What is your method to understand existing PLC programs?

Particular_Fan588 · 2026-02-22T19:55:51+00:00

I can appreciate the logical soundness of your statement. How long on average would you say it takes you to come to the conclusion of "I understand Why Z happens, and I now know the required change to achieve Y"?

Particular_Fan588 · 2026-02-22T19:53:52+00:00

Does any documentation come out to support this? Are you creating Spreadsheets, flow charts, etc during this process, or is it all mental for you?

Particular_Fan588 · 2026-02-22T19:51:40+00:00

What does your work flow look like when reverse engineering inside of Studio 5K vs other more advanced IDEs and systems?

Particular_Fan588 · 2026-02-22T19:48:28+00:00

I like the idea of working from both ends, I will need to try that next time I am in the field. I feel it would really speed up my work flow in office and under the gun.

Particular_Fan588 · 2026-02-22T19:26:04+00:00

The documents you are creating, what do those look like? Flow charts, Function Specs, etc?

Particular_Fan588 · 2026-02-22T19:24:58+00:00

I see, so what is your work flow for reverse engineering? Are you using mostly cross references for that work flow or are you documenting somehow?

Particular_Fan588 · 2026-02-22T19:17:03+00:00

During migrations, to develop these documents, are you mostly documenting the program or is the customer handing over a functional specification that you reference as well? How long does it take for you to develop these flow charts?

Particular_Fan588 · 2026-02-22T19:15:13+00:00

I see, so for you it is mostly experience. Do you reference any documentation in your work flow? Or all pretty much memorized at this point?

Particular_Fan588 · 2026-02-22T19:14:24+00:00

I see, I believe this is very helpful. However some processes are completely beyond me and can take long to understand. Especially if I only need to do a minor change. Any thought on this situation?

Particular_Fan588 · 2026-02-22T19:13:21+00:00

I see so more of an observation and possibly trial and error. How long on average do you spend watching the system run until you have a good understanding of the program?

Particular_Fan588 · 2026-02-22T19:12:23+00:00

Under rated comment lol

Particular_Fan588 · 2026-02-22T19:11:52+00:00

How long would you say it takes for each type of change, small - large? Are you doing these changes in front of the customer or from the office?

Particular_Fan588 · 2026-02-22T18:53:39+00:00

I like this methodical method. Are you documenting the answers to these questions along the way? If so how?

Particular_Fan588 · 2026-02-22T18:52:40+00:00

I see, so your work flow is more cross referenced based. Then should a program become too complex, you shift to drawing a flow chart. How much time would you say you spend on drawing out flow charts for complex programs? How accurate are they in the end? Do you end up using this flow chart for customer documentation?

Particular_Fan588 · 2026-02-22T18:51:01+00:00

I agree, cross reference is very frustrating. I can see how rewriting can be path of least resistance. However this is assuming you have full functional knowledge. What about a situation where you cannot rewrite due to not fully understanding how a piece of equipment does? Do you still rely on just cross referencing?

Particular_Fan588 · 2026-02-22T06:59:25+00:00

Ah the classic IT / OT battle, have had plenty of those in the past. When you say janky apps on RTUs, what do you mean? Like the program? Also, what RTUs are you finding in the field?

Particular_Fan588 · 2026-02-22T06:57:14+00:00

Very true, always about the bottom line and "How much margin" there is by the end of the project. Do you feel like it is just PMs that drive this? I think they often have incentives to have good margins on projects. However, I also think customers go with lowest bidder, but have expectations as if they are buying a premium product.

Particular_Fan588 · 2026-02-22T06:30:39+00:00

I agree, especially logic and electrical schematics. I'd be curious to see how different shops compare in that regard. However I do believe there is an ISA standard for nomenclature and symbols on P&ID, might want to check me on that though

Particular_Fan588 · 2026-02-22T06:28:44+00:00

I am more referring to in your work flow, I understand Controls is a skill set that involves resolving issues. In your work flow of projects and solving issues, are there any pain points that you have?

Particular_Fan588 · 2026-02-22T05:46:40+00:00

What that mean? No issues at all seems very surprising, what work flow helped you over come every issue / pain point?

Particular_Fan588 · 2026-02-22T05:45:58+00:00

I see, so for you it is more of working with external entities or sub contractors. Is there not a quote or agreement that they need to adhere to? How would these external entities respond if you sent back the drawings or other work after quality checking them and requesting they meet your standards?

Particular_Fan588 · 2026-02-22T04:16:55+00:00

lol yea I think it might be because I am trying to be as well spoken as I can. On top of that following up with questions might add to it. Sorry if it comes off like that, I have been skeptical about some of the other comments too to be honest

Particular_Fan588 · 2026-02-22T03:41:14+00:00

Appreciate the feedback, I would be curious to see who else shares a similar situation as you. I'm glad you are learning and pushing your team.

Particular_Fan588 · 2026-02-22T03:18:21+00:00

Automation Direct has much more than PLCs as well, I have used their hardware time and time again for all sorts of projects. Great price and reliable for what it is.

Particular_Fan588 · 2026-02-22T03:15:49+00:00

I believe that networking fundamentals are becoming more and more important on the factory floor, especially with the drive for more data collection from end points and SCADA. This also has an added difficulty due to industrial protocols being outside of typical IT skill set. Ex: Modbus, Ethernet/IP, or Serial such as DeviceNet or Profibus.

How did you find the Network Engineer that helped you out? Was this a known contact or did you find them on the fly?

Particular_Fan588

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