Today’s business environment is more challenging than ever. To
remain competitive, original equipment manufacturers must constantly
reduce costs and enhance equipment performance with new features and
functions.
On the surface, cost reductions have been achieved by utilizing standard “off-the-shelf” controls
such as operator interfaces, industrial controllers and I/O. However,
these products never seem to quite satisfy all of the equipment or application
requirements. There are either more functions offered than necessary
or not enough functions available, which ultimately forces a compromised
solution.
Custom controls are best suited to satisfy cost reduction objectives
while providing enhanced features and functions that match exactly to
the OEMs equipment and application requirements – without compromise.
The following considerations will assist the evaluation process when
deciding between custom and “off-the-shelf” controls.
Custom
Controls |
“Off-the-Shelf” Controls |
Standard Features, Functions
and Performance |
Exact requirements for equipment and applications
are precisely met. Unique features, functions, diagnostics and
performance are embedded in the control, often times through
software for little or no added cost. |
Designed with standard features, functions and performance
to satisfy a broad range of applications and industries. Built-in
operability and flexibility is limited to only what is useful
for the most common applications. |
Product Interoperability |
Device functions and performance, developed concurrently,
are integrated and embedded in the custom control. This eliminates
any interface problems caused by using separate components and
necessary support from multiple vendors. |
Substantial design effort and testing is required to insure
reliable interoperability between separate components. Product
support and troubleshooting is more difficult, especially when
products from multiple vendors are utilized. |
Product Life Cycle |
A custom control is your product – you determine
its product life cycle and obsolescence. In addition, you can
ensure compatibility and full functionality with past and future
equipment requirements. |
Product life cycle may be short and is dictated by the control
supplier. Product/control migration is often difficult when a
selected device becomes obsolete – forward and backward
compatibility may not be possible. |
Control Architecture and
Panel Wiring Complexity |
A single custom control can replace many individual,
separately installed components. Inter-wiring can be eliminated
making installation fast and easy. Control architecture is simplified
since all protocol and messaging is integrated in the control. |
Multiple control panel components, often with different construction
and design platforms make panel wiring more complex. This can
increase the possibility of assembly and installation errors.
Gateways may be required to bridge different communication protocols. |
Proprietary Programming
Code |
Your intellectual property is protected because
customers don’t need access to the programming code – all
of the equipment functions are pre-defined in the controller. |
To achieve desired performance and integration with other
components, users often require and demand access to the equipment
supplier’s application program. |
Anti-Tamper Proof Design |
Equipment operation and proper performance are
protected, ensuring unauthorized personnel from making changes
causing an unsafe condition. |
Access to the application program and the use of standard
configuration software enables users to incorrectly change equipment
performance or function – possibly creating an unsafe condition
or damaging the equipment. |
Future Sales |
A custom control is your product, with your brand
name and part number. Repair and replacement devices are ordered
from you – not from a third party. Future orders ensure
an ongoing relationship and dialog with customers. |
“Off-the-shelf” component suppliers may receive
repair and replacement part sales. The equipment manufacturer
can loose valuable customer feedback on device performance or
problems possibly putting their product at risk and affecting
future orders. |
Reliability |
The custom controller is application specific, thus simplifying
overall panel and equipment design while increasing reliability.
Built-in diagnostics will lower costly maintenance and repair
time. |
The more components in a panel, the lower the reliability
of the equipment – there is more chance for incorrect wiring,
improper installation or defective parts that fail prematurely.
Finding defective components can be more difficult because there
are more failure possibilities. |
Programming Languages |
Different programming languages are available in custom controllers.
Typical languages include: ladder diagram, function block diagram,
sequential function chart, structured text, instruction list,
C+, and BASIC. |
Most standard controllers are limited to ladder diagram programming
only. |
Service and Support |
BTR Controls is your strategic partner and prides itself in
providing unmatched service. We will immerse ourselves in your
business to understand your exact requirements. We supplement
your industry and application specific experience with our years
of control expertise. We are your single source and contact throughout
the entire life of the custom control from design specification
to obsolescence and the introduction of the next generation product. |
Service and support personnel from “off-the-shelf” product
suppliers typically have very little knowledge about your specific
equipment and requirements. This makes configuration, commissioning
and troubleshooting extremely time consuming and frustrating. |
Cost |
Custom controls provide the lowest total installed cost giving
you a competitive advantage. Installed cost savings are realized
from:
- Reduced material costs.
- Reduced installation costs.
- Reduced maintenance costs.
- Reduced engineering costs.
- Future expandability.
- Lower inventory.
- Simplified supplier relationships.
|
Direct material costs may be lower, but total installed costs
are almost always higher after accounting for engineering, installation,
customer support, maintenance, upgrades, inventory and managing
the supply chain. |
Brand Identity |
A custom control carries your brand name and company image – it
can have a common look and feel to the associated equipment in
which it is installed. |
There may be no brand identity other than the brand of the “off-the-shelf” device
supplier. The overall equipment brand is often overlooked. |
