Automation made easy : everything you wanted to know about automation and need to ask

235 Pages·2010·5.289 MB·English

by  Hale, Gregory, Martin, Peter

Automation Made Easy
Everything You
Wanted to Know
about Automation––
and Need to Ask

Automation Made Easy
Everything You
Wanted to Know
about Automation––
and Need to Ask
Peter G. Martin and Gregory Hale
Ebook ISBN: 978-1-937560-11-9 PDF ISBN: 978-1-937560-73-7
I dedicate this book to my best friend, love, and wife – Liz, and to my children,
Derek and Erin, their spouses, Jennifer and David, and
my beautiful granddaughter Karly. I love you all!
—Peter Martin
There comes a time when a person understands you just don’t want to go
through life alone. I came to that realization almost 30 years ago when I met
my wife, Sharon, and that sense became even stronger with my children,
Lindsay and Chris. While I seriously doubt they will ever read it, I dedicate this
book to Sharon, Lindsay, and Chris. In their own inimitable way, they make it
easy for me to strive to be a better person every day. Thank you.
—Greg (a.k.a. Dad)

Contents
About the Authors ................................................ ix
Acknowledgments ................................................ xi
Preface ..................................................... xiii
Chapter 1 Manufacturing and Production Processes: The Raw Facts .......... 1
Chapter 2 Control of Discrete Processes .............................. 13
Chapter 3 Control of Continuous Processes: Stay In the Loop .............. 21
Chapter 4 Process Control Systems: A Theory of Evolution ................ 35
Chapter 5 Control of Batch Processes: Let Them Eat Cake ................. 49
Chapter 6 Advanced Process Control: Beauty Beats the Beast .............. 59
Chapter 7 Optimization: Math Gone Wild ............................. 67
Chapter 8 Simulation and Modeling: A Look Before You Leap . . . . . . . . . . . . . . 77
Chapter 9 Safety Management Systems: Expect the Unexpected ........... 83
Chapter 10 Automation System Security: Checkmate ..................... 89
Chapter 11 SCADA Systems: Beyond Four Walls ......................... 97
Chapter 12 Quality Management: A Tale of Two Processes ................ 101
Chapter 13 Asset Management—
Maintenance Management: Coming of Age .................. 109
viii Automation Made Easy
Chapter 14 Human-Machine Interfacing—
SCADA Software: Breaking Away from a DCS ................ 117
Chapter 15 Manufacturing Execution Systems: Two Becoming One ......... 123
Chapter 16 Enterprise Resource Planning: Business Software
on Top of Automation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Chapter 17 Automation System Integration: Enabling the Right Solution ..... 137
Chapter 18 Business Measurement and Intelligence Systems:
Real-Time Knowledge ................................... 147
Chapter 19 Operations Business Excellence: A New Frontier ............... 157
Chapter 20 Enterprise Control Systems: Grabbing the Technology Edge ...... 169
Chapter 21 The Bottom Line: Automation’s Business Impact ............... 177
Glossary of Terms ............................................... 185
Bibliography .................................................... 207
Index .................................................... 217
About the Authors
Peter Martin has worked in industrial automation for more than 30 years in a variety
of roles, primarily with Invensys, although he also worked at Automation Research
Corporation (ARC). He was named one of the 50 most influential innovators in
control and automation by InTech magazine and as a Hero of U.S. Manufacturing by
Fortune for his work in real-time performance measurement and management, for
which he also holds multiple patents. He has authored two other books, Bottom-
Line Automation (ISA) and Dynamic Performance Management: A Pathway to World
Class Manufacturing (Van Nostrand Reinhold), and is a contributing author to A
Guide to the Automation Body of Knowledge (ISA) and Metrics that Matter (MESA).
Dr. Martin has also published numerous papers and articles in the area of industrial
automation. He holds a BA and an MS in Mathematics, an MA in Administration
and Management, a Master of Biblical Studies, a Doctor of Engineering in Industrial
Engineering, and a Ph.D in Biblical Studies.
Gregory Hale is the editor of InTech magazine, the official publication of the
International Society of Automation. Prior to starting at InTech in 1999, Hale was the
editor in chief at Post-Newsweek’s Reseller Management magazine. His extensive
editorial, web, and management experience includes executive editorial positions with
CMP’s Computer Reseller News and Tour & Travel News, the Times Herald-Record
(Middletown, NY), The Knickerbocker News (Albany, NY), The Boston Globe, and
various other New England newspapers.