oee - PLC Programming & Automation

OEE and Downtime Reason Codes from the PLC

Ladder rung with four contacts, Auto examined on, Fault, Starved and Blocked examined off, driving the Running output coil that feeds the availability run timer

How a PLC state model feeds OEE, downtime reason codes and SPC triggers on a rotary filler: the ST block, the tag structure and the classic mistakes.

Assembly Line Station Logic: State Machine, Takt, Downtime

by PLC

Ladder rung releasing a body from an assembly station: body present, torque batch complete and vision result OK in series, with a normally closed contact for the downstream station blocked, driving the release output

Station and line PLC split, a PackML state machine in Structured Text, torque tool error proofing, andon stops and downtime that blames the right station.

PLC Data Logging and Remote Monitoring: Practical Rules

by PLC

Timing chart comparing periodic and change based logging: a one second sample tick, a deadband window where the process value is moving, and the six rows actually written to the database

PLC data logging that stays useful: sampling rates, retention math, a ring buffer in the controller, FactoryTalk datalog, SQL logging, safe remote access.

PLC MES Integration: Tags, Handshakes and Work Orders

by PLC

Timing chart of an MES to PLC work order handshake showing Request from the MES, Ack from the PLC, Done when the order is latched, and both bits clearing after Request drops

What MES really needs from the controller: OEE counters, downtime reason codes, a work order UDT, a request and acknowledge handshake, an OPC UA bridge.