Control Engineering's Buyers Guide 2004 Purchasing Study

To gain a better understanding of industry buying power, Control Engineering and Reed Research Group surveyed Control Engineering subscribers about purchases across 26 product categories to determine numbers of units purchased in the past 12 months as well as how much was spent on those purchases.

08/15/2004


To gain a better understanding of industry buying power, Control Engineering and Reed Research Group surveyed Control Engineering subscribers about purchases across 26 product categories to determine numbers of units purchased in the past 12 months as well as how much was spent on those purchases. The full survey, available at Control Engineering 's Resource Center, / , also shows average cost per unit and most preferred vendors.

Leading categories of "products purchased" are sensors and/or transmitters (flow, level, temperature, pressure, etc.), programmable logic controllers (PLC) hardware and software, switches (flow, level, temperature, pressure, etc.), I/O products and systems, and ac motors (including brushless).

The survey, conducted in late January 2004, received more than 750 responses from subscribers—56% percent manage as many as 20 employees—with the following job function breakdown:

  • Control and/or instrument engineering: 19%;

  • Systems design engineering including applied R&D: 13%;

  • Other engineering, including product, software, plant, electrical and/ or electronic: 12%;

  • Systems integrators and/or consultants: 12%;

  • General or corporate management: 10%;

  • Operations and/or maintenance: 10%;

  • Product design engineering including applied R&D: 9%;

  • Production engineering, process or manufacturing: 9%;

  • Evaluation, quality control, standards, reliability, test engineering: 4%; and

  • Basic research: 1%

The following tables illustrate purchasing levels across the 26 product categories surveyed as well as details on specific categories: sensors and/or transmitters (flow, level, temperature, pressure, etc.); programmable logic controllers hardware and software; switches (flow, level, temperature, pressure, etc.); I/O products and systems; AC motors (including brushless); control valves (throttling valves), actuators, and related accessories; and PC-based control software.

Products purchased

Switches (flow, level, temperature, pressure, etc.)

37%

I/ O products & systems

36%

AC motors (including brushless)

33%

Control valves (throttling valves), actuators, and related accessories

33%

Photoelectric & proximity sensors

31%

Adjustable speed (variable frequency) drives (ac, dc)

31%

PC-based control software

28%

HMI/ SCADA software & operator interface hardware (including PCs)

27%

Motion controller and/ or positioner hardware & software, including feedback devices (encoders, resolvers, tachometers, torque sensors, etc.)

26%

Electromechanical motor starters

23%

Data acquisition (DAQ) equipment hardware & software, including remote terminal units (RTUs)

23%

Distributed and/or hybrid control systems (hardware & software)

23%

Single & multi-loop controllers (including stand-alone)

23%

Servo motors (ac, dc, brushless)

22%

Block (on/ off) valve, actuators, and related accessories

21%

DC motors

18%

Solid-state motor starters

17%

Power elements for motor control (power modules, power switching devices, etc.)

16%

Process analyzers (pH, CO 2 , chromatography, CO, etc.)

16%

Paper and/ or paperless recorders

14%

Step motors & related controls

12%

Vision system software & hardware components

11%

Advanced optimization software & related computing hardware

10%

Robotic system hardware, software, and related devices

8%

None of the above

29%


Sensors and/or transmitters

Total Dollars

Total Units

Respondents

% of Total Respondents

Avg. units per resp.

ABB

$339,250

101

9

7%

11.2

Ametek

$23,800

59

6

4%

9.8

Anderson

$22,150

68

4

3%

17.0

Ashcroft

$63,950

94

10

7%

9.4

Druck

$4,100

6

2

1%

3.0

Emerson Process Management

$1,401,500

858

30

22%

28.6

Endress+Hauser

$161,000

88

14

10%

6.3

Flowline

$6,140

12

3

2%

4.0

Honeywell

$183,925

225

18

13%

12.5

ifm efector

$75,567

513

17

13%

30.2

Invensys Production Management

$97,300

80

7

5%

11.4

Johnson Controls

$4,700

16

6

4%

2.7

K-Tek

$30,500

20

5

4%

4.0

Magnetrol

$4,900

4

4

3%

1.0

Masoneilan

$9,000

10

1

1%

10.0

Milltronics (Siemens)

$19,250

17

7

5%

2.4

Omega Engineering

$39,550

163

22

16%

7.4

Sensotec

$3,300

7

2

1%

3.5

Siemens/Moore

$6,650

13

3

2%

4.3

Wika Instrument

$5,000

20

1

1%

20.0

Yokogawa

$142,500

43

6

4%

7.2

Other

$257,737

2577

35

26%

73.6


Programmable logic controllers (PLC) hardware & software

Total Dollars

Total Units

Respondents

% of Total Respondents

Avg. units per resp.

AutomationDirect

$30,450

31

12

12%

2.6

Baldor Electric

$6,500

2

1

1%

2.0

Emerson Process Management

$62,000

11

2

2%

5.5

GE Fanuc

$646,900

134

13

13%

10.3

Mitsubishi Electric

$19,140

7

4

4%

1.8

Moeller

$18,000

11

2

2%

5.5

Omron Electronics

$64,100

10

3

3%

3.3

Opto 22

$1,500

5

1

1%

5.0

Rockwell Automation/Allen-Bradley

$4,115,276

761

78

75%

9.8

Schneider Electric

$430,800

122

13

13%

9.4

Siemens

$810,000

99

11

11%

9.0

Other

$207,100

138

6

6%

23.0


Switches (flow, level, temperature, pressure, etc.)

Total Dollars

Total Units

Respondents

% of Total Respondents

Avg. units per resp.

Acromag

$24,500

16

2

3%

8.0

Ametek

$23,000

30

2

3%

15.0

AutomationDirect

$2,500

21

4

5%

5.3

Banner Engineering

$109,100

2026

6

8%

337.7

Bindicator

$3,050

5

3

4%

1.7

CCS Dual Snap(Custom Control Sensors)

$700

1

1

1%

1.0

Eaton Electrical/ Cutler-Hammer

$3,600

10

2

3%

5.0

Drexelbrook

$13,700

24

3

4%

8.0

Dwyer Instruments

$27,500

199

13

17%

15.3

Emerson Process Management

$8,000

58

3

4%

19.3

Endress+Hauser

$8,900

13

3

4%

4.3

Flow-Tek

$675

6

1

1%

6.0

Fluid Components International

$15,450

14

4

5%

3.5

Gems

$4,000

6

2

3%

3.0

Honeywell

$7,600

48

5

7%

9.6

ifm efector

$7,950

17

5

7%

3.4

Invensys Production Management

$300

2

1

1%

2.0

Magnetrol

$11,000

15

4

5%

3.8

McDonnell & Miller

$300

2

1

1%

2.0

Micro Switch (Honeywell)

$4,895

59

5

7%

11.8

Moeller

$200

2

1

1%

2.0

Omega Engineering

$17,300

91

10

13%

9.1

Pepperl+Fuchs

$1,000

2

1

1%

2.0

Rockwell Automation/ Allen-Bradley

$27,200

217

8

11%

27.1

Schneider Electric

$7,690

57

4

5%

14.3

Siemens

$6,800

6

2

3%

3.0

Sor

$5,700

10

3

4%

3.3

Turck

$16,000

146

4

5%

36.5

United Electric

$27,300

101

6

8%

16.8

Westlock

$8,700

35

2

3%

17.5

Other

$44,275

236

11

15%

21.5


Control valves (throttling valves), actuators, and related accessories

Total Dollars

Total Units

Respondents

% of Total Respondents

Avg. units per resp.

Dezurik

$33,500

58

3

4%

19.3

Durco (Flowserve)

$20,000

20

1

1%

20.0

Emerson Process Management

$3,605,100

1500

27

38%

55.6

Fluid Tech

$2,000

1

1

1%

1.0

Honeywell

$344,000

460

12

17%

38.3

Jamesbury (part of Metso Automation)

$1,100,000

343

7

10%

49.0

Masoneilan

$205,450

43

4

6%

10.8

Samson

$15,000

10

1

1%

10.0

Tri-Clover (Alfa Laval)

$13,500

10

4

6%

2.5

Tyco

$160,000

70

3

4%

23.3

Valtek

$558,000

24

8

11%

28.0

Other

$10,617,590

5250

22

31%

238.6


I/O products & systems

Total Dollars

Total Units

Respondents

% of Total Respondents

Avg. units per resp.

ABB

$11,200

21

2

3%

10.5

AutomationDirect

$5,250

14

6

8%

2.3

Bosch Rexroth

$5,000

1

1

1%

1.0

GE Fanuc

$160,800

375

9

12%

41.7

Honeywell

$37,000

34

1

1%

34.0

Invensys Production Management

$10,000

5

1

1%

5.0

Mitsubishi Electric

$500

1

1

1%

1.0

National Instruments

$49,200

26

12

16%

2.2

Omron Electronics

$11,000

16

5

6%

3.2

Rockwell Automation/Allen-Bradley

$674,350

1055

38

49%

27.8

Schneider Electric

$925,800

1105

12

16%

92.1

Siemens

$8,475

14

4

5%

3.5

Other

$120,900

161

8

10%

20.1


AC motors (including brushless)

Total Dollars

Total Units

Respondents

% of Total Respondents

Avg. units per resp.

AO Smith

$1,200

3

1

1%

3.0

Baldor Electric

$257,095

536

39

57%

13.7

Bosch Rexroth

$3,000

3

1

1%

3.0

Danaher Motion

$600

5

1

1%

5.0

Grainger

$19,745

58

12

18%

4.8

Leeson Electric

$41,600

125

7

10%

17.9

Lincoln Electric

$4,500

7

3

4%

2.3

Marathon Electric

$11,150

14

5

7%

2.8

Nord

$1,000

1

1

1%

1.0

Oriental Motor

$20,000

71

3

4%

23.7

Rockwell Automation/Allen-Bradley

$251,500

183

14

21%

13.1

Siemens

$102,300

56

3

4%

18.7

Sumitomo

$13,600

16

2

3%

8.0

TECO-Westinghouse

$42,600

34

5

7%

6.8

Toshiba

$700

1

1

1%

1.0

Emerson Motor Technologies/US Motors

$1,800

3

2

3%

1.5

Other

$644,400

1118

12

18%

93.2


PC-based control software

Total Dollars

Total Units

Respondents

% of Total Respondents

Avg. units per resp.

Eaton Electrical/Cutler-Hammer

$1,400

2

1

2%

2.0

Emerson Process Management

$105,000

21

2

3%

10.5

Entivity

$3,000

1

1

2%

1.0

GE Fanuc

$128,600

21

6

10%

3.5

Honeywell

$41,000

4

2

3%

2.0

Iconics

$9,000

2

2

3%

1.0

Invensys Production Management

$2,275,500

260

6

10%

43.3

National Instruments

$68,650

20

15

26%

1.3

Phoenix Contact

$800

1

1

2%

1.0

Rockwell Automation/Allen-Bradley

$319,800

48

16

28%

3.0

Schneider Electric

$750,000

1000

1

2%

1000.0

Siemens

$320,500

24

4

7%

6.0

Other

$190,895

40

8

14%

5.0





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