IDEC Blog

Stay ahead in food production safety: the IDEC KW2D RFID reader for precise worker traceability and accurate data logs

When you think of ‘traceability’ in food supply chains and production, you may think of the food itself. People want to know where their food comes from, and the journey that it took to reach their plate. If you work in food production, you’ll also want key information about the workers who helped that journey happen. There are food safety risks at every stage of the supply chain. As food products move along conveyor belts and between processing facilities, inspections and quality controls help to prevent defects and other issues. Under many food safety regulations, keeping comprehensive records of these checks and inspections is mandatory. The global food manufacturing industry is under constant pressure to maintain the highest levels of safety and hygiene, and to comply with laws and regulations. RFID systems – such as the IDEC KW2D – offer a centralized, real-time solution for worker traceability and record keeping. IDEC supports the food production industry with safety and security solutions The IDEC KW2D RFID reader has both the features needed for inspection history management and for reliable use in food production environments: Easy installation : designed for mounting on metal surfaces Dedicated software : easily adjust tag and reader settings Credential control : customize up to 500 tags with up to 255 authorization levels Visible/audible feedback : white/green/red LEDs and a buzzer Added authentication layer : recognizes IDEC tags Ethernet connectivity : for use with touch panel HMIs and PLCs IP65/IP67 rating : highly resistant to water, dust, and oil Find out more about the KW2D here on the IDEC website. How RFID supports worker traceability and inspection history management To register their work history, employees simply hold their ID card or keyfob up to the reader. Every time the RFID reader detects a tag, it registers the UID, the holder’s authority level, and the verification result. When used to create inspection history logs during food production processes, RFID system records can show you: When an inspection took place Who carried out the inspection How long the work took to complete (start and finish times) The number of days since the previous inspection Whether more than 1 inspection took place on the same day Whether anyone else attempted to access the area/equipment These time-stamped records can be transmitted to a host controller. Digital records have the added benefit of bridging physical gaps between work locations and different stages of the production process. With data collected and transmitted almost instantly, everyone has the latest information at any given time. Safety, quality, and traceability levels can be increased across all work sites. Added worker visibility in environments that demand protective equipment In many industries, including food production, inspections must be carried out by a “qualified person” – a formally named representative, and/or someone with recognized qualifications. As such, workers with the authority to inspect certain items need to be uniquely identifiable. Using biometrics and other facial/visual recognition can be difficult in food production facilities. Workers must wear protective equipment such as face masks, hair nets, goggles and gloves. This equipment is essential for food hygiene – but also makes traditional identification methods, such as checking ID cards, ineffective. In these situations, manufacturers need another way to be sure the appropriate person has done the necessary work. RFID tag data is separate to the holder’s appearance – workers can easily be identified even when fully covered. The identifying data includes the holder’s authority level, so the RFID reader can instantly confirm that person’s credentials on detecting the tag. This also enables user-specific customization of control options on a connected HMI display. RFID systems and their applications in manufacturing: the basics RFID stands for ‘radio-frequency identification’. RFID readers send out an electromagnetic pulse (radio waves) to identify nearby RFID tags. The radio wave frequency often used for RFID tags embedded in keyfobs and contactless cards – common access methods at factories, warehouses and other manufacturing facilities – is 13.56MHz. Every tag has a unique ID code (UID), which is set during production. Tags contain other identifying data, such as the holder’s name and authority level, which can be set and changed using software. In industrial settings, RFID systems can be used to efficiently record and manage: Entry/exit times (start/finish times) Access to areas and equipment Use of tools and materials Operational restrictions (user authority) Settings changes Inspection history etc.

Exploring the benefits of PCAP technology and tempered glass for industrial HMIs

UV resistance The glass top on a PCAP touchscreen prevents fogging and discoloration (e.g. turning yellow) caused by long-term exposure to UV rays. IDEC operator interfaces with PCAP technology also claim a wide operating temperature range – up to 60°C for the HG2J, and up to 55°C for the HG1J, FT2J and FT1J. Industrial applications where tempered glass PCAP touch panels can shine Heavy industries : PCAP touch technology isn’t affected by mechanical deterioration, and reinforced glass is robust in harsh environments. Hot and cold working environments (including outdoor use) : tempered glass can withstand high and low temperatures. Food and packaging : displays can be washed with disinfectant or water sprays to maintain hygiene, without causing accidental ‘touch’ inputs. Agricultural : glass panels left constantly exposed to natural light won’t fog or fade over time. Scratch resistance In general, glass is more resistant to scratches than plastic and polycarbonates. This benefit is often cited by opticians, to help people decide which type of lenses to choose with their new pair of glasses. Tempered glass is resilient enough that scratches are almost always attributed to a manufacturing defect. Safety Tempered glass is commonly used as safety glass. It doesn’t break easily – in our in-house testing, the FT2J’s glass panel passed a drop test with a 1kg steel ball. (Note: steel ball dropped onto the center of the glass from a height of 60cm. Our in-house test results don’t guarantee real-world performance.) If tempered glass does break, it doesn’t splinter in the same way as standard glass. It crumbles into smaller pieces with dull edges that are less likely to cause damage and harm. Tempered glass: tough enough to withstand daily use, environmental factors, and regular washdowns A protective glass layer is a key component of PCAP touch panels. It covers the sensor board and detection wiring, acting as an insulator. Overall, PCAP glass displays have fewer layers than traditional analog resistive plastic film tops. A tempered glass top doesn’t interfere with the touchscreen – in fact, it enhances and protects the display. The many advantages of tempered glass include: Easy cleaning Clean workspaces are important for hygiene, efficiency, and employee well-being. When a touch panel is covered in fingerprints, dust, dirt, or all 3, you may also notice issues with device responsiveness. Some touchscreens can’t be cleaned with dry cloths or harsh chemicals. Using the wrong cloth may leave lint and scratches on the display, and using chemicals could damage the device itself. Tempered glass can be cleaned with a water or chemical washdown, or by using a cloth wipe soaked in water, alcohol, or disinfectant. Durable, responsive, highly visible, efficient, and intuitive to use: PCAP touchscreen HMIs can offer you more than meets the eye When PCAP touch displays were introduced with smartphones, they changed the way we interact with our personal devices. They have just as much potential to transform your working environment. Water resistance When water hits a PCAP touchscreen, the size and force of the water droplets could cause accidental ‘touch’ inputs. Moisture on the screen can also reduce the device’s overall sensitivity and responsiveness. IDEC HMIs with PCAP technology and tempered glass are IP66F/IP67F rated for resistance to water, oil, dirt and dust. We tested that resistance to IPX6 and NEMA4 standards, using direct high-power water jets. Durability HMIs in work environments are put under literal stress and pressure with every tap on the touchscreen. In high-traffic areas of a facility, this type of repetitive wear and tear on the display’s surface can continue throughout the working day. Compared to untreated glass, tempered glass can be significantly stronger. It’s a more robust material that holds up to heavy use in industrial settings. HMIs used in industrial settings need to be durable, reliable, and easy to maintain. In harsh conditions – extreme temperatures, messy/dirty environments, etc. – a resilient touch panel keeps working effectively. When comparing displays to use in these environments, a HMI with a projected capacitive (PCAP) touch panel and reinforced glass top is often the leading option. Let’s look at why. PCAP touchscreen technology: established in some applications, continuing to evolve and advance in others The use of PCAP technology in industrial HMIs has grown in recent years. Many people are familiar with the technology – PCAP displays are how we interact with smartphones, tablets, and other personal touchscreen devices. The ‘capacitive’ element of PCAP touch panels enables them to recognize gestures such as finger swipe directions, and to sense multiple points of contact. The technology also enhances the sensing accuracy and responsiveness of displays. A barrier to entry for older versions of capacitive touchscreens was difficulty of operation when wearing gloves. In food production and other industries with strict hygiene standards, gloves protect both factory workers and the items they handle. Newer PCAP displays work effectively with certain types of gloves. For example, IDEC FT series and HG series operator interfaces – all with a PCAP touch panel – can be used while wearing gloves less than 1.5mm thick. (Note: touchscreen operation with gloves always depends on the glove material and operating environment.) As a result of this and other technological advances, PCAP is now a preferred type of interactive display for industrial use.

To calculate ROI on industrial safety equipment for your business, you should consider more than just the RRP

In our ROI calculation for the ez-Wheel Assist Wheel Drive system, we’ve suggested that some users could see a return on their investment in less than 1 year. You may have some questions about that statement: Would I really achieve return on investment (ROI) in under a year with Assist Wheel Drive? How did you calculate that ROI? How should I calculate safety equipment ROI for my business? What counts as ROI on safety equipment? It’s natural for people to view and calculate ROI differently. For someone in the finance department, spending on safety equipment adds another line to the expenses list. For someone on the factory floor, the company is paying for their well-being and sense of security as they work. Let’s take a closer look at ROI for safety equipment such as Assist Wheel Drive, and how to try and estimate it for your business. Indicative value for handling trolley, with handles positioned at an average height of 95 cm from the ground, pushed by a male operator over a distance of 15 meters with a starting frequency of once every 5 minutes. (C aution: values may change depending on condition of use) The push/pull force exerted by a worker quickly adds up, especially when transporting heavy loads. For example, the initial effort used to move trolleys weighing 300kg or more can soon reach or exceed 25 daN, depending on the trolley caster type, slope angle, and surface friction. When using AWD, workers will feel less pressure on their musculoskeletal system: their bones and muscles, joints and ligaments, and other connective tissue. The AWD 150 Series provides 35 daN of pushing force on an equipped trolley, greatly reducing the amount of physical effort needed. (The AWD 160 Series provides 27 daN.) Weigh up the cost of installing an electric power-assisted wheel against: Sick leave for injured employees Lost time and wages during treatment and recovery Penalties for failing to meet workplace safety standards A long-term decline in working speed and productivity The ROI for your workplace becomes much clearer when you think about it in this way. We’re confident that AWD demonstrates strong value in industrial environments. When you invest in safety, try to put yourself in someone else’s work shoes It’s important to class safety equipment purchases as ‘investments’, not as ‘expenses’. The adoption, installation, and proactive maintenance of industrial safety equipment should be seen as a necessary, worthwhile investment in a facility and its workers. All business managers understand this on some level – they’re human too, after all. However, when you’re comparing future savings to the cash you currently have on hand, making the initial purchase can feel harder to justify. Measure the cost of solutions against the real-world cost of inaction The true ROI for safety equipment is: the cost of doing nothing. Businesses need to calculate how much an accident, malfunction or other workplace incident would actually cost, compared to how much the prevention measures will cost to implement. This calculation should include as many factors as possible. There are always direct and indirect costs of an incident. Those amounts depend on the industry, the severity of the incident, how many people it affects, how long it takes to resolve, etc. They could include: Damage to facilities and machinery Losses of productivity and data during downtime Decline in output quality and quality control (wastage) Failure to meet deadlines/commitments Employee medical bills and compensation Higher insurance premiums Legal fees and fines Employee turnover (loss of knowledge and expertise, labor shortages) Loss of customers (temporarily or permanently) Reputational damage Factor in the many potential knock-on effects, and the real cost of inaction could be much higher than you first assumed. Some research has shown that – regardless of industry – ROI on safety investments (accident and injury prevention) is double or higher. The advantages of safety equipment go far beyond their financial value Cash cost is not – and should never be – the only factor in creating or upgrading a safety system. Knowing the ROI of your investment in safety equipment is important, but the final decision should be based on a wider variety of business considerations. The potential mix of financial and non-financial benefits includes: More efficient and productive work processes Longer working lifespan of machinery Happier, more motivated employees Increased compliance with laws, regulations, and international standards Any issues are quicker and cheaper to resolve if they do occur Stop the risk of physical pain from becoming a business pain point for your employees Assist Wheel Drive (AWD) can potentially offer you ROI within a short period of time. It’s ergonomically designed to prevent physical injuries in the workplace – once installed, the benefits quickly become clear. As we’ve explained, the full cost of a worker being injured can quickly outpace the cost of keeping them safe from the start. AWD brings electric power assistance to industrial trolleys. Each wheel is simple to install, can be retrofitted to existing trolleys, and can transfer a load of up to 1 ton. Once fitted, the system greatly reduces the manual force a worker needs to use to move the load. Exerting too much of their own physical strength could result in a back sprain or strain – some of the most common workplace injuries. AWD is compliant with the international safety standard ISO 11228-2, which defines recommended physical effort (pushing and pulling) limits for manual workers. The standard applies to tasks that involve lifting and transporting objects weighing at least 3kg, and is based on an 8-hour working day. The effort and force limits set by ISO 11228-2 are measured in Decanewtons (daN): “You can’t put a price on safety.” – or on the health and well-being of workers Effective safety measures are always worth the initial investment and more. Contact IDEC for: More information about Assist Wheel Drive More information about other IDEC safety devices Advice on adopting industrial safety equipment at your workplace

How ISO-compliant equipment, devices and systems enhance and assure long-term industrial safety (part 2)

1. Effects of automation The ISO notes that, as part of Industry 4.0, the number of machines that can outperform humans at specific tasks is rapidly increasing. Factory automation solutions are advancing at the fastest pace in recent history. ISO standards for automation may need to be revised more frequently to keep up. Long-term studies and forecasts of this evolution note that automation will eventually create just as many jobs as it replaces, if not more. Safety compliance is integral to this cultural shift. Manufacturing sites will need workers with specialist technical skills to manage and troubleshoot their new automated systems. Relevant ISO standards: ISO/TR 23087 (Automation systems and integration – The Big Picture of standards) ISO 3691-4 (Industrial trucks – Safety requirements and verification, Part 4: Driverless industrial trucks and their systems) 5. Data privacy and cybersecurity There are concerns that the Internet of Things (IoT), safety sensors, and devices designed to collect and transmit data could all negatively affect personal privacy. This is an issue that businesses handling personal data on connected devices need to consider. As one example, RFID readers grant workers access to facilities, areas and equipment based on customized authorization data. Data security is already paramount in every industry. Businesses with water-tight personal data privacy policies enjoy higher levels of consumer trust and respect – privacy protection is now a competitive advantage. Gaining the same level of trust from employees enhances workplace well-being. This has the added effect of improving worker focus and productivity levels, driven by their strong peace of mind. Relevant ISO standards: ISO/TR 22100-4 (Safety of machinery – Relationship with ISO 12100, part 4: Guidance to machinery manufacturers for consideration of related IT-security (cyber security) aspects) 3. Internet of Things (IoT) In 2022, experts predicted that an average Internet user would interact with IoT-connected devices nearly 4,900 times every day by 2025. This includes IoT in the workplace – also known as the Industrial Internet of Things (IIoT). A typical IoT-enabled industrial safety system includes safety input devices, relays, a PLC or other host device, and safety output devices. Systems can be highly customized, including devices with wide-ranging capabilities. Japan was first to propose an international standard for IoT system lifecycle processes, one that covers IoT products and services: ISO 30147 (see below). Before looking at ISO standards related to individual devices, businesses should start with the guidance for effectively integrating an industrial IoT system. A fully researched, well implemented system is easier to maintain, audit, adapt and enhance in response to changing requirements. Relevant ISO standards: ISO/IEC 30147 (Information technology – Internet of things – Methodology for trustworthiness of IoT system/service) ISO/IEC 21823 series (Internet of Things (IoT) – Interoperability for IoT systems) ISO/IEC 30162 (Internet of Things (IoT) – Compatibility requirements and model for devices within industrial IoT systems) ISO/IEC 30165 (Internet of Things (IoT) – Real-time IoT framework) 2. Robotics The ISO singles out the automotive industry as a sector that will lead increases and advances in the use of industrial robots. Changes in the automotive industry will affect both input and output. Robots can quickly increase production and efficiency levels at manufacturing sites. The safe use of industrial robots is comprehensively covered by multiple ISO standards. The adoption of collaborative robots – a type of industrial robot designed to work alongside humans – has rapidly grown in recent years. So that these robots can safely operate in close range of workers, maintaining compliance with international standards for human safety is becoming a greater challenge for many companies. Relevant ISO standards: ISO 10218 series (Robots and robotic devices – Safety requirements for industrial robots) ISO/TS 15066 (Robots and robotic devices – Collaborative robots) ISO/TR 20218 series (Robotics – Safety design for industrial robot systems) IDEC continues to work to ensure ISO safety standard compliance The ISO sets clear benchmarks for industrial safety that businesses worldwide need to meet. The many advantages of ISO compliance in the workplace go beyond health and safety, including enhanced data security, increased manufacturing efficiency, and a competitive edge in global expansion. The IDEC Group has departments and teams dedicated to international standardization and compliance in the industrial sector, constantly working to innovate and improve. In 2024 IDEC was recognized at Japan’s Ministry of Economy, Trade and Industry (METI) Industrial Standardization Awards, with the Minister of Economy, Trade and Industry’s Commendation. We received the award as an organization that substantially contributes to international standardization and leverages it to create new markets and solve social issues. We publish details about ISO standards that apply in industrial settings on our regional websites, so you can learn more about international safety standards and compliance. Safety is a top priority in every industry. In manufacturing, achieving relevant certifications and maintaining compliance with international safety standards is a competitive advantage, with positive impacts on and off the factory floor. Safety standards set by the International Organization for Standardization (ISO) protect manufacturing facilities and workers worldwide. Compliance with ISO standards improves workplace security, efficiency, and health and safety. In the first article in our series on ISO safety standards, we explained how these guidelines became the global benchmarks for compliance. The next step is to look at the future influence ISO standards will have, as industrial safety systems and technologies continue to change with the times. In this article: The 5 safety compliance trends and considerations that will transform industries 1. Effects of automation 2. Robotics 3. Internet of Things (IoT) 4. Ethics of technology (AI) 5. Data privacy and cybersecurity IDEC’s continued work to ensure ISO safety standard compliance Safety compliance trends and considerations that will transform industries As there are tens of thousands of ISO standards, multiple standards apply to each industry. When existing standards are revised and new ones are introduced, businesses must respond accordingly. ISO looked at the future of standardization and compliance in 2022. It identified 15 ‘drivers of change’ – areas where societal and technological advances will further increase the need for global safety standards and guidelines. Of those 15 ‘drivers of change’, we’ve listed 5 that will continue to affect safety requirements in industrial applications: 4. Ethics of technology (AI) For AI-related ISO standards to remain relevant on a global level, countries need to agree on ethical frameworks for using AI. According to the ISO and other sources, global agreements on ethical uses of AI will affect business automation systems, AGVs/AMRs, cobot training, and predictive maintenance. This includes deciding when it would be unethical not to use AI. For example, in the healthcare and pharmaceutical industries, AI technology with the power to accelerate medical developments could save lives. The real-world impacts of AI, LLMs and other advanced technology make the decision more complicated. Relevant ISO standards: ISO/IEC TR 5469 (Artificial intelligence – Functional safety and AI systems) ISO/IEC AWI TS 22440 series (Artificial intelligence – Functional safety and AI systems)

How TERAL INC. is enhancing employee safety and their work environment with Assist Wheel Drive (case study)

An existing company-built trolley can be converted into an electric power-assisted trolley in half a day. With only a small investment, this company quickly realized the benefits! Assist Wheel Drive Assist Wheel Drive can be quickly installed (in appx. 10 minutes by 2 people), and provides immediate electric power assistance to the trolleys you already use. It adds supporting force to push the trolley when transporting heavy objects. The controller is mounted on the trolley handle for easy access. The forward/reverse speed can be adjusted to suit the operating environment. The Assist Wheel Drive 150 series can transport a maximum load of 1,000kg (1 ton), and the Assist Wheel Drive 160 series can transport up to 750kg and has an IP66 rating for dirt, dust, and water resistance. "Before, heavy trolleys couldn't immediately be stopped, and there was a risk of danger." (Left: Mizoue-san, Center: Sato-san, Head of the Production Department, Right: Kai-san) TERAL INC. develops and manufactures a variety of products that control the flow of air and water, such as pumps and fans. The company has installed the Assist Wheel Drive system at their headquarters. We spoke with Kai-san and Mizoue-san from the company's Logistics Section (Production Department) about the issues they faced at the time, why the system was introduced, and the results. (video has English subtitles:) Following Assist Wheel Drive's introduction, in Kai-san's own words, not only has worker fatigue dropped, but the company is also satisfied with increases in work efficiency and safety at the factory. As for ease of operation, Mizoue-san (Logistics Section Group Leader), who demonstrated how Assist Wheel Drive is used at the factory, commented: "You quickly get used to operating the lever. Just pull it back lightly to stop. It doesn't act like an emergency brake, and there's no need to use force - it stops without travelling too far." Comfortably moving trolleys weighing over 500kg in a 'just-in-time' inventory system. With only a small investment, this company has greatly reduced the physical burden on workers! As previously mentioned, the trolleys used at TERAL's work sites are heavy models made in house. Reflecting on when Assist Wheel Drive was introduced, Mizoue-san said: "There are surprisingly few electric power-assisted trolleys that can be created by retrofitting existing company-made trolleys. When Assist Wheel Drive was presented to us, we thought 'this might work'." From there, we carried out an on-site demo, and showed that Assist Wheel Drive can reduce the physical burden on workers. TERAL started by fitting Assist Wheel Drive on 1 trolley, but quickly moved to install the system on every trolley. "With the first unit, we had to try a few times to get the installation position right. After that, it took only half a day to a day to introduce the system on the factory floor. Assist Wheel Drive comes as a package with all the parts needed: the battery, the controller, the suspension, etc. That makes it easier to retrofit existing trolleys and start using them. With only a small investment, we quickly realized the benefits of Assist Wheel Drive, and on-site workers are very pleased with the system." Finally, a message to TERAL INC.: we'd like to sincerely thank you for taking the time to share your insights during the interview. We also appreciated your cooperation during photography and filming on-site at your facility. Hearing about the real impact and changes you've made since implementing Assist Wheel Drive gave us useful feedback and even more pride in the system. From all of us at IDEC Corporation, we wish you continued growth and success. Aiming to create a more comfortable work environment for employees As Japan's working population declines, it's said that businesses (regardless of industry) will need to create an environment suitable for a diverse workforce. Manufacturing sites in particular are still associated with the 3Ds (Dirty, Dangerous, and Demeaning). Kai-san: "The managing director tells us 'You must not carry anything heavier than I can carry' (15kg)." On hearing this, we were curious about the assembly site. It doesn't have the typical image of an area used for handling heavy objects. Pallets move through the assembly process on roller conveyors. At each stage, a rotating table and lifter are used to hold the pallet in position for simpler working. The ability to assemble parts without changing position or posture reduces the physical burden on workers, and helps to prevent accidents. Referring to the Assist Wheel Drive system being installed on every trolley, Kai-san commented: "Up to now, only men were able to move the trolleys because it was heavy work. With Assist Wheel Drive, we found that anyone could control a trolley." "Depending on the work environment, people tend to avoid 3Ds work and other difficult tasks. We believe that using trolleys fitted with Assist Wheel Drive is a highly effective way to reduce that burden and create a more comfortable work environment for employees." Company Overview: TERAL INC. TERAL INC. was founded in 1918. The company has been developing and manufacturing a variety of products that control the flow of air and water, such as pumps and fans, for over 100 years. Production Department, Logistics Section This team purchases, receives, and inspects products delivered by suppliers. They send items to each production line (line-side logistics) to help achieve the 'just-in-time' inventory system, and handle internal logistics such as shipping products and components within the company. (Kai-san, Logistics Section, Production Department) The company's pumps are made primarily using metal components. The 'standard type' parts that are shipped in large quantities weigh roughly 50kg each. If 8 of them are carried on 1 trolley, the total load weight is close to 400kg. In addition, the parts are positioned to match the height of the workbench, so that there is no need to raise and lower them at the assembly site. This positioning means that the trolley must be stable. The company makes its own trolleys for transportation within the factory. They are made with solid metal, and are also heavy. At work sites that use the 'just-in-time' inventory system, numerous trolleys and forklifts come and go all day. Trolleys over 500kg (including the weight of the trolley itself) sometimes need to be stopped at intersections and turned 90 degrees (or 180 degrees at line-side). Before Assist Wheel Drive was introduced, workers had to lean in diagonally with their hips to set off, take a firm stance and lean backwards to stop, and pivot on 1 foot while turning. All of these actions were physically demanding for workers. Furthermore, as Kai-san recalls: "(under the 'just-in-time' system) We must prepare the parts needed as and when they are needed and in the quantities needed, all of which puts strain on workers."

How ISO-compliant equipment, devices and systems enhance and assure long-term industrial safety (part 1)

The challenges involved in meeting global safety standards The first hurdle in meeting an ISO safety standard is correctly understanding the requirements. ISO ensures that its standards are worded to be easily understood by all. Key technical terms are defined at the start, and the ISO ‘house style’ is based on Plain English. At the same time, standards are comprehensive in their scope. Finding the relevant sections and working out what needs to be done can take time. After that, implementation presents other challenges, such as: working with limited time and resources replacement and disposal of non-compliant equipment investments in and installation of compliant equipment employee training and skills development sustaining commitment and motivation levels These efforts are worth it in the long run – it’s important to remember that achieving ISO compliance isn’t a one-time event. ISO standards are worded to encourage businesses to actively monitor and ensure their ongoing compliance levels. Manufacturers who focus on safety compliance, international standards and certification aren’t just doing it for show. There are wide-ranging advantages of ISO compliance at every stage of the manufacturing process. Ensuring operational compliance and worker safety is vital for businesses to meet regulatory requirements and industry benchmarks. For those in charge of maintaining compliance levels, it can also be seen as a moral responsibility. International safety standards, set by independent regulatory bodies such as the International Organization for Standardization (ISO), provide robust frameworks and clear guidelines for businesses to follow. In the first part of this 2-part series, learn more about the history of the ISO and how global safety standards have changed with the times. We also provide some insights into how important ISO-compliant equipment can be in industrial settings. In this article: ISO standards and their lasting positive impact on industrial safety The wide-ranging benefits of using ISO-compliant equipment The challenges involved in meeting global safety standards Examples of IDEC products that meet specific ISO safety standards How IDEC strategically uses ISO compliance to achieve safety, security, and well-being Wide-ranging benefits of using ISO-compliant equipment ISO standards are created to answer a simple question: “What’s the best way to do this?” ISO compliance signals that a business is following best practices for safety, agreed on by experts. When a business meets the requirements outlined by a specific ISO standard, they have achieved ISO compliance in that area. Some standards are universal: quality management, IT security, occupational health and safety, sustainability, etc. Some of them can be applied to equipment and devices, and to systems. If a system contains a technology or function covered by an ISO standard, that part of the system can be assessed and judged as compliant. There are safety standards for pressure-sensitive devices, emergency stop functions, interlocking devices, collaborative robots, AGVs/AMRs, and many other industrial safety devices. Depending on the standard, meeting it can lead to several business advantages: comprehensive risk management improved hygiene and food safety levels increased data security higher operational efficiency fewer workplace accidents and injuries lower pollution and waste levels cost savings Examples of IDEC products that meet specific ISO safety standards IDEC constantly works to ensure that our products and processes achieve ISO compliance and keep customers safe. IDEC ISO-compliant products include: HT3P and HT4P Safety Commander : ISO 10218-1 (Robots and robotic devices – Safety requirements for industrial robots, Part 1: Robots), ISO 10218-2 (Robots and robotic devices – Safety requirements for industrial robots, Part 2: Robot systems and integration) XA/XW series emergency stop switches : ISO 13850 (Safety of machinery – Emergency stop function – Principles for design) KW2D RFID reader : ISO/IEC 14443 series (Cards and security devices for personal identification – Contactless proximity objects) HR series safety relay modules : ISO 13849 (Safety of machinery – Safety-related parts of control systems) HS series safety interlock switches : ISO 14119 (Safety of machinery – Interlocking devices associated with guards – Principles for design and selection) EW2A (Safety Wheel Drive) : ISO 3691-4 (Industrial trucks – Safety requirements and verification, Part 4: Driverless industrial trucks and their systems) As a company, we also comply with ISO 14001 (Environmental management systems), ISO 9001 (Quality management systems), and ISO 45001 (Occupational health and safety management systems). ISO standards and their lasting positive impact on industrial safety The ISO was officially formed in 1947 and created its first standard in 1951. ISO safety standards cover almost every aspect of manufacturing, technology, and management. There are over 25,600 standards as of November 2024. New standards are developed by 800+ technical committees and sub-committees. ISO releases updates to standards on a regular basis, to reflect advances in technology and societal changes. For example, ISO 14001 – the first standard for environmental management systems – was released in 1996 in response to concerns about climate change. ISO revised the standard in 2004, and again in 2015. Workplace safety has also come to the forefront over time. Measures to foster a culture of safety in the workplace have grown to encompass more than just physical protection. Employees who know they are always safe and secure in their work environment enjoy better mental health and well-being. The universal acceptance and implementation of international safety standards puts them at the top of the regulation hierarchy. Businesses that comply with certain ISO standards can be certified by a third party, to demonstrate their commitment to safety. In some industries, this could be a contractual or legal requirement. Importantly, ISO compliance and certification are not mandatory for all businesses in every country. However, the global reputation of ISO standards is so strong that non-compliance can damage industry/market competitiveness and consumer confidence. The work needed to comply with ISO safety standards compels businesses to look closely at their current setup and identify weak points and risk factors. Any issues need to be addressed – and once compliance is achieved, it must be maintained. ISO compliance is the foundation of effective industrial safety systems worldwide ISO is the gold standard for industrial safety. Businesses that comply with ISO standards – and develop products and services that comply with ISO standards – have the reputational advantage needed to compete on a global level. More information about international safety standards, and specific ISO standards, is available on all of our regional IDEC websites. Strategically using our ISO compliance to achieve safety, security, and well-being IDEC has a dedicated International Standardization & Collaborative Safety Department. We actively contribute to the international standard creation process, from initial proposals to final decisions. We take part in the development of ISO standards for industrial robots, AGVs/AMRs, and other relevant industry applications, as well as machine safety and functional safety. We are also involved in proposing and formulating international standards for Collaborative Safety – which we see as the next generation of safety. Through this work and more, IDEC aims to achieve safety, ANSHIN, and well-being for people around the world. (ANSHIN denotes a sense of trust and assurance without any fear or stress. Well-being is a concept that denotes that individuals are in good physical, mental, and social condition, where one’s rights and self-actualization are realized.)

IDEC Engineering Insights #1: the dedicated worker in our Assist Wheel Drive promotional videos

IDEC Engineering Insights is a series of interviews with IDEC employees who hold specialized product knowledge. Through this Q&A format, they share some of their professional experience and personal opinions on IDEC products and solutions.

An overview of the IDEC KW2D RFID reader and how it simplifies access management on factory floors

Security challenges in factories: the human element In some industries, it’s estimated that over 80% of errors, accidents and other security issues at manufacturing sites are caused by humans. Among the many causes of human errors, unauthorized access is a universal concern. Employees and visitors may enter restricted areas – accidentally, or deliberately. Factory workers should know the ins and outs of the access management system at their facility. They should be aware of their authorization level and what they can and can’t do. The KW2D’s smart RFID reader technology, in simple terms RFID systems use radio waves set to a certain frequency. For the IDEC KW2D, this is 13.56MHz. Many industries use high frequency 13.56MHz RFID readers – the most common application you may be familiar with is contactless payment cards. IDEC KW2D key features and advantages 1. Compact design and easy mounting IDEC provides a wide variety of control panel pushbuttons and switches in the 22mm mounting hole size. The KW2D is also this size, easily and cohesively fitting in with other control panel equipment. As the KW2D is designed for mounting on metal surfaces, you can install it close to machines, access doors and safety fences. The main unit can be fitted with or without the custom holder. Wiring up to the power supply is quick and simple, thanks to the push-in terminals. RFID readers support individual authorization level settings Any user’s ability to access the system and change settings depends on their authorization level. You can customize and manage employee access using the KW RFID Configurator software. If a user has authorization, the ‘success’ status is indicated with a green LED and/or buzzer sound. A red LED and/or buzzer sound indicates an ‘error’ – an attempt at unauthorized access. RFID readers help to restrict access to areas, machines, and specific controls With an RFID system, workers who want to operate devices are first checked against an access rights database and authenticated. A KW2D RFID reader is mounted on the machine, and users must present their ID to gain access. Workers don’t need to remember passwords or use a keyboard – access is granted with one tap. RFID readers contribute to building digital records of user activities Work logs and inspection checklists written on paper by hand take more time to record, use more physical storage space, and can be harder to read and understand later. Instead of holding a clipboard and checking off items on a list, workers can hold their ID card over an RFID reader when each process is complete. Data entered on a touch panel is linked to the user who entered it, increasing traceability and accountability. Example 1: machine user traceability A customer in the factory automation industry needed more reliable data on who had operated machinery and when. The customer chose the KW2D over competitors after successful product trials. The tests demonstrated how consistently accurate and reliable RFID access control systems can be. IDEC case studies: customers who benefit from access control using RFID The IDEC KW2D RFID reader has repeatedly proven itself as a reliable access management solution. These anonymous case studies come from our international sales teams. Manufacturing facilities are also businesses and workplaces. As such, security around sites and equipment must be tightly controlled to prevent unauthorised access and changes by workers or visitors. Traceability – of people and their actions – is essential. Many companies are looking to radio frequency identification (RFID) systems to efficiently manage individual access rights and data logs. In this article, we introduce the IDEC KW2D smart RFID reader. It’s an advanced industrial RFID tag reader with strong connectivity and compatibility. 3. IP65/IP67 environmental protection rating High water, dust and oil resistance levels keep the KW2D’s authentication functions fast and accurate in harsh industrial environments. The reader can be wiped clean – or washed down with industrial water jets – without affecting the ability to transmit signals and identify tags. Example 2: preventing accidental operation A customer in the semiconductor industry was dealing with severe productivity issues caused by unintentional changes. Some workers were unfamiliar with the equipment, so the number of human errors made on the factory floor was unusually high. In this case, employee education alone didn’t solve the problem. The customer needed an automated access system to eliminate as many opportunities for human error as possible. A major reason behind the customer’s decision to implement KW2D RFID readers was customization. Using the KW RFID Configurator software, security managers can customize up to 500 tags with up to 255 authorization levels. Now, only the site manager has the authority to change settings. RFID readers for higher security and operational efficiency on factory floors The security benefits of using RFID-based access management in the manufacturing industry are reassuringly comprehensive. Protect your factory against unauthorized access, data leaks, property damage, and human errors – all with one automated system. The IDEC KW2D RFID reader, access cards, keyfobs and other accessories are on sale globally. Visit the product page to find out more. 2. Audio/visual alerts The RFID reader’s smart design includes green, red and white LED status indicator lights that are visible from the front and sides. White is used as the ‘standby’ color. As green and red are respectively recognized as the ‘success’ and ‘error’ colors internationally, the reader’s status can be quickly understood by all users. The KW2D also comes with an auxiliary buzzer as standard. The same ‘success’ and ‘error’ statuses can be set as audible feedback, with a different sound for each. The LEDs and buzzer settings are controlled via KW RFID Configurator.

Safe, Simple, Smart – and also secure: push-in terminals maintain reliable grip on industrial control panel wiring connectors

What makes a push-in terminal so secure? When you push a wire into the wiring port, it pushes back a spring-loaded clamp inside the terminal. Once the wire is in place, the clamp starts to push back against the connector. This consistent pressure prevents the wire from moving. As the amount of pressure is constant, there is no risk of it eventually loosening. A push-in terminal maintains the same level of grip on an installed wire – and the direct, reliable electrical conductor connection – throughout its lifespan. Feel secure knowing that push-in terminals enhance convenience and safety Push-in terminals can drastically reduce control panel wiring times. Once wired, they maintain a secure grip on the connections for long-term system safety. IDEC has implemented S3 (Safe, Simple, Smart) push-in connection technology across a wide variety of safety devices: PLCs, safety relay modules, switches, pilot lights, and more. Explore the range and your options with your regional sales team. We’ve previously explained how quick and efficient push-in terminal wiring can be. This time, learn more about one of the biggest benefits that push-in terminals provide after wiring is complete: reassuringly secure grip. Vibration resistance: reliable when installed near machines and moving parts As the wire is held firmly in position, the potential effects of vibration and shocks are significantly reduced. Industrial equipment can vibrate during operation – often caused by the motor or generator running the machine, or components moving inside. This vibration is normal, and typically minimal. In other cases, repetitive back-and-forth movement is essential to the machine’s function. Industrial sanding machines, sorting conveyor belts and precision machine tools can all be classed as vibration-assisted machinery (VAM). There are also times when stronger vibration is a sign that the equipment needs maintenance. Wear and tear, misalignment and balance issues affect the dynamics of machine components. These problems can increase the amount of vibration and noise produced by affected equipment. No matter how the vibration is caused, nearby control panel components and wiring terminals feel the effects. For example, screws holding wires, connectors and parts together can be turned and loosened by vibrations – especially if they haven’t been tightened properly. Pull resistance: wires can’t be removed by accident In our catalogs and manuals for IDEC products with push-in terminals, we explain that wiring is simple: Step 1: push the wire straight in, to the back of the wiring port, as far as it can go. Step 2: lightly pull on the wire to confirm that it’s properly installed. We suggest giving wires a light pull – but they can withstand much more force than that. The pull-out force for push-in terminals is higher than that for screw terminals and spring clamp terminals. A wire that’s been correctly installed in a push-in terminal won’t loosen or fall out. The chances of pulling a wire out by accident are reassuringly low. This level of reliability is essential in many industrial settings. International safety standards and best practice guides for industrial control panel wiring emphasize the importance of correctly installing wires and storing slack. Loose or disconnected wires can lead to significant equipment downtime and workplace safety hazards. The simple, safe way to remove wires from a push-in terminal – when ready – is: press and hold down the pusher with a flat blade screwdriver, and carefully pull out the wire.

Easily convert your existing trolley into electric power-assisted rolling equipment with ez-Wheel® Assist Wheel Drive

Industry applications where Assist Wheel Drive excels Manufacturing : retrofitting rolling equipment that moves materials between production lines and different stages of the manufacturing process can streamline workflows. Healthcare : the Assist Wheel Drive 160 is specifically designed for use in medical settings. Hospital trolleys and other trolleys used to transport patients and supplies are easy to upgrade – maintaining a high safety level for everyone involved. Pharmaceuticals : turn sterile containers, stainless steel lifting trolleys, pharma rolling material trolleys and more into motorized equipment for smoother transportation. Logistics (retail, etc.) : workers who focus on picking and packing won’t need to spend as much time and effort on the process. Power-assisted trolleys are also easier to push across longer distances (such as warehouse floors). Food and packaging production: in temperature-controlled environments, time is of the essence to prevent hygiene/health risks and waste. Electric wheels keep things moving – forwards or in reverse. 4. Productivity, efficiency, and well-being Heavy loads can be moved more quickly, without rushing or compromising on workers’ safety. As less effort is needed to transport the load, it may require fewer workers to do so – they can then focus on carrying out other tasks. Making the work simpler and safer drastically reduces the chances of someone being injured in the process. Sick days lead to more than just lost productivity: employee motivation levels and their willingness to do the work are equally important. 1. Compatibility with existing equipment The ability to fit Assist Wheel Drive to any rolling material trolley you already use is an advantage in many industries. No matter what the equipment is made of – wood, steel, etc. – the electric wheel and controller are simple to install. At most, only minor modifications to the frame of the rolling equipment are needed. There is no reason, or need, to replace parts that are otherwise in good working order. By implementing Assist Wheel Drive, you can avoid the downtime and costs normally associated with replacing equipment. 2. High transferable load limit The two versions of the Assist Wheel Drive system have different load capacities – both are impressive and can meet the demands of various industry applications. The Assist Wheel Drive 150 is designed for industrial environments. Thanks to the cast iron housing, it can support a maximum transferable load of 1,000 kg. The Assist Wheel Drive 160 is built for use in controlled environments and logistics, with a load capacity of 750 kg. Assist Wheel Drive: the fully integrated industrial autonomous wheel Assist Wheel Drive is a clever system that works with you. It acts as a highly effective, flexible parts and material transport solution at distribution centers and warehouses, and in other industrial settings. Assist Wheel Drive is designed to both handle substantial amounts of weight and reduce physical stress on the workers transporting those loads. Electric assistance keeps the movement smooth and steady, reducing the risk of accidents and injury. Once installed, Assist Wheel Drive can support a maximum transferrable load of one ton (depending on the model – keep reading for more details). 3. Ergonomic and safety benefits Assist Wheel Drive facilitates compliance with the ISO 11228-2 standard for ergonomics (manual handling part 2 – pushing and pulling). The system has been carefully designed to help reduce musculoskeletal disorders in the workplace. 5. Long-term savings (ROI) Depending on the number of trolleys that need to be converted, implementing Assist Wheel Drive may represent an up-front investment. However, the potential cost savings over time are just as much of a benefit as the increased safety and enhanced productivity. In some cases, return on investment could be achieved in less than 12 months. Top 5 features and benefits of the Assist Wheel Drive system In fast-paced industrial environments, moving materials (especially heavy loads) efficiently from point A to point B is key to success. Manually-powered trolleys are still in widespread use, but aren’t always optimized for ergonomics – adding to workers’ fatigue and limiting their productivity. An innovative solution that’s gaining traction in various industries is Assist Wheel Drive. The all-in-one electric wheel system is designed to be fitted on existing trolleys, instantly transforming them into electric power-assisted rolling material trolleys. Supported by Assist Wheel Drive, factory teams can transport heavy loads more easily, enhance their overall working efficiency, and improve workplace safety. In this article, we explain how rolling equipment can be converted into power-assisted versions with Assist Wheel Drive. Read on to learn more about the technology behind the system, the benefits, practical use cases, and tips for installation. Fitting Assist Wheel Drive to your rolling equipment: what to think about Step 2: Decide which version of Assist Wheel Drive meets your needs The Assist Wheel Drive 150 is made for industrial applications. It’s the ideal power-assisted wheel on a mobile workstation, factory trolley or other rolling equipment. The Assist Wheel Drive 160 has an IP66 rating – full protection against dust, and strong water resistance. It’s suited to use on food and catering trolleys, as well as gurneys, chairs and beds. Step 4: Make sure workers are comfortable using Assist Wheel Drive The system is made to be user-friendly and reliable – even so, workers who will use Assist Wheel Drive-powered trolleys will benefit from training. Giving employees the opportunity to try the system in a real-world setting and learn the controls in advance will prevent future issues. Use a trolley fitted with Assist Wheel Drive, and you won’t go back to manual handling Assist Wheel Drive is helping manufacturing businesses power ahead with improvements to both their industrial material handling and worker well-being. By retrofitting existing factory trolleys with electric powered wheels, you can improve operational efficiency, protect employees from physical harm, and bring down labor and equipment costs. Are you ready to bring a fleet of electric power-assisted rolling equipment into your manufacturing facility? IDEC offers the Assist Wheel Drive system in several global regions. How does Assist Wheel Drive work? The Assist Wheel Drive system is composed of an electric wheel and an ergonomic wired controller. The motor and battery are integrated within the wheel. This space-saving design also protects the parts inside, with reinforced cast iron and a shockproof housing. In the same way as the wheel can be installed on the underside of the rolling equipment, the controller is designed to fit onto the handle. It has an on/off button, forward and reverse controls, and a stop button for braking. Step 3: Install and test the system The installation process is straightforward. Everything needed to convert standard rolling material trolleys will be provided: the wheel, the controller, cables, buttons and the mounting bracket. Once Assist Wheel Drive is fitted to the equipment, you can start using it immediately. The intuitive controls are simple to learn. See how it works in our installation video (with English subtitles): Step 1: Inspect and assess your equipment first In advance of installing the Assist Wheel Drive system, evaluate your current manual trolley fleet. Identify which ones are regularly used to transport heavy loads, and which ones would function more effectively with electric power assistance.

The power of IoT-enabled PLCs for predictive maintenance

Predictive maintenance: decision-making support based on real-time data The Internet of Things (IoT) is a network of devices that collect and share data. Connected smart devices (e.g. voice-controlled lighting, appliances that can be used remotely, security cameras with motion sensors) are the ‘things’ in the IoT. When used in industry applications, the IoT is also commonly known as the Industrial Internet of Things (IIoT). IoT-based predictive maintenance is more proactive than preventive maintenance. This approach is also driven by data, making greater use of real-time information compared to prescriptive maintenance. The IIoT is ideally placed to bring predictive maintenance to industrial applications. As predictive maintenance depends on the IoT to provide the most accurate data, the PLC must also be compatible with, and connected to, the network. All of this means that a PLC with IoT integration is essential to build the most effective predictive maintenance systems for industrial equipment. IDEC FC6A Plus: a PLC designed to handle large volumes of IoT data IDEC offers several PLCs with integrated IoT functionality. The FC6A MicroSmart Plus PLC has one of the most comprehensive feature lists: Up to 2,060 I/O points (a maximum of 511 analog I/O points) for connecting devices (when using expansion modules) Unlimited number of I/Os can be configured using the IDEC SX8R bus coupler module MQTT Sparkplug B Dual Ethernet ports , can be configured for FTP server/client communication Data logging via the SD memory card slot Compatible with open network protocols such as EtherNet/IP, Modbus TCP, and BACnet/IP 800kb of program memory (100,000 steps) , over double the data memory capacity of a typical micro PLCWeb server function, reporting and alerts via email The key to unlocking the FC6A Plus’s potential for user-centric predictive maintenance is the built-in WindLDR (Automation Organizer) software. It enables PID controls, custom reports and alerts, with no HTML programming knowledge needed. IoT-enabled predictive maintenance: IDEC PLCs make it a reality Unlock the potential of the data that’s already available in your manufacturing system. Explore the IDEC website for more on the FC6A Plus and our other IoT-enabled PLCs. The role of PLCs in collecting and analyzing data from IoT-connected devices A PLC is the central control hub of many modern manufacturing systems. A PLC in the IoT (or IIoT) becomes one of the most important ‘things’ in the network. Connected devices use sensors to gather data from various equipment: temperature, liquid levels, energy usage, vibration and noise, and other key factors. Once gathered, the available data gives a comprehensive overview of the current state of the equipment. The next step is for the PLC to effectively help the operator to analyze this data and determine when maintenance is needed. Historical data (including failure data) and real-time data are used to precisely estimate the remaining lifespan and future health of the equipment. Operational issues can be identified far enough in advance to mitigate them. This means predictive maintenance is only carried out when genuinely needed (rather than on a fixed schedule), reducing downtime and associated costs. Required maintenance can be flexibly scheduled to minimize the impact on operations and productivity. Factories and other work sites that use industrial machinery rely on equipment maintenance to keep things running smoothly. Each part and component will need servicing at some point – without any maintenance at all, every machine will eventually break down. However, nobody can perfectly predict the future. The frequency and amount of maintenance needed depends on many factors: the equipment type, how long it’s been in use for, overall condition, etc. That’s a lot of information for workers to remember and keep track of. What if your manufacturing system could collect that information, analyze and present it in a way that makes industrial machine maintenance easier? IoT-based predictive maintenance using a PLC could be the answer you’re looking for. Before technological advances, humans had to simply wait and see For a long time, the most common form of equipment maintenance has been corrective maintenance (also called reactive maintenance). In other words: fixing something after it breaks. Downtime, repair costs and lower productivity are unavoidable in these cases. This type of unplanned maintenance is the most costly and time-consuming overall. Investing in the technology needed to perform other types of maintenance – explained below – may be expensive at the outset, but often results in higher long-term ROI. Preventive maintenance: planned manual servicing on a set schedule As a broad term, preventive maintenance covers several types of proactive work: Usage-based (related to frequency of equipment use) Calendar/time-based (carried out on a pre-set schedule) Manual predictive maintenance (estimated based on equipment condition) Prescriptive maintenance (standardized strategy based on historical data) The schedule and maintenance level are based on the expected condition of the equipment at the time the work is done, not the actual condition. Even so, proactive preventive maintenance is preferable to corrective maintenance. With data collection, automation and other forward-thinking technologies, manual predictive maintenance of industrial equipment can be taken a step further.

When implementing a smart manufacturing system, an IoT-enabled PLC is the brains behind your operations

Every business wants to work ‘smarter’ to stay competitive in their field. That could mean streamlining their processes, using project management systems, or making the most of automation tools. In industrial settings, a smart manufacturing system can reduce labor costs, improve product quality control, lower the risk of accidents, and prevent wasted energy and resources. These wide-ranging advantages mean that the adoption and use of smart manufacturing is growing rapidly on a global scale. The automotive, food and packaging, semiconductor and construction industries are leading the way, transforming their facilities into ‘smart factories’. The shift towards the smart factory model is led by a familiar piece of equipment: programmable logic controllers (PLCs). They continue to play a vital part in industrial automation, and can support smart manufacturing systems with forward-thinking features. Consider building your smart manufacturing system around an IDEC PLC Even as smart factories evolve, they continue to revolve around PLCs with IoT integration and strong adaptability. Read more about the FC6A Plus and our other IoT-enabled PLCs here on the IDEC website. How and where a PLC fits into a smart manufacturing system PLCs act as the hubs of modern industrial automation systems. As physical devices, they are central to OT architecture. The latest PLCs can do far more than just control and monitor equipment. They integrate and communicate with other systems, gather data, and provide visualizations and analytics to help operators make key decisions. Of these functions, it can be argued that connectivity and data collection are the most important – to smart manufacturing, to the IoT, and to Industry 4.0 overall. Many devices can now supply large amounts of operating data. The PLC that receives this information has to be able to handle, interpret and display it effectively. A PLC is the brain of a smart manufacturing system, and the Industrial Internet of Things (IIoT) becomes the backbone. The data collected from connected devices is shared throughout the system. The PLC can be programmed to analyze and present this information in the most suitable way for the specific application. Instead of OT vs. IT thinking, the IoT (and IIoT) can bring them together Traditional production models rely on operational technology (OT) architecture – human control and monitoring of devices and processes, and of the systems needed to run them. Robots, safety systems, PLCs, lighting controls, programming software, and scientific/technical equipment are all examples of OT. They can all be supported by information technology (IT) – data and cloud application management. Companies may see their IT system as separate to their manufacturing system, only relevant to emails, accounting, and other back-end information processes. However, technological advances mean that IT’s focus on data and OT’s focus on equipment are far more effective when combined. The fusion of OT and IT can create even greater possibilities than ever before, thanks to the Internet of Things (IoT). A network of connected devices sharing data is maybe the best example of how well they work together. The role that the IoT plays in smart manufacturing is to facilitate full system integration. Device compatibility is no longer an issue. Access to real-time information enables more responsive – and even proactive – decision making. IDEC FC6A Plus: an IoT-enabled PLC with numerous smart features IDEC PLCs can provide the integrated IoT functionality needed to implement a smart manufacturing system. As one example, the FC6A MicroSmart Plus PLC has a variety of clever built-in features: Scalability of digital/analog I/O points : up to 2,060 I/O points (up to 511 analog I/O points) (when using expansion modules) IIoT ready : dual Ethernet ports, compatible with open network protocols such as EtherNet/IP, Modbus TCP, and BACnet/IP MQTT Sparkplug B Reliable data handling : more than double the memory capacity of a standard micro PLC E-mail notification : e-mail instruction can be used for alerts when a connected device causes an error The FC6A Plus makes it simple to combine OT (connected devices) and IT (data transfer and management). Over 800kb (100,000 steps) of program memory and fast basic instruction processing and execution speeds ensure reliable responses to user needs and system changes. What makes a manufacturing system ‘smart’? In the context of Industry 4.0, ‘smart manufacturing’ means using digitalization and modern technologies to make basic manufacturing processes even more efficient. Importantly, those technologies (sensors, data analytics, the IoT and IIoT, robotics, automation, AI, machine learning and more) are built into the system from the start. Other, more traditional manufacturing models have fixed systems that are harder to change and upgrade in response to technological advances. Digital integration is limited as a result, and replacing individual parts of the system is only a temporary solution.