
industrial cleaning to keep manufacturing

equipment free of dirt and grime, parts
wear faster, breakdowns occur more often,
and efficiency and productivity suffer. The
Immersion cleaning is a better option for cleaning

irregular shapes that have surfaces that are difficult to
reach with spray washers.
flow of fluids, lubricants, heat, and air all
suffer when parts become dirty. Increased
friction means greater heat buildup, which
may lead to premature equipment failure.
For equipment that undergoes routine
maintenance, more thorough cleaning can
extend the time between scheduled maintenance, which keeps machines running lon-
42 September 2014
plant engineering
ger and eliminates downtime. If a machine

or component is not cleaned well enough
during routine maintenance, then it will
need to be cleaned more often, shortening
the time between scheduled maintenance.
The result is lost productivity due to a
production line that is frequently down.
Furthermore, todays manufacturing
plants are made up of many complicated systems in motion at all times. This
includes employees and equipment. As all
good business people know, production
flow is critically tied to revenue, so interruptions to productionespecially chronic
disruptionscan severely impact revenue.
Different cleaning systems
Industrial cleaning equipment is most

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turing process or in settings where parts
must be regularly cleaned to function at
peak efficiency. An industrial washer is a
machine that removes contaminants from
the surfaces of a part or component before
its sent to the next step in the manufacturing process.
An industrial washer is a machine that removes

contaminants from the surfaces of a part or component before its sent to the next step in the manufacturing process.
Depending on how the part is made, the
foreign materials can include machine oil,
casting sand, metal shavings, polishing
compound, and even human skin and oil.
To expedite the process and manage labor
costs effectively, manufacturers often use
an industrial washer to clean the parts
rather than spend the time and money to
clean each one by hand.
Different types of industrial cleaning
equipment remove contaminants with
varying effectiveness, depending on the
intricacy of the part. For example, almost
any type of system can clean a smooth,
highly polished surface, whereas complex and intricate parts require a more
sophisticated cleaning process. If a part
has blind or drilled holes, internal passageways, sharp inside corners, or rough
surfaces, removing contaminants for
improved reliability can be problematic.
Since any contaminant can cause reliability issues, starting with the cleanest possible surface is imperative, and choosing
the right industrial cleaning equipment
becomes paramount.
Spray washers or power washers operate
much like a dishwasher, with revolving
high-pressure water jets that spray the
parts to remove foreign materials. This
type of industrial cleaning unit is used
for general cleaning and removing gross
contaminants, such as heavy dirt or rust,
from large, smooth, and/or flat-faced surfaces. A good example of an effective use
of a spray washer is for the external surface of a large steel mold or the external
surface of a car engine to remove grease
and dirt. A spray washer will not perform
any precision cleaning and is best suited
for raw external surfaces. For example,
44 September 2014
plant engineering
a spray washer is not a good choice for

cleaning the internal exhaust ports of an
engine because the streaming water cant
necessarily get into those hidden areas.
Immersion cleaners soak parts in cleaning solutions to dissolve the contamination from the surface. Immersion cleaning
is a better option for cleaning irregular
shapes that have surfaces that are difficult
to reach with spray washers. Typically, the
parts are placed in a basket or barrel and
the process can include agitation.
Solvent cleaners are a specific type of
immersion industrial washer. Parts are
bathed in solvents like acetone, naphtha,
or mineral spirits. This type of cleaner is
very effective at removing oil and grease,
and sometimes requires a special enclosure to control the dangerous vapors and
hazardous waste materials it generates.
Manual cleaning involves cleaning done
by hand, often using toxic chemicals and
an endless variety of implements, including rags, toothbrushes, wire brushes, cotton swabs, air compressors, fingertips, and
more. Not only is hand labor the most
time intensive industrial cleaning method,
potentially wasting many hours of manpower, but the cleaning itself often is hit
or missnooks and crannies that cannot be seen or reached dont get cleaned.
Sometimes, even parts cleaned in immersion tanks dont come out clean enough
and require additional hand cleaning.
Manual cleaning may be the best option
for manufacturers that have a very low
volume of parts to wash. A cost-benefit
analysis can help determine at what volume an industrial washer would make
sense.
Outsourcing parts cleaning to a thirdparty is a route that some manufacturers
take when they find that manual cleaning
is uneconomical within their operations.
Outsourcing has some disadvantages as
well, though, chiefly that manufacturers
must accumulate parts before sending
them out to qualify for a bulk discount.
The time it takes to accumulate enough
parts can impact lead times and cause production delays, not to mention the personnel time spent on, and cost of, shipping,
packaging, and paperwork.
Ultrasonic cleaners are used when a part
is very complex, it needs to be super clean,
or the manufacturer wants to save on labor
and energy costs. Unlike spray washers,
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immersion cleaners, or using sol- dirt, residue, and other contaminants. Cleaning and safety
vents, industrial ultrasonic cleaners The implosions work similarly to The type of industrial cleaning equipdecontaminate at a near-microscopic small vacuum cleaners that literally ment manufacturers choose has implilevel and can clean threads, drilled pull off caked on residue from any cations for worker safety. The less
and blind holes, sharp inside corners, area, removing contaminants down contact workers have with the parts
rough surfaces, and inaccessible to hundreds-of-thousandths of an and equipment they are cleaning, the
less likely injury will occur someinternal cavities not reachable by inch in size.
where during the process.
other types of indusSolvent parts washers
trial washers.
use
toxic solvents, which
When items are
Manual cleaning may be the best option for
are dangerous for a numplaced into an ultrasonic cleaning tank
manufacturers that have a very low volume ber of reasons. First, they
are extremely volatile.
using environmenof parts to wash.
Workers exposed to the
tally friendly, watervapors can experience
based cleaning soaps,
both short- and longan energy-converting
transducer produces sonic frequenM a n u f a c t u r e r s t h a t a r e h a v - term health effects. In addition, the
cies approaching 40,000 cycles per ing trouble achieving the level of vapors are flammable, which means
second. These high-frequency sound cleanliness they want will turn to accidental introduction to heat from
waves produce millions of micro- an ultrasonic cleaner. Due to its any source could start a fire or trigscopic vacuum bubbles that implode gentle nature, ultrasonic cleaning ger an explosion. Solvents require
when they come in contact with a also is suitable for industries like special handling, storage, reporting,
surface. Energy is released by the printed circuit manufacturing. When and personal protection equipment
creation and collapse (called cavita- the proper cleaning frequencies are while in use. They are toxic to wildtion) of these bubbles. The resultant used, ultrasound wont damage the life if accidentally spilled or released,
and they pollute the atmosphere. The
shock waves break up and lift off final product.
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vapors must be vented and captured

Tools are another safety issue. are even more dangerous when used
when the washer is used, and spent C l e a n i n g p a r t s b y h a n d o f t e n in the wrong combinations.
solvents must be disposed of as haz- requires wire brushes, high-speed
What this all boils down to is that
ardous waste, adding to the operating power tools, scrapers, files, sand- while cleaning equipment and parts
costs for the unit.
ers, utility knives, and hand picks. seems mundane, it is an essential
Because the risk of fire and explo- All of these tools have the potential component to a profitable entersion is so high in places
prise. Manufacturers
where solvents are stored
have many variables
and used, insurance underto take into considerUltrasonic cleaners are used when a part
writers may require higher
ation, including how
is very complex, it needs to be super clean, parts cleaning affects
deductibles and higher premiums for those facilities.
their product reliabilor the manufacturer wants to save on labor ity, productivity, and
Manufacturers may also
be required to install and
worker safety. Manuand energy costs.
maintain extra fire protecfacturers each need to
tion systems like sprindo their own analysis
klers and fire extinguishto determine the soluers around solvent parts washers, and to injure workers during use, from tion that works best for themin
could be subjected to extra inspections cuts and scrapes to puncture wounds. a nutshell, what makes their lives
from the fire marshal and insurance Not to mention that hand cleaning easier and makes their businesses
carrier.
also requires the use of spray sol- most profitable. PE
An ultrasonic cleaning system, on vents, degreasers, corrosive alkalis,
Frank Pedeflous is the president of
the other hand, has none of these issues and acids. Not only are most of these
since it usually cleans with water- chemicals injurious to the body in Omegasonics, a California-based manubased detergents that are nontoxic and some wayattacking workers skin, facturer of ultrasonic cleaning systems.
nonflammable.
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MECHANICALSOLUTIONS
Figure 1: Creating an adaptable weld cell offers numerous benefits for companies, including improved productivity
and throughput; reduced costs; an improved environment for employee health and safety; and the ability to generate continuous improvement. All images courtesy: Miller Electric Mfg. Co.
Welding cells adapting

to manufacturing changes
John Leisner and Ed Crum
Miller Electric Mfg. Co.
n t o d a y s c h a n g i n g m a n u f a c t u r i n g
environment, many companies find
themselves having to adapt to various
jobs, contracts, and competitors. This
necessity can stem from a change in the
type of product being manufactured,
a change in the material being used, or
changing rules and regulations regarding employee safety, such as weld fume
exposure.
With this frequency in manufacturing
changes, taking steps to plan out the features in a weld cell can help companies
make the space and equipment much more
functional for the job at handand for the
jobs to come.
Creating an adaptable weld cell goes
beyond just improving the physical space,
but that is also a very important component. Choosing flexible and modular
welding equipment is an important way
that manufacturers can maximize the value
and useful life of that equipment, even as
needs change.
What to consider in the weld cell
The goal of establishing an adaptable weld

cell is to make the space usable for any job
that comes through the door and to put the
company in a position to still gain the best
productivity and quality.
The process of making a weld cell adaptable to manufacturing changes includes:
Considering the footprint of the weld
cell
Determining how the equipment is
arranged
Assessing the modularity and overall
capabilities of the equipment.
It should be noted that there are benefits for both automated and semiautomated
welding processes when it comes to optimizing the weld cell for change. There are,
however, different priorities for the two
processes. For example, safety, including
weld fume management and ergonomics,
may be a bigger priority in semiautomatic
welding, whereas maximizing efficiency
may be more important in an automated
PLANT ENGINEERING
September 2014 49
mechanicalSOLUTIONS
Figure 2: With the increasing frequency of manufacturing space changeover, optimizing the weld cell can help companies
make the space and equipment much more functional for the job at handand for the jobs to come.
weld cell. Likewise, tracking quality

is likely a priority in both welding processes, but in an automated cell, that data
may be used to improve throughput. In a
semiautomatic cell, the data may be used
instead to identify welding operator training opportunities.
Manufacturers also need to consider the
entire welding process as it impacts the
weld cells. The way parts are loaded into
and out of the fixtures, or how easily the
tivity initiatives and helps create a leaner

process as production demands change. A
properly organized weld cell can contribute
to a smoother workflow, ensuring that parts
arent touched as frequently and that they
move through the weld cell quickereven
if those parts change over time.
Plus, having flexible equipment can
improve productivity. Power sources with
various process capabilities, such as those
with MIG and Pulsed MIG offerings, are
Creating a weld cell that can be adapted to manufacturing

changes offers numerous benefits for productivity, cost savings,
and employee health and safety, among others.
needs of the cell can be modified if there
is a change in product or material type are
both important.
Benefits of creating an adaptable weld cell
Creating a weld cell that can be adapted to

manufacturing changes offers numerous
benefits for productivity, cost savings, and
employee health and safety, among others.
Improved productivity and throughput.
Streamlining the weld cell supports produc-
50 September 2014
plant engineering
a good option. They allow welding operators to simplify the transition between processes as needed for specialty jobs, such
as welding thin materials or gap filling for
different jobs that go through a weld cell
without incurring excessive downtime.
Reduced costs. A weld cell that emphasizes maximum flexibility can save manufacturers money in the long run by reducing
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mechanicalSOLUTIONS
For instance, if a new job demands
faster cycle times, the ability to
modify a welding process to reduce
spatter or the time spent on post-weld
cleanup is invaluable. Such a benefit
can often be realized by purchasing
welding equipment that can be updated with new software and is a much
less expensive option than purchasing

new power sources.
Also, having equipment that is
flexible and modular can minimize
costs for retooling that space. In automotive manufacturing, for instance,
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Choosing flexible and

modular welding
equipment is an important
way that manufacturers
can maximize the value
and useful life of that
equipment, even as
needs change.
about five years. If, at the end of
that platform life, the equipment can
be broken down and redeployed on
another line within the operation, it
can result in cost savings and longer
useful lifespan of that equipment.
Employee health and safety.
Implementing equipment, such as
mobile fume extraction systems or
fume extraction systems with reusable ductwork and components that
can be deployed in various areas, can
help companies provide a cleaner and
safer environment for employees.
Such systems also can help
employers meet increasingly strict
rules and regulations regarding weld
fume exposure, regardless of the area
where they are used and the product
they are welding. Should a company
need to reconfigure its weld cell layout for a new job, having portable
fume extraction equipment makes the
transition simpler.
Other safety benefits associated
with proper equipment layout in the
weld cell include the reduction in
clutter, which helps reduce trip and
fall hazards for employees. Ergonomics should also be considered when
configuring the weld cell. Design
work fixtures at the appropriate
work heights, and implement the
right welding gun and cable length
for the job.
The ability to generate continuous improvement. The addition of
welding information management
systems in the weld cell can provide wide-ranging, real-time data to
help companies improve productivity, quality, throughput, efficiency,
and welding operator training, even
as manufacturing needs change.
52 September 2014
plant engineering
These systems can often be retrofitted to existing machine fleets (via

a 14-pin receptacle), making them
a cost-effective addition to gather
information on a variety of welding
applications.
Using the data generated by this
technology can help manufacturers improve the welding process in
their entire manufacturing operation,
from fabrication to final assembly, by
allowing them to gather data that can
serve as a baseline for current and
future needs. As applications potentially change, the system can help
companies assess productivity, quality, and cost factors for new parts.
It can also provide knowledge about
the welding process that will help
management configure their weld cell
in the most effective manner.
and repurposed can save companies

money; if there is a need to reconfigure
the weld cell, the ductwork can simply
be unclamped and reused elsewhere.
4. Consider purchasing welding

equipment that offers flexibility for
use with different materials. Compa-
nies can benefit from a system that

is flexible enough to handle changing
material types and strengths, and the
varying processes that go with those
changes.
5. Equipment that is mo v ab l e
(e.g., fixtures on wheels) and
Get a grip on surface

nishing costs.
Practical tips to adapt the cell
Making a weld cell flexible and

adaptable for a changing manufacturing environment might seem like
an overwhelming process, but there
are some practical steps that can help
companies position themselves for
changes.
1. Measure the productivity and

efficiency of the existing cell to
understand where there is room for
improvement. Look for areas in the
weld cell that can be augmented (e.g.,
via new workflow, the investment in
modular equipment, etc.), as having
these factors in place can position the
company for future change.
2. Choose a supplier or product
manufacturer that offers good aftersales support and service. As needs
change in the weld cell, the supplier
can continue to provide expertise and
help.
3. Consider products that are
designed to be scalable for future
evolving needs. Implementing a
basic welding information management system that can be upgraded to
more advanced capabilities would be a
good option to address manufacturing
changes. Also, fume extraction ductwork that can be clamped together
plant engineering
September 2014 53
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mechanicalSOLUTIONS
It should be noted that
there are benefits for both
automated and semiautomated welding processes
when it comes to optimizing
the weld cell for change.
Train welding operators to understand the importance of weld cell
layout and maximizing equipment
use, so they understand how it ties
into productivity and efficiency
efforts.
Competitive adaptability
Figure 3: Training welding

operators to understand
the importance of weld
cell layout and maximizing
equipment use is important
so they understand how it
ties into productivity and
efficiency efforts.
54 September 2014
includes running gear typically offers

more flexibility in adjusting to space
needs or changes in a weld cell. Implementing booms where applicable also
helps maximize reach and overall cell
flexibility.
Some companies make the mistake

of buying equipment thats just
sufficient to meet todays welding needs. In reality, companies
should consider products that offer
flexibility or at least the capability
of doing more when needs change.
Choosing a more flexible welding
system or fume extraction system,
as examples, prepares a manufacturer for greater growth and productivity and allows it to be more
competitive in an evolving market.
It should be noted that equipment that offers greater flexibility and modularity may require a
larger upfront investment, but it
can save money in the long run.
Companies that cant justify the
upfront investment should consider
a manufacturer that offers accessories that can help accommodate
future growth and changing needs.
That way, additional capabilities
can be added via the accessories
without having to invest in a completely new welding system.
Having a weld cell that is adaptable,
both in equipment and in layout, can
poise a company to address manufacturing changes as they occur, while also saving money in equipment purchases and
improving functionality of the space. PE
6. Purchase guns that are customizable

for the job, such as those with interchangeable necks, to help improve the adaptability of that equipment.
John Leisner is senior product manager

and Ed Crum is segment market manager
for advanced manufacturing for Miller
Electric Mfg. Co.
plant engineering
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ELECTRICALSOLUTIONS
Reaping the rewards of
data-driven efficiency
Yolanda Smith
Digital Lumens
ith surprising swiftness, the era of to secure truly massive energy savings
big data analytics has reached the upwards of 90% over traditional HID and
manufacturing domain, ushering HIF lightingthe most discriminating faciliin unpreceties invested in intellidented advances in how
gent LED lighting. In
Historically, collecting and
facilities are managed
the process, they solved
to optimize energy
managing the large volumes of the big data sensor/netusage and operational
w orking/p r o cesso r s/
results. Leading manu- data required to enable big data analytics challenge.
facturers, for example,
As a framework for
analytics has posed significant
are already leveraging
big data analytics, intelchallenges for plant facilities
big data to slash facilligent LEDs offer sevfrom both a logistical and a
ity-wide energy use,
eral distinct advantages
improve space utilizaover stand-alone data
financial perspective.
tion, optimize schedulcollection alternatives,
ing, and decide when
including:
new capital equipment investments make
The ubiquitous nature of lighting, which
sense based on accumulated data, among
reaches into every corner of a facility
other valuable insights. Big data accomwhere people, systems, and machinery
plishes this by providing an unparalleled
reside, turning lighting into an intellilevel of visibility into facility operations,
gence gathering solution for promoting
based on real (versus observed or anecdotal)
facility-wide energy and operational
operational data.
efficiency.
Historically, collecting and managing the
Integrated sensors in every fixture, which
large volumes of data required to enable big
generate copious amounts of data for
data analytics has posed significant chalevaluating both lighting and non-lightlenges for plant facilities from both a logistiing-related events, such as energy loads
cal and a financial perspective.
and occupancy patterns.
This is because, at a minimum, big data
Integrated wireless networking in every
requires the deployment of a large number
fixture, which can be used to collect data
of sensors to monitor physical systems (e.g.,
from any type of sensor (occupancy, load
machinery, HVAC components, lighting)
monitoring, temperature, and so on),
and plantwide occupancy patterns. Furtherconnected to the system.
more, widely distributed sensors must be
Integrated reporting and analysis tools,
supported by wired or wireless networks to
which provide facility managers with a
transmit the data, processors to analyze it,
single, uniform and, importantly, familand applications to transform the data into
iar way of evaluating performance metinformation that can be used to improve
rics, by system, facility, or multi-facility
facility operations.
rollups.
The rapidly growing numbers of plants
now deploying big data analytics, however,
Although facilities are consistently paydidnt necessarily set out to solve this spe- ing for intelligent LEDs in less than two
cific problem. Instead, spurred by increas- years through lighting-related energy savingly aggressive energy efficiency mandates, ings, the operational insights afforded by
they invested in lighting upgrades, which the data the system collects go well beyond
plantwide energy audits routinely singled lighting, enabling the era of big data mining.
out as the fastest, highest return path to sub- For example, facilities are currently using
stantial year-over-year energy savings. And, this data to:
PLANT ENGINEERING
September 2014 57
ELECTRICALSOLUTIONS
of people over time, enabling corrective or,
alternatively, supportive measures.
Identify where inventory should be placed
to improve access, reduce transit times, and
improve workplace safety.
Decide whether or not to invest in more
capital equipment based on usage data.
Granted, plants have only begun to see
the benefits of big data mining, but it is
already changing the face of facility management, driving everything from simple
forklift routing to more complex energy load
management in search of energy savings.
The fact that it leverages an already-paidfor network of distributed sensors, wireless
communications, and centralized analytical
tools simply makes it a logicaland economically justifiablechoice for facilitywide deployment.
BEFORE
Figures 1 and 2: The Creed

Monarch facility before and
after replacing its 400 W
high-pressure sodium lighting with an LED lighting
system. Creed Monarch has
projected energy savings
of 1,036,669 kWh annually,
or $108,436. Both images
courtesy: Digital Lumens.
AFTER
Consolidate high usage spaces by tracking
the movement of people and equipment
over time.
Identify opportunities to save energy
through load balancing or the scheduling
of energy-intensive activities during lower
kWh-cost periods.
Optimize production and maintenance
schedules by tracking machinery utilization
rates through lighting and occupancy data.
Identify operational anomalies, such as
energy spikes or unusual concentrations
58 September 2014 PLANT ENGINEERING
In much the same way that ISO, Six

Sigma, and TQM revolutionized plant processes and procedures, big data is doing
the same for the buildings that house, and
the activities that support, these highly
optimized operations, begging the question: Isnt it time to expect more from your
infrastructure investments? PE
Yolanda Smith is an applications engineer
at Digital Lumens.
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AUTOMATIONSOLUTIONS
Can there be a single wireless
protocol for field devices?
One fieldbus protocol has emerged as the leading solution for process
applications, and our industries have benefitted. Perhaps the same thing can
happen with wireless field devices.
Dick Caro
CMC Associates
rocess industries do not adopt new

technologies instantaneously. On
the contrary, they normally begin
gradually and methodically with
applications where that technology provides enough benefits to overcome the risk
that it will not work at all or will not work
reliably. Many users will test the new technology on a few pilot installations, usually
for noncritical processes. With operational
success and sufficient economic incentive,
the new technology will be specified for
new plant construction in locations where
vendor support is available. Eventually the
new technology will be specified for greenfield plant construction, major revamps,
and modernization projects, ultimately
becoming an industry norm. Foundation
fieldbus (FF) has followed this pattern with
ISA100 was designed explicitly for communications

with smart process control field instrumentation, and
for easy configuration to a specific set of highperformance requirements.
the basic technology becoming a standard
in 1996, and now almost 20 years later, it
is the industry norm for new plant construction and modernization in continuous
flow process industries such as petroleum
refining, petrochemicals, and chemical
manufacturing.
Like wired process control communications standards in 2000, today there are
directly competing standards for wireless field instrumentation: IEC 62734
(ISA100.11a) and IEC 62591 (WirelessHART.) These two standards appear
to be very similar because they are both

based on the same IEEE 802.15.4 radio
chip, but they are actually quite different
and not interoperable. WirelessHART was
designed by the HART Communications
Foundation specifically to transport HART
data over a wireless network as simply as
possible, and to be installed and managed
with the familiar HART tools and methods. ISA100 wireless was designed by an
open standards organization with technical experts from more than 250 countries
to be a wireless Internet-based telecommunications protocol for process control
data now and for future applications not
yet invented. It was designed for efficient
transportation of HART and practically any
fieldbus data objects that use standard IEC
61804 (EDDL).
Following the fieldbus example
One of the problems that is delaying broader acceptance of wireless field instrumentation is that most new plant installations
and major modernization projects are now
using Foundation fieldbus, a wired alldigital network of very intelligent field
instruments. A wireless equivalent or
version of FF H1 is not yet available,
although both WirelessHART and ISA100
wireless networks can exchange simple
data from either wireless network through
a ROM (Remote Operations Manager), a
Fieldbus Foundation-specified gateway.
However, lack of a true wireless version of
FF with the same intelligent but wireless
field instruments is not available. Not yet
tested by the Fieldbus Foundation is FF
HSE (high-speed Ethernet) working on
Wi-Fi, or this same HSE protocol working
on an ISA100 wireless IP-based network.
PLANT ENGINEERING
September 2014 61
aUTOMaTIONSOLUTIONS
Figure 1: Multiple field temperature transmitters in a refinery application can handle more than one probe. Courtesy: Yokogawa
There is no wireless version of FF HSE and applications are not for fast control
linking device offered or registered by loops.
any vendor.
Users are very concerned that there are Comparing ISA100 to WirelessHART
effectively two competing wireless network What are the features of ISA100 that make
standards being supported by the major it the better choice as a wireless network for
a new process control
instrument compaapplications? As the
nies. Of even greater
WirelessHART technology
HART Communicaconcern is that often
tion Foundation says
the wireless network
allows users to access the
in its description of
standard used by their
the platform, Wirefavorite field instruvast amount of unused infor- lessHART technology
ment supplier is not
allows users to access
compatible with the
mation stranded in these
the vast amount of
wireless network
unused information
standard support by
their favorite DCS installed HART smart devices. stranded in these
installed HART smart
supplier. Users look
devices.
to their suppliers to
ISA100 was designed explicitly for comsolve such problems; vendors must bring
solutions to their customersnot problems. munications with smart process control
Lack of a single wireless network norm, or field instrumentation, and for easy configugenerally accepted industry practice, has ration to a specific set of high-performance
hampered user acceptance of wireless field requirements. There are many configurable
instrumentation except in a few areas where choices possible in the preparation of an
the benefits of wireless are overwhelming, ISA100 wireless device that are specified
62 September 2014
plant engineering
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aUTOMaTIONSOLUTIONS
in the standard. The set of default values for
these choices, which appears in the standard, is called the router profile, which has
Users of wireless process control field instrumentation

do not need to configure new wireless instrumentation
to meet any of the options of this standard.
been optimized for secure mesh networking
of process control field instrumentation.
Therefore, users of wireless process control field instrumentation do not need to
configure new wireless instrumentation to
meet any of the options of this standard.
Manufacturers of other wireless devices
may have specific cost, performance, or
security needs which may use the I/O profile also specified in the standard for lowcost devices, or may require adjustments to
some other ISA100 attributes to customize
it to their needs. Customized versions of
ISA100 are guaranteed and compliance
tested to interoperate with field instruments
conforming to the router profile, but adjustment of the ISA100 wireless profile is not
something that users need to worry about.
During the design of ISA100, the same
basic set of requirements was used that was
used many years before during the design
of FF. Essential to the architecture of both
ISA100 and FF is peer-to-peer transfer of
data without requiring a host or gateway
relay. Both ISA100 and FF devices have a
synchronized real-time clock to support the
scheduling of objects resident in intelligent
network devices. ISA100 devices have a
synchronized real-time clock accurate to
this data to a DCS doing such control with

time synchronous accuracy. WirelessHART
has no time synchronization capability.
When flow control requiring updates faster
than once per second is to be configured,
only ISA100 can deliver data with a synchronous response more often than once per
second. Typical distillation column flow
control requires data to be scanned two
to four times per second. To deliver this
type of performance, the data collection
times for the flow transmitters should be
configured with minimal network meshing
to guarantee synchronous sample times.
ISA100 explicitly supports a maximum
latency of 100 ms and the field backhaul
routers necessary to enable data to reach the
controller in a single hop without the nondeterministic delays of a mesh network.
When applications are even more
demanding than 4 Hz flow control, it may
become necessary for the user to configure the ISA100 data-link layer to allow
processing up to 12 Hz, which is the current design limit. The advantage of ISA100
is that the user has this option available
without needing to change the protocol, or
to create new function blocks that are not
supported by Fieldbus Foundation interoperability testing.
Resolving the dilemma
Users of process control field instrumentation face a dilemma in choosing which

wireless network to install. Their choices
are the following:
1. Do not install any wireless field

instrumentation
2. Only install ISA100 wireless

3. Only install WirelessHART
Like wired process control communications standards in 2000, today

there are directly competing standards for wireless field instrumentation:
IEC 62734 (ISA100.11a) and IEC 62591 (WirelessHART).
1.0 ms. This clock precision is also necessary to support an electric power utility
industry user requirement for post-mortem
trip sequence analysis.
For example, most process control field
instrumentation sampled once per second
(1 Hz) is adequate for monitoring and most
closed-loop control. ISA100 can deliver
64 September 2014
plant engineering
4. Because each plant site typically
standardizes on one manufacturer

of DCS, install the wireless network
integrated with that DCS
5. Purchase only dual-boot devices
that can be configured at installation to support either standard, or
6. Install another standard such as
Figure 2: Wireless field devices communicate with gateways placed in strategic locations around a facility. Courtesy: Honeywell Process Solutions
WIA-PA, ZigBee, Bluetooth, Wi-Fi,

or a proprietary network.
Each choice has its own practical considerations that users will have to sort through.
1 or 6: Avoiding wireless field instrumentation entirely, installing another standard, or installing a vendors proprietary
network is against a companys interests if
it wants the benefits of standard wireless
field instrumentation. Both WirelessHART
and ISA100 have the field-proven, strong
security needed to assure users of privacy
and intrusion protection.
4: Installing both ISA100 and WirelessHART within the same company and
depending on support from the DCS supplier sacrifices the experience and volume
that can be obtained with a single wireless
network selection.
5: Purchasing only dual-boot devices that
contain both protocols or can be initialized
with either meets only the need to reduce
inventory. It will create much greater comwww.plantengineering.com
Customized versions of ISA100 are guaranteed and

compliance tested to interoperate with field instruments
conforming to the router profile, but adjustment of
the ISA100 wireless profile is not something that users
need to worry about.
plexity during installation and maintenance
since both networks need to be understood
and maintained.
2 and 3: Installing either standard alone
limits the companys ability to select the
best DCS for the plant site, and may make
that plant site obsolete if the network chosen does not become the wireless network
norm.
Can there be a network norm?
While instrumentation suppliers and some

end users might be drawn to supporting
both networks via the dual-boot method,
plant engineering
September 2014 65
aUTOMaTIONSOLUTIONS
this does not achieve the long-term establishment of an industry norm, which has
been at the root of requests by all end
users. ISA100 can be the core of future
wireless industrial networking technology
in much the same way as Ethernet TCP/IP
and Wi-Fi have become norms for IT networks. ISA100 is totally built upon wellestablished network standards. This means
that ISA100 is an application-independent,
Internet-based telecommunications net-
are now recognizing the fact that ISA100

wireless alone meets the needs of a longterm wireless architecture.
Conclusions
Early users of wireless process control

instrumentation had application requirements that centered only on obtaining process data from locations that were either
too costly or impossible to wire. Most of
these applications can be satisfied with
Users that decide to use WirelessHART as their plant wireless network are committing
themselves to a control system architecture in which there is little intelligence in the field
devices and no possibility of CiF with its benefits.
work designed for critical and noncritical
industrial automation environments, just
like Ethernet TCP/IP and Wi-Fi are application-independent Internet-based telecommunications for business networks.
As long as the applications are built to use
common network standards based on IP
protocol, they can be transported across
any standard network, such as ISA100, as
long as there is adequate bandwidth for
the task, and it has been suitably adapted
to the particular needs of the automation
industry.
Moreover, like Ethernet TCP/IP, use of
ISA100 is independent of the network hardware. As microprocessors and communications semiconductors evolve, and frequency
assignments change, ISA100 wireless will
be able to make these transitions without
requiring any changes in the applications
that are carried on this network technology. If history is a good predictor of future
development, wireless network technology
is destined to get less expensive, use less
power, and become much faster. ISA100
will naturally be able to fit right onto the
new wave of wireless network technology
as commercial availability grows.
Manufacturers of process control equipment are concerned primarily with meeting
customer needs and in reducing product
cost to enable competitive pricing. Customer needs often start with solving shortterm problems, but most would also like to
develop a long-term architecture for their
process automation needs. WirelessHART
has been, due to its earlier product introduction, available to solve the short-term
needs, but several end-user organizations
66 September 2014
plant engineering
either WirelessHART or ISA100 wireless, and have now been field-proven and
accomplished their goals.
Users that decide to use WirelessHART
as their plant wireless network are committing themselves to a control system architecture in which there is little intelligence
in the field devices and no possibility of
CiF with its benefits. Their DCS must
do all the work of signal processing and
closed loop control. ISA100 can certainly
connect to those same HART field devices,
but its open architecture allows synchronous two-way wireless data transfer with
full function (intelligent) field devices
when they are ready, without changes in
the basic network. And we know that there
is a strong trend toward FF with its intelligent field devices and highly synchronous
data transfers.
While the early efforts have now resulted
in two non-interoperable wireless standards, users still want to establish a single
wireless network norm suitable for a wide
range of applications well beyond acquisition of remote data points. Leading users
have recognized that the wireless network
norm must not only be an international
standard, but must be suitable for demanding applications such as wireless FF and
Internet web servers in field instrumentation. Only a highly secure IP-based protocol can do this, and only ISA100 wireless
can meet these needs. PE
Dick Caro is CEO of CMC Associates, an
industrial networking consulting company.
He is the author of Wireless Networks for
Industrial Automation.
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Since 1978, Integrity Integration Resources (I2R) has served manufacturers using business intelligence and automation to meet
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injuries. When such accidents happen, companies spend hundreds of thousands (if not millions) of dollars settling
or fighting lawsuits because their products lacked adequate warnings.
Key best practices are shaping the current state-of-the-art for product safety label design.
KEYWORD: SAFETY LABELING
Growth in operator
terminal market
According to a recently released report by IHS,

the Americas are projected to be the fastest growing
regional market for operator terminal revenues to
2018 (8.8%). 2013 was a particularly successful
year for the Americas with revenues growing to over
$550 million (24% of the world total, and nearly 15%
growth from 2012). Although revenues are by no
means forecast to overtake EMEA or Asia Pacific, it
is certainly a region with great growth potential, with
the fastest growth forecast in 2015.
While all regional markets (EMEA, The Americas,
Asia-Pacific and Japan) are forecast to experience
positive growth to 2018, The Americas in particular,
has been highlighted as a potential growth area for
some vendors, said analyst Alexandra Whiting.
The United States unsurprisingly accounted for
over 70% of operator terminal revenues in 2013 and
is forecast to remain at a stable percentage share to
2018. However, it is the countries with a marginally
smaller current installed base, such as Mexico
and Brazil that will provide future opportunities for
operator terminal sales.
KEYWORD: OPERATOR TERMINALS
70 September 2014 PLANT ENGINEERING
Women in manufacturing
facing unique challenges
According to Women in Manufacturing (WiM), women are
underrepresented in manufacturing not because they are
not able, but because they still believe the manufacturing
field is a better fit for men. The biggest challenges women
face when considering the manufacturing sector are the
untrue stigmas that surround manufacturing today. Women
in manufacturing are constantly fighting to show modern
manufacturing for what it is - a high-tech field with many
available jobs well-suited for both men and women workers.
While the U.S. manufacturing sector grows, women
working or aspired to work in this field still face unique
challenges. Recent data shows that the manufacturing
sector in the U.S. has expanded for 14 straight months
with continuous growth. That should be good news for
everyone working in the field. But the simple reality is that
the number of women working in the sector is not following
that trend. Data from the U.S. Commerce Department
shows that, although women hold about half of the jobs
in the U.S. economy today, only 30% of the estimated 14
million Americans who work in manufacturing are women.
KEYWORD: WOMEN IN MANUFACTURING
Combine safety, production goals

In a perfect world, production would flow seamlessly. Materials would always be available and equipment would
never break down. Purchase orders from clients would never have rush deadlines, production would never fluctuate
and your operations would be smooth and effortless.
The real world simply does not work that way. Production flows decrease and increase, and in the meantime you
need to keep your business operational and workers safe. You must use techniques to maintain your employees
health and safety while still meeting your production goals. Start by understanding some of the causes for fluctuations
and safe solutions.
Any equipment failure can dramatically reduce your companys ability to keep production flowing. Equipment maintenance is important for both safety and volume issues. Many businesses face an inability to keep up with required
service due to production goals that do not allow for machine downtime.
Unless your facility runs 24 hours a day, try to arrange for equipment servicing to be performed during off production hours. Without the proper maintenance, your machinery will fail. The cost of the failures outweighs the cost of
occasional downtime.
KEYWORD: SAFETY AND PRODUCTION
Lean implementation,
step by step
The maintenance leader is often the key to a

successful, reliable, and performing maintenance
department, such as in the case we are studying
here. But success never happens by pure luck.
It is the result of bold moves, relentless work,
and believing in human empowerment to solve
problems. This case study is one example of how
that can be accomplished. We used the Lean A3
process and nomenclature to follow step by step
the exact formula to achieve results. As is often
the case in Lean methodology, it is important to
follow each exact step
At the various phases of the project, we
integrated TPM elements or tweaked old ones
that were already in place, but we also closely
monitored the process over a three-year period
and its impact on the crucial KPIs for the
business: Percent Uptime (versus the more
negative term of Percent Downtime), MTTR
(Mean Time To Repair), MTBF (Mean Time
Between Failures) and Maintenance Response
Time (MRT) to Emergency Work Order.
KEYWORD: STEP BY STEP LEAN
Take a fresh look at Lean

Youve got senior leadership commitment to long-term
lean success, and youre refining and rolling out continuous
improvement strategies. Meanwhile, youre striving to build
organization-wide commitment, from production to maintenance,
office, logistics and field service operations, to these new
ways. Yet you may have overlooked a key element of sustained
lean success: effective metrics that not only signal todays
performance, but also support the drive toward your companys
future competitiveness gains.
Take a critical look at how well your organizations key metrics
enable world-class customer service, innovative product/process
development and overall business success. You may discover
the need to revamp how your company measures performance,
to be aligned with todays business environment. Simply adding
more metrics is not the answer.
Leadership plays a key role in focusing activity on what
matters to customers (internal and external) and how day-byday improvements contribute to business success. In turn, longterm, sustainable high performance depends on increasinglymature improvement capabilities. Metrics reflect so much more
than numbers. Share your passion and enthusiasm for your
organizations improvement journeyand celebrate milestones
along the way.
KEYWORD: LEAN METRICS
A tip for change initiatives
As you start any large change initiative one of the first things you do is form a guiding coalition, a leadership team.
That group will champion the change. One of the first things that group is then tasked with is to create a vision and
mission for the change initiative. Where do we want to go? How will we get there? This vision and mission is then
ratified by the group and should then be communicated to the larger organization.
The suggestion is to take time to practice, as a leadership team, conveying the message to each other. It is
expected that everybody will deliver the message slightly different using their stories, filters, and life experiences to
add the context to the vision. However, in the end the message received by the organization needs to be the same
regardless of the communicator or the communication style.
KEYWORD: CHANGE MANAGEMENT
plant engineering
September 2014 71
Plant Engineerings electronic newsletters

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latest trends in manufacturing in
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Plant engineers and managers
refer to these sources of
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IN NOVATIONS
Send new product releases to: peproducts@cfemedia.com
Air nozzle
Maraging steel electrodes

The two maraging steel electrodes, EutecTrode XHD
6860 and 6855XHD have high toughness levels at
maximum tensile strength, which are also much
appreciated in the Tool & Die manufacturing industry.
The electrode feature smooth, regular weld surface
requiring minimal machining, low temperature ageing treatment, which eliminates quenching defects
and distortion, retention of aged hardness up to
higher service temperatures, as well as good weldability without preheating for practical engineering
applications.
Castolin Eutectic
www.castolin.com
The EXAIR PEEK Pico

Super Air Nozzle
delivers a small blowoff
with an efficient, high
volume, high velocity
airflow. Its thermoplastic
construction provides
self-lubricating qualities
with a low coefficient
of friction to produce
non-marring protection
for sensitive materials.
It can withstand harsh
environments found in
chemical, plating, etching and metal cleaning processes and
thrives in seawater environments. Safe operation is assured
since the airflow cannot be blocked, which meets the OSHA
standard for dead-end pressure 29 CFR 1910.242(b). Sound
level is at 68 dBA and meets OSHA noise requirement 29
CFR 1910.95(a), as well as being CE compliant.
EXAIR Corp.
www.exair.com
Input #201 at www.plantengineering.com/information
Rugged rackmount server

The Wildcat 2U rugged rackmount server, optimized for high
meantime between failure, is based on the KTQ77/Flex motherboard. The Wildcat 2U rackmount server offers extended
temperature operation through efficient cooling. The design
features a front-accessible dust filter, cable tie downs, holddown brackets for expansion cards, and memory and shockmounted drive bays to ease transport. I/Os include 4x USB
3.0, 2x USB 2.0 and 3x Gigabit Ethernet ports. The system can
power up to three individual displays and supports HD audio.
The Wildcat 2U has three removable hard drives (2.5 in or 3.5 in) as well as a slim DVD +/-RW drive.
Kontron
www.kontron.com
PLANT ENGINEERING
September 2014 73
IN NOVATIONS
Compact parts cleaning and collection unit

The MiJet standaline unit cleans parts by capturing expensive coolants for
reuse. This unit captures chips for recycling while minimizing the risk of
workers inhaling coolant aerosol and having it settle on floors. One-touch
operation allows parts to be blown off and cleaned after machining, while
your machine continues to cut parts resulting in improved cycle time and
increased productivity. It can also be used at an inspection station to clean
off oily parts prior to inspection. Air is driven out a nozzle while vacuum suction simultaneously pulls the valuable coolant into the container.
MiJET
www.mijet.com
Serial interface converters

The SC-232 series converters feature
Send Data Control (SDC), which automatically enables the RS485 driver
when data is present on the RS-232
side. Additional features are port
power and Opto-isolation on some
models. Each converter ships with a
DB9 female to screw terminal block
adapter for connection flexibility. The
converters operate at temperatures 40
+ 85 C and have point to point 2-wire
half duplex support as well as point to
multi point 2-wire half duplex operation. The converter has port powered
options and Opto-solation options.
Ethernet redundancy device

The Ruggedcom RS950G is designed to operate reliably in harsh industrial environments such as power
generation and distribution, and for rail transport. The
RS950G meets the demands of the high-speed communications networks of the future by achieving a
transmission rate of 1 Gbps on HSR and PRP while
supporting future-oriented standards such as IEC
61850-3 and IEEE 1588.
Siemens
www.siemens.com
L-com
www.l-com.com
74 September 2014
PLANT ENGINEERING
Learn about the latest

engineering technologies
and applications from your
desktop or mobile device.
Check out some of our
Plant Engineering webcasts
on topics like
ARC FLASH
MANUFACTURING
SAFETY
ENERGY MANAGEMENT
and more
www.plantengineering.com/webcasts
IN NOVATIONS
Cable testers
The Scout Pro 2 is a multi-functional tester that tests voice, data, and video connections. It locates cable runs with location ID remotes, supports multiple tones to
decipher wires, and can measure cable length to a fault, on a reel or in a box. The
cable tester tests continuity on voice (RJ11/12), data (RJ45), and video (F-connector) connections. It locates cable runs to wall outlets with location ID remotes
and supports multiple tones and control of pins carrying tone with integrated tone
generator. The remotes can support multiple tones and control of pins carrying
tone with integrated tone generator. The remotes can test and identify up to eight
locations at once.
Klein Tools Inc.
www.kleintools.com
Drop in anchors
The Drop-In Anchors provide performance for applications such as anchoring sprinkler, HVAC, plumbing, electrical elements and suspended interior finishing elements.They have been redesigned with a new stepped plug, which requires
less impact energy to fully set the anchor. When using the HDI+ or HDI-L+ Drop-In Anchors fewer tools and less steps
are needed for installation which means saving up to 50% of the time it takes using traditional methods.
Hilti
www.ca.hilti.com
Pneumatic valves
The NITRA line of pneumatics products now includes additional directional
control solenoid valves available in a variety of configurations to meet a broad
range of pneumatic valve applications. There are now more valves choices in
size and volume with all the same features and benefits of the inexpensive and
popular existing valves. Configurations include: single solenoid, two-position and
double solenoid in two-position, three-position center closed, and three-position
center exhaust.
AutomationDirect
www.automationdirect.com
76 September 2014
PLANT ENGINEERING
PRODUCTMART
Why Should You
Filter Your Water?
Scale formation reduces the heat transfer rate and

increases the water pressure drop through the heat
exchanger and pipes. In fact, one study has shown
that .002" fouling will increase pumping needs by 20%.
The Best Engineered Water Filtering

Solution Always Costs Less
2 67 2 S . L a C i e n e g a B l v d . L o s A n g e l e s , C A 9 0 0 3 4 U S A
( 8 0 0 ) 3 3 6 - 194 2 ( 310 ) 8 3 9 - 2 8 2 8 F a x : ( 310 ) 8 3 9 - 6 87 8
w w w. t e k l e e n . c o m
info@tekleen.com
3.5" wide x 4.5" high
Ti400
OIL MIST & SMOKE

Pantone
382cSHOP?
IN YOUR
PRO SERIES
www.mistcollectors.com
Tel: 1-800-645-4174
The Fluke Ti400

is equipped with
LaserSharp Auto
Focus for consistently
in-focus images.
Every. Single. Time.
CFE Medias Apps for Engineers is a free

interactive directory of more than 170 engineeringrelated applications for Android and iOS
operating systems. This app of apps contains links
to more than 170 different mobile applications.
For more information visit our Interactive Media Kit:
mediakit.cfemedia.com

201311cfe_app4Eng_hlfHZ.indd 1
11/19/2013 5:32:58 PM
PLANT ENGINEERING
September 2014 77
For more information on how to advertise in Plant EnginEErings

Internet Connection, call Jim Langhenry at 630-571-4070 x2203
adalet.com
flexicon.com
movincool.com
Manufacturing explosion proof enclosures, ATEX enclosures and electrical enclosures for over 80 years.
Adalet
Flexicon designs and manufactures bulk handling equipment and custom-engineered and integrated plant-wide
systems.
Flexicon Corp.
The MovinCool division of DENSO has been responsible

for pioneering the use of portable air conditioning solutions for a wide variety of U.S. markets since 1982.
MovinCool
aggreko.com
Aggreko is a global leader in generator rental, providing
efficient and cost effective industrial generators and power
distribution.
Aggreko plc
flir.com
orival.com
FLIR Systems designs, develops, manufactures, markets, and distributes thermal imaging infrared cameras.
FLIR Systems Inc.
Orival is a leading manufacturer of self-cleaning water

filters, automatic water filters and strainers, for use as
industrial water filters, irrigation filters, cooling tower filters, and more.
Orival Inc.
alliedelec.com
fluke.com
Allied Electronics is a small order, high service level distributor of electronic components and electromechanical
products with over 50 sales offices across North America.
Allied Electronics
Fluke is the world leader in the manufacture, distribution,

and service of electronic test tools and software.
Fluke Corp.
atlascopco.us
Gardner Denver is a global manufacturer of industrial

compressors, blowers, pumps, loading arms, and fuel
systems.
Gardner Denver Inc.
Atlas Copco produces and markets compressed air equipment and generators, construction and mining equipment,
industrial tools, assembly systems, services and rentals.
Atlas Copco
automationdirect.com
AutomationDirect offers 6,500+ industrial automation products through their free catalog and online store, including
PLCs, operator interfaces, sensors, and more.
AutomationDirect
gardnerdenver.com
greenheck.com
Greenheck is a leading supplier of air movement and control equipment, including fans, dampers, louvers, kitchen
ventilation hoods, and energy recovery and make-up air
units.
Greenheck Fan Corp.
baldor.com
hyster.com
Baldor Electric designs, manufacturers, and markets a

broad line of industrial energy-efficient electric motors,
mechanical power transmission products, and more.
Baldor Electric Co.
Hyster offers a comprehensive range of warehousing

equipment, industrial lift trucks, container handlers and
reach stackers as well as quality material handling parts.
Hyster Co.
bimba.com
idc-usa.com
Bimba Manufacturing provides pneumatic, hydraulic and

electric solutions, including a variety of stainless steel body
air cylinders that are easy-to-use and reliable.
Bimba Manufacturing Co.
IDC-USA is a growing cooperative with a rich history of

helping independent distributors remain competitive on a
national level within a free enterprise system.
IDC-USA
camfilfarr.com
us.kaeser.com
Camfil Farr is the worlds largest and leading manufacturer of filters and clean air solutions.
Camfil Farr
Manufacturer of air system products, including rotary

screw compressors, portable compressors, rotary lobe
blowers, vacuum packages, refrigerated and desiccant
dryers, filters, and condensate management systems.
Kaeser Compressors Inc.
distanceissafety.com
CBS ArcSafe remote racking systems increase safety.
Rack low- and medium-voltage draw-out circuit breakers
while standing outside the arc-flash hazard protection
boundary.
CBS ArcSafe Inc.
donaldson.com
Compressed air purifications solutions, compressed air
filters, dryers and process water chillers.
Donaldson Company Inc.
erectastep.com
Modular work platforms and aluminum stairs pre-engineered for unlimited configurations. Platforms and metal
steps bolts together with no fabrication required and are
easily repurposeable.
ErectaStep
exair.com
Exairs product line includes Vortex Tubes and products
utilizing Vortex Tubes, Air Amplifiers, Air Knives, air-operated vacuums and ionizing products for static elimination.
Exair Corp.
78 September 2014
plant engineering
keysight.com
Keysight Technologies is an electronic measurement
company that offers wireless, modular, and software solutions.
Keysight Technologies Inc.
lubriplate.com
Lubriplate manufactures more than 200 high quality lubricants, including high performance synthetic lubricants
and NSF-H1 lubricants for food processing and beverage.
Lubriplate Lubricants Co.
mobilindustrial.com
ridgid.com
Every tool that bears the RIDGID brand is engineered to
the same high standards of quality, strength, and endurance as was the first heavy-duty pipe wrench.
RIDGID
rogers-machinery.com
Manufacturer of rotary screw and reciprocating air compressors, fixed and variable speed drives, rotary and
centrifugal compressors, blowers, and vacuum systems.
Rogers Machinery
rosler.us
The Rosler group supplies surface finishing equipment
and consumables. Products include mass finishing and
show blast equipment, wastewater treatment systems,
and compounds for mass finishing.
Rosler Metal Finishing USA
rotronic-usa.com
Rotronic offers a comprehensive line of reliable humidity probes, indicators, meters, data loggers, and fixed
installed transmitters.
Rotronic Instrument Corp.
seweurodrive.com
One of the largest global suppliers of drive technology,
SEW-EURODRIVE specializes in gear reducers, motors
and electronic motor controls.
SEW-EURODRIVE USA
spminstrument.com
SPM offers a wide product range from high-tech portable instruments to online systems and a comprehensive software.
SPM
sullair.com
Sullair is a designer and manufacturer of stationary and
portable rotary screw air compressors, air treatment
equipment, and pneumatic tools.
Sullair
yaskawa.com
Yaskawa is the worlds largest manufacturer of ac inverter
drives, servo and motion control, and robotics automation systems.
Yaskawa America Inc.
Mobil Industrial Lubricants offers premium quality synthetic and mineral grade oils and greases to the industrial
market. Additionally, we support our products with a full
slate of expertise services.
Mobil Industrial Lubricants
Place next to your computer or go online to www.plantengineering.com for hot links to these companies.
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er 201
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m
e
Sept
CONTACTS
Advertiser Contacts for plant engineers
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www.adalet.com
IDC-USA
866-575-2025
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216-267-9000
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Aggreko LLC
866-215-7966
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Allied Electronics
800-433-5700
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Atlas Copco Compressors

866-688-9611
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800-633-0405
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800-442-4622
Camfil Air Pollution Control
800-479-6801
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888-878-1839
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Orival, Inc
800-567-9767
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www.ErectAStep.com
www.flexicon.com
www.flir.com/seespotrun
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PLANT ENGINEERING
September 2014 79
INCONCLUSION
Time to take a chance on this next generation
Bob Vavra
Content Manager
Unless they can
throw a football
or dunk a basketball, we dont take
chance on young
people, especially
in manufacturing.
We dont train the
next generation the
way we used to, and
we dont pay for
potential the way we
should.
80 September 2014
he concept of planned obsolescence

has been part of the American manufacturing discussion since the 1920s.
In the consumer-driven years of the
1950s and 1960s, it seemed every
product, every year was new and improved.
From cars to detergent to electronics, we want
the latest and greatest, the most cutting-edge
technology we can get.
Except when it comes to people.
Unless they can throw a football or dunk
a basketball, we dont take chance on young
people, especially in manufacturing. We dont
train the next generation the way we used to,
and we dont pay for potential the way we
should. Younger workers today have a decidedly different skill set, and a different life
experience. Theres much debate about training techniques and relating to a plugged-in
and tuned-out generation. For those of who
in my generation who have forgotten, they
said the same thing about us.
The difference was that we got a chance
to prove out mettle. Employers were more
willing to experiment with workers, to look
for potential beyond a resume or an education. In valuing a college education, we have
forgotten to equally value skills that do not
translate into a college degree. We have forced
some round pegs into some square holes, and
with inconsistent success.
To re-energize our recruitment and training efforts to plug the massive and growing
manufacturing skills gap, we cannot count on
these young people to find us. We cannot count
on the old ways and the old techniques. Were
going to have to create a new set of incentives
and a new sense of possibilities.
Above all, were going to have to take a
chance on this new generation of workers and,
as it was for us, build training and education
into those goals. We have to show workers a
path to successpersonal, financial, and business. We have to equate work in manufacturing
with creating something permanent.
The problem with planned obsolescence is
that its primary tenet is that nothing is permanent. While thats certainly true, nobody goes
into a manufacturing plant with the idea that
what they make will break someday. Indeed,
some of our best manufacturers are realizing
that many of their products have survived
PLANT ENGINEERING
and remained useful from the prior century

well into the current one.
The PLC has become more sophisticated
in its design and function, but its still programmable logic, and its still control. It
may be new and improved but we havent
really improved the foundation on which it
is built. Were just using more 0s and 1s.
Motors power our lives, even if they are powered with electricity or LNG. Inclines help
us defeat gravity.
There are a few things we havent really
improved on. A screwdriver can be batterypowered today, but you can still turn the
manual one and get the screw to stay in place.
The same holds true for a hammerbut as the
old saying goes, if all you have is a hammer,
every problem is a nail.
What we do well today is in adapting and
improving our machines so that we have
something for every kind of problema hammer for every nail, if you will. Why havent
we been able to do the same for the people
who wield these new and amazing tools?
The problems are getting solved in small
ways in individual regions. Smart people
have not just recognized the problem, but
are devising solutions that explain the value
of a manufacturing career today and in the
future, demonstrate the skills needed to
achieve in that career, offer a path to personal, professional and financial reward,
and provide the training and support in order
for the individual and the manufacturer to
achieve those rewards.
All that is happening, but it is happening
on too small a scale, and much too slowly. We
have been at this nexus for too long now. The
huge gains we have made as a manufacturing
industry, and a manufacturing economy, are
threatened by the glacial pace of resolving
this fundamental issue. Our only salvation at
this time is that most of the rest of the world
has the same issue.
It starts, though, with the people. We dont
need new and improved people. We need a
new and improved process to recruit, train, and
retain people. I think we will find that these
young people are worth taking a chance on.
And if we dont, we at least ought to
remember that someone was willing to take
a chance on us. PE
VISIT US AT IMTS
BOOTH N-6600
YOULL LOVE WHAT WE DO FOR YOU.

Weve been passionate about automation for nearly 100 years.
With such a rich history of innovation and industry leadership, its no wonder
Yaskawa Motoman WELDING SOLUTIONS are delivering unmatched benefits
for customers who demand application flexibility and increased efficiency,
while boosting productivity and ROI.
300,000+ industrial robots, 18,000,000 inverter drives and
10,000,000 servos installed worldwide
Global network of integration partners with the experience
to support any application in any industry
MOTOMAN ROBOTICS DIVISION
Comprehensive line of arc welding robots, work piece positioners,

welding power sources, spot welding robots, integrated spot harnesses
and servo-controlled spot guns
Pre-engineered, versatile ArcWorld, FabWorld and SpotWorld solutions
DRIVES & MOTION DIVISION
High bandwidth and advanced tuning algorithms of our AC servo

and spindle products help machine builders achieve high
cutting speeds, reduced following error, and mirror-like finishes
for vertical milling, grinding, plasma, waterjet and
laser cutting machines.
GLOBAL EXPERTISE SPANNING DIVERSE INDUSTRIES,

MARKETS AND APPLICATIONS.
YA S K A W A A M E R I C A , I N C .
1 - 8 0 0 - YA S K A W A | YA S K A W A . C O M
For more info:
http://Ez.com/yai670
Learn how our automation solutions

can help solve your toughest
manufacturing challenges.
FEATURING
DX200 with
FUNCTIONAL SAFETY UNIT
Improve safety and
reduce floorspace requirements.
ULTRASONIC
ROBOTIC TRIMMING
New alternative to waterjet cutting
with easy clean-up for non-metal
trimming, routing and deburring.
KINETIQ TEACHING
Enables job shops to easily
implement robotic welding with
minimal programming experience.
MPIEC CONTROLLERS
Single to 62-axis controllers adhering
to IEC61131-3 and PLCopen global
programming standards
Industry Tested
Whether you power fans, dryers, compressed air...any industrial

air handling system, Baldor provides the most extensive line
of motors, bearings, speed reducers, couplings, pulleys and
mechanical drive components for the air handling industry.
And, with specialists offering decades of air handling industry
application experience, machine designers and air handling
pros across North America rely on energy efficient, optimum
lifecycle products and experts from Baldor to keep their
operation up and running.
Tested in the field and proven to excel in the most demanding
conditions, you can count on Baldor people and products to
deliver the service, performance and reliability you expectday
in and day out.
baldor.com
479-646-4711
2014 Baldor Electric Company

Plant Engineering Sep14

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27 Meet the 2014 Engineering Leaders Under 40

Its easy to be a PRO at

Productivity3000 programmable controller

Easy DAQ or SCADA with flexible

Use the technology built into the Productivity3000 programmable controller to

Monitor data by type

View Event and Error

Choose one approach, or all - its that flexible.

Order Today, Ships Today!

Research, price, buy at:

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As our second president, John Adams focused

Its a fact: Compressed air is inherently inefficient.

Our 25-125 hp compressors feature true direct drive design,

Kaeser Compressors, Inc. 866-516-6888 kaeser.com/PE

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LASER & PLASMA CUTTING

Farr Gold Series

Industrial Dust Collector

Chop Saw Dust

Laser Cutting Smoke

Thermal Spray Dust

LOOKS LIKE A SAFE BECAUSE ITS

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Jennifer Wafalosky, N. Central JWafalosky@CFEMedia.com

Jerry Preston, West Coast

Stuart Smith, International

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The industrys best research

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Cooling a roll with 20F

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Effectiveness Only a Major

The Lead Flexicon Project Manager

Engineering teams on four continents

As one of the worlds largest manufacturers

Strict adherence to your unique standards,

Over 20,000 bulk handling installations

Commitment to the successful performance

Ability to work with the engineering firm

Greater efficiency and control than available

2014 Workforce Development Study: 6 key findings

Worker development can focus on partners and employees

Smart business leaders know that to

educational and development programs

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