What role does the PLC play in digital transformation?

Did you know that every machine in your manufacturing plant has a brain? Perhaps in the age of artificial intelligence such information is not surprising, but by no means the advanced algorithms I want to tell you about today. Our hero is the PLC, or programmable logic controller. It’s the kind of industrial computer that, like a skilled conductor of an orchestra, directs every movement of your machine. Today I’m going to show you how to use its potential to the maximum and get your factory on the path of digital transformation.

PLC (Programmable Logic Controller, Programmable Logic Controller) is such an industrial computer that works in harsh factory environments. It can be compared to a pilot on a spaceship – without it, nothing will work. This controller performs sequences of actions that are crucial for the proper functioning of machines. Imagine that each PLC is a small maestro that conducts the whole orchestra of machines.

The origins of programmable logic controllers date back to the 1960s. The first model was developed in the United States. It was a device the size of a small closet in my bedroom, weighed tens of kilograms and had a memory measured in… kilobytes (nowadays that’s how much a picture of a cat takes up on a phone)! Today we are dealing with small devices that can process huge amounts of data. PLC analyzes data from sensors, makes changes to the machine and communicates with the environment in milliseconds. In a word, it’s a little genius.

Before taking advantage of the PLC’s benefits, it’s useful to know how it works. First, the controller performs self-diagnostics (after all, the maestro has to check that everything is in place and playing before the concert starts). Then it collects information from all the sensors (as the conductor reads the notes), then processes this data according to a stored program, and finally sends the appropriate signals to the executive devices: motors, pumps and other machines (like the movement of a baton that directs the actions of the musicians).

This perfectly demonstrates that the PLC is the focal point of data management in a manufacturing plant.

Imagine that your company is a stage, your customers are the audience. You stand in front of them and have a souffler at your side who

This is PLC – a source of invaluable data. The problem is that its role is often underestimated. Meanwhile, thanks to it you can document the production process in an automated way. And what does this mean for you? You save time and eliminate errors!

Let’s assume that reporting in your company takes 15 minutes per shift. On a yearly basis with a four-shift system, we are talking about costs reaching several hundred thousand zlotys. Now imagine a PLC doing the same thing in seconds. What do you choose: manual transcription or automation?

But that’s not all! PLC also allows you to:

Now let’s get to the point: how to use PLC data step by step? Here are some practical tips.

Make a list of all the machines in the plant and see what kind of controllers they have. Look in each control cabinet (yes, the dusty one too!) and see what treasures are hiding there. Inventory the controllers, verify data access and analyze communication capabilities.

Make a list with all the information you want to collect (from production counts to process temperatures). It’s like making a shopping list – you better not leave anything out! While doing so, remember that the more standardized the list, the better!

You must find the information you need in the controller’s memory. Every parameter in the PLC has an address – you must know it, just as our conductor must know the location of each musical section. Act in cooperation with suppliers and on the basis of technical documentation.

Choose the right IT system for data collection and make sure everything works as it should. If you don’t know which information system to choose, I recommend my book “15 Steps to Buying an Information System.”

It’s time to visualize! A good dashboard serves the same function as a maestro dashboard, it helps you visualize data in real time. Remember to validate your readings and customize the interface.

The final step is to automate reports. Goodbye, manual transcription of data into Excel!

A PLC is not just a machine controller, it’s a veritable goldmine of data that can help you make better business decisions. Look at this machine brain as the conductor who will lead your orchestra to digital transformation.

By taking advantage of the PLC’s capabilities, you know what’s going on in your business here and now, not just hours later. You save time, eliminate errors and gain money – sounds good, right?

So don’t wait! Take the first step towards automation and discover the potential of your machinery today! And if you need more information or tips – go ahead and write! Together we can change the face of your production!