“My application is the automation of a batch reaction and packaging system,” writes an engineer whose company does not permit identification. Using a recent release of distributed control and asset management software, the writer notes that the positive point about the new software is the ability to develop and simulate the application code on a personal computer (PC).

This engineer also finds several “challenges” stemming from the use of modern application software. “The software is relatively new and very ‘open,’ in that code configuration is not what it was like ten years ago, which involved entering data into a system workstation via standard configuration entry screens. One must be well versed in Microsoft Windows operating systems to work with this software, plus training on the new system software is rather extensive. Further, company standards must be developed for effective and consistent implementation. The software has a number of idiosyncrasies (called ‘features’ by the manufacturer) that are only discovered with use. Various objects within the code are linked to each other, and if the links are broken, the code won’t work and the system may crash. Finally, multiple servers are required to support the production system and they can be very temperamental.”

Just about everyone uses a computer these days, especially in manufacturing. And just about everyone uses various software applications to accomplish their tasks on those computers. There are two crucial times when decisions must be made about software use. One is when a supplier releases a “version upgrade,” that is, a revision with enough new features to warrant moving the version number to the next whole number. The other is when one’s current supplier is acquired by another company. The decision to be made is whether the pain of the upgrade is worth the new functions to be gained.

Readers speak

In a Web-based survey, Automation World asked readers to rate their experiences with both version upgrades and with their suppliers’ acquisitions. In total, we received 72 detailed responses. Many readers commented about specific situations and several others were interviewed later. Suppliers were asked how they handled upgrade programs and about their software design strategy for upgrades. While readers did not hesitate to voice unhappiness with their experiences, suppliers were confident that their designs negated any chance of upgrade pain. The survey is not statistically valid, but it does point out that suppliers still have a way to go to satisfy their customers.

Specifically, Automation World readers are less than enthusiastic about the cost and support received for version upgrades, and are downright unhappy when another company acquires their software. They are generally positive, however, regarding version upgrades.

In the software industry, it has become standard practice for new versions of the same application to be numbered in a whole number and decimal format. A new whole number, for example, moving from version 4.5 to 5.0, suggests a major upgrade. Adding to the decimal, say from 5.0 to 5.1, suggests minor upgrades and bug fixes. Major upgrades, as almost all computer users have experienced, often offer cool new features at the cost of some installation and usage headaches. Automation World readers responded with average scores of around 3 on a scale of 1 to 5 (1 being low or unsatisfied, 5 being very pleased) when asked about their experiences with version upgrades in automation software. Concern about the cost of upgrades was more noticeable than concern about installation or support.

On the other hand, when readers saw their software supplier acquired by another company, their experiences were decidedly unsatisfactory. In four out of five categories, a majority indicated either a very unsatisfactory or unsatisfactory experience. These categories included (in order beginning with most unsatisfactory) support for legacy product, cost, easy move and forced upgrade. In the last category, overall support, almost half voiced displeasure (48 percent) with the average creeping closer to 3 (2.69) but still not good.

Happiness is Linux

Josh Lane, SCADA engineer (for Supervisory Control and Data Acquisition) with Auburn, Calif., systems integrator Aqua Sierra Controls, was thrilled with the software he has been using. He was the only person who responded to the survey noting the use of the open-source Linux operating system. Open-source software is free to the user and can be freely adapted to whatever application the user is working on. The expectation of the open-source community is that any improvements the programmer makes to the software will be sent back to the community for incorporation in later releases. As might be expected, ...