Controls News 13
37
Focus issue:
User costs of lean technology for the operator
also be possible, for example those relating to a new bus sys-
tem or connection technologies. In such cases, adjustments
and extensions to firmware and application software alone
are not sufficient. The key is to ensure that the hardware is
highly modular using a variety of electromechanical plugs.
Additional expenditure on production and service
capacity compared to cheaper methods
Even at the outset of the first development step, Saia-Bur
gess engineers must take account of the long usage time
–
on average 20 years – with regard to test and inspection
equipment. Thus all production goods from the last 20
years must be stored efficiently.
With discontinuation after 10 to 15 years, the product is
One of our carousels with testing equipment for decades-old
devices.
Example of
Saia®PCD2 modularity:
up to 12 interfaces can be
operated in parallel; extensible to 1024 I/O
no longer recommended for new installations. But as part of our
service commitments, we keep for several years enough mate-
rial for any repairs or replacements. In addition, technicians who
know the old device ranges in detail are always present. Com-
panies that perform the service well before the end of the typi-
cal useful life can save on these extra costs.
Additional costs on software development
and maintenance
All the reputable controller manufacturers have long since
mastered the core components of the «runtime system» (logic
machine), the «engineering tool» (programming environment)
and the control hardware. There’s a good reason for this – they
have the monopoly over hardware and software in house and
can carry out maintenance independently of third parties. The
development and maintenance of software – the engineering
tools and runtime system – require comprehensive expertise
on the part of the manufacturer, which translates directly into
higher personnel costs. Many smaller firms do not have this
expertise, or want to save on the extra expenditure. But they
nevertheless want to provide control technology, and of course
at cheaper prices than those of reputable manufacturers. The
software is treated as a necessary evil.
So companies draw on the PC technology, terminals or driver
technology from software products known on the market
as «SoftPLC» or «SoftLogic». The systems are from quite well-
known software companies such as 3S, KW-Software and Infor-
mation team, to name the most famous brands of the German-
speaking world. These software PLCs are then embedded into
actuators, bus terminals or drives (Embedded PLC). Then the en-
gineering tool is given its own name, and the component sup-
plier can enter the market as an automation system supplier.
Outsourcing core competencies results in substantial savings
for the cost minimizer. But in this constellation it is not possible
to get the life cycle of an automation system unter control – the
interdependencies and interactions are myriad.
Life cycle from the perspective
of operators/customers
Company A Company B Company C Company D
Reputable manufacturers
of PLC control technology
Life cycle from the perspective
of operators/customers
Soft PLC/
Manufacturer
The source of compulsory investment by facility operators in automation systems
The manufacturers of intelligent software such as actuators, PCs, bus
Each additional step in the creation of added value and each component supplier
has its own, autonomous life cycle for some of its products. The operator therefore
sees far too many opportunities for innovation, which it then has to run after.
The life cycle of the control systems of reputable manufacturers
(
Rockwell, Siemens Simatic, Schneider, etc.). Only for the Windows
life cycle is innovation compulsory.
