If you work in manufacturing, you have probably heard of PLCs. But you might be wondering, “What are PLCs used for, and why are they so important?” A PLC is a programmable logic controller that has been integral to manufacturing for years. Used across many industries, PLCs are ruggedly designed, powerful computers that can help automate production processes, gather decision-making data, and work with IoT and machine learning algorithms to streamline operations.
These tools are built to handle the harsh environments of manufacturing and have been used to reduce the burden of mechanical control and human labor. As an important part of the digitization progress of manufacturing, it is becoming increasingly important to have a PLC and know how to operate it effectively.
Continue reading to learn what PLCs are used for, how they can enhance the manufacturing process, and how they can work alongside IoT to offer better results.
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PLC uses and factors to consider
If your business has experienced recent growth but is struggling to meet the demands, it’s time to find a PLC. Not only will they improve productivity, but they will help you streamline your manufacturing operations to ensure there is minimal downtime — all while optimizing each complex step in the process.
These controllers come in many different sizes and forms. The size you need will depend on the amount of information or data you need to gather and the complexity of your manufacturing process.
When choosing a PLC, start by considering these six factors to find the right model for your needs:
- Durability in harsh environments: Whether your facility works with harsh chemicals or heavy machinery, manufacturing can be an intense workplace and put equipment under extreme pressure. The tools used need to be able to handle these circumstances, including your PLC. For example, if the machinery is becoming overheated, your PLC needs to be able to recognize the problem and shut it down instantly to avoid further damage or a potential emergency.
- Dependable machinery: Speed and precision are essential in all manufacturing facilities. Reliable recruitment that can handle the fast-paced environment without sacrificing precision is critical. Since PLCs are so robust, they can take on large amounts of work and heavy demands without glitching or shutting down. This enhances productivity by avoiding downtimes or production delays.
- Support business growth: As your business grows and you begin to experience a higher demand, the equipment and processes will also increase. To do this successfully, you will need a tool that can seamlessly grow with you without taking up more space or effort. With a simple software update, PLCs can handle the changing demands, saving you time and money with no hardware upgrades.
- Improved efficiency: Put simply, PLCs are powerful computers that are easy to program and operate. As PLCs continue to evolve, the newer models are increasingly efficient and resilient. New PLCs offer high-speed syncing and fast execution of instructions.
- Easy maintenance: One of the most important aspects of a PLC is that they do not need regular updates or maintenance. Even if a PLC does need some work, it will be much less intense than other equipment. As PLCs are made for demanding, harsh environments, they do not break down often. They also provide predictive analytics to avoid breakdowns in your connected machinery, saving you from unforeseen downtime in the future.
- Simple integration: In addition to their easy integration with manufacturing processes, they can also integrate with other tools used for industrial devices. For example, PLCs can be connected to multiple devices on the factory floor and act as an interface between your equipment and an HMI. With the added integration of IoT, these capabilities can go even further with a reliable internet connection.
How to get data from a PLC
PLCs traditionally communicated with a poll-response method. Although this can be an effective type of communication, it can only work if the manufacturing layouts require short distances and have the ability for the PLCs to be mostly hardwired. Using a poll-response system allows the PLCs to be in constant communication to find any changes in data or issues to address.
However, as IoT continues to gain popularity in the manufacturing space, there is an increasing need for data from remote locations. Cellular networks are now a common use of communication with edge devices that require data transmission across longer distances.
Unfortunately, this can come at a higher cost due to the high frequency of the poll response system. Manufacturers who rely on the poll response may need to reconsider how they gather their information. IoT could be the answer, as it is cost-effective but can reach those long, remote distances we just mentioned.
How is IoT used in manufacturing?
IoT and machine learning algorithms have started to make their way into the manufacturing industry. Though these will not replace PLCs, they will work together to offer real-time manufacturing data. The machine-learning algorithms will study the information and data being gathered by the PLC to learn how to make future predictions. These predictions will turn into effective decision-making processes that require no re-programming.
It may sound too good to be true, but as these machines learn from each other, they will identify what works and what does not, how to enhance operations, and how to streamline processes. This will result in a system that can provide predictive maintenance and produce useful information that will prevent downtime, respond to issues that may occur, and improve quality control through actionable production insights.
This will improve productivity and keep the facility safe. For example, if a machine suddenly malfunctions, the machine-learning algorithm will recognize that this is not normal and can immediately shut it down before a catastrophe happens.
Data processing in IoT
Since the IoT can learn from past experiences and make future predictions, it will act as a real-time data source for all of the devices or sensors attached to it. With this collection of large data files, manufacturers will have an easier time designing and producing products that are better tailored to customer needs.
Combining the collection of this data with the ability to constantly streamline processes will improve efficiency and allow manufacturers to tweak processes for optimal operations. IoT can reconfigure how production should run or how manufacturing facilities should be organized, taking the guesswork out of creating a production that you hope will work.
Access manufacturing IT services with Applied Tech
PLCs have been an integral part of manufacturing. From improving efficiency to automating processes and providing predictive analytics, it is essential to have this tool accessible to your facility. As industries continue to integrate IoT and machine learning into their systems, PLCs will have an even larger impact on optimizing production, reducing downtime, and offering data for real-time decision-making. However, to take full advantage of these capabilities, manufacturers need the right understanding of how to integrate, manage, and maintain their systems effectively.
That’s where Applied Tech can help. Our manufacturing experts help businesses improve efficiency, streamline operations, and increase productivity by aligning operations with the latest automation and data-driven technologies.
From optimizing PLC performance to ensuring compliance and security standards are up to date, our team can provide guidance and support to keep your manufacturing facilities running at peak performance. Contact us today to learn more about our manufacturing IT services.
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