Unlocking Productivity: The Role of PLC Software in Manufacturing Asset Optimisation.
In order for manufacturing companies to thrive in a competitive marketplace, they must find continuous improvement in productivity. One of the most effective ways to do this is optimized resource planning through asset management. Manufacturing repetitive processes employ Programmable Logic Controllers (PLC) that play a critical role in delivering manufacturing process and operations. This post will explore the role of PLC software in manufacturing asset and process management, how it can be used to unlock efficiency and take a business to new productivity heights. Interested? Keep reading to find out more.
What is PLC software?
So, what exactly is PLC software? Essentially, a PLC is a specialised computer used to automate industrial processes. PLC software, meanwhile, is the brain behind the operation that interprets inputs from sensors, executes logic-based instructions, and controls outputs, such as motors and valves.
PLC software is most commonly programmed in a ladder logic format, with instrumentation inputs and program sequences designed to control machinery in repetitive tasks such as manufacturing (and other industrial sectors).
PLC are considered to be more robust operating systems than PC processors and best suited to equipment and process control. The key components of a PLC system include:
Input modules: Capture digital and analog input from the system, such as switches and sensors.
Output modules: Send digital and analog instructions to the system components, such as motors and motor speed controllers.
Central Processing Unit (CPU): Contains the PLC operating system and bespoke PLC program.
Human Machine Interface (HMI): A graphical interface that allows operators to interact and review data locally.
SCADA interface: Allows remote system data monitoring and system control.
The Benefits of PLC Software in Manufacturing
There are many benefits to using PLC software in manufacturing. These include:
Automation
PLC software facilitates the automation of key manufacturing processes. This can speed processes up, reduce errors and create more time for staff to focus on other areas. In addition to this, automation can improve safety on the work floor as many potentially dangerous tasks can be completed without requiring human input.
Improve Efficiency
With automation, process optimization and improved resource usage, PLC software is an effective way to improve overall efficiency. Efficiency is key to success in manufacturing, so this software is invaluable in enhancing the daily operation while making work easier for your team.
Faster Response Time & Better Decision Making
The capability to monitor industrial equipment performance in real-time can enable faster response time to issues and improve decision making. This helps manufacturing companies take timely action and keep downtime to a minimum, which can save the company huge sums.
Scalability
PLC software is scalable and can be adjusted to suit the demands of the company. This is useful in manufacturing due to seasonality, with some periods being quieter than others. Additionally, it is helpful when looking to grow the business by scaling up operations or integrating new industrial equipment into the operation.
Important Considerations When Using PLC software
It is clear that PLC software can have a huge impact on the efficiency and overall success of a manufacturing company. There are a few key considerations to keep in mind though, which will help you get the most out of your software and maximise efficiency.
Hardware Compatibility
First, you want to make sure that the PLC software is compatible with your hardware and equipment. Keep in mind that many manufacturing operations rely on old hardware and technology, so you want to check that the software is compatible beforehand or consider upgrading to the latest manufacturing equipment.
Customisation
Of course, every manufacturing company is different and will have unique processes. Therefore, it is important that you choose software that allows you to customise the system to your specific needs.
Data Access
PLC software can provide useful data that can improve the decision making process, but there is still a lot of data that is kept in the dark. This is why you want to use embedded Data Memory (eDM) solutions that connect to your PLC network and harvest previously hidden data. No changes are required as the solution works alongside your SCADA and HMI graphical user interface programs. By fixing your PLC data gap, you can optimise your machinery, identify faults and keep your manufacturing equipment in peak condition.
Data Security
Data security is another key consideration during a time when cybercrime is rampant. Manufacturing companies are frequently targeted due to the proliferation of interconnected devices, so it is vital that you choose a PLC software solution with robust cloud security features. This will help you safeguard your sensitive data and operations. Having robust cloud security features will also provide peace of mind, knowing that you are protected against the latest and most sophisticated threats.
PLC software can play an instrumental role in modern manufacturing. With the ability to unlock efficiency by streamlining operations, automating tasks, monitoring performance in real time and providing data insights, this software can help any manufacturing company modernise and remain competitive in a fast changing, dynamic landscape.
Get in touch with the datumpin team today to discuss how our eDM solution can shine a light on your hidden PLC data and maximise efficiency for higher levels of success.