Technology solutions addressed by the Performance Operations team generally break down into two categories, Information Technologies and Process Automation.  Within each area, specific applications are presented, along with technology capabilities.  Please note that the following are very brief introductions of each topic area only and are certainly not intended to be construed as comprehensive descriptions.  The intent of this page is to provide the reader with sufficient information to consider each application area or capability.

All Performance Operations consultants have been applying process automation technologies since 1980, including more than 200 Programmable Logic Controller (PLC) and Human Machine Interface (HMI) applications.

With the improved availability of relational database products in the late '80s, the we began implementing Information Technology projects in and around manufacturing.  Starting with mainframe based systems, moving into client/server solutions and into today's web based thin client solutions, we have lead implementations of every major type of computer technology used in manufacturing and distribution operations for more than 50 projects.

Our uniqueness in the applications area is the ability to fuse the functionality of the process automation world into information technology applications.  For example, we can acquire materials usage information from a process control system and use it in inventory, production and yield reporting.  We can take data from a process control system and use it to further qualify inventory.  We can combine information from a process system with data collected from a shop floor environment to create one batch, lot or serial number record.

One of our fundamental goals in any IT project is to create new or expand existing databases such that they:

	Correctly model plant floor processes
	Provide a meaningful level of data resolution
	Connect to the appropriate applications in an automated, timely fashion
	Are normalized to a practical extent
	Provide data to the appropriate users considering security

Additionally, it is typically a goal of a Performance Operations project to provide an automated connection between plant floor and enterprise systems.  We ensure valid data is immediately available to the enterprise while providing high speed, 24 x 7 systems availability to plant floor personnel.  Additionally, we are dedicated to the concept of making sure that the systems implemented on the plant floor are flexible, easy to use and that they work within the operator's work flow.

The following Information Technology applications and capabilities are addressed:

See also Laboratory Information Systems (LIMS) and Statistical Process Control (SPC).

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The following Process Automation Applications and Capabilities and  are addressed:

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Information Technology Applications

We have extensive experience with the implementation of the following Information Technology Applications:

Data Collection Systems (Bar Code and RF ID) - These applications include all manner of shop floor data collection systems, typically using bar code technology but sometimes utilizing Radio Frequency (RF) Identification as well.  The goals of these applications are to:

	Reduce the amount of paperwork on the plant floor
	Eliminate time spent handwriting forms
	Eliminate time and data errors involved with interpreting handwritten forms
	Simplify and update the data being collected
	Ensure the significance of the data being collected
	Reduce labor
	Provide on-line data to other applications and all users in a timely manner
	Connect data collected to Enterprise Systems

Project experience includes 25 projects.

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Portable Hand Held and Wireless - These applications include those applications using the now widely available commercial and industrial portable devices, whether they connect through site specific Local Area Networks (LANs), company specific Wide Area Networks (WANs) or commercially available digital voice services.  Portable applications typically have goals similar to data collection in general, with the following additional:

	Put up to the minute information in the hands of users who move outside the office or facility site
	Enter order information directly while users are on location
	Provide on-line requests and get answers for all manner of technical and customer support questions
	Move capabilities from organization employees to customers or third parties
	Collect data faster and make it available more quickly to the organization
	Capture customer or third party signatures digitally
	Connect data from remote users to Enterprise Systems

Project experience includes 20 projects.

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Inventory Control Systems - Inventory control applications may be viewed as a subset of Data Collection and Portable Hand Held and Wireless applications.  These applications typically use bar code technology to track inventory of raw materials, work in process and finished goods, through their various lifecycles.  In some systems inventory may also be tracked via connection to process control systems (see following section).  Better Inventory Control Systems use "license plate" technology to uniquely identify specific units of inventory (such as pallets).  See also the white paper "Comprehensive Shop Floor Solutions for Process Industries" and "License Plating, Lot Codes and Serialization" on the Performance Operations White Papers page.  Inventory Control Systems typically have the following goals in addition to those described for Data Collection and Portable Hand Held applications:

	Put inventory information in the hands of plant, warehouse, store personnel
	Connect suppliers, customers and third parties to on-line inventory information
	Improve inventory accuracy
	Improve the timeliness of inventory data
	Reduce replenishment time and manufacturing cycle time
	Track inventory previously approximated (eliminate the MRP "back flush" for example)
	Connect inventory data to Enterprise Systems

We have extensive experience in the area of graded inventory, including the ability to track, specify and fill orders with products more specifically by grade or other quality attribute.

Project experience includes 30 projects.

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Lot Tracking, Traceability and Genealogy - Lot Tracking, Traceability and Genealogy applications are one of the specialty domains of Performance Operations.  These applications are typically part of an Inventory Control System, which itself is a Data Collection and Portable Hand Held and Wireless application.  These applications track raw materials through manufacturing and order fulfillment processes to customers.  Often these systems include tracking of raw materials information supplied by the vendors, and carry data through to distributors.  See also the white paper "Comprehensive Shop Floor Solutions for Process Industries" and "License Plating, Lot Codes and Serialization" on the Performance Operations White Papers page.  Lot Tracking, Traceability and Genealogy Systems typically have the following goals in addition to those described for Data Collection, Portable Hand Held and Inventory Control applications:

	Track vendor information through to manufactured products
	Determine which manufactured products have been affected by lot code problems from vendors
	Determine the location and status of manufactured products affected by lot code problems from vendors
	Track manufacturing problems to manufactured lot codes
	Track manufactured lot codes to distribution entities and customers
	Determine which customers which received specific manufactured lot codes
	Determine the location and status of manufactured products affected by manufacturing problems
	Determine problems caused in manufacturing due to out of specification raw materials
	Relate problems with manufactured products to information acquired during manufacturing processes
	Identify other products which may be affected by discrepant raw materials
	Identify other products which may have similar problems to other manufactured products due to processing errors
	Connect lot code information to Enterprise Systems

Project experience includes 20 projects.

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Warehouse Management Systems (WMS) -  Warehouse Management System applications are Inventory Control applications which focus outside of manufacturing, usually on Finished Goods warehousing.  Better WMS applications also include various functions intended to increase productivity in the warehouse.  The Performance Operations team has experience implementing Warehouse Management Systems since 1988.  Systems typically have the following goals in addition to those described for Data Collection, Portable Hand Held and Inventory Control applications: 

	Reduce or eliminate paperwork in the warehouse
	Improve warehouse productivity
	Optimize which products are used to fill which orders (such as specific grades or lot codes)
	Reduce errors in filling orders
	Improve inventory accuracy
	Speed receiving and order fulfillment processes
	Reduce time spent on and the number of physical inventories required
	Provide connectivity to Order Entry, Customer Service and/or Enterprise Systems

Project experience includes 20 projects.

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Manufacturing Execution Systems (MES) - MES applications are essentially "shop floor" for process manufacturing (batch or continuous as opposed to discrete).  MES applications typically focus on control of a process manufacturing sequence, including data collection of critical processing parameters from humans and control systems which are part of manufacturing  processes.  MES often addresses data collection, lot traceability through manufacturing, and sometimes inventory control.  MES was created for the pharmaceutical industry with the goal of reducing the extensive paperwork requirements for operating validated processes, but is often applied today to food and beverage, bio-tech and other "lot traceable" manufacturing.  As formal MES solutions are inherently very "controlling" of the manufacturing process, many end users opt to apply individual applications, such as inventory control, lot tracking and process data acquisition to achieve much of what MES provides without the additional complexity and inflexibility of true MES applications.  See also the white paper "Comprehensive Shop Floor Solutions for Process Industries" on the Performance Operations White Papers page.  MES applications typically address the following goals in addition to those goals which are associated with Data Collection Systems:

	Control manufacturing procedures so they must follow stringent, pre-defined sequences
	Collect critical control information from operators and process systems
	Track lots through manufacturing to WIP and/or Finished Goods produced
	Track production and yields
	Provide connectivity to Enterprise Systems

Project experience includes 8 projects.

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HACCP Systems - Hazard Analysis Critical Control Points (HACCP) Systems are applications which are at the juncture of Shop Floor Data Collection and Document Management Systems.  These systems reduce the extensive amount of paperwork collected and maintained so as to meet food safety guidelines, including but not limited to HACCP.  These systems always include some sort of data collection technology (such as bar coding and usually forms automation) as well as some level of document management.  The most complete HACCP solutions are well integrated into process automation systems which are used to control and monitor manufacturing processes, as well as lot traceable inventory control systems.  HACCP Systems address the following goals in addition to Data Collection:

	Reduce time spent managing data collected
	Reduce violations by proactively controlling sampling procedures
	Publish advanced reporting from HACCP data
	Predict food safety issues from process conditions (before going out of specification)

Project experience includes 1 project.

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Quality Assurance Information Systems - This application area includes systems which are specifically designed to collect quality assurance information and relate it to inventory.  This means that information pertaining to the quality of the product can be used to identify specific inventory (by pallet or lot code).  See also the white paper "Inventory Control of Products with Grades" on the Performance Operations White Papers page.  Many QA Information Systems also provide Statistical Process Control (SPC) functionality, which in general strives to reduce out of specification conditions by statistically significant control of sampling and data analysis processes.  Some Laboratory Information Systems (LIMS) may fall into this category as well, which focus on management of laboratory data.  More complete QA Information Systems can also relate quality information with data acquired from Process Automation Systems.  The goals of QA Information Systems are to:

	Get all QA information into a single, centralized database
	Relate QA information to product which was produced, so these products may be selected for specific orders or further processing
	Detect trends in product quality so that raw materials or processing many be improved
	Track QA parameters as specified by customers
	Provide on-line data to other applications and all users in a timely manner
	Provide connectivity of important QA information to Enterprise Systems

Project experience includes 8 projects.

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Production and Yield Reporting - These systems track production quantities and sometimes process yields.  Production quantities are typically tracked by counting inventory units produced, either individually and/or when they are palletized.  Process yields may be calculated automatically if materials usage (raw materials, work in process and finished goods consumed into production processes) can be determined.  Usages may be tracked via an Inventory Control System (typically using bar code technology) and for bulk materials via Process Automation equipment (such as PLCs).  Production and Yield Reporting may be part of a Manufacturing Execution System (MES), or integrated with an Inventory Control System and/or Lot Tracking System.  The goals of a Production and Yield Reporting System are to:

	Accurately track production quantities produced in a timely manner
	Accurately track materials usage and relate these quantities to production
	Determine process yields
	Provide production and yield information on-line to other applications and all users in a timely manner
	Use production information to improve productivity
	Improve yield information to improve process yields and reduce materials waste
	Predict daily or shift production during the shift instead of waiting until after the fact
	Provide connectivity of production and/or yield information to Enterprise Systems

Project experience includes 15 projects.

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Planning and Scheduling - Planning and Scheduling applications determine materials, labor and equipment requirements for production schedules.  Starting at the planning level and assisting in the development of detailed production schedules, this is one application area which is ideally implemented within an enterprise system.  That being said, we have found that many smaller facilities need only rudimentary production planning and scheduling needs.  In these specific situations, the Performance Operations Team implements simple plant floor solutions which address the following goals:

	Provide a centralized planning and scheduling environment
	Predict materials requirements for predicted schedules, taking into account current inventories
	Provide a flexible production scheduling environment which is on-line to all users
	Provides scheduling information to Enterprise Systems

Project experience includes 6 projects.

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Downtime Tracking - Applications which provide downtime tracking functionality are used to track lost time in production processes, relating lost time to specific downtime categories.  Sometimes simple Downtime Tracking applications are provided with or integrated into process control systems , such as are provided by an equipment vendor with a machine.  Better solutions, however, are those which work across multiple machines or processes and which are integrated with other information systems.  More comprehensive Downtime Tracking solutions include the ability to connect to Process Automation systems to retrieve run and lost time data from machine controllers as well as the ability to prompt for and handle manual data entries from operators.  Various types of reports and data analysis mechanisms should be provided to relate the data to the specific production group, date, shift, product being manufactured and production line.  The goals of a Downtime Tracking application are:

	Track downtime in real time
	Make downtime data immediately visible to operators on the line and managers
	Formalize the way downtime is tracked so that comparisons may be made
	Facilitate continuous improvement in production uptimes
	Provide connectivity of downtime information to Enterprise Systems

Project experience includes approximately 10 projects.

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Time and Attendance - Time and Attendance solutions replace time clocks and the manual collection of payroll attendance data with completely electronic systems.  These solutions are commonly provided "canned" and "stand alone" from other applications, although some of the Time and Attendance Solution providers can provide enterprise connectivity on a project by project basis.  The better solutions store the data in modern SQL relational database formats which makes the data more available to other applications and "ad hoc" analysis by authorized users.  More comprehensive solutions integrate with Labor Tracking or are part of Comprehensive Shop Floor Control solutions.  The main goals of Time and Attendance Systems is to:

	Eliminate administrative time spent reading time cards and calculating payroll hourly information
	Automatically apply standardized rules (overtime, off shift bonuses, etc.)
	Eliminate time and data errors involved with interpreting punch cards
	Provide on-line data to other applications and all users in a timely manner
	Provide connectivity of payroll information to payroll software and/or Enterprise Systems

Project experience includes 4 projects.

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Labor Tracking - Labor Tracking applications track labor hours through manufacturing and supporting processes.  Sometimes this information is used for payroll purposes, but more commonly it is used for cost accounting and improvements in production efficiencies.  Labor Tracking Systems typically track direct hours spent against work orders, associating the time to individuals or work groups, and can handle indirect hours by cost account.  Better systems provide Time and Attendance functionality as well.  Labor Tracking applications invariably use Data Collection technologies to get the required information into the system.  In addition to the goals addressed by Data Collection Systems, the goals typically addressed by Labor Tracking Systems includes:

	More closely track where labor hours are going
	Facilitate project cost accounting
	Improve labor efficiencies on the shop floor
	Provide on-line data to other applications and all users in a timely manner
	Provide connectivity of payroll information to payroll software and/or Enterprise Systems

Project experience includes 6 projects.

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Comprehensive Shop Floor Systems - Shop Floor Systems in general refer to the application of Data Collection technologies to reduce the paperwork used on the shop floor to track products through discrete manufacturing steps.  The basic focus for Shop Floor Systems is tracking and control of Manufacturing Sequences.  The flow of parts through a specified sequence is controlled with a bar coded traveler or containers (totes) which are tagged (bar codes or RF ID). Sometimes the term "Shop Floor" is used generally to reference any manufacturing process, but Shop Floor Systems typically implies the sequential manufacturing through individual (discrete) manufacturing steps.  Our reference here to "Comprehensive Shop Floor Systems" means the integration of Manufacturing Sequence Control with Inventory Control, Production Reporting and Yield Tracking, Labor Tracking, Downtime, and some level of Quality Assurance functionality.  The goals of a Comprehensive Shop Floor System, in addition to the other application areas mentioned above, are to:

	Control the flow of parts through the correct manufacturing sequences
	Track, predict and report on part cycle times through manufacturing sequences
	Provide part serialization and tracking of production and quality information to part serial numbers
	Relate together inventory, production, yield, labor, downtime and QA information into a complete picture of the manufacturing process for a specific production lot or even individual (serialized) part
	Provide all information necessary to determine the actual cost to produce a production lot or individual part
	Provide on-line data to other applications and all users in a timely manner
	Provide connectivity of payroll information to payroll software and/or Enterprise Systems

Project experience includes 8 projects.

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Information Technology Capabilities

The Performance Operations team has significant experience with the following Information Technology Capabilities:

Systems Design - The Performance Operations Team provides highly evolved systems design capabilities for information technology projects.  Starting from the foundation of system lifecycles from space probe projects in the 1980s, we have continued to improve our design processes so as to be flexible enough for commercial/industrial projects, but formal enough to ensure project control.  We customize our design approach for each specific project, taking into account the personality of the client organization and team, the skills of the implementation team and type of application.  Typically a project is broken down into 3 phases - 1) Feasibility Analysis, 2) Systems Design and 3) Implementation.  Components of a Performance Operations Team design typically include:

	Functional Requirements - A detailed list describing what functionality must be provided by a particular system
	Storyboards - A graphic depiction of user workflow showing technology integrated into the workflow
	System Overview Document - An overview of a proposed project, suitable for all persons interested in the project
	System Design Document -  A document describing, in detail, how a system will be constructed
	Detailed Design Documents - Individual, very detailed documents suitable for use by a technologist configuring or coding

See also more on the above on the Performance Operations Methods page.

Project experience includes 30 projects.

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Standards Development - The Performance Operations Team can provide corporate and/or plant standards which provide the necessary controls for IT project implementations and the application of canned software products.  These standards strike a balance between the control necessary to control cost, timelines and ensure individual projects can be integrated and the flexibility needed to allow individual projects to be effective without unnecessary constraints and overhead.

See also more on the above on the Performance Operations Consulting and Methods pages.

Project experience includes approximately 6 projects.

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Relational Databases - The Performance Operations Team specializes in the application of relational database technology to manufacturing operations.  We have developed Structured Query Language (SQL) databases, including tables and fields with the appropriate relationships as well as the stored procedure logic to address all of the IT Applications listed previously on this page.  Typically these databases are implemented such that they are integrated into the client's business or enterprise applications, or they may actually be implemented within an enterprise data environment.  Performance Operations Team databases are provided complete, including:

	Complete E-R Diagrams
	Annotated Stored Procedures
	Detailed Design Documents

Project experience includes 30 projects.

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Web Systems Development - The Performance Operations Team has been implementing new projects exclusively with complete web interfaces since 1999.  Because it is part of our Principles to keep things simple, we typically utilize standard HTML and JavaScript, with the addition of VBScript when necessary.  We continuously evolve a set of web tools and libraries, including the addition of Microsoft .Net components as of December, 2002.

Project experience includes 8 projects.

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Enterprise Connectivity - Most Information Technology projects lead by a Performance Operations Team provide connectivity of operations information to supervisory Enterprise Systems.  We have been providing information to business systems in general since about 1990, with the following information typically being efficiently collected from manufacturing processes and automatically supplied to the business or enterprise environment.  Detailed and/or summary information about:

	Receipts - Inventory quantities and location, vendor information, materials condition, etc.
	Inventory Adjustments - Inventory adjustment quantities made due to inventory due to cycle counting, physical inventory and scrap transactions
	Production Inputs - Materials quantities, lots or serial numbers input into production and/or returned to inventory
	Production Outputs - WIP and Finished Goods produced, including lot or serial number information
	Order Fulfillment and Shipping - Inventory quantities filled to work or sales orders, when staged and/or shipped, including lot or serial information
	Inventory Transfers - Inventory quantities shipped or received on transfers to other inventory controlled locations

Project experience includes 15 projects.

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Manufacturing Solutions within Enterprise Systems - The Performance Operations Team has been effective at implementing IT solutions for manufacturing directly within the context of an Enterprise System as well as via integrated systems which can stand alone when necessary.  See also the white paper "Shop floor solutions within the enterprise environment or integrated solutions which can stand-alone?" on the Performance Operations White Papers page.  The advantages of a solution implemented directly within an ERP environment are that there are no external systems to connect or maintain.  This approach will only be successful, however, if the enterprise product can both model the manufacturing environment with suitable data resolution and if the product can be flexible enough to be made to work efficiently with plant floor operators.  Applications which may be considered to be implemented directly within and enterprise product are:

	Inventory Control
	Shop Floor Control
	Lot/Serial Tracking

Project experience includes 2 projects.

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Process Automation Applications

Process Automation experience is broken down into applications and capabilities.  Applications describes the specific Process Automation application areas the Performance Operations team is capable of addressing.  Capabilities describes the Process Automation capabilities in which the Performance Operations team is proficient.

Blending and Cooking - Experience includes numerous processes requiring blending of ingredients (both batch and continuous).  These applications include all manner of processes, from simple blending of food ingredients to control of exothermic chemical reactions.  These applications typically include the application of PLC and HMI/SCADA technologies integrated with relational databases and often bar code technology as well.  The goals of these applications are to:

	Standardize formulations and sequence of operations
	Improve batch to batch consistency
	Reduce labor
	Improve yields
	Control reformulation
	Reduce batch corrections and waste
	Improve quality through improved process control
	Eliminate first batch problems
	Capture true actual ingredient usages
	Eliminate manual batch tracking
	Include bar code data collection in the process control system
	Connect data collected to Enterprise Systems

Project experience includes 15 projects.

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Pasteurizing, Aseptic Processing and Sterilization - Experience includes numerous processes for food and beverage and pharmaceutical industries.  These applications include both in-line and in-container types.  Gene Kaplan developed process control systems for some of the first aseptic units used in food and beverage in the USA and has worked with units for juice, dairy and pharmaceuticals. These applications typically include the application of PLC and HMI/SCADA technologies and of course are subject to validation.  The goals of these applications are to:

	Very closely control and monitor the process
	Control and monitor "forward flow" for food/drug safety purposes
	Safety interlocks (temperature, pressure, flow)
	Integrate with CIP or SIP systems
	Provide records of actual process performance (for internal use and governing agencies)
	Eliminate the possibility of raw product reaching further processing or packaging
	Reduce waste
	Improve quality through tighter temperature control
	Reduce start-up time and eliminate waste
	Connect data collected to Enterprise Systems

Project experience includes 10 projects.

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Filling Line Controls - Experience includes many complete systems for glass and plastic bottling, powders and bag in box lines.  Gene Kaplan was one of the first providing integrated variable speed line controls for bottling.  Experience includes lines with control of OEM machines, in-line accumulation and end to end control through packaging.  Results include doubling line efficiency and cutting the cost per case for a major liquor supplier in half.  These applications typically include the application of PLC and HMI/SCADA technologies and invariably include working with various machine suppliers to create a completely integrated overall process.  The goals of these applications are to:

	Improve line efficiency and reduce cost
	Eliminate labor
	Reduce changeover time
	Allow one line to handle a wider variety of container types and sizes
	Reduce noise and improve operator safety
	Keep the bottleneck (typically the filler) running at all times!
	Reduce container waste
	Improve fill quality and reduce rejects
	Reduce start-up time and eliminate waste
	Connect data collected to Enterprise Systems

Project experience includes 20 projects.

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Integrated Packaging Lines - Most packaging machine vendors provide individual machines or groups of machines coupled with conveyors.  While there are exceptions, typically each vendor provides a machine which stands alone and takes care of its own infeed and discharge.  Integrated systems improve throughput by coordinating the operating parameters of each machine and the speeds of the interconnecting conveyors and/or accumulation systems to that the overall area functions as a system.  The Performance Operations Team has many years of experience with these types of systems including both high volume bulk case packing and automated palletizing as well as high speed stacking/de-nesting of discrete packaging products. These applications typically include the application of PLC and HMI/SCADA technologies and invariably include working with various machine suppliers to create a completely integrated overall process.  Many times these systems integrate with bar code package labeling verification systems, production reporting and inventory control systems.  The goals of these applications are to:

	Improve packaging system efficiency and reduce cost
	Eliminate labor
	Reduce damaged product and waste
	Allow one system to handle a wider variety of container types and sizes
	Track and optimize packaging material usage
	Connect data collected to Enterprise Systems

Project experience includes 10 projects.

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Sortation Systems and Conveyors - The Performance Operations Team has experience with Sortation Systems and package conveyor systems from the mid 1980s.  These projects include large scale distribution center sortation systems which scan package bar code labels at high speed and direct a large number of packages simultaneously to multiple drop areas for trailer loading.   Superior sortation algorithms allow packages to be inserted into the sequence without affecting existing packages.  Encoder driven "Healing logic" provides the ability for package position to be updated during long conveyor runs.  Results include systems which sort 50,000 packages/day through 4 miles of conveyor to 60 drop areas with an overall accuracy of 99.8%.  Project experience includes office products, medical products, consumer goods and baggage. These applications typically include the application of PLC and HMI/SCADA technologies and invariably include working with material handling equipment suppliers to create a completely integrated overall process.  Additionally these systems must integrate with order fulfillment and inventory control systems.  The goals of these applications are to:

	Accurately sort a high volume of items
	Be able to be implemented with one or only a few bar code scanners
	Operate with very little human interaction (largely unattended)
	Integrate to order fulfillment systems
	Reduce labor
	Sort more packages with fewer errors
	Reduce damaged product and waste
	Allow one system to handle a wider variety of package types and sizes

Project experience includes 12 projects.

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Bulk Material Handling - Bulk material handling expertise by the Performance Operations team includes vacuum and pressure conveying of dry ingredients and powders in food and plastics.  Experience includes numerous applications including rail car and tank truck unloading and loading, blenders, mixers/reactors, coolers and bulk silos.  These projects typically handle all bulk materials for complete plant sites and are the basis for 24 by 7 continuous operation.  State logic driven controls with advanced technician displays allow for on-line troubleshooting which reduces downtime when sensors fail.  These applications invariably include the application of PLC and HMI/SCADA technologies and include working with material handling equipment suppliers to create a completely integrated overall process.  Often these systems integrate with inventory control systems.  The goals of these applications are to:

	Rapidly convey large quantities of bulk materials to remote destinations
	Accurately ingredient delivery and control blending/mixing/reacting processes to predefined recipes
	Manage bulk inventories and report to enterprise systems
	Operate with very little human interaction (largely unattended)
	Reduce ingredient and product waste

Project experience includes 30 projects.

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Metal Finishing and Plating - Metal Finishing and Plating expertise by the Performance Operations team includes both dip plating and continuous/strip plating systems.  Gene Kaplan and other Performance Operations partners developed state of the art random plating line control algorithms in the 1990s, many of which are still in use today.  Random algorithms allow parts following different patterns through dip plating tanks to be processed simultaneously.  Advanced positioning systems are used to ensure precise motion control of hoists and cranes.  Ancillary equipment is controlled by the same system and all controls are supervised by modern HMI/SCADA systems.  The latest relational databases (SQL) maintain part/process information for traceability purposes.  Plating rectifiers are precisely controlled and precious metals usage is monitored to standards.  Experience includes small parts such as semiconductors and electrical connectors, mid-sized components such as automobile bumpers and very large parts such as galvanizing up to 12 boat trailers on a single flight bar.  Often these systems integrate with inventory control systems and manage chemical balances and replenishment.  The goals of these applications are to:

	Handle processing of multiple types of parts simultaneously
	Ensure part/process requirements are met precisely
	Track process conditions and maintain part/lot traceability
	Operate with very little human interaction (largely unattended)
	Reduce chemical usage, optimize energy efficiency and eliminate part scrap

Project experience includes 50 projects, including systems for OEMs (original equipment manufacturers).

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Press Controls - Automated press expertise by the Performance Operations team includes vacuum laminate presses for decorative laminates and circuit boards as well as proprietary press technologies for advanced materials.  Press controls typically include all aspects of automatic press operation, including loading and unloading, press cycle management, control of auxiliary processes, ramp/soak, etc.  Integration of one or more presses into press cells and automated feed and discharge material handling systems is well within our proven capabilities.  Control systems may be direct computer control or may be distributed control systems using Programmable Logic Controllers (PLCs).  The goals of these applications are to:

	Completely automate press operations
	Ensure part/process requirements are met precisely
	Track process conditions and maintain part/lot traceability
	Operate with very little human interaction (largely unattended)
	Provide on-line troubleshooting to reduce press out of service time

Project experience includes more than 20 projects, including systems for OEMs (original equipment manufacturers), and one large completely automated project with 48 presses arranged in 4 large press cells.

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Extrusion Line Controls and Monitoring - The Performance Operations team has implemented numerous extrusion line control and monitoring systems, including systems for wire and cable and various plastics components (sheet, pipe, etc.)  These systems typically include complete control of takeoff, extruder and takeup, along with advanced monitoring of all pertinent process parameters such as temperature, pressure, thickness, conductivity, etc.  We have experience with co-extrusion, tri-extrusion and integrated tandem extrusion lines.  We have tied Statistical Process Control (SPC) methods back into supervisory control of extruders.  Systems may be directly controlled by PCs, or in a distributed control architecture using PLCs.  We have extensive experience networking multiple extrusion lines into work cells, including centralized relational databases (using Structured Query Language, SQL technology).  We have provided bar code lot and serial tracking, inventory control and downtime management into extruder lines and have integrated into Enterprise Resource Management (ERP) systems.

  The goals of these applications are to:

	Completely automate extruder operations
	Ensure processing requirements are met precisely
	Track process conditions and maintain part/lot traceability
	Track out of tolerance process conditions and relate to location of the defect on the extruded part
	Operate with very little human interaction (largely unattended)
	Provide on-line troubleshooting to reduce extrusion line out of service time
	Automatically send production, part and process information up to the business system

Project experience includes more than 35 projects, including more than 15 years' of continuous project services to a large Fortune 100 wire and cable manufacturer with multiple sites worldwide.

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Proprietary Processes - Besides improving existing operations, the Performance Operations team has helped develop several exciting and influential new technologies.   This list includes helping a major beverage company implement the first aseptic juice packaging in the USA, cutting edge composite technologies for helicopter blades and airplane fuselages and a new compostable packaging for a worldwide fast food chain which is a replacement for polystyrene.  Our ability to deliver results in strategic and tactical business areas, while simultaneously addressing technology, manufacturing operations and the human element make us a powerful addition to the planning and implementation stages of a new manufacturing process.

Project experience includes more than 30 projects considered new technology.

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Special Machine Controls

Project experience includes 10 projects.

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Process Automation Capabilities

Gene Kaplan has significant experience with the following Process Automation Capabilities:

Process Automation Systems Design - The Performance Operations Team provides highly evolved systems design capabilities for process automation projects.  We typically start with documentation of the process itself, building a database of the pertinent process, instrumentation, control and interface system information.  This information is entered one into the database one time only and is then linked to the various appropriate environments, such as a Computer Aided Design (CAD) system for Process and Instrument Design (P&ID), Data Acquisition and/or Programmable Logic Controller (PLC), and Human Machine Interface (HMI) software environments.  Starting with from the foundation of system lifecycles from space probe projects in the 1980s, we have continued to improve our design processes so as to be flexible enough for commercial/industrial projects, but formal enough to ensure project control.  We customize our design approach for each specific project, taking into account the personality of the client organization and team, the skills of the implementation team and type of application.  Typically a project is broken down into 3 phases - 1) Feasibility Analysis, 2) Systems Design and 3) Implementation.  Components of a Performance Operations Team design typically include:

	Functional Requirements - A detailed list describing what functionality must be provided by a particular system
	Process Systems Database - A relational database documenting everything pertinent about a system's construction
	System Overview Document - An overview of a proposed project, suitable for all persons interested in the project
	System Design Document -  A document describing, in detail, how a system will be constructed
	Detailed Design Documents - Individual, very detailed documents suitable for use by a technologist configuring or coding

See also more on the above on the Performance Operations Methods page.

Project experience includes over 100 projects.

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Process Automation Standards Development - With PLC and HMI experience back to the early 1980s, the Performance Operations Team has developed process automation standards for systems integrators, OEMs and end users.  These standards ensure that all vendors supplying systems to an end user provide compatible systems which may be easily supported by the end user team.  Standards go well beyond simple "product selection" criteria, typically to include control panel design, electrical installation design,  PLC code structure, graphic, configuration and networking standards for HMIs and, most importantly of all, documentation.  It is the Performance Operations Team's fundamental belief that process automation systems should not require the end user technician to read ladder logic or examine HMI configuration logic to troubleshoot the system.  The appropriate form of documentation, in an easy to understand human oriented format (there are several), is required.  Most PLC and HMI programmers do not adequately document their software solutions, resulting in systems which are slower to troubleshoot, hard to modify and expand, and may require the original programmer be called in for even the simplest of changes.  Standards development projects typically include:

	Control Panel Standards - Allowable products, basic wiring techniques, electrical safety, maintenance/troubleshooting
	Electrical Wiring - Required installation styles and rules, safety, maintenance and troubleshooting
	PLC - Hardware and software standards, including structured logic
	HMI - Configuration and network standards, including graphics and user interface standards
	Documentation - Rules for formal documentation submittals and acceptable documentation formats

Project experience includes 20 projects.

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Programmable Logic Controllers (PLCs) - Gene Kaplan has been designing and implementing PLC systems since 1980.  State logic design methods document control logic prior to implementation.  Structured ladder logic and automated sequencers ensure PLC code is readable and provide an organized environment for technicians to maintain and add to.  Database based design solutions maintain electrical installation, PLC and HMI information in a single location.  Fully documented code ensures for longevity of the system.  PLC projects typically include:

	Standardized state logic design methods
	Structured ladder logic
	Automated software sequencers
	Standardized Hand-Off-Auto logic for controllers outputs
	Standardized alarm and event logic
	Documentation - Fully annotated code

Project experience includes over 100 projects.

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	Human Machine Interfaces (HMIs) - The Performance Operations partners have been designing and implementing HMI solutions since their inception in the market (early '80s).  We regularly implement today's HMI solutions in Wonderware, Intellution and Rockwell Automation from an extensive set of solution libraries.  In addition to the traditional process graphics, events and alarms, our HMI implementations typically include many features not provided by other sources, including Auto/Manual (Hand-Off-Auto) controls, on-screen state logic displays, engineering setpoints and other features which address the technician's needs as well as the operator.  Our HMI solutions integrate to our Information Technology solutions, including integration of inventory control, lot traceability and downtime into complete shop floor solutions.  HMI solutions provided by Performance Operations typically include:
	Human engineered process graphics (optimized for functionality, not "style")
	Different operator functions for different modes of operation (processing versus cleaning modes, for example)
	Functions which address the technician as well as the operator
	Manual control functions, the activation of which are tracked in the event log
	On-line technician troubleshooting tools which dramatically reduce downtime
	Access to PLC setpoints so that technician's can make adjustments without accessing PLC logic
	On-screen display of state machine logic
	Integration to relational database servers for recipes and data logging

Project experience includes over 500 projects.

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Process to Enterprise Connectivity - Process Automation solutions provided by Performance Operations partners typically include connection to enterprise information systems.  This means that process automation applications, such as process and machine control systems and data acquisition systems do not "stand alone" from the business system.  Many manufacturers find that their operators have to enter data into multiple systems, including a process system and the business system.  For example, the process system may track materials usage, but then the operator has to re-enter that information into an inventory control system as well.  Besides wasting time, this leads to errors.  By integrating the information in the process application to the business system, we are providing better data to the enterprise while improving shop floor efficiency.  Enterprise connectivity solutions provided by Performance Operations typically include:

	Connection of work orders and production orders to the process application
	Standardized access to recipes, formulations and quality control parameters
	Integration of lot and inventory control information into the business system
	Capture of actual production, process run time and/or batch information for quality and traceability purposes
	Supply of downtime data to the business system

Project experience includes 100 projects.

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Data Acquisition Systems and Data Historians - Data Acquisition and Data Historian systems provided by Performance Operations partners collect data from manufacturing processes and format into information which can be displayed and queried by data mining and reporting tools.  Information gathered from processes may include analog process information, such as temperature and pressure, as well as discrete event data, such as alarms, operator oriented events and internal system events.  Once this information has been sampled, conditioned and stored in a relational database format, then it may be accessed by plant floor users, managers and executives as well as various dedicated computer applications.  The most important function of these types of systems is the ability to relate data collected from one part of the process to another.  For example, data from raw materials entering the process can be collected and related to data collected from the process itself, yielding comprehensive sets of information which are much more valuable to the organization.  Data Acquisition and Data Historian solutions provided by Performance Operations typically include:

	Unattended operation
	Connection to plant floor control systems
	Conditioning, filtering and normalizing of data acquired
	Integration to other plant or shop floor systems (such as bar code inventory control systems)
	Connection to various data mining and reporting applications
	Supply of relevant data to the business system

Project experience includes 50 projects.

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Instrumentation - Performance Operations principals and partners have well over 20 years of experience in the selection and specification of process instrumentation.  Our process instrumentation and controls experience, combined with our experience integrating OEM systems, shop floor and enterprise information systems experience allows us to achieve more functionality and closer integration than using specialists for each separate discipline.  Instrument solutions provided by Performance Operations typically include:

	Database approach to specifications
	Specification of Intelligent Instrumentation
	Networked instrumentation solutions which save on installation complexity and costs
	Self-diagnosing instrumentation systems

Project experience includes over 200 projects.

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Control Room Design

Project experience includes 15 projects.

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Control Panels

Project experience includes over 100 projects.

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Control Networking

A balance of a solid foundation in classic Distributed Control and modern Information Systems philosophies

Project experience includes 60 projects.

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