Enhancing Manufacturing Efficiency with Hybrid PLC and IoT Solutions
- Jan 26
- 3 min read
Manufacturing facilities often face challenges in gaining clear, real-time insight into their equipment status, energy consumption, and process conditions. Many factories rely on traditional PLC (Programmable Logic Controller) systems that provide local control and limited visibility through onsite HMI screens. This setup restricts operators and management from accessing critical data remotely or analysing trends across the entire site.
A factory operator recently confronted this exact problem. They needed a solution that would offer remote visibility, centralized dashboards, and alerts for abnormal conditions without disrupting their existing control systems. The answer came in the form of a hybrid PLC and IoT architecture, combining the reliability of local PLC control with the power of cloud-based monitoring and analytics.
Why Traditional PLC Systems Fall Short
PLC systems have been the backbone of industrial automation for decades. They excel at controlling machinery and processes locally with high reliability and speed. However, their limitations become clear when it comes to:
Remote access: Operators cannot easily monitor equipment status or process data from offsite locations.
Centralized data: Data remains siloed at individual machines or control panels, making it difficult to get a holistic view.
Alerts and analytics: Local HMIs rarely provide advanced alerting or trend analysis capabilities.
Energy monitoring: Most PLCs do not track energy consumption in detail, missing opportunities for cost savings.
These gaps can lead to slower fault detection, inefficient energy use, and missed opportunities to improve operations.
Eye-level view of industrial control panel with PLC and IoT sensors installed
Building a Hybrid PLC and IoT Architecture
The factory operator partnered with ProSense to implement a hybrid solution that extended their existing PLC system with IoT capabilities. This approach preserved the trusted local control while adding remote monitoring and analytics through the cloud.
Key Components of the Solution
PLC data extraction: Critical process values were extracted from the PLC to feed into the cloud system without interfering with control functions.
Energy monitoring: Single and three-phase energy meters were installed to track power consumption in real time.
Environmental sensors: Sensors were placed in critical areas to monitor temperature, humidity, and other conditions affecting equipment and processes.
Secure remote access: A gateway device provided encrypted, secure access to data from anywhere.
Cloud dashboards: ProSight, the cloud platform, offered centralized dashboards for both operations staff and management, showing live data, trends, and alerts.
This hybrid architecture allowed the PLC to continue managing the process locally while ProSight handled visualization, analytics, and notifications.
Benefits Realized by the Factory
The new system delivered several tangible improvements:
Real-time visibility: Operators and managers gained instant access to equipment status and process data from any location.
Faster fault detection: Alerts for abnormal conditions enabled quicker response times, reducing downtime.
Energy optimization: Detailed energy usage trends helped identify inefficiencies and opportunities to reduce costs.
Centralized management: Dashboards consolidated data from multiple sources, simplifying decision-making and reporting.
By complementing the existing PLC system rather than replacing it, the factory avoided costly disruptions and leveraged their current investments.
High angle view of manufacturing floor with energy monitoring devices and IoT sensors
Practical Steps for Manufacturers Considering Hybrid Solutions
Manufacturers interested in similar improvements can follow these steps:
Assess current systems: Identify what data is available from existing PLCs and what additional sensors are needed.
Choose a cloud platform: Select a solution like ProSight that integrates easily with PLCs and supports secure remote access.
Plan for minimal disruption: Design the system to extract data passively without affecting control operations.
Implement energy and environmental monitoring: Add meters and sensors to capture comprehensive site data.
Train staff: Ensure operators and managers understand how to use dashboards and respond to alerts.
Review and optimize: Use collected data to continuously improve processes and reduce energy consumption.
Moving Forward with Confidence
The hybrid PLC and IoT approach offers a practical path for manufacturing facilities to gain modern visibility and control without overhauling their entire automation system. It bridges the gap between traditional control and digital transformation, providing actionable insights that improve efficiency, reduce costs, and enhance responsiveness.
Manufacturers ready to enhance their operations should explore hybrid architectures that combine trusted PLC control with cloud-based monitoring and analytics. This strategy delivers the best of both worlds: reliable local control and powerful remote insight.
By adopting this approach, factories can stay competitive, reduce downtime, and make smarter decisions based on real-time data.
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