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We’re all moving fast, and companies that adopt smarter, simpler control systems are gaining a real advantage. In a recent discussion featuring Chuck Ridgeway from Horner Automation and Andrew Jagger from Power/mation, several key topics were explored, including PLC programming software, industrial networking, all-in-one controllers, and remote access solutions.

If you’re an OEM machine builder, controls engineer, manufacturer, or plant operations leader, this conversation offers valuable insight into where industrial automation is headed and why modern PLC systems are becoming the preferred choice.

Why Simpler PLC Systems Matter More Than Ever

One of the biggest takeaways was clear. Industrial customers want systems that are easier to deploy, easier to program, and easier to support long term.

Traditional PLC systems often required:

  • Separate PLC hardware
  • Separate HMI hardware
  • Multiple software platforms
  • Complex wiring layouts
  • Spreadsheet-based memory mapping
  • Added hardware for remote access

Today, manufacturers are looking for integrated automation platforms that reduce complexity while improving performance. That is why Horner Automation all-in-one PLC and HMI systems continue to gain momentum.

What Makes Modern PLC Software Better?

Andrew Jagger shared experience from training customers across the Midwest, from first-time users to seasoned controls engineers.

For experienced PLC programmers, a modern software platform can be learned quickly when the interface is intuitive. For newer users, ease of use is even more important.

Modern PLC software that combines the following into one package creates a much smoother learning curve:

  • Ladder logic programming
  • HMI screen development
  • Networking setup
  • Variable management
  • Diagnostics and troubleshooting tools

This saves time during training and helps users become productive faster.

Why Tag-Based PLC Programming Is Replacing Old Addressing Methods

Another major topic was the shift from register-based programming to tag-based PLC programming.

Older systems often relied on memory addresses like:

  • %R1
  • %R100
  • %M12

The problem is simple. Years later, those names often mean nothing to the next technician or engineer.

Modern PLC programming uses clear variable names such as:

  • Start_Button
  • Tank_Level
  • Conveyor_Run
  • Cook_Timer

This creates built-in documentation and makes programs much easier to understand.

Benefits of Tag-Based Programming

  • Faster troubleshooting
  • Easier maintenance
  • Cleaner code
  • Better readability
  • Simpler training for new employees
  • Fewer programming errors

For many manufacturers, especially those facing workforce turnover, this is a major advantage.

Why All-in-One PLC Controllers Continue to Grow

All-in-one industrial controllers combine multiple functions into a single device, including:

  • PLC processor
  • Touchscreen HMI
  • Built-in I/O
  • Networking ports
  • Communication tools

Instead of managing several separate devices, machine builders can simplify design and reduce installation time.

Benefits of All-in-One Controllers

  • Smaller control panels
  • Less wiring labor
  • Faster commissioning
  • Lower hardware costs
  • Easier troubleshooting
  • Fewer spare parts to stock

This type of system is especially useful for OEM machine builders looking to improve efficiency without sacrificing capability.

Why Compact Automation Matters in Medical Manufacturing

One especially interesting point involved the Twin Cities manufacturing market, where many companies produce small medical devices.

These machines often need to be:

  • Compact
  • Clean
  • Precise
  • Efficient
  • Easy to validate

Large traditional control cabinets are not always the best fit. Compact PLC control systems help reduce machine footprint while still delivering reliable automation performance.

This can be a major benefit for:

  • Medical device assembly
  • Packaging systems
  • Benchtop testing equipment
  • Small robotic cells
  • Precision manufacturing lines

Remote PLC Access Is Becoming Essential

Modern machine builders ship equipment across the country and around the world. When a problem occurs, sending a technician onsite can be expensive and slow.

That is why secure remote PLC access is becoming a must-have feature.

What Remote Access Can Provide

  • Upload and download PLC programs remotely
  • Diagnose faults faster
  • Monitor machine performance
  • Reduce travel costs
  • Improve support response times
  • Increase machine uptime

Remote connectivity is also helping more companies adopt Industrial IoT solutions without adding unnecessary complexity.

Industrial Networking Still Drives Automation Growth

Nearly every modern automation project depends on reliable industrial networking.

Several important protocols were discussed:

Modbus TCP

  • Still widely used because it is simple, proven, and supported by many devices.

PROFINET

  • Common in advanced manufacturing and large automation systems.

EtherNet/IP

  • Highly popular in North America and widely supported across industrial devices.

Why EtherNet/IP Support Matters

Many third-party products rely on EtherNet/IP, including:

  • VFDs
  • Servo drives
  • Valve banks
  • Sensors
  • Vision systems
  • Motion control devices

For OEMs standardizing machine designs, broader protocol support creates more flexibility.

Free PLC Software Still Matters

Software cost was another strong point in the conversation.

Many automation platforms now charge for:

  • Programming licenses
  • Annual subscriptions
  • Support contracts
  • Feature upgrades

That can add up quickly, especially for growing teams.

Why Free PLC Software Is Valuable

  • Lower ownership cost
  • Easier rollout across multiple users
  • No license limitations
  • Faster training
  • Better long-term scalability

For many companies, this can save thousands of dollars over time.

Why Long Product Lifecycles Matter

Obsolescence is a serious concern in industrial automation. Machine builders may support equipment for 10 to 20 years or longer.

If hardware changes too often, redesign costs rise and support becomes harder.

Platforms that maintain compatibility across generations offer major benefits:

  • Easier upgrades
  • Lower redesign costs
  • Better spare parts continuity
  • Simpler customer support
  • Stronger long-term ROI

That long lifecycle support can be a deciding factor when selecting a PLC platform.

Contact us today to discuss your automation goals, and watch the full video for expert insights on modern PLC systems, industrial networking, and smart manufacturing solutions. You can also visit shop.powermation.com to explore products, kits, and configuration tools designed for smarter manufacturing.