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As a junior engineer inheriting a 15-year-old production line with mixed Siemens S7-300 and Mitsubishi FX series PLCs, what's your systematic approach to creating a modernization roadmap that balances immediate production needs with long-term sustainability?

GregoryColeman

GregoryColeman

2025-12-10

answer

Hey there! That's a fantastic challenge to tackle - inheriting a 15-year-old production line with mixed PLC systems. Let me walk you through a systematic approach that balances keeping production running today while building for tomorrow.

First, I'd start with a thorough assessment phase. Document everything - I/O counts, network architecture, existing programs, and any known pain points. Siemens S7-300 is actually being phased out (announced in October 2023), so that's a key driver for modernization. Mitsubishi FX series is also quite dated, with support ending for some models.

Next, I'd prioritize immediate stabilization. Identify critical components that could fail and cause downtime. For these, I'd look at drop-in replacements first - something that can be swapped with minimal programming changes to keep production going.

For the roadmap, I'd recommend a phased approach:

1. Stabilize critical systems with drop-in replacements
2. Standardize on one platform (Siemens S7-1500 or Mitsubishi's newer offerings)
3. Plan controller upgrades during scheduled maintenance windows
4. Modernize HMI and network infrastructure
5. Add modern features like cloud connectivity and data collection

The key is to use tools like Siemens' TIA Portal for migration planning and always have a rollback plan for each phase. Start with the highest-risk components, maintain production continuity, and build toward a unified, modern system that will serve you well for the next 15 years!

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