Legacy PLC Upgrade Eliminates Unplanned Downtime
Client: National FMCG Manufacturer
96%
Downtime Reduction
+17pts
OEE Improvement
14 months
ROI Timeline
The Challenge
An ageing Modicon PLC system on a high-speed packaging line was causing 4–6 hours of unplanned downtime per week. Spare parts were no longer available, putting production at serious risk.
The Solution
MACH performed a complete PLC migration to Allen-Bradley ControlLogix with new HMI touchscreens and integrated OEE monitoring dashboards. The upgrade was completed over two planned weekend shutdowns with zero production loss.
The Result
Unplanned downtime reduced from 280 hours/year to under 12 hours. OEE improved from 71% to 88%. ROI achieved in 14 months.
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