5 Costly PLC & Automation Mistakes That Kill Uptime
And How to Fix Them Fast – Free Guide by Anoop Automations
1. Poor PLC Wiring & Earthing
- Random intermittent faults
- False input signals
- Frequent PLC resets
- Communication errors
Pro Tip: Perform a wiring & earthing audit every 3–6 months to prevent major downtime.
2. No Program Backups or Version Control
- Lost PLC logic after power failure
- Extended downtime during recovery
- No version tracking
Pro Tip: Always maintain versioned backups before and after modifications.
3. Ignoring Security on IoT Controllers
- Unauthorized access risks
- Ransomware threats
- Data leaks
Pro Tip: Use VPN + multi-factor authentication for secure monitoring.
4. Encoder Misalignment in Retrofits
- Inaccurate positioning
- Product scrap increase
- Servo following errors
Pro Tip: Always run full calibration testing after retrofits.
5. Weak Power Supply & No Surge Protection
- PLC card failures
- Voltage fluctuation damage
- Monsoon-related breakdowns
Pro Tip: Install surge arrestors + UPS for reliable protection.
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