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PLC Logic Optimization & HMI Revamp for Production Lines
Control Systems
2024

PLC Logic Optimization & HMI Revamp for Production Lines

Optimized PLC control logic and parameters on high-volume automotive production lines at Veoneer to improve cycle time, stability, and run-rate consistency. Actively tuned live control logic without disrupting operations and helped design a revamped HMI for new production lines, improving alarm clarity, operating mode visibility, and operator interaction during changeovers and fault recovery.

Project Visuals

Figure 1: HMI revamp for new lines
Figure 1: HMI revamp for new lines
Figure 2: Auto Pincheck detection
Figure 2: Auto Pincheck detection

Technologies Used

PLC ProgrammingMATLABStatistical AnalysisCPK AnalysisGage R&R

Key Features

  • PLC parameter tuning and logic optimization for cycle-time improvement
  • Revamped HMI design for new production lines
  • Improved alarm visibility and operating mode clarity
  • Live production tuning without disrupting operations
  • Enhanced operator interaction during changeovers and fault recovery

Challenges

  • Optimizing cycle time while maintaining process stability
  • Making PLC changes on live, high-volume production lines
  • Designing HMIs that are intuitive for operators under time pressure
  • Balancing automation efficiency with human interaction constraints

Outcomes

  • Improved cycle time through targeted PLC parameter optimization
  • Delivered a revamped HMI adopted on new production lines
  • Reduced operator ambiguity during alarms and changeovers
  • Improved production stability and smoother line launches
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