How can you reduce human error in PLC programming and operation?

1 Use standardized and consistent naming conventions

One of the easiest ways to reduce human error in PLC programming and operation is to use standardized and consistent naming conventions for your variables, tags, functions, and modules. Naming conventions help you to organize your code, avoid confusion, and ensure readability and clarity. You should follow the guidelines and best practices of your PLC vendor, industry, and organization, and document your naming conventions for future reference and reuse.

2 Apply modular and structured programming techniques

Another way to reduce human error in PLC programming and operation is to apply modular and structured programming techniques. Modular programming means breaking down your PLC program into smaller and simpler units that perform specific tasks and can be reused and tested independently. Structured programming means following a logical and hierarchical flow of control and avoiding unnecessary complexity and redundancy. Modular and structured programming techniques help you to reduce errors, enhance maintainability, and increase efficiency and productivity.

3 Implement error handling and prevention strategies

A third way to reduce human error in PLC programming and operation is to implement error handling and prevention strategies. Error handling means detecting, reporting, and correcting any errors that occur during the PLC program execution. Error prevention means avoiding or minimizing the potential sources of errors before they happen. Some of the common error handling and prevention strategies include using watchdog timers, fault routines, alarms, interlocks, limits, checks, and backups.

5 Follow proper documentation and communication practices

A fifth way to reduce human error in PLC programming and operation is to follow proper documentation and communication practices. Documentation means creating and updating clear, concise, and accurate records of your PLC program design, development, testing, and maintenance. Communication means sharing and exchanging relevant information and feedback with your team members, stakeholders, and end-users. Documentation and communication practices help you to ensure consistency, quality, and transparency, and avoid misunderstandings, conflicts, and gaps.

6 Train and educate yourself and your staff

A sixth way to reduce human error in PLC programming and operation is to train and educate yourself and your staff on the best practices, standards, and regulations of PLC programming and operation. Training and education means acquiring and updating the necessary knowledge, skills, and competencies to program and operate PLCs safely and reliably. You should seek formal and informal learning opportunities, such as courses, workshops, webinars, books, articles, and forums, and encourage a culture of continuous improvement and learning.

7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?