An investigation into programmable logic controller software design techniques in the automotive industry

Purpose - This paper aims to describe the results of an investigation into the techniques used to design factory control systems in the body-in-white section of car-manufacturing plants in Germany, the UK and the USA. Design/methodology/approach - Research was conducted through a set of semi-structured interviews with the individuals responsible for planning control system architectures in a number of companies world-wide. Findings - The challenges faced by the users of industrial control systems, such as the need to conduct changes quickly, accurately and without errors, are identified. Each organisation participating in this study was seen to use a company-specific standard to bring commonality to systems and to improve the ease of developing, maintaining and modifying their control systems. Similar software structures were seen to be in use in many of the companies participating in this survey, though in some cases differing attitudes to the use of the same tools were observed. Practical implications - This work captures, documents and reviews industrial practice in a structured manner, providing an insight into the factors affecting the selection of control system technology by industrial users, and serves as a starting-point for researchers wishing to investigate the relative importance to industrial practitioners. Originality/value - Existing work on industrial programming practice is extended by detailing specific software structures used in manufacturing operations in the car industry