Shawn Orr

Heat Treat E-Commerce: A Growing Trend or a Passing Fad?

OCE-commerce? In the heat treating industry? Heat Treat Today was curious about this new trend, so we asked three heat treat insiders about their industry e-commerce experiences. Is e-commerce coming to the industry? Where has it succeeded; where has it failed? Is e-commerce a growing trend or is it just a passing fad? Find out if your future will include heat treat e-commerce or not!

Contributors include Shawn Orr, engineering manager, and Jonathan Lance, senior marketing specialist, at Televac®—The Fredericks Company and Clint Hall, the vice president of Marketing at Olsträd Engineering Corporation and Combustion 911.


Introduction

CBRE Group, Inc., an American commercial real estate services and investment firm, projects that U.S. e-commerce sales will increase $330 billion between 2020 and 2025. Others, like market research firm Statista, project an increase by about one-third.1 This may be the case for industry in general, but are purchasing habits of heat treaters changing, too? Could “e-commerce” be the next big thing for heat treaters?

We asked several heat treat industry insiders what they thought e-commerce could offer to heat treaters and how this service addresses a variety of purchasing needs.

What is “E-Commerce”?

Shawn Orr & Jonathan Lance: “Televac® is a designer and manufacturer of vacuum gauges, so to us e-commerce means offering our products for sale through our website and making them as easy as possible to purchase with the shortest possible lead times. Having online pricing and the ability to order online eliminates any lag time associated with waiting for a quote, email, or call from one of our sales representatives.”

Clint Hall: “We view e-commerce as (spare) part sales via the internet. We sell combustion equipment heat treaters use to keep their furnaces running.” Hall represents Olsträd Engineering Corporation’s Combustion 911 service.

[accordion style="colored"][acc title="Televac®—The Fredericks Company"]Televac® serves the heat treat industry by providing low-cost, robust, full range vacuum gauging solutions. With Televac®’s new e-commerce website, they are able to reduce lead times, while providing the same high-quality products, services, and support. [/acc][acc title="Combustion 911"]Combustion 911 is an e-commerce website which serves the heat treat industry by providing spare parts, but also complete combustion systems. Heat treaters use combustion systems to safely transport combustible fuels.[/acc][/accordion]

Getting on the Cutting Edge

These insiders shared that their initiative to implement e-commerce for heat treaters largely came from looking at the growing use of web retail in other manufacturing and service industries. They also elaborated on several practical lessons that come with spearheading a web-based, transactional initiative.

Hall: “We started Combustion 911 in 2009. We saw companies like Amazon and Walmart create a space for retail on the web, and we reasoned we could do the same thing for combustion parts. Our initial thought was to create and maintain a space where maintenance staff could easily source parts using a purchasing card, removing barriers and red tape that might keep them from getting the part quickly.”

When asked about lessons he and his team learned, he shared, “The lessons we learned were many and varied. For example, our first lesson was the need to include our phone number on the website. We thought this was going to be hands-off for us, and we were dead wrong. There are a lot of people in the world who don’t trust online shopping carts and will not use them. There are also a lot of people working with combustion equipment who need some reassurance they’re buying the right replacement part, and they’d rather speak on the phone than hash it out over email.

Second, we learned there aren’t nearly as many maintenance folks out there with purchasing cards (p-cards) as we’d thought. Most of our Combustion 911 transactions go through purchasing staff or third-party buyers.”

"[Our] first lesson was the need to include our phone number on the website. We thought this was going to be hands-off for us, and we were dead wrong." -Clint Hall, Combustion 911
Orr & Lance: “At Televac® we always do our best to position ourselves as innovators in the heat treat industry by adopting modern design and manufacturing trends. In today’s world of online retailers, we thought e-commerce was essentially a requirement to allow us to continue providing the highest quality products and services for our clients.”

They continued, “Building e-commerce functionality into an existing website wasn’t always an easy task. It was a challenge to maintain the look and feel of our website while also offering a streamlined e-commerce experience for our clients. One of the major takeaways was that it isn’t always about making an online sale, but instead it’s about maintaining quick access to the resources that our website offers to clients, like datasheets, manuals, application notes, instructional videos, and interactive tools, among others.”

The Evidence: How E-Commerce Helps Heat Treaters

Orr & Lance: “There are many instances where we’ve seen our e-commerce website help our clients. One specific example was when a client needed 8 of our 2A thermocouple vacuum gauges to ship the same day because they had a system down. They were able to place the order on our website within minutes of realizing their need and make a payment that was processed immediately, allowing us to quickly receive the order and ship out the gauges the same day.

“We’ve also found that our e-commerce website significantly reduces the amount of time and effort required for our clients to place an order. An online order eliminates multiple emails or phone calls between our clients and the team, and streamlines the payment process. Because of these improvements, we can often reduce our lead times by several days, getting our products to our clients faster.

Example of MX4A and a 2A Thermocouple.
Photo Credit: The Fredericks Company

Hall: “The combustion market has been going through an upheaval due to the consolidation and eradication of many legacy brands. End users find themselves in a position where they need replacements for parts that have been discontinued or aren’t immediately available. We’ve been able to help users get back up and running using alternative parts with the same function, from stock.

“Additionally, e-commerce gives us a chance to reach a wider audience, which means we can help those in need find the assistance they’re looking for. It takes sustained effort to be relevant on the web, but the result is higher visibility, and the rewards are of equal benefit to us and our clients. They get the help they need, and you get the opportunity to serve them.”

The “Preferred” Purchasing Method

All three insiders attest to the ease-of-use for their clients. Whether it is measured in increased traffic to their website or how the tool has become the preferred purchasing method.

A screen capture of the navigation on Combustion 911, the e-commerce website associated with Olsträd Engineering.

Hall: “Combustion 911 has been going strong since its inception (and once we added our phone number). An unlooked-for boon in this website has been the generation of leads for system sales. We offer combustion and automation engineering, suites of parts, assembled manifolds, control panels, installation, service, the works. These services are available piecemeal or all together, and we’ve developed long-term clients from Combustion 911 inquiries in every category.”

Screen capture of the embedded functionality of e-commerce on The Fredericks Company's website.

Orr & Lance: “Since we launched our e-commerce website in 2020, we have seen a significant increase in online orders each month from clients purchasing our vacuum gauging. We’ve found that many of our clients prefer purchasing online because they want the same experience they have with other online retailers.”

Final Thoughts

Perhaps you are on the frontier of either purchasing or selling heat treat equipment, parts, or services online. As has been discussed, streamlining purchasing habits, finding a new heat treat product provider, or being able to “click” the most up-to-date product with quick shipment options are all appealing reasons to try e-commerce. But as with any change or innovation: Do your research to make sure that this service is right for you before you dive headfirst. Happy buying!

 

References

1 David Sparkman, “Industrial Real Estate Demand Rising,” Material Handling & Logistics (7 July 2021). www.mhlnews.com.

About the Authors:

Shawn Orr, engineering manager at Televac®The Fredericks Company, is responsible for the company’s engineering department and all engineering projects related to research and development and manufacturing.

Jonathan Lance, senior marketing specialist at Televac®The Fredericks Company, is responsible for addressing all marketing needs for the company, including website development, graphic design, digital advertising, and analytics.

Clint Hall is the vice president of Marketing at Olsträd Engineering and Combustion 911. Olsträd provides advanced combustion, controls, and automation systems across a broad spectrum of industries, and represents ESA (burners, flame safety, combustion solutions) and Elektrogas (combustion controls) in North America.

Heat Treat E-Commerce: A Growing Trend or a Passing Fad? Read More »

EthernetIP

EthernetIP is the future of vacuum gauge communications for vacuum furnaces. It’s simple to integrate and improves accuracy by reducing latency from legacy analog 0 to 10 V DC outputs.

Shawn Orr, Technical Business Development Manager,
Televac – The Fredericks Company

Learn about EthernetIP and its place in your heat treat department in this Technical Tuesday original Heat Treat Today article by Shawn Orr, Technical Business Development manager with Televac – The Fredericks Company

This article first appeared in the latest edition (March 2020) of Heat Treat Today’s Aerospace Heat Treating magazine.


What is EthernetIP?

Figure 1.

EthernetIP (IP for Industrial Protocol) is an implementation of the digital communication standard referred to as the Common Industrial Protocol (CIP). It’s a modification of standard Ethernet and is managed by the organization ODVA, Inc. If you’re familiar with the OSI model (Open Systems Interconnection), EthernetIP defines the session layer, the presentation layer, and the application layer, with the other layers (1 through 4) defined by standard Ethernet.

EthernetIP uses standard RJ45 connectors (Figure 1) which are 8P8C (8 position 8 contact). The widespread use and availability of standard Ethernet cables makes them a more affordable solution compared to custom cables and connectors used by many manufacturers for their devices.

Figure 2. Ring topology with a PLC, MX4As, and MX7Bs. Each active gauge is connected to the previous active gauge.

EthernetIP can be configured with various topologies including ring (daisy chaining) and star (point-to-point) configurations (Figures 1 & 2). This can further reduce integration complexity and cable complexity by daisy chaining various components together on the same EthernetIP connection. Each device will have a unique IP address (or they can be grouped together in some cases depending on the implementation), but all configurations will allow you to communicate with all devices individually and digitally.

Figure 3. Star topology with a PLC, MX4As, and MX7Bs. Each active gauge is connected directly to the PLC.

Communications are done in one of two ways; cyclically (Class 1 EthernetIP connection) and acyclically (Class 3 EthernetIP connection). Cyclic communications output the same set of data over and over at a specific rate. Acyclic communications allow you to send commands and receive data back from the EthernetIP device at any time. Acyclic communications give you more control, but cyclic communications can be simpler to integrate.

How Does It Apply to Heat Treating?

So, you might be wondering, how does this apply to vacuum furnaces? All vacuum furnaces have a PLC (programmable logic controller) which is essentially the brain of the furnace. In North America, one of the most common types of PLCs is a Rockwell Automation® Allen-Bradley® PLC which has, you guessed it, EthernetIP capability! PLCs almost always have an HMI (human machine interface) where the operator can control various functions of the furnace.

The PLC takes a variety of inputs from other controllers and sensors which come in many shapes and forms. Some of the most basic are analog signals like 0 to 5 V DC or 0 to 10 V DC. Others are more complex forms of digital communication like EthernetIP. This means that you can use your PLC and HMI to take readings and adjust settings on connected EthernetIP devices.

What Are the Benefits of EthernetIP?

We already talked about some benefits of EthernetIP, but there are many others. Another significant benefit is having digital communications to your vacuum gauging and other devices on the furnace. Let’s use the example of vacuum gauge calibration.

Benefit 1 – Calibration

Many who have worked with devices on vacuum furnaces like vacuum gauges know that calibrating them can be a real hassle. Gauges often have potentiometers (sometimes called pots) that are adjusted with a set screw. This means that you’re trying to look at one reading on the HMI of your furnace while adjusting a gauge that’s possibly on top of the furnace, meaning you need two people. This is a worst-case scenario, but you get the idea; it’s not convenient.

Having digital communications over EthernetIP means that your calibration can be done from the HMI, because you can adjust the calibration digitally with most digital vacuum gauges. No more climbing on top of the furnace and adjusting pots! This is especially useful as Nadcap and AMS (specifically AMS 2769) standards become stricter, you may want to start doing more calibration at your facility instead of sending your gauges out to another facility for calibration.

Benefit 2 – Cost

One of the most significant benefits is the cost of using EthernetIP enabled devices. In addition to cheaper standard Ethernet cables, most furnaces will include other devices with EthernetIP capability, so an EthernetIP communications module for the PLC is already included. This means that if you have analog devices (such as 0 to 5 or 10 V DC), you can remove the need for costly ADC (analog to digital converter) modules by switching your devices to EthernetIP.

Benefit 3 – Power

Another benefit is powering your devices. Because there are open pins on a standard Ethernet cable with standard EthernetIP connections, it’s possible to utilize the unused pins to supply power over the Ethernet cable. There are other implementations where the power is supplied over the data lines. This is called PoE (Power over Ethernet). This eliminates the need for additional, potentially costly and complex power connections for your EthernetIP enabled devices. PoE is done many different ways, but three have been standardized by IEEE called Alternative A, Alternative B, and 4PPoE.

Benefit 4 – Accuracy

(Photo source: Solar Manufacturing/Solar Atmospheres)

The last benefit is accuracy. Using an analog signal can cause signal loss and is susceptible to signal degradation from noise depending on the cable length, particularly in industrial environments. The speed of an analog to digital conversion is also typically done with an equation and can be slow and somewhat inaccurate for a variety of reasons. Eliminating analog to digital conversions improves the latency and accuracy of readings on your HMI. No more mismatches between your gauge display and your vacuum furnace HMI!

How Do You Integrate EthernetIP into an Existing System?

Talk to your furnace manufacturer or a system integrator. First, you’ll need to make sure you have an EthernetIP enabled PLC, then you’ll need to make sure that your furnace configuration supports the addition of specific EthernetIP devices. Since each type of device communicates differently over EthernetIP, you may need to have PLC code and HMI changes made to your system to support something like an EthernetIP vacuum gauge.

About the Author: Shawn Orr is the technical business development manager for Televac – The Fredericks Company and has served as the technical liaison between its customers and engineering, responsible for identifying and implementing new growth opportunities.

(Photo Source: Figures 1-3: Televac – The Fredericks Company)

EthernetIP Read More »