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How can you optimize a PLC system to minimize downtime?

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Downtime is a costly and frustrating problem for any control engineer who works with PLC systems. PLCs are the brains of many industrial processes, but they can also be vulnerable to failures, errors, and malfunctions. How can you optimize your PLC system to minimize downtime and maximize productivity? In this article, you will learn some practical tips and best practices for PLC programming, maintenance, and troubleshooting that can help you achieve this goal.

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Jorge Cano Carmona

Technical and Technological Solutions Manager for Process Automation
Muzzamil Baig MSc CEng CMSE

Automation Manager@ Amazon | Industrial Automation, Process Optimisation, MBA@Deakin
Tinotenda Mutami

Transforming Logistics with Technology | Founder & CEO - Omni Logistics

1 Choose the right PLC

The first step to optimize your PLC system is to choose the right PLC for your application. You need to consider factors such as the size, speed, memory, communication, and compatibility of the PLC, as well as the complexity and requirements of your process. You also need to evaluate the reliability, quality, and support of the PLC manufacturer and supplier. Choosing the right PLC can save you time, money, and hassle in the long run.

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Jorge Cano Carmona

Technical and Technological Solutions Manager for Process Automation
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Choosing a PLC according only to its memory and processing capabilities could be a old practice. Instead choose it according to the process you want to automate and the diagnostics desired (no matter if they will be programmed at the beginning or later), according to the adjacent technologies of the process (like another controllers, safety systems and of course information systems).

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Tinotenda Mutami

Transforming Logistics with Technology | Founder & CEO - Omni Logistics
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When selecting a PLC for automation, key factors like communication protocols, I/O capacity, scalability, and programming capabilities are crucial. Effective communication with HMIs and SCADA systems relies on compatible protocols. Sufficient I/O capacity and module flexibility ensure seamless integration. Scalability allows for future expansion, while diverse programming capabilities (FBD, ladder, ST) enable optimization through data manipulation, PID control, and mathematical functions. Choose wisely for efficient automation.

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Muzzamil Baig MSc CEng CMSE

Automation Manager@ Amazon | Industrial Automation, Process Optimisation, MBA@Deakin
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When choosing a PLC for cross compatibility, it is important to select the write programmming environment. For instance Mitsubishi offers a GX IEC developer which is in line with the IEC61131-3 programming standard. Codesys is an excellent alternative when selecting a programming multifunctional programming environment.

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2 Follow programming standards

The second step to optimize your PLC system is to follow programming standards and conventions. This means using consistent and clear naming, formatting, and documentation for your PLC code, as well as following the best practices for logic, structure, and error handling. Programming standards can help you avoid bugs, errors, and confusion, as well as make your code easier to read, modify, and debug. They can also help you ensure compliance with industry regulations and safety standards.

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Muzzamil Baig MSc CEng CMSE

Automation Manager@ Amazon | Industrial Automation, Process Optimisation, MBA@Deakin
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Familiarise yourself with the IEC61131-3 standard and try to write your code based on this standard, your program should in theory then be portable to various manufacturers. Another good standard to be familiar with is PACK ML which is industry technical standard for packing machinery. Last but not the least, depending on the industry or process you’re working with you may want to refer to the various standards developed by International Society of Automation (ISA) such as ISA-95 which is for interfacing control system with enterprise systems and ISA-88 for batch process control.

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Jorge Cano Carmona

Technical and Technological Solutions Manager for Process Automation
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Always be sure the process requirements are written in a cross reviewed document and approved bu the customer, the programmer and the project manager at least. Ask what if something goes wrong, ask yourself how the process must work and of course ‘how it could fail’ to prevent and be aware of it.

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3 Test and simulate your code

The third step to optimize your PLC system is to test and simulate your code before deploying it to the PLC. Testing and simulating your code can help you verify its functionality, performance, and accuracy, as well as identify and fix any potential problems or errors. You can use various tools and methods to test and simulate your code, such as debugging software, simulation software, test benches, and test cases. Testing and simulating your code can help you prevent downtime caused by faulty or incompatible code.

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4 Perform regular maintenance

The fourth step to optimize your PLC system is to perform regular maintenance on your PLC and its components. Maintenance can help you extend the lifespan, efficiency, and functionality of your PLC system, as well as prevent or detect any issues or failures. Maintenance can include tasks such as cleaning, inspecting, updating, backing up, and calibrating your PLC and its components. You should follow the manufacturer's recommendations and schedule for maintenance, as well as keep records and logs of your maintenance activities.

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5 Monitor and analyze your data

The fifth step to optimize your PLC system is to monitor and analyze your data. Data can help you measure and improve the performance, quality, and productivity of your PLC system, as well as identify and diagnose any problems or anomalies. You can use various tools and techniques to monitor and analyze your data, such as data logging, SCADA systems, dashboards, reports, and charts. Monitoring and analyzing your data can help you optimize your PLC system and reduce downtime.

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6 Troubleshoot and resolve issues

The sixth step to optimize your PLC system is to troubleshoot and resolve any issues that may arise. Issues can range from minor glitches to major breakdowns, and they can affect your PLC system in different ways. You need to be prepared and equipped to troubleshoot and resolve any issues quickly and effectively, using your knowledge, skills, and tools. You can use various methods and strategies to troubleshoot and resolve issues, such as fault finding, root cause analysis, corrective actions, and preventive actions. Troubleshooting and resolving issues can help you restore your PLC system and minimize downtime.

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Jorge Cano Carmona

Technical and Technological Solutions Manager for Process Automation
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Troubleshooting is quick and easy when the program is documented, when there is a standard in the programming and it was done “as simple as possible” (this is a must every time you need to program something). Otherwise it would take the most important resource: Time, and impact the KPIs related of course.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Sanjay Tembe

CEO IntelliThing Technologies, Director United Engineers - IIoT, Industry 4.0, IT & OT integration, MES systems .
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To minimise downtime you must also consider using redundant architecture at the time of selection. You have to check the trade off between possible downtime and increase in the initial capital cost. Options of using power supply redundancy, CPU redundancy etc. should be considered. While distributing field I/Os on PLC modules a care should be taken to ensure a minimum process interruption because of failure of one I/O module.

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How can you optimize a PLC system to minimize downtime?

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1 Choose the right PLC

2 Follow programming standards

3 Test and simulate your code

4 Perform regular maintenance

5 Monitor and analyze your data

6 Troubleshoot and resolve issues

7 Here’s what else to consider

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