HMI Platforms Evolve to Become Key Automation Solution Components

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1 OCTOBER 20, 2011 HMI Platforms Evolve to Become Key Automation Solution Components By Craig Resnick Keywords Human Machine Interface, HMI, Automation Platform, KPI, OEE, TCO Overview The worldwide human machine interface (HMI) platform market continues to evolve to meet the needs of both discrete and process manufacturers and the OEMs that serve these markets. Rather than being just a standalone component, the HMI device is evolving into a platform that helps solve manufacturing problems to improve business performance. Furthermore, users are turning to open systems and commercial-offthe-shelf technologies to meet their increasing de- The use of object-based technologies coupled with Internet mands for high performance, ease of use, and lower access is an example of a trend that will change the HMI platform from a total cost of ownership. standalone, application-specific device to a key component of an Although technological advancement will continue to automation solutions portfolio. be an important factor, the focus of manufacturers, processors, and OEMs has moved toward seeking solutions that help them manage their manufacturing operations while dealing with the reality of having to pare back their in-house capability to engineer and support automation systems. In addition, global competitive pressures require users to increase integration of automation with other enterprise applications. Suppliers have responded to these requirements by providing HMI platforms that use object-based technologies and provide Internet access to move their solutions from standalone, application-specific platforms to become a key component of an automation solutions portfolio. Market Drivers Increasingly, HMI platforms help users visualize key metrics and KPIs, such as overall equipment effectiveness (OEE) and energy savings, to help them quantify the benefits of their automation investments. These users are VISION, EXPERIENCE, ANSWERS FOR INDUSTRY

2 ARC Insights, Page 2 all too aware of global competition and escalating energy costs, as well as the need for automation equipment that can help them achieve more flexible production while reducing environmental impacts. However, users must go through a business justification process before they can replace their existing, less-efficient equipment. This business justification requires clear metrics regarding the return on investment (ROI) and return on assets (ROA) of each purchase. Increasingly, they use their new HMI platforms as the digital dashboard to visualize and quantify these metrics. Minimizing Total Cost of Ownership HMI platforms designed with open systems interoperability to achieve rapid implementation can help companies minimize their total cost of ownership (TCO). Interoperable HMI platforms ease integration of components and systems and can more easily accommodate subsequent changes. Ease of integration is vital to provide the lowest possible TCO. Another primary factor is providing a platform that requires little to no maintenance. HMI platform suppliers are achieving this by eliminating failure-prone mechanical components, such as fans and hard drives. Initial Design and Development A major impetus today is to lower the initial design and engineering efforts for OEMs, SIs, and end users. Many automation configurations typically require frequent changes after installation, as new process issues surface over time. HMI platforms that utilize an open, interoperable, standardized approach help users make subsequent changes Ease of integration is vital to provide the with ease and at minimal cost after initial design lowest possible TCO. Another primary and development. This is critical because users factor is providing a platform that requires are establishing criteria in which they can evaluate automation solutions, such as HMI platforms, little to no maintenance. HMI platform suppliers are achieving this by eliminating failure-prone mechanical components, based on the ability to lower their initial design such as fans and hard drives. and development costs without compromising manufacturing performance and reliability. The Emerging Demand for HMI Platforms Today, HMI platforms in conjunction with PLCs or PACs have become a primary building block for industrial automation systems in many manufacturing plants. Increasingly, however, users want the HMI platform to serve not only as an operator interface window into the application, but

3 ARC Insights, Page 3 as an enterprise integration tool. As the trend toward open systems in the automation and enterprise markets continues to unfold, the HMI platform emerges as a single device to support a wide range of applications. At the low end of the market (characterized by small, fully integrated, low-cost products), HMI platforms can form the basis of an embedded control product for a wide range of OEM product applications. At the high end of the market (characterized by manufacturing processes integrated to global operations), HMI platforms provide data and information visibility across the plant floor and throughout the enterprise. Reduced Wiring and Space Plus Easy Design and Modification Over the past 15 years, HMI platforms have displaced conventional operator input devices and display elements such as hardwired push buttons, lights, and LED numerical displays providing As the trend toward open systems in substantial savings in wiring and space. The tremendous cost efficiency of graphical display devices the automation and enterprise markets continues to unfold, the HMI platform emerges as a single device to and commercial software technology has largely support a wide range of applications. displaced hardwired panels and pushbuttons. The simplicity of the design and the flexibility afforded by the easily modified software programs also drive the market toward scalable HMI platforms in lieu of panels and pushbuttons. Highly Reliable Hardware and Software With continuously shrinking component costs and improved designs, processors, and software-based systems, today's HMI platforms offer compact configurations, flexible handling, rich features, and competitive pricing. They can also offer increased reliability, with mean times between failures (MTBF) for hardware components typically measured in years of continuous operation. Hardware reliability is achieved by minimizing physical faults by eliminating failure-prone components and performing extensive burn-in testing, so reliability should not become an issue until well along in the platform's service life. Software reliability, however, is not measured as a direct function of time. It is achieved by eliminating design faults and performing extensive functionality testing and debugging. Unlike hardware, software reliability does not diminish over time. However, software reliability can be affected each time an upgrade is made. This has been an argument that bodes well for the HMI platform, as the embedded software has been included as part of

4 ARC Insights, Page 4 the extensive functionality and burn-in testing is performed prior to delivery to the user. As a result, the HMI platform is not subject to continuous software upgrades that could negatively impact reliability. Operations Management End user companies are increasing their agility by accessing and visualizing real-time information and applying it to speed up and improve operations; integrating business, manufacturing, and production within the operations management realm. These users are deploying End user companies are increasing their operations management solutions based on industry standards to standardize visualization agility by accessing and visualizing realtime information and applying it to speed and IT infrastructure across multiple facilities. up and improve operations; integrating This standardization of visualization is a driving force in the growth of HMI platforms. business, manufacturing, and production within the operations management realm. These users seek to reduce IT and engineering costs by implementing rapidly deployable and easy-to-manage visualization applications. They want to take the pain out of expanding and managing disparate systems by transforming their HMI platforms into enterprise-wide collaboration tools, without disrupting their current operations. Maintenance A key reason that HMI platforms are growing in popularity is their ability to lower maintenance time and expense for OEMs and end users. HMI platforms that support automation and enterprise applications can provide the control room operators and maintenance technicians with information to speed up maintenance operations and reduce interruptions. These HMI platforms provide maintenance crews with access to the company's maintenance management system at either the control room level or directly at the machine, equipment, or unit level. Some HMI platforms are configured to incorporate HMI, configuration procedures, programming languages, and maintenance procedures. This provides a common interface, and allows the user to achieve the operational benefits of transparent integration between each domain. Last Word End users and OEMs now also place higher value on visualization of the information provided by the asset, rather than the asset itself, as this infor-

5 ARC Insights, Page 5 mation transcends all production requirements. This End users and OEMs now also place has created a strong focus on what to do with data higher value on visualization of the provided by assets and how data is converted into the information provided by the asset, rather than the asset itself, as this information needed to manage their business. HMI information transcends all platforms are playing a key role in the way an asset s production requirements. information is viewed and analyzed. For example, HMI platforms enable proliferation of asset management and condition monitoring applications, which are critically important as users look to minimize the lifecycle costs of their capital assets. ARC's upcoming latest worldwide HMI Software study, along with ARC's worldwide Operator Interface Terminal study, addresses in depth many of the issues and trends relating to HMI platforms. For further information or to provide feedback on this Insight, please contact your account manager or the author at cresnick@arcweb.com. ARC Insights are published and copyrighted by ARC Advisory Group. The information is proprietary to ARC and no part of it may be reproduced without prior permission from ARC.