Successfully managing large and complex integration projects is a focus for Polytron Inc., and the company is looking to continue to grow the digital manufacturing presence. Ron Rich, CEO of Polytron. discusses his company’s philosophy and its approach to innovation in an interview with CFE Media.
Posts by Betsy Brannen:
- CEO Insights
- Digital Transformation
- Emulation & Virtual Commissioning
- Industrial Network and Security
- Manufacturing Intelligence
- News & Events
- Project Management
- The Future of Manufacturing
- Workforce Development and Training
Duluth, Georgia – December 5, 2018 – Polytron, Inc. today announced the promotion of Richard Phillips, PE, PMP to Director of Polytron’s Smart Manufacturing and Digital Transformation Group. Richard has been acting as the practice lead over the past several years providing guidance and thought leadership to Polytron’s manufacturing clients that are embarking on their Digital Transformation journeys. As Director of the Smart Manufacturing and Digital Transformation Group, Richard will report directly to Polytron’s CEO, Ron Rich, in order to provide the agility required to effectively address this rapidly growing segment. READ MORE
Duluth, GA – 17 October 2016 – Polytron, Inc., a leading engineering consultancy and systems integration firm based in Duluth, Georgia, proudly announces that Lynn Moriarty, PE, CAP, Project Lead has earned his ISA 99/ IEC 62443 Cybersecurity Fundamentals Specialist Certification. The ISA Cybersecurity Fundamental Specialist Certification deepens Lynn’s expertise to provide solutions appropriate to SCADA and plant floor environments. Lynn has over twenty years of engineering experience providing industrial automation, systems integration and electrical engineering services to the food and beverage, consumer products, pharmaceutical and automotive industries. The increase in the exposure and cybersecurity threats to the SCADA and process control networks demand that manufacturers protect critical control systems. The ISA Cybersecurity certification provides Polyton’s clients with solutions for advanced SCADA protection through Risk Analysis and building the business case for industrial security.
The ISA Certification includes Security for Industrial Automation and Control Systems standards: ANSI/ISA-62443-1-1 (ANSI/ISA-99.00.01-2007), ANSI/ISA-62443-2-1 (ANSI/ISA-99.02.01-2009), ANSI/ISA-62443-3-3; Security for industrial automation and control systems; System security requirements and security levels. Full Press Release
Even with a highly complex installation, our manufacturers get to market in about half the time that they originally planned. Such a tall claim is a good reason for suspicion, but that’s not all. Our solution doesn’t just expedite projects, it also requires half the effort and half the cost.
One Word: Emulation
The single best way to manage risk and eliminate unknowns is to emulate your new controls virtually prior to installation. Emulation lets you troubleshoot and perfect new solutions in a safe digital environment. With emulation, you will:
- Slash time and expense associated with new installations.
- Train operators and maintenance in real time with maximum learning and minimum fear.
- Test multiple scenarios without wasting materials.
- Turn traditional field-testing on its head by debugging before you deploy.
The possibilities are endless. For example, you can test a long term production forecast on your finished goods handling system today, and compare them to new package sizes or formats with no wasted time and product. As you watch various scenarios unfold you can identify and resolve issues before they actually occur.
Emulation is a simple, three-step process:
- Test everything in-house on the PolySim model.
- Make adjustments.
- Conduct a final Factory Acceptance Test.
By the time of installation, 95% of debugging and verification process is complete. Your line will run at full capacity prior to your original deadline.
How PolySimSM Emulation Works
PolySim is a technology model that interacts with an existing PLC program controlling the line. The PLC appears to be running the line while in fact, it’s just a perfect “emulation” of the line—a digital clone. The PLC reads the input from this dynamic model and directs the outputs in the model according to the logic. The interaction allows you and your team to verify the logic, confirming that the line will in fact operate as you intend it to. As well, the HMI can be linked to the PLC to verify all operator controls, alarms and annunciators.
“I’d never do another project without it.”
You can’t predict the success of a line change or acquisition, but you can gain more insight. As an early and successful adopter of PolySimSM Emulation, Polytron has helped diverse manufacturers use it to grow without the guesswork. Take the guesswork out of your new line by giving us a call today.
This article is based on our free ebook, What Manufacturers Should Know About the Industrial Internet of Things.
As one generation of machine operators prepares for retirement, manufacturers face the increasingly difficult task of preparing their replacements. We know training is a necessity, but it’s also costly and time consuming. Even then, the end results aren’t always guaranteed.
A component of the problem is in manufacturers’ training structure itself. Training and practical experience are clearly two different things, but now, we can build training tools directly into the line so that the workforce can learn as they do. When manufacturers align their training programs with what’s needed on the plant floor, they achieve improved operational efficiency faster and more affordably.
To analyze a training program, you start with documentation. Manufacturers need to document the existing knowledge so that line operators in training receive the right information at the right time. Through documentation and analysis, manufacturers can create the alignment necessary for the proper execution of a training program.
High operational performance rests on line operators’ abilities to make informed decisions. Informed decisions need information that is concise and timely. After knowledge is gathered and analyzed, organizing the information in a way that makes sense for line operators in training is imperative.
The last step in the process is where the analog process of gathering and organizing information meet the high tech process of presenting information. Technology Transfer and Training delivery tools ensure a knowledgeable workforce, such as:
- Job Aids or placards at the point of use
- HMI embedded process documentation
- Near-field technology to deliver information when device is approached
- Wireless and handheld devices with knowledge-based data references
- Computer-based training aids with validation
Operators and technicians can deliver high operational performance when they have everything they need to do a job “at their fingertips.” To learn more about What Manufacturers Should Know About the Industrial Internet of Things, click to download our free eBook.