Automation in Industry The People make the Difference!

Steve HuffmanVice President, Mead O’Brien, Inc. St. Louis, MOChairman, Gov’t Relations, Automation Federation

Do you ever think about helping to solve the biggest challenges our world faces?

People are the value proposition, as they have been forever.

What are the World’s biggest challenges?

Energy Water Food Environment Health Chemicals Minerals Material goods

A career in industrial automation will be a career designed to help meet and solve

these daunting challenges!

In order to see the future, one must recall the past and how we got here.

History of The Value of People in Industry

1. Era 1 - Early manufacturing

2. Era 2 - Industrialization

3. Era 3 - Automation

4. Era 4 - Technology

5. Era 5 - Empowerment

The Earliest Industries

People were the heart of the business

Manager

Miller

Buyer

Sales

Marketing

Maintenance

Role and Value of People

1. Era 1 - Early manufacturing

2. Era 2 - Industrialization

3. Era 3 - Automation

4. Era 4 - Technology

5. Era 5 - Empowerment

Exponential Increase in Complexity

Specialization

Shippingg

Buyer

Sales

Maintenance

Management

Operations

Accounting

Engineering

InstrumentValve

Controller Desired value --- Set point

Process Measurement

Process

People were in Control!

Mission – Safely increase efficiency

Role and Value of People

1. Era 1 - Early manufacturing

2. Era 2 - Industrialization

3. Era 3 - Automation

4. Era 4 - Technology

5. Era 5 - Empowerment

Fewer Operators – Broader View

Becoming Information Craftsmen

“They replaced me with a controller”

Solution Perspective

Challenge Solution Technology enabler Talent

Role and Value of People

1. Era 1 - Early manufacturing

2. Era 2 - Industrialization

3. Era 3 - Automation

4. Era 4 - Technology

5. Era 5 - Empowerment

A Change in Perspective Occurred

New TechnologyFind a Problem

From

To

Challenge What Is the Solution? Technology enabler

Throw Technology at It!

CIM

Lights-Out

SPC-SQC

E-Manufacturing.com

Expert Systems

3D Graphics

Object Orientation

ArtificialIntelligence

Fieldbus Intelligent Instruments

Dashboards OPC

Internet

Technology has great value –only if applied to solve a problem!!!

MAP

Scorecards

Client-Server

6s

Pixel Resolution

Bandwidth

Ethernet

Executive Concerns

Experience drain – Graying of workforce

Difficult to attract/retain high performing staff

Engaging the employees in the business

Helping employees understand their value

Attracting new employees

Real-time is the final frontier

STRATEGY

EXECUTION

QuartersMonthsWeeks

.

.

.Hours

MinutesSeconds

Right MarketsRight CustomersRight Suppliers

Right Profits...

Right QualityRight LocationRight Quantity

Right CostRight Product Mix

.

.

.Right Temperature

Right ChemistryRight Energy Cost, Etc.

Production Control

BusinessControl

ProcessControl

Conquering the Real-time frontier

Reliability, Cyber Security, Sustainability,… to name a few

Reliability…“Top performing plants spend an average of 1.4% on maintenance. A $1 billion plant = $14 million whereas poorly performing plants spend 3.5 times more = 49 million!”

R. DiStefano, Reliability Consultant, Emerson

Cybersecurity….“If an industrial control system or criticalinfrastructure is attacked, or even unintentionally compromised, the result could include regulatory violations, equipment damage, production loss, harm to the environment, and even public endangerment.”

S. Huffman, Automation Federation

Sustainability….Meeting the needs of the present without compromising the ability of future generations to meet their own needs.

Automation Competency Model, USDOL

Why Empowerment – a time problem!

When You Can Control – DoWhen You Cannot Control - Manage

Management(Transactional)

Control(Real Time)

Efficiency

Profit

AssetQuality

Environmental

Safety

Efficiency

ProfitAsset

QualityEnvironmental

Safety

1990 2015

Enterprise Control principles

Operationscontrol

Businesscontrol

Process control

STRATEGY

EXECUTION

Optimizing Profitability and Efficiency

Production VolumeEnergy Consumption

Materials Consumption

Process Control

Process Empowerment

ProcessMeasurement

BusinessControl

BusinessEmpowerment

BusinessMeasurement

Plant

Business

Enterprise

$

Cascade of Operational Performance “Loops”

Industrial Plant

ProcessControl

AdvancedControl

PlantBusinessControl

EnterpriseBusinessControl

“Workplace Departures”• Increasing Baby Boomer retirements

– 10,000 per day for next 20 years– 400,000 years of experience being lost per

day– Huge amount of experience leaving

workforce– Hiring was suppressed through the last 15

years– Lack experienced workers to fill the gapBoomers

Characteristics of Millennials (1980-95)

• Meaningful careers• Tech Savvy• Diverse• Cyber Literate• Collaborative – part of team• Environmentally Conscious• Innovative• Realistic

Millennia's have the characteristics for success!

Millennials are ideal- Looking for meaning in their work

Slide 29

Measuring the real value of every person in the operation

Millennial’s are ideal – Team-based, collaborative, desiring to know their work contributes to the bigger picture

Millennials are ideal – Tech-savvy, collaborative, networked, multitasking, balancing work/home life

Not Your Father’s Automation Industry!

Millenniels Want a Career with Meaning

Help solve world energy

Help provide clean water

Help solve world hunger

Help clean and sustain the environment

Help meet chemical & mineral needs

Help provide material goods

It would be difficult to find a career with greater impact!