Case Studies

AB RSLogix to Siemens S7 Conversion

Posted in Food and Beverage, HMI and SCADA, Machine Vision, Manufacturing Automation and Intelligence, Motion Control, PLC Programming, Siemens PLC, Test & Measurement Automation


DMC developed the PLC and HMI program for a high-throughput automated valve application machine. The machine stamped one-way air valves onto the packaging material in order to ensure coffee placed in the bag would remain fresh as long as possible. The system included interfaces to multiple outside systems including several smart camera vision check stations, a precision servo stamping mechanism, and another manufacturer’s downstream production lines


DMC was asked to rewrite code from a similar machine that was created in the Allen Bradley PLC programming environment. The customer had specified the use of a Siemens S7-300 PLC, and required the help of an integrator intimate with both the original and new controllers. The main concerns for the customer were reliability, passing the production speed specifications, and keeping integration costs low. 

In order to accomplish these goals, DMC used a hybrid approach to the program creation process. Where applicable, DMC utilized existing codebase from the customer’s previous projects. This was useful to both keep integration costs low as well as leverage code already proven out in prior commissionings. Where this codebase failed to meet specifications, DMC either re-wrote portions from scratch or modified existing code. When re-writing code, DMC maintained the existing programming styles in order to make any future programming upgrades in the future “seamless” regardless of who programmed it. This strategy allowed DMC to finish the project on budget with all of the customer’s requirements met.

Customer Benefits

  • Multiple HMIs with redundant functionalities to ensure continued runtime in the event of an HMI failure
  • Smooth interface with existing outside systems (smart camera vision checks and valve placement servo systems) to eliminate the need to re-program systems from past projects
  • Higher valve per minute production speed than any other competitor’s system at the time
  • Programming checkout at end-customer done remotely to eliminate travel costs during startup