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ATMI BizDEC
Training Program Automation & Control

PLC Maintenance & Troubleshooting for System Reliability

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Program Description

This program develops participants’ competency in maintaining, diagnosing, and troubleshooting PLC-based industrial control systems to support reliable machine operation. Participants learn PLC hardware and system diagnostics, preventive and corrective maintenance, fault identification, program monitoring, I/O troubleshooting, and systematic root-cause analysis through practical industrial cases and hands-on exercises.

Certification -
Duration 40 JP

Method

Instructor-led technical sessions, demonstrations, hands-on PLC diagnostics, guided troubleshooting exercises, simulation, industrial case studies, fault-finding practices, and competency-based practical assessment.

Requirements

Basic knowledge of electrical systems and industrial automation.
Basic understanding of PLC operation and programming.
Ability to read basic electrical and PLC I/O diagrams is recommended.

Target Participants

Maintenance engineers and technicians, automation engineers, electrical engineers, control technicians, production technicians, machine maintenance personnel, and vocational or higher-education instructors involved in PLC-based equipment maintenance.

Learning Output

Participants are able to perform PLC system maintenance, monitor PLC operation, identify electrical, hardware, I/O, and program-related faults, apply systematic troubleshooting and root-cause analysis techniques, and implement appropriate corrective actions to improve PLC system reliability and minimize equipment downtime.

Program Advantages

The program focuses on practical maintenance and fault-finding skills required in manufacturing environments, enabling participants to diagnose PLC-related problems systematically, reduce troubleshooting time and unplanned downtime, and support reliable operation through appropriate preventive and corrective maintenance practices.

Subject Materials

  • PLC System & Maintenance Fundamentals
  • 1.1 PLC architecture, hardware, I/O, and system configuration
  • 1.2 PLC operating conditions and common failure modes
  • 1.3 Maintenance safety and good maintenance practices
  • Preventive & Predictive Maintenance
  • 2.1 PLC inspection and preventive maintenance procedures
  • 2.2 Monitoring system conditions and operational parameters
  • 2.3 Maintenance documentation and reliability indicators
  • PLC Diagnostics & Fault Identification
  • 3.1 PLC diagnostic functions, status monitoring, and error codes
  • 3.2 I/O, sensor, actuator, wiring, and communication fault identification
  • 3.3 Program monitoring and identification of logic-related faults
  • Troubleshooting & Root-Cause Analysis
  • 4.1 Systematic troubleshooting methodology
  • 4.2 Fault isolation and root-cause analysis
  • 4.3 Corrective actions, verification, and system recovery
  • Reliability Improvement Project
  • 5.1 Practical PLC fault diagnosis and troubleshooting case
  • 5.2 Testing and verification after corrective action
  • 5.3 Maintenance recommendations for improved system reliability