As manufacturing operations seek ever greater efficiency and flexibility, the capabilities of automation systems take on increased importance. Upgrading to the latest programmable logic controller (PLC) platforms from Rockwell Automation provides immediate benefits today while positioning organizations for smarter factory connectivity in the future.

Partnering with an experienced Rockwell Automation systems integrator like Pacific Blue Engineering ensures your upgrade project is seamlessly executed.

Enhanced Productivity and Throughput

By leveraging the improved speed and connectivity of contemporary Rockwell Automation systems, organizations gain in performance from cost-effectively replacing outdated mechanical lines with advanced synchronized automation. This leads to impressive OEE improvements from faster changeovers, increased repeatability, reduced downtime, and higher-quality end products.

For example, a beverage bottler doubled the number of production lines supported per plant supervisor by upgrading to ControlLogix, allowing increased staff focus on value-added production support versus troubleshooting outdated PLCs.

Upgraded Safety and Reliability

Industrial control systems provide the backbone for safe, reliable manufacturing operations. Failure is not an option when production lines handle hazardous voltages, extreme temperatures, powerful mechanical forces, and more.

Upgrading aging Rockwell Automation PLCs enhances system reliability substantially compared to stretching older equipment past intended lifespans. The improved electronics in ControlLogix and CompactLogix deliver greater environmental tolerance and voltage resilience for demanding facility conditions.

Furthermore, new Rockwell Automation PLCs promote operational safety through native implementation of safe torque off (STO) functionality. This allows equipment power removal without added safety relays, simplifying validations. Integrated safety protocols also enable graceful performance degradation to maintain production under minor component failures versus complete stoppages requiring resets.

Certified system integrators like Pacific Blue Engineering leverage the newest PLC safety features while conducting layered hazard assessments and implementing redundancies for risk mitigation per leading standards. The latest controllers support wireless signaling and remote notifications to operations staff for emerging issues.

More Robust Cybersecurity

PLCs are central to automation systems. However, as they become more integrated into larger networks, they can also be prime targets for threat actors. Exploiting gaps in security lapses or project files can open the door to breaches. Between ransomware attacks, intellectual property theft, and threats of lost operational control, industrial cybersecurity has become mission-critical.

The latest Rockwell Automation PLCs include advanced cybersecurity provisions for comprehensive protection. ControlLogix and CompactLogix platforms provide encryption and certificate management, protecting systems from intrusions. This keeps manufacturing operations resilient to emerging threats. Proactive upgrades lower risks substantially compared to relying on aging equipment.

Improved IIoT Connectivity

Smart manufacturing powered by the Industrial Internet of Things (IIoT) promises game-changing visibility and control in once largely analog factories. Transitioning to Ethernet-based ControlLogix or CompactLogix systems optimizes connectivity and data accessibility for MES/MOM software, SCADA, and cloud analytics.

This connectivity lays the foundation for rich statistical process control, predictive notifications, and AI-driven decision support. Newer Rockwell Automation PLCs seamlessly support smart sensor implementation and advanced telemetry without the need for external I/O modification.

Operational Continuity and Supportability

Since first launching the venerable PLC-5 platform in the 1980s, Rockwell Automation has delivered industry-leading continuity across controller generations. This relieves integration headaches and complexity when upgrading versus alternatives that may require full-scale rip-and-replace.

Pacific Blue Engineering leverages RSLogix 5000 software portability to simplify your upgrade implementation. Further, Rockwell Automation supports PLC products long after they leave active production through services, documentation, and ongoing training. By upgrading now, manufacturers hedge against growing supportability issues with aging PLCs.

The Path Forward

Migrating from legacy PLC-5, SLC 500, or MicroLogix systems to new ControlLogix or CompactLogix platforms represents a high-reward, low-risk endeavor for industrial operations. Partnering with Pacific Blue Engineering, a Rockwell Automation-recognized systems integrator, ensures your PLC upgrade project checks all the boxes:

• Assessment/scoping design sessions
• Build testing and staging
• Installation support
• PLC code migration
• Operator training
• Validation documentation

With exponential advances in smart manufacturing, connectivity, and security on the horizon, now is the time to upgrade control systems for sustainable benefits. Pacific Blue Engineering helps manufacturing clients, big and small, across industries seamlessly transition to the latest PLC hardware. By upgrading now, savvy manufacturers gain the production assurance and safety confidence that outdated equipment can no longer provide.

Protect your people, brand reputation, and bottom line through proactive upgrades. Trust Pacific Blue Engineering to implement contemporary PLCs with security and sustainability central to the design.

Contact the experienced Rockwell Automation systems integrators at Pacific Blue Engineering today at (657) 201-8603 or request a consultation online to discuss an upgrade.