How to Wire Your Factory to Code Without Blowing the Budget

Introduction

Wiring a factory to enable code-based manufacturing can seem daunting, but with some planning and smart decisions, it doesn't have to break the bank. As the owner of a small manufacturing company, I have worked to implement coding and automation in my factory in a cost-effective way. In this article, I will walk through the step-by-step process I followed to wire my factory to code without blowing my budget.

Assess Current Infrastructure and Needs

The first step is to thoroughly assess the current state of your factory infrastructure and identify what needs to be added or upgraded.

• Examine current wiring and electrical systems. Are they sufficient to handle an increase in power demands? If not, upgrades will be needed.

• Evaluate network connectivity. Is there Ethernet cabling throughout the facility? Wireless networks? You'll need reliable, high-speed connections.

• Consider power needs for new automation equipment like PLCs (programmable logic controllers).

• Make a list of coding/automation goals - areas of processes to automate, equipment to connect, software integrations required. This will inform infrastructure needs.

Thoroughly understanding current systems and end goals is crucial to develop the right wiring plan. Don't skip this step!

Develop a Strategic Wiring Plan

Next, develop a strategic plan for factory wiring focused on supporting coding and automation in a cost-effective manner.

• Consider phasing upgrades over time instead of all at once. What are top priorities?

• Explore a mix of wired and wireless connectivity as needed. Wireless can reduce cabling costs.

• For new wiring, balance cost and functionality. Higher-end cabling offers more bandwidth but isn't always necessary.

• Use common communication protocols like Ethernet and serial connections for broad compatibility.

• Plan wiring routes efficiently - minimize cable lengths and access points.

• Include capacity for future expansion and flexibility.

The goal is to enable coding/automation functionality without over-engineering. An incremental, standards-based approach can save substantially on costs.

Leverage Existing Infrastructure

Maximize the use of existing wiring and infrastructure to control costs:

• Use existing power systems and make targeted upgrades only where needed.

• Check for existing Ethernet runs that can be leveraged before running new cabling.

• Evaluate existing equipment like PLCs. Can existing units be programmed vs replaced?

• Use daisy chaining for wiring devices like sensors to avoid excess cable runs.

• Repurpose old equipment like control cabinets to house new automation hardware.

Finding ways to repurpose and minimize new infrastructure keeps wiring costs down. Being creative with what's already available goes a long way!

Choose Cost-Effective Components

Carefully select automation and wiring components with cost in mind:

• Compare PLC models and choose units with sufficient capabilities without overbuying.

• Consider open-source PLCs like Arduino-based options to save substantially.

• Shop around for deals on cables, connectors, conduits, and related supplies. Buying in bulk can also cut costs.

• Use lower-cost communication protocols like serial vs fieldbus for non-critical links.

• Specify the right wire gauges - larger than necessary wires add expense.

• Buy generic terminal blocks, power supplies, etc. instead of name brand versions.

Finding the "sweet spot" for components in terms of functionality and price makes wiring more affordable.

Work With a Knowledgeable Electrician

Don't go it alone - an experienced industrial electrician is invaluable for cost-effective wiring:

• They have technical expertise to make recommendations on equipment, wiring methods, and compliance.

• They can accurately estimate labor time and material needs to avoid unexpected costs.

• They have relationships with suppliers to get the best deals on required components.

• They can implement installations efficiently and correctly the first time, avoiding costly redos.

Partnering with the right electrician will optimize the wiring process and budget. I found an excellent local electrician that helped keep my project on-time and on-budget.

Summary

Wiring a factory for coding and automation can absolutely be accomplished without blowing the budget. By thoroughly assessing needs, strategic planning, maximizing existing infrastructure, choosing affordable components, and utilizing experienced help, I was able to implement cost-effective wiring for coding and automation in my facility. Careful attention to controlling costs at each step resulted in significant savings while still achieving my modernization goals. With the right approach, you can wire your factory to code without breaking the bank either.