Why train my technicians on PLCs since most problems are caused by field devices? 

The "short answer" is because the PLC is located precisely at the center of your plant's control wiring. Technicians who don't know what goes on inside that mysterious "black box" often waste troubleshooting time - and needlessly replace parts - even if the root problem has nothing to do with the PLC.

Reality check: In many plants the following scenario is a common occurrence. The machinery is down - and the plant's technicians are stumped. An outside contractor is called in to troubleshoot the system. Eventually he arrives and goes online with the PLC. A few minutes later he points out the problem – usually a simple field device. The technicians replace the part – and the contractor sends a hefty "minimum charge" bill. It doesn't take many episodes like that before effective PLC training becomes a highly attractive investment.

In the days before PLCs, the plant's maintenance technicians were able to track down many problems simply by "following the wire" between the input devices and the output devices. Minor adjustments like timer settings were easy to do. The wiring for each field device was usually brought back to a centrally-located control cabinet. Input and output devices were tied together with "hard wired" connections. Control devices such as relays, timers, and counters were easily accessible by the plant's maintenance technicians.

Today the "hard wired" connections which once tied the plant's field devices together have been replaced by the PLC's ladder program. To an untrained technician, the PLC represents a mysterious "black box" located at the precise center of every control circuit. Tracking down a problem is no longer just a matter of following a physical wire – but instead requires significant computer skills to access and interpret the PLC's program. Even simple problems often appear excessively complicated when confusion surrounds the PLC. Confusion wastes time and money. Production downtime, troubleshooting time, and needlessly replaced parts are all common examples of how inadequate training can affect the plant's bottom line. Even simple adjustments such as timer settings often require an expensive outside contractor if the plant's technicians lack the skills to access and understand the PLC program.

Effective training for your maintenance technicians removes the mystery and confusion about what goes on inside the PLC. The interconnections between the plant's field devices become easily accessible – so troubleshooting takes less time. Production downtime can be minimized. Needless "part-swapping" can be reduced. Minor adjustments to the controls can be made in-house without the delay and expense of outside contractors. The key to success is making sure that the PLC training you purchase is effective – and that it provides the specific job skills required by your plant's maintenance technicians.

Note: If this hasn't completely answered your question, just contact us at:

843-437-1883          - phone

843-225-0512          - fax

ronbeaufort@gmail.com - email

© Copyright - R.H.Beaufort - Charleston, SC – Updated: May 14, 2008