We can expect more progress on this topic in 2013. Even though the concept of standardizing machine user interfaces seems straightforward and easy, it really is an area that defies standardization. Especially in a packaging line, individual cells and operations have distinctly different needs. So it will be interesting to keep an eye on the work of the OMAC Packaging Workgroup this year.
The overlap between these two trends -- baby boomer retirement and lower-skilled operators taking over plant functions -- may be opportunisitic. If the baby boomers are retiring, it's a good time to switch from an engineer to an operator.
Ann, I think the trend here is younger, less technically educated operators rather than engineers being replaced by younger engineers. With the level of automation in some plants, even fewer operators are required. This movement is toward integrating training resources (ready access to documentation, training videos and more) from the HMI itself. That enables more self-teaching, and innovative use of machine animations which can "show" how to perform a maintenance task, for example, versus reading a series of steps. This type of animation using 3D models is still expensive to develop but doesn't seem beyond reach in the not-too-distant future. Some automation vendors are moving in this direction but getting photo-realistics 3D animation is still in the future. Great to see how things are moving ahead in this area.
The new thing here is the standardization of HMIs screens to a common look and feel. OEM machinery builders, apart from the packaging industry, might resist this just because the operator interface is a clear part of the value added of the machine. It will be interesting to see how widely this is adopted, especially adding the functionality of changing system parameters directly from the HMI (versus using the automation vendor's computer tools). Overall, the operator interface is going through a significant transformation with lower cost, much more capable hardware and now also touchscreens joining in. Should be interesting to see how it develops toward becoming more of a "Dashboard" for machines.
Yes, Ann, I was under the impression the shift from baby boomers to younger workers is still within the community of engineering. But maybe not. Maybe they're replacing the boomer engineers with non-engineers. I would make an interesting article.
Interesting, Rob. I hadn't connected the dots between the baby boomer retiring trend and younger workers with the cost-cutting trend of using less expensive operators instead of engineers on the factory floor. I'm not sure they're the same thing. First, the engineer vs operator trend is usually described as being due to improved HMI, as we were originally discussing. Plus, isn't the first trend occurring mostly within engineering?
I guess that shouldn't be surprising, Ann. This could be part of the trend of replacing the baby-boomer engineers at plants. As the boomers retire, I hear they are being replaced by younger workers who have less automation and control experience, but more computer experience, which is mostly appropriate given the changing nature of automation. And of course they would be lower-cost workers simply because of their youth and inexperience.
The decision-making can shift to lower-cost operators because they're making fewer decisions--and more low-level ones--as more functions get automated. This is by no means the case everywhere, but it's yet another cost-cutting trend. That's what I've heard, anyway.
New versions of BASF's Ecovio line are both compostable and designed for either injection molding or thermoforming. These combinations are becoming more common for the single-use bioplastics used in food service and food packaging applications, but are still not widely available.
For industrial control applications, or even a simple assembly line, that machine can go almost 24/7 without a break. But what happens when the task is a little more complex? That’s where the “smart” machine would come in. The smart machine is one that has some simple (or complex in some cases) processing capability to be able to adapt to changing conditions. Such machines are suited for a host of applications, including automotive, aerospace, defense, medical, computers and electronics, telecommunications, consumer goods, and so on. This radio show will show what’s possible with smart machines, and what tradeoffs need to be made to implement such a solution.