PLC SCADA Automation for Manufacturing Plant

Description

Automotive components plant, two lines, Siemens S7-1500 with WinCC. The control logic has been extended by four different people over nine years and nobody has the full picture. We have a line that stops for reasons we cannot reliably explain. The engagement is an overhaul: document what the logic actually does today, restructure it into something maintainable, and improve the SCADA layer so an operator can see why a stop happened instead of guessing. This is a live plant. Changeover windows are Sunday nights and they are short. A plan that requires extended downtime will not be approved regardless of technical merit, so phasing matters as much as the engineering.

• Document the existing S7-1500 logic as-is before changing anything
• Restructure the program into maintainable, documented blocks with a clear naming standard
• Improve WinCC so stop causes are surfaced to the operator with the triggering condition named
• Phase all cutover work into Sunday changeover windows with tested rollback per phase
• Hand over to our maintenance team with documentation they can actually work from

• As-is documentation of the current control logic
• Restructured PLC program deployed in phases
• WinCC stop-cause visibility for operators
• Maintenance handover pack and training