PLC Hardware Integration & HMI Improvement

Overview

As part of a continuous improvement initiative across multiple assembly stations, I redesigned the operator interface by integrating physical push buttons, selector switches, and control hardware directly into existing PLC-controlled manufacturing equipment. The original systems relied heavily on touchscreen HMIs for operator acknowledgements and machine control. Over time, frequent use caused excessive wear on the touchscreens, reducing reliability and slowing production. Working with Siemens TIA Portal, I programmed the required PLC logic to interface the new hardware with the existing control system while maintaining the original machine functionality. I also modified each workstation to position controls in locations that were intuitive and ergonomically accessible for operators, reducing unnecessary movement during repetitive assembly tasks. The hardware upgrades were implemented across multiple production benches, including compressor, fuel pump, blower assembly, burner head assembly, and PCM fixtures. These improvements increased equipment reliability, extended the service life of the HMIs, and provided operators with a faster and more ergonomic interface for everyday production tasks.

Key Deliverables

• Integrated physical push buttons, selector switches, and control hardware into existing PLC systems.
• Developed ladder logic in Siemens TIA Portal for hardware interface and machine control.
• Modified manufacturing benches to improve operator ergonomics and accessibility.