From an idea to a consistent system

Article#: 00001

Date: 2020-04-11

Author: Radim

A machine or a plant is designed with the idea of WHAT we want to do and WHY and HOW we want to do it.

The mechanical construction of the machine is designed.
Electrical components (actuators, sensors, relays, PLCs, inverters, ...) enable the functionality of the machine.
The software of the programmable logic controller (PLC) ensures the functionality of the machine.
And the visualization (HMI = Human Machine Interface) makes the machine functionality accessible to the users.

All four layers (visualization, control software, electrical components and the mechanical parts of the machine) must be considered and designed together.
They must have the common understanding of "WHAT", "WHY" and "HOW" in order to achieve a consistent and transparent system.
Understanding and operating of such a consistent and transparent system is intuitive and easy.

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Comment#: 00001

Date: 2021-06-22

User: Radim

"Break down barriers between departments. People in research, design, sales and production must work as a team, to foresee and solve problems of production."

- William Edwards Deming

Comment#: 00002

Date: 2022-01-08

User: Radim

A machine is almost always part of the production chain. It is therefore necessary not to consider the machine in isolation, but to take into account the material output of the previous link and the material input for the next link in the chain so that the machines are well coordinated. By properly integrating the machine into the production chain, it is possible to speed up production, save on manpower and achieve smoother and better coordinated production.

Comment#: 00003

Date: 2022-10-31

User: Radim

"There is often a significant gap between the process control requirements as set by process engineering and the definition needed to create the actual system configuration. This is because the process engineers do not speak the configuration engineers' language. Translating the process engineer's control requirements into the format of the configuration functional specification is required. In addition to requiring an understanding of the underlying process, this translation is a highly specialized task requiring resources with deep configuration expertise on the control platforms. A similar translation is required of mechanical, civil, and electrical disciplines as well. Any errors or omissions in the resulting functional specifications cause changes down the line."

- https://blog.isa.org/industrial-automation-projects-challenging-management

Comment#: 00004

Date: 2022-11-23

User: Radim

Once you are sure about your vision, share your vision with everyone involved. Explain the vision to them and let them give their opinion.
When people are part of the project from the beginning and can see and influence how the vision becomes a real product, they identify with the product.
Otherwise people will not identify with the innovation and will reject it.

Comment#: 00005

Date: 2022-11-29

User: Radim

"A good software development team should include developers, testers, designers, product managers, and executive stakeholders so that all views are taken care of."

- 5 Tips for Developing an Effective Software Quality Testing and Assurance Culture.
- https://technofaq.org/posts/2017/04/5-tips-for-developing-an-effective-software-quality-testing-and-assurance-culture/

Comment#: 00006

Date: 2023-01-19

User: Radim

"There are several steps that can be taken to turn an idea into a consistent system:

1. Define the problem: Clearly define the problem that the idea is trying to solve. This will help to ensure that the system being developed is addressing the correct issue.

2. Research: Conduct research to gather information about existing solutions, technologies, and best practices. This will help to inform the design of the system and ensure that it is based on sound principles.

3. Design: Create a detailed design for the system, including a description of its functionality, components, and interfaces. This will help to ensure that the system is well-structured and easy to maintain.

4. Implement: Develop and implement the system, following best practices and established standards. This will help to ensure that the system is robust, efficient, and easy to use.

5. Test: Test the system thoroughly to identify and fix any bugs or issues. This will help to ensure that the system is stable and reliable.

6. Deploy: Deploy the system to the production environment, and monitor it to ensure that it is working as expected.

7. Maintenance and improvement: Regularly monitor the system and improve it based on feedback and new requirements.

8. Document: Document the system thoroughly, including information about its design, implementation, and usage. This will help to ensure that the system is easy to understand and maintain.

Throughout this process, it is important to keep the end user in mind and focus on providing value to them. It's also important to have a system development methodology that works for your team, like Agile, Waterfall, etc."

- https://chat.openai.com (How do we get from an idea to a consistent system?)

Comment#: 00007

Date: 2023-07-11

User: Radim

"Iteration is more than a process.
Regardless of the actual steps involved in the process you choose, iteration is a best practice. It's an approach that can be applied to any process, and it gives you a better chance of delivering what is needed, on time and on budget. Whateber process you end up using, iteration should be a major part."

- Dan Pilone and Russ Miles. O'Reilly Media (2008). Head First Software Development. (Page 24)

Comment#: 00008

Date: 2023-08-16

User: Radim

Should a PLC software developer design the graphical user interface himself?

"Whether a PLC (Programmable Logic Controller) software developer should design the graphical user interface (GUI) themselves depends on several factors, including the developer's skillset, the project's requirements, and the available resources. Here are some considerations to keep in mind:

1. Developer's Skillset: If the developer has the necessary skills and experience in GUI design, they can certainly handle the task themselves. However, if the developer lacks expertise in designing user-friendly and effective interfaces, it might be better to involve a dedicated UI/UX designer.

2. UI/UX Design Expertise: Designing a user-friendly and efficient GUI requires a good understanding of user experience (UX) principles, usability, and visual design. If the developer lacks expertise in these areas, collaborating with a skilled UI/UX designer can lead to a better user interface and overall user satisfaction.

3. Project Complexity: The complexity of the project can also play a role. If the GUI is relatively simple and straightforward, the developer may be able to handle the design aspect along with their programming responsibilities. However, for more complex applications, involving a dedicated designer can ensure a more polished and professional interface.

4. Time and Resources: Designing a GUI can be time-consuming, especially if it requires iterations and adjustments based on user feedback. If the developer's primary role is programming and they have limited time to allocate to GUI design, it might be more efficient to delegate the design to someone else.

5. Collaboration: Collaboration between the developer and a dedicated designer can lead to a more well-rounded solution. Developers can provide insights into the technical aspects and constraints of the PLC system, while designers can focus on creating a visually appealing and user-friendly interface.

6. User-Centered Design: If the PLC application will be used by non-technical users or operators, it's important to prioritize user-centered design. A dedicated UI/UX designer is more likely to have the expertise to create interfaces that are intuitive and easy for users to navigate.

In summary, while a PLC software developer can design the GUI themselves if they have the necessary skills and the project's requirements are relatively simple, involving a dedicated UI/UX designer can lead to a more effective and user-friendly interface, especially for complex projects or applications intended for non-technical users. Collaborative efforts can often result in a better overall outcome, balancing technical functionality with a well-designed user experience."

- https://chat.openai.com (Should a PLC software developer design the graphical user interface himself?)

Comment#: 00009

Date: 2023-08-24

User: Radim

What does this saying mean? "We work like in kindergarten." Why is that?

"The saying "We work like in kindergarten" typically implies that the way people are working or collaborating resembles the simple and unstructured activities often associated with a kindergarten classroom. In other words, it suggests that the work environment lacks professionalism, organization, or efficiency, and might involve behaviors or practices that are chaotic, unstructured, or overly casual.

In a kindergarten classroom, children engage in various activities, play, and exploration, and while this is suitable for their developmental stage, it wouldn't be effective or appropriate in a professional or complex work setting. Therefore, using this saying might be a way to highlight the lack of seriousness, order, or productivity in a work context.

People might use this saying to express frustration about a lack of proper procedures, discipline, or focus in a work environment. It could also indicate that individuals aren't taking their responsibilities seriously or aren't adhering to professional standards. Overall, the saying conveys a sense of dissatisfaction with the way work is being carried out."

- https://chat.openai.com (What does this saying mean? "We work like in kindergarten." Why is that?)

Comment#: 00010

Date: 2023-10-05

User: Radim

After the internal tests, how much time does the project need for further software development until it is ready?

From my point of view, several pieces of information about the status of the project are needed for the most accurate estimation:

1. Who is the project leader? Is he still available?

2. What is the project plan?

3. Has the list of all requirements been summarised? How many have been fulfilled and which are still open?

4. On which platform was the software developed?

5. Who developed the software? Is he / she still available?

6. Are there dependencies on external companies?

7. How is the project documented - requirements, software concept, architecture, code, test cases, etc.?

8. How clean and modular is the software?

9. Do the electronic parts and processes of the machine remain unchanged after the internal tests?

10. How successful are the internal tests? What new findings, to-dos / pending issues result from this?

Have I forgotten anything?

Comment#: 00011

Date: 2024-01-11

User: Radim

"Boeing wasn't started to make money, it was started to make airplanes. Bill Allen was CEO of Boeing from 1945-1968. During that period, he said their mission was to: "Eat, breathe and sleep the world of airplanes".
During that period Boeing made the best airplanes in the world and the company grew to become the most successful company on Earth. Then they screwed it up.
Boeing appointed Phil Condit as the new CEO with the goal of maximizing shareholder value and improving investors returns. Phil changed the original mission of "Eat, breathe and sleep the world of airplanes" to something more mature and corporatey: "To maximize the value for our shareholders by low cost structures and the use of modern accounting standards".
The result? Boeing started to produce crappy airplanes, customers stopped buying them and Boeing started to lose money and nosedive into a downward spiral. What Boeing and 99% of the world doesn't understand is that business [ life ] isn't about "making money", it's about "adding value" to others. Money is the byproduct.
Businesses who aim to make money directly fail to make money at all. Businesses who aim to add value by enhancing the lives of others make money as an indirect byproduct. This is a BIG lesson for those trying to get ahead!
Stop trying to get rich, start trying to genuinely add value to humanity. (They will in-turn make you rich in the process)."

- https://www.linkedin.com/pulse/copy-you-creating-value-just-money-greg-smith-ddtye/

Comment#: 00012

Date: 2024-09-05

User: Radim

"It is important that the mechanical design is intelligent. Software can never compensate for the shortcomings of a stupid mechanical design. For this reason, it is essential that all developers talk to each other right from the start."

- Christian
- https://www.radim-automation.com/Page_Article00001_De.php#Comment00001
(translated from German)