Integrator Highlight: eGenietech Software Services

This month we interviewed Vipul Shah, MES Division Head, of eGenietech Software Services about his experience with Inductive Automation software.

IA: Tell us a bit about your company - do you have a focus on any particular industry?

Vipul: eGenietech is a software solutions provider in the area of IT for manufacturing. Since we have a good domain experience in the Process Automation Domain, our focus area has been providing solutions in the area of MES and Plant to Enterprise Integration.

IA: Why did you choose Inductive Automation software?

Vipul: For quite a long time we have been using custom software development for providing solutions to our client. But as the scope and complexity of the projects started increasing we started thinking of a product based approach to reduce the implementation time and maintenance cost. We evaluated a number of products for process data logging and finally chose FactorySQL because of its flexibility, configuration capabilities and its cost advantage due to support for unlimited tags. Another factor was we got very fast response during product evaluation which increased our confidence in Inductive Automation.

IA: What system features do your customers need that you can provide using FactorySQL and FactoryPMI?

Vipul: Most of the customers and our projects demand flexibility in configuration, openness to third party integration and extensibility. I feel both FactorySQL and FactoryPMI meet these requirements.

IA: What have you and your customers found to be the main benefits of the software?

Vipul: Our project involved providing a solution for metals industry, where we needed to seamlessly integrate an Oracle Based Production Management and Scheduling System and RSView Scada and provide a bidirectional transfer of process data among these two systems. Additionally the customer needed extensive data reporting and analysis.
The most important benefit we found was that we could deploy the project in a relatively short time with all the IT friendly features of FactorySQL and also could easily incorporate new requirements given by the customer during actual implementation at the customer site.

IA: How do you plan on using IA software in the future?

Vipul: Though we were initially a bit wary of using third party products in our projects, and of a vendor who is separated from us by a 12 hour time zone, based on our initial success of using IA products we have decided to aggressively propose solutions to our clients around their products.

IA: Is there anything else you can say regarding your experience with Inductive Automation?

Vipul: The best experience was the fast turn around time both from the sales and support side. The most important thing was we didn't actually require much support during actual implementation and that is very credible. Other good thing is the continuous information on new ways to exploit the products that we get through the newsletters. In view of all this we foresee a long term relationship with IA and wish them luck to create new innovations in their products.

Integrator Highlight: MCS Integrations

SACRAMENTO, CA DECEMBER 11, 2007 - This month we interviewed Pat Callaghan of MCS Integrations about his experience with Inductive Automation software in the field of water/wastewater.

IA: Tell us a bit about your company - do you have a focus on any particular industry?

Pat: MCS Integrations is a systems integrator working primary in the Water/Wastewater Treatment industry. We create control systems used in the treatment and distribution of drinking water and the processing of wastewater.

IA: Why did you choose Inductive Automation software?

Pat: We were looking for a web based SCADA application. Some of our customers require access to their SCADA application through the Internet. This has been possible in the past but we were looking for a product that better accomplishes this. The more we started working with IA’s software the more pleased we were with it.

To start FactoryPMI is a web launched application running in a Java environment. This gives us two benefits: 1) we do not have to install software on every client that needs to access the application this is handled automatically by FactoryPMI and 2) since the visualization part is processed on the client’s hardware this allows for the server to be smaller saving on overall system cost. Note that it is possible to run IA’s software as a standalone application, a central server is not required, but most of our customers have multiple clients accessing the system in which case a central server makes the most sense.

IA software has superior database support. We don’t have to create some crypt procedure in order to have the SCADA application access a database, all we need to do is write a simple SQL statement. IA’s software was created with database access in mind, not as some add-on.

Licensing, what could be easier? Whether you want 100 tags or 50,000 tags, whether you have 1 client or 100 clients, it’s all the same cost. In the past we would have to determine how many tags the system would need and how many clients would need to access the system in order to determine the cost of licensing; now it’s just one simple price. Plus there’s no separate cost for runtime licenses and development licenses, they are both part of the licensing.

IA: What have you and your customers found to be the main benefits of the software?

Pat: As an integrator the main benefit that IA’s software offers is freedom. We are able to create the application as we see fit. We can create the database (data storage) as we see fit, this allows us to optimize the application based on each customer’s needs. The development can be as simple as drag-and-drop to complex scripting, this allows us to create an applications look and feel to exact customer requirements. The inclusion of Python in FactoryPMI gives us access to a real programming language which allows us to create some complex applications; we no longer have to say ‘We can’t do that with this software’.

IA: How do you plan on using IA software in the future?

Pat: One of our customers is so pleased with the visualization part of the system that we are getting ready to incorporate record keeping into the system. Operators will enter data such as daily tests and chemical usage into the system. Once the data is in the system operators will be able to pull up charts and trends showing this data instead of having to fumble through paper and excel spreadsheets.

IA: Is there anything else you can say regarding your experience with Inductive Automation?

Pat: Great tech support. I can’t say enough about the tech support team you guys have, they are top notch. IA is a company that listens to customers recommendations for improvements to the software and actually implements them.

Here is a screenshot from one of his FactoryPMI projects:

Integrator Highlight: MSolutions Inc.

SACRAMENTO, CA JULY 12, 2007 - This month we interviewed Andrew Shwiff and Majdi Rajab of MSolutions Inc. about their
experiences with Inductive Automation software.

IA: What does MSolutions offer its customers?

MSolutions: MSolutions, Inc. is a provider of consulting and software development services in the areas of Manufacturing Execution, Production Planning, and Condition Based Monitoring.

IA: Could you describe a job that you've done with Inductive Automation Software?

MSolutions: FactorySQL and FactoryPMI were implemented into our current project to demonstrate how data acquired by wireless vibration monitoring devices can be forwarded to a SCADA system via an OPC Server.

IA: What was your experience like getting started with FactorySQL and FactoryPMI?

MSolutions: For the most part, the interfaces were very intuitive. Getting up to speed with FactoryPMI was quite easy, since it contains drag-and-drop and property setting functionality, similar to Microsoft's Visual Studio.

IA: Have you found IA tech support helpful?

MSolutions: Can't say enough good things about the support we've received.

IA: Do you have any other plans with IA software?

MSolutions: IA software will continue to be a part of our application demo, as we have had favorable responses from those who have seen it. We are planning to offer IA as option to our Condition Based Monitoring Product Suite.

IA: Is there anything else you would like to say regarding your experience with IA software?

MSolutions: One of the best products I've ever worked with, support is exceptional ...
Screenshot:

Integrator Highlight: Widaq Systems LLC

SACRAMENTO, CA MAY 1, 2007 - This month we interviewed Anthony Purdom of Widaq systems about their
first project for McDougall & Sons Inc. Widaq specializes in high-tech data acquisition systems in the agricultural sector.

IA: What does Widaq offer for its customers?

Tony: WiDAQ Systems provides the Northwest Agricultural Industry with cutting edge SCADA technologies. Our goal is to help agricultural crop producers improve operational effectiveness through enhanced visibility of business operations. Through the application of state-of- the-art Wireless Sensor Networks for data acquisition and web distributed interface for data visualization, we provide decision makers with global on-line access to high resolution operational data.

Our primary products are integration services and network engineering. We're also marketing a product, a whole system wireless sensor network, for data acquisition in tree fruit orchards and grape vineyards.

IA: Could you describe a job that you've done with Inductive Automation Software?

Tony: McDougals was the first. We have 4 orchards online now - spread out in central Washington in remote locations. We've had to do some creative things with Internet connections to make this work. The customer wanted to monitor orchard temperatures in realtime, primarily for frost control. We gave them a higher resolution picture of what was going on in the field, a microclimate throughout the orchard instead of a single temperature probe. There are 2 pieces to the system - wireless sensor networks and Internet connections to acquire data that logs to the central office, and the data logging and analysis system. The second is part is what we've done with FactorySQL and FactoryPMI. They're talking about expanding to as many as 10 other orchards for temperature monitoring. On top of that, your system will allow us to introduce other sensor types: Leaf wetness, relative humidity, soil moisture (for saving water), fruit surface temperature (for preventing sunburn on Apples, saving water on evaporation control systems). They want to add output capabilities to their FactoryPMI system for controlling irrigation values, wind machines, and integration.

IA: How have you used IA software to accomplish this task?

Tony: It's allowed me to very easily bring the data in and build the database without having to be a DBA or programmer. FactorySQL even built the all tables. I then created an interface for our executive managers here in the office, and the orchard managers at each location. They can watch those realtime values and I didn't have to set up a complex computer system. They just need a basic PC with an Internet connection. They use laptops with wireless data cards.

One of the big advantages with your product is that I can easily make changes on a system that's 2 1/2 hours away. I can't drive to each site to upgrade software all the time. The web distribution has really made that a non-issue.

IA: Do you use alerting in FactorySQL?

Tony: We're sending emails (text messages) to orchard managers' cell phones. That's another really valuable piece of the system that they hadn't had before. Typically, a frost event happens in the middle of the night, so having that additional notification is important to them. They then run wind machines in the field. The clear message is just as important as the alarm - it shows that their frost control is working and that they can start turning things off. Between the better picture provided by multiple sensors and the accurate realtime view, they have a much better picture of the orchard.

Prior to this system someone would have to be there to check alcohol temperatures - taking a half hour to get through the orchard, until someone determines that it's warm enough to shut off the machine. Now they can see what's going on in realtime throughout the entire orchard by checking on a laptop, ultimately saving them money on fuel and allowing them to be more precise with their frost control.Their existing HMI had some trending capabilities, but couldn't get the data out to spreadsheets or SQL databases without additional licensing.

IA: What do you think about the trending in FactoryPMI?

Tony: They've been happy with it. They keep temperature records at the time that they spray the particular products. Rather than looking at thermometers, they use the FactoryPMI history graph for their logs. Executive managers look at the entire system each morning allowing them to know what's happened at all the orchards.

IA: How do you use Inductive Automation software at Widaq?

Tony: My whole business is now based on 2 components - wireless sensors and Inductive Automation software that I customize for each customer. These packages have allowed me to provide 2 different levels. One is an entire system that I implement with a server, software, and sensor network, all managed by the customer. The flexibility of your product has given me a second option, which is really awesome for my smaller customers. I provide them with the system, but with FactorySQL and FactoryPMI I can bring the data into my server and provide a product interface. The customer then doesn't have to maintain the server.

I can't say enough good things about Inductive Automation - you have great products that are super flexible! Having the ability to make huge changes to the system that are immediately available to the end user with very little effort - is incredible.

IA: Did you try this with any other packages or custom code?

Tony: I did a lot of research when looking for a backend system. I looked at products from Wonderware and a few others, the big household name automation products, and I couldn't make anything fit well. Specifically I couldn't find anything that interfaced through OPC well - the web interface of FactoryPMI is really what sold it for me.

IA: Is there anything else you would like to say regarding your experience with IA software?

Tony: I could talk about how great it is all day! I've been pleasantly surprised on how flexible, easy, and powerful your software is. I feel like I could build a custom system however the customer wanted with ease. It's pretty amazing!

Here is a screenshot from one of his FactoryPMI projects:

Integrator Highlight: Industrial Control Integration

SACRAMENTO, CA MARCH 1, 2007 - Industrial Control Integration is a full service integration house in Orange, CA that specializes in process controls for the food processing industry. In this issue we interview owner Jeff Taylor about his first experience with Inductive Automation products.


IA: What does Industrial Control Integration offer?

Jeff: PLC programming, HMI programming, control system design, electrical installation, and equipment troubleshooting. My company is based on reputation and taking care of the customer. The relationship doesn't end when the contract is complete; customer service is vital. I'm able to focus on smaller jobs and deliver a good product for any size project.

IA: Please describe your first project with the Inductive Automation software.

Jeff: My first project was to retrofit a refrigeration control system for Del Real foods in Mira Loma, CA. They are a food processor specializing in Mexican food that has cold storage rooms, processing rooms, and shipping and receiving docks, all of which need to maintain specific temperatures. The system is a PLC based control that monitors and controls room temperatures, handles defrost cycles for the air coil units in each room, controls building ventilation and monitors the ammonia refrigerant equipment in the engine room. The job was to replace a competitors HMI package.


IA: What made Del Real decide to replace their existing HMI?

Jeff: They are expanding their production capabilities. They also wanted better access to their data. The licensing structure of their existing package was cost prohibitive to get the system to do what they wanted. The bottom line was that it got really expensive way too quickly.

IA: What specific goals did Del Real have in terms of data access?

Jeff: The first was being able to get to their data without paying additional license fees. Different departments from within their company needed access to historical temperature data for reporting and troubleshooting purposes. Their QA department needs access to historical temperature data for reporting to government agencies. Their maintenance department needs access to historical data on the various equipment for maintenance, troubleshooting and failure analysis. Further out, they are looking to tie in their production machinery and actual production data into the system.


Their existing HMI had some trending capabilities, but couldn't get the data out to spreadsheets or SQL databases without additional licensing.

IA: Have you been able to satisfy your customer’s data access requirements?

Jeff: At this point, yes. They're now able to access their data history, both temperatures and equipment downtime, from anywhere within the organization. Maintenance has better tools to analyze historical data on the machinery, allowing them to quickly find the root of the problem. QA can now access the data as far back as they need to, from any computer. I think as they see the power of this package, their requirements are going to expand even further. I feel extremely confident that I will be able to deliver solid solutions with your software suite.

IA: What's next for Del Real?

Jeff: I see the FactoryPMI Reporting Plugin as the next phase of this project. The first phase was to functionally have the package working like the existing HMI. With the reporting Plugin I will help the QA department get to their data and create and structure their reports. I think the email notification capability within FactorySQL will be expanded as well. After that, they are looking at monitoring and data logging at some of their remote facilities on their retail side.


IA: How did you find IA?

Jeff: The customer asked their IT department and me to investigate alternative HMI options. One of their IT guys found you on the Internet and asked me to evaluate FactorySQL and FactoryPMI.

IA: What was your experience like getting started with FactorySQL and FactoryPMI?

Jeff: Surprising right out of the gate. I called and immediately reached a human being. I wasn't sure who I needed to talk to, so I was put in touch with Travis from tech support. I gave him a quick overview of what I was trying to achieve. His response was very positive. I expected a 10 minutes overview of the software, then putting me in contact with a salesman - that seems to be everyone else's standard. Instead he spent the next 3 1/2 hours walking me through the system. His enthusiasm for and knowledge of the products were readily apparent. At that point, even without having any hands on experience with the software, I decided to sign on as an integrator.


IA: How would you describe the learning curve with FSQL/PMI?

Jeff: Initially it was steep. I was somewhat intimidated. However, the IA team was always a phone call away and always took the time to get me through the learning process, helping with specific tasks that I needed to do. Knowing now that you were going through a major version upgrade leaves me even more impressed. I never felt that any of the guys in tech support were just trying to get me taken care of and out of their hair. It was apparent that they wanted to make sure that I understood the technical issue before letting me go.

IA: What do you think about the SQL database centric model?

Jeff: Well, there was the wheel, sliced bread, and then this. It allows so much flexibility - and I don't even know all the intricacies. The more I've learned about the software the more I see in terms of capability. This is where everyone else wants to be. I haven't seen any false claims or vaporware. This actually works!

IA: What about the web deployed model?


Jeff: I think it's great! We're no longer tied to one machine in a room somewhere. It's really handy for remote support and remote monitoring. The maintenance guy is extremely happy that he can look at the system from home and determine the nature of the problem. After receiving an alarm he can more accurately assess the problem, and in a quicker timeframe. This is especially true on weekends.

IA: Do you have any other plans with IA software?

Jeff: This will be my first choice for any complete control system that I install. I plan on showing this to customers as a way to collect the data and better monitoring and control of their remote facilities. This fits perfectly as an economical solution for smaller processes that can still benefit from a full scale SCADA system, all with complete confidence that it's going to work. The database centric model is somewhat new to me - I wish this would have been around 10 years ago.

IA: Is there anything else you would like to say regarding your experience with IA software?


Jeff: The way you guys take care of integrators is phenomenal. I look forward to working with you in the future.