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If AI is really coming to PLC programming, what specific repetitive tasks in ladder logic or structured text do you think will be automated first - and what skills should my technicians be developing now to stay relevant?

answer

Great question! As someone who's been in industrial automation for years, I've been watching AI developments closely. Based on what I'm seeing, here's what I think will happen:

First, the repetitive tasks that AI will likely automate include:

1. **Basic I/O mapping and configuration** - AI can handle the tedious work of mapping inputs/outputs and setting up basic control logic

2. **Standard control patterns** - Things like motor start/stop sequences, conveyor control logic, and basic safety interlocks that follow predictable patterns

3. **Code documentation and commenting** - AI can automatically generate documentation for ladder logic rungs or structured text functions

4. **Error checking and debugging** - AI can scan code for common errors, suggest optimizations, and even predict potential failure points

5. **Code conversion** - Converting between ladder logic and structured text, or adapting code for different PLC platforms

For your technicians to stay relevant, they should focus on developing these skills:

**1. AI Collaboration Skills** - Learn how to effectively prompt AI tools, validate AI-generated code, and integrate AI suggestions into real-world systems

**2. Systems Integration** - Understanding how PLCs interact with other systems (MES, SCADA, IoT devices) will become more valuable as AI handles basic programming

**3. Problem-Solving & Troubleshooting** - AI can write code, but humans will still need to understand complex systems, diagnose issues, and make judgment calls

**4. Cybersecurity** - As systems become more connected and AI-assisted, security knowledge becomes critical

**5. Data Analysis** - Understanding how to interpret sensor data, optimize processes, and use predictive maintenance tools

Think of it this way: AI will be like having a super-efficient junior programmer who never gets tired of writing basic code. Your technicians will become more like senior engineers - overseeing the AI, making strategic decisions, and handling the complex, non-repetitive work that requires human judgment and experience.

The key is to start experimenting with AI tools now, learn their strengths and limitations, and develop the skills to work alongside them effectively.

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