IEN: How can/will vendors address concerns related to robustness, open protocols, and flexibility?

Berner: Vendors will utilize Ethernet much more in the future. It allows the most flexible and robust solution for I/O and communications. It is the least expensive technology, and is being improved at such a rate that nothing else I see on the horizon will outperform Ethernet in either the price or performance arena.

IEN: What advances do you see in plant floor connectivity, web services?

Berner: I see advances in the area of connectivity on the plant floor incorporating HTML capability that is very cost effective within the next year. We are developing a product right now at Ramco Innovations that will provide this solution to the customer. There are already some solutions on the market [with] a very expensive price tag, but this price will be decreasing greatly over the next two years.

IEN: Will wireless become more prevalent?

Berner: Wireless will become much more prevalent in automation products as the cost for the technologies decreases. I expect to see wireless capability built into a product such as a PLC or motion controller within the next 1-2 years.

IEN: Will remote monitoring of key manufacturing / processing operations take hold?

Berner: Yes! More and more automation users will be incorporating remote monitoring. Users will be able to monitor information such as production levels and order status via their cell phones. This capability will be coming on strong in the next 3-5 years.

IEN: Where are other R & D hot spots?

Berner: I see hot spots being in the standard arena of decreased size and increased functionality. I also see an increase of controllers that will utilize Linux or Windows CE (.Net) as an operating system.

IEN: How can security issues be resolved?

Berner: Software components are becoming available that allow tight firewalls and the ability to securely pass data back and forth at reasonable speeds through these firewalls. This will not be developed in the automation market. Automation venders will work with off-the-shelf software products to perform this function.

IEN: In what ways can companies design integrated systems to insure maximum lean/flexible manufacturing?

Berner: Companies can accomplish this task by using control products that are Microsoft friendly; products that will easily hook up with SQL and other database software; products that can be programmed with VB or VC+. Companies will need to stop hiring programmers who know PLC language and start hiring programmers who know VB, VC+ and other PC languages. Companies will need to have programmers who provide easy to understand pop-up screens for their maintenance staff, and they will have to keep their maintenance staff out of their controllers. The guy with a hammer and a crowbar should not be messing around inside the brain of a $250,000 to $5,000,000 machine

IEN: How much progress do you see toward tying together the plant floor with the overall enterprise?

Berner: The companies that are successful in the future will obtain this goal, as it is a necessity. They will have to hire key management personnel who can communicate to engineering, production, and IT, and the complete task of these persons will be to put in place a strategy and personnel who can obtain the goal. It will be key that they put in place the appropriate personnel who understand the goal and how to get there. They have to invest the money to modernize, and if done right they will reap the rewards.

IEN: Given the sophistication of technology, how can companies maintain legacy equipment as a part of integrated systems, in the spirit of lean enterprise?

Berner: The customer can seek out companies who specialize in upgrading legacy equipment. These machines don't need to be thrown out: they can be upgraded to fit the company's strategy for far less than the purchase of a new machine.