How to Justify a PLC Upgrade

Prevent Downtime and Improve Operations with a Convincing Argument

Programmable Logic Controllers (PLCs) are industrial computers, with various inputs and outputs, used to control and monitor industrial equipment based on custom programming. PLCs are used for many things from temperature control, activating and deactivating entire machines, data management, and more. These controllers are completely integral to most industrial day-to-day operations, which is why keeping them up and running is crucial. If you feel your facility needs PLC improvements, it’s important to voice your concern before things are too late. That’s why we compiled a list on how to justify a PLC upgrade to your superiors.

Use Real Dollars and Numbers

Let’s face it: the bottom line is the most important thing at your facility. If you can provide real dollar amounts to your superiors, it can help sway them toward an upgrade (or at least put the idea on their radar.)  Calculate downtime costs of production lines combined with lead times on PLC replacements or parts. Remember: failure can occur at any time! Provide them with worst case scenarios and remember to take into account, not only the cost of lines being down, but also the cost of covering employees, any lost product, and the damage to reputation. If replacement parts are mentioned, counter with the age of your current PLC and how replacement parts are not longer in production. You don’t want your facility to be at the mercy of eBay! (And, speaking of eBay, you can also sell your old PLCs to help recuperate any costs.)

Working in Budgets and Schedules

Bottom line is most important, right? If you know what your facility’s budget is for maintenance and replacement parts, show how replacing some PLCs at a time is feasible. Or, if you know that one particular PLC in your facility is requiring more maintenance and parts than others, show how replacing that one can bring ROI to the company. This can make your argument a bit more plateable. And if just getting one upgraded PLC in the facility can show benefits, additional units should be easier to the fit into future budgets.

Retiring Employees and Systems

There are a few loyal employees who have worked at your facility for many years that know these old PLCs inside and out. However, as these employees reach retirement and the younger generation come to fill their shoes, understanding these ancient systems goes out the window. New PLCs offer familiar technology to young workers:

• Ethernet connections for remote access
• Digital manuals that can easily be found online
• And easy-to-understand controls and LED screens

Allowing these young employees more simple technology can decrease turnover and increase confidence. Not only that, industrial software companies also retire older programs, denying any support, and essentially forcing upgrades whether you’re ready or not. Don’t be left with an operational PLC with non-functioning software!

Present Your Argument

The best way to justify a PLC upgrade is to create a convincing presentation with your research. Headwaters recommends the following when creating your presentation:

• Images of old PLCs in your facility
• Graphs and charts
• Easy to read and look at
• Bright colors that are on theme with your organization
• Infographics and icons

A bland presentation will leave your superiors disinterested and feel like you’ve wasted their time. However, something nice to look at will get everyone’s attention and actually have people listening to what you have to say.

Don’t have time for any of this? Contact Headwaters Engineering + Consulting! Not only can we calculate your real downtime dollars (with high accuracy), we can create budgets and schedules that will work for your facility, and compile all of the information in an easy to digest presentation. Contact one of our engineers today and let’s get your facility up to date.