Distribution Center PLC Fault Detection Techniques Streamline Parcel Sortation Operations

E Tech Group helped a global parcel services provider with PLC program development, troubleshooting, and system start-up to meet a tight timeline and improve productivity.

Our recent addition, Automation Group, an E Tech Group Company, completed this case study. A summarized version is below. Click here to read the full case study on their site.


E-commerce growth and expedited shipping demands have posed challenges for distribution centers. To keep up, many centers are implementing automation solutions to maximize throughput and reduce fault recovery time. A global parcel services leader outsourced PLC program development for their sortation systems but faced a tight timeline. Automation Group, an E Tech Group Company was hired to quickly develop and troubleshoot the programs, and lead system startup and testing.


The parcel operations required extensive fault monitoring and suppression, as well as package flow rate tracking, to maximize throughput and reduce system downtime. Automation Group, an E Tech Group Company, prioritized the commission of the primary sorter systems, including diagnosing and correcting errors and setting up communication between the PLC and the customer’s warehouse management system. They also set up numerous conveyor belts that were required to run with the package tracking logic.


Automation Group, an E Tech Group Company completed changes to the primary sorter systems and stayed on board to support testing and commissioning of the remaining parts of the primary sorter line. With our programming support, the system became fully operational within a few months. This helped the parcel services leader to maximize its large-scale distribution center operations. As a result, Automation Group, an E Tech Group Company was later invited to lead the development, startup, and testing of the second phase which included an additional five sortation systems.