THE PROBLEM

The plant faced recurring downtime cause by random PLC/I/O failures linked to end-of-life ET200S modules and heat-induced instability.

SOLUTION

Within two days, we upgraded the system by replacing heat-stressed ET200S units with ET200SP modules, installing an S7-1500 PLC, and fully restoring Profinet and SCADA communication.

RESULTS

Downtime was reduced by nearly 90%, random failures were fully eliminated, and the new Siemens-standard hardware significantly impoved overall plant reliability.