A successful industrial automation project doesn't start with programming — it starts with engineering preparation. Below is the complete PLC project implementation process.
1. Requirements & technology consultation On-site survey, understanding the technological process, recording operator and technologist requirements. Output: User Requirement Specification (URS).
2. Concept & device selection PLC platform selection (Siemens S7-1200/1500, Mitsubishi iQ-R, Allen-Bradley CompactLogix) based on system size, I/O count, communication needs. Network topology, remote I/O concept, HMI/SCADA platform selection.
3. Functional Design Specification (FDS) Detailed functional description: operating modes, interlocks, safety functions, alarm management, recipe handling. IO list, network diagram, HMI mockups.
4. Electrical design & panel manufacturing Electrical detail design (EPLAN), control panel design and manufacturing. Standards: EN 61439-1/2, EN 60204-1.
5. PLC/SCADA development Structured PLC programming (IEC 61131-3), SCADA/HMI screen development, communication configuration, IO-Link parameterization.
6. Factory Acceptance Test (FAT) Systematic factory testing per FDS — all functions, modes, interlocks, alarms. FAT protocol with customer witness.
7. Installation & SAT Panel installation, wiring, point-to-point I/O testing. Site Acceptance Test under real process conditions.
8. CE compliance & documentation Machinery Directive 2006/42/EC, EN 60204-1, IEC 62061 / ISO 13849-1 functional safety. Risk assessment per EN ISO 12100.
9. Training & handover Operator and maintenance training. Handover documentation: FDS, PLC source code, electrical drawings, FAT/SAT protocols.
10. Fine-tuning & support Post-commissioning optimization — PID tuning, cycle time adjustment, alarm threshold calibration. Remote VPN support during warranty period.