to plant.

The absence of a middle software connection layer is viewed as a major benefit of these connectivity technologies. “Having something that takes the middle layer out of the connectivity eliminates the security issues, the abuse issues. That makes a lot of sense
to us,” says Trayton Jay, director of special projects at vendor Mitsubishi Electric Automation Inc., in
Vernon Hills , Ill. He notes that some of the connectivity technology based on translation standards has proved difficult. “There are more people having challenges with OPC (an open connectivity standard) than might

The xCoupler eliminates the need for a PC in between the plant data and the enterprise database. “Companies like ILS Technology provide a bridge solution that takes data directly from a Rockwell control system and feeds the data directly into an IBM server on WebSphere,” says ARC’s Resnick. “The bridge allows the server to communicate directly to the backbone of the control pack.”

Why connect?

There are a number of reasons companies seek greater data connectivity between the plant and the enterprise. Much of the drive comes from the changing competitive environment manufacturers face.

“As competition with foreign markets goes up, manufacturers want their downtime reduced,” says
Wilson, of Online Development. “Manufacturers don’t want to warehouse finished goods, so they are building their products to order. That means they have to go through more configuration changes.” Plants are working to meet this increased demand on operations by using better data between the plant and the corporate office. “Our customers are using the xCoupler to eliminate downtime and increase throughput.”

Rockwell’s Pantaleano sees a wide range of uses for the data exchange between the plant and the enterprise. “In the food industry, you see data used for regulation. The manufacturer has to have information as to where the raw materials come from. That’s driving the data connection to the plant.” He notes that companies are also using plant data for total quality management programs, and to shift to build-to-order and just-in-time manufacturing. “People can’t afford to make products that sit on a shelf.”

ARC’s Resnick adds that manufacturers are using plant data to improve business decisions. “You can use the data to see what you’ve made—12,000 widgets at the factory in
Shanghai—and you can compare that to your sales forecast,” says Resnick. “That also lets you know you need to purchase the raw materials for the Shanghai factory, and you know that in real time, rather than at the end of a shift or the end of the week.” He notes that the database is the right place to keep the data. “The database is important because it can be shared by the factory and the enterprise. It’s like a junction box.”

The bottom-line benefit of this technology is better manufacturing processes, as well as improved business practices. “You can really use this technology to make your business more responsive, more flexible and more competitive globally,” says Resnick. “You can cut down on inventory and come close to just-in-time production.”

The big attraction of xCoupler-type technology is its ease of use. It doesn’t require an integration team and it doesn’t need middleware to send data back and forth between the plant and the enterprise.

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