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What challenges can you anticipate when managing a team of PLC programmers?

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PLC programming is a valuable skill for control engineers who design, implement, and maintain automated systems. However, managing a team of PLC programmers can pose some unique challenges that require careful planning, communication, and coordination. In this article, you will learn about some of the common issues that PLC programming teams face and how to overcome them.

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1 Hardware compatibility

Ensuring that the code written is compatible with the hardware used is one of the first challenges for PLC programming teams. Different PLC brands and models have varying features, specifications, and programming languages. Additionally, some PLCs may require additional modules, interfaces, or adapters to communicate with other devices. To avoid hardware compatibility issues, it is important to define the hardware requirements and specifications before starting the programming phase. Furthermore, you should select a PLC brand and model that fits your project needs and budget, and test your code on the actual hardware as early and as often as possible. Additionally, provide your team with adequate training and support on the hardware they use, and keep them updated on any changes or upgrades. Documenting any errors or bugs is also essential.

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Mohamed Abdelsalam

Industrial Automation Engineer at Ezzsteel | PCS7 | TIA | WinCC | Step7 | C# | python | JavaScript
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The more your program follows the concepts of object-oriented programming, the more you avoid hardware compatibility issues. Writing codes in modular functions or functions blocks that interface with the real hardware from the outside block interface. Avoid using hardware-dependent memory (bit memory, timers, and counters) instead, you can use the global data blocks and IEC timers and counters.

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2 Software standards

PLC programming teams often struggle with maintaining consistent and high-quality software standards. This is because different programmers may have different approaches when writing code, which can lead to inconsistent, unclear, or inefficient code. Additionally, if they use different software tools, versions, or formats, it can create compatibility or integration issues. To address this challenge, you should establish and enforce a common set of coding guidelines, conventions, and best practices for your team. Make sure these are documented and accessible. Additionally, use a standard software tool or platform for your team that is kept up-to-date and synchronized. Implementing a code review process where a senior programmer checks and approves the code before deployment is also important. Finally, using a version control system such as Git or SVN to track and manage the changes and revisions of your code is essential.

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Mohamed Abdelsalam

Industrial Automation Engineer at Ezzsteel | PCS7 | TIA | WinCC | Step7 | C# | python | JavaScript
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You can have a style guide shared between the team members and followed. You can apply automatic style testing using tools like the Tia portal test suite which will ensure the consistency of your style throughout the all project.

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3 Communication and collaboration

PLC programming teams may face a third challenge when it comes to effective communication and collaboration among team members and other stakeholders. This is due to the complexity and iterative nature of the programming process, as well as potential remote or multi-location working. To avoid communication and collaboration issues, you should define roles and responsibilities, assign clear and realistic tasks with deadlines, use project management tools, communication tools, collaboration tools, and schedule regular meetings. For instance, Trello or Asana can be used to monitor progress and status of the project, while Slack or Teams can facilitate information sharing. Additionally, Google Drive or Dropbox can be used to store and share project files. Finally, regular reviews and feedback sessions should be conducted with team members and other stakeholders.

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4 Troubleshooting and testing

PLC programming teams often face the challenge of performing effective troubleshooting and testing of their code and hardware. Errors, bugs, and failures can have a negative impact on the performance, safety, and reliability of the automated system. Additionally, some errors may only manifest in certain conditions, making them difficult to detect or reproduce. To avoid troubleshooting and testing issues, you should adopt a proactive and preventive approach to anticipate and prevent potential errors or bugs before they occur or escalate. Utilizing debugging tools such as PLC Simulator or PLCLogix can be beneficial for simulating and debugging code and hardware in a virtual environment. Testing tools like PLC Test or PLC Ladder Logic Tester can be used to verify and validate code and hardware in a real or simulated environment. Moreover, logging tools such as PLC Logger or PLC Data Logger can help record and analyze data and events of code and hardware in operation. And reporting tools such as PLC Report or PLC Data Report can generate and share the results of troubleshooting and testing activities.

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5 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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What challenges can you anticipate when managing a team of PLC programmers?

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1 Hardware compatibility

2 Software standards

3 Communication and collaboration

4 Troubleshooting and testing

5 Here’s what else to consider

Control Engineering

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