IEN: How are manufacturers using existing technologies in new ways?
Moldoveanu: One of the most relevant paradigm changes is related to the fact that once the I/Os are out of the picture in a PLC base control and automation system, all the devices left are actually very similar. They all contain a microprocessor-based controller, a power supply, a communication card and an enclosure. Under the circumstances why not combine as many as reasonable under one hood, beef up the controller and unify the software? This is exactly what Nematron has done.
And what better place to lodge all the equipment than the HMI? It is there where the operator needs it, collects and processes all information related to the machine or installation and provides useful information "upstairs." Since the unit does a lot more than its predecessors do we are calling it Control and Information Station, with a heavy accent on the information, truly the new significant benefit of the technology. Nematron was in the best position to observe the trend and take advantage of it as a pioneer of the operator station about 15 years ago.
In effect the technology was there for some time. However, improvements in both microprocessor raw power as well as in software are only now making this approach economically attractive.
IEN: What are the major concerns facing this sector in the next few years?
Moldoveanu: The HMI function will become increasingly integrated in the control, SCADA and MES emerging conglomerate. As such it will have to obey several masters. One is the machine operator: he needs simply to understand and use graphics, the ability to change simple configurations without penalty, and quick linkage to the control software. The other is the plant management and engineering. They need sophisticated tools to represent complex relationships at the machine/installation level. As an MES server and a factory floor network node, a Control and Information Station will need to represent also complex factory level realities. Juggling these opposite requests and reducing the overall cost will be an increasingly challenging task for HMI and Control and Information Station vendors.
IEN:What innovations are in store for users?
Moldoveanu: The big one we have already seen is the integration of multiple functionalities in the Control and Information Stations. The Windows support environment adds a tremendous value in that it helps integrating the HMI in the overall automation scheme. Just one example illustrates this trend handsomely: ActiveX components. Using them one can create very fast complex graphical systems and link them to plant variables, most times using no scripting at all. ActiveX objects are available on the Web for anyone who values their time.
IEN: How are software and equipment being integrated in today''s HMI/MMI world?
Moldoveanu: As mentioned above, Nematron has pioneered the Control and Information Station concept that essentially packages in an industrial grade panel HMI enclosure the following software functions: real time Windows extension (HyperKernel), logic control (OpenControl), HMI and SCADA (Paragon). Having the whole development system under the same software platform saves customers significant design time since only one database is used and the data is shared through a simple system architecture.
IEN: Are we entering a new era of E-manufacturing?
Moldoveanu: No question about it. The Supply Chain Management is in principle responsible for this. By fostering cooperation between various enterprises it forces a real time assessment of the materials and resources available to be made in order for it to deliver its substantial cost reduction promises. This in turn requires manufacturers to go down to the machine level on a real time basis. The machine has to be able to process the raw information it gets from field devices and operator input. It also needs to be able to keep the operator involved in the automation process that sometimes is invisible to him. All these trends are forcing plant management to reconsider automation strategies in favor of a lean architecture capable of delivering information reliably controlling the process.
IEN: How will the drive toward lean manufacturing impact this sector?
Moldoveanu:One of the best examples in this direction is the fact that one of our major customers, GM Powertrain division, used Nematron''s Control and Information Stations to run several complete manufacturing lines. GMPT is one of the most advanced promoters of lean architecture solutions leading to substantial savings both in the design phase but especially in production. One of the strongest benefits of the information processing capabilities residing in the software is troubleshooting. The intuitive graphical control language points easily to the default and can guide the operator or the maintenance personnel, sometimes using photos or drawings, to the solution. It can also alert specific trades if more elaborate servicing is required. It can help pinpoint the warehouse storing the replacement for the defective part.