26 Disadvantages of Being a PLC Programmer (Syntax Struggles)

disadvantages of being a plc programmer

Considering a career in PLC programming?

It’s easy to be drawn in by the appeal:

  • Opportunities for problem-solving.
  • Potential for high earnings.
  • The satisfaction of creating efficient industrial automation solutions.

But there’s more to the tale.

Today, we’re delving in. Deeply in.

Into the complex, the demanding, and the downright challenging aspects of being a PLC programmer.

Intricate programming language? Check.

Initial investment in learning and equipment? Certainly.

Mental strain from diverse project requirements? Absolutely.

And let’s not ignore the unpredictability of technological changes.

So, if you’re contemplating stepping into PLC programming, or merely curious about what lies beyond those lines of code and successful system integrations…

Keep reading.

You’re about to gain a comprehensive understanding of the disadvantages of being a PLC programmer.

Contents show

Need for Continuous Learning and Skill Upgradation

PLC Programmers need to continuously update their skills and knowledge due to the rapid pace of technological advancements.

The functionality and capabilities of PLC systems are constantly evolving, which means that programmers must be aware of the latest trends and developments in this field.

They will need to invest time in learning new programming languages, techniques and technologies to stay relevant.

This could involve attending training courses, conferences or self-learning.

The need for continuous learning and skill upgradation could be stressful and time-consuming, especially when balancing it with their regular work responsibilities.

Additionally, there may be costs associated with further education and training.


On-Call Responsibilities and Unscheduled Interventions

PLC Programmers often deal with on-call responsibilities, which can disrupt their personal life.

Since manufacturing and industrial processes run 24/7, there is a constant need for PLC programmers to be available for any emergencies or system failures.

These unforeseen issues can occur at any time, including nights, weekends, or holidays, requiring immediate intervention to avoid production loss or potential safety hazards.

Unscheduled interventions may also be necessary, demanding the programmer to be flexible with their time.

This unpredictability can lead to stress and a lack of work-life balance.


Pressure to Minimize Downtime in Automated Systems

As a PLC (Programmable Logic Controller) programmer, you are responsible for creating and adjusting the software that controls automated systems.

These systems are often critical parts of manufacturing or industrial processes.

Any downtime in these systems can result in significant operational and financial losses for the company.

Therefore, PLC programmers often face immense pressure to quickly diagnose and fix any issues that arise to minimize downtime.

This can be particularly stressful in industries that operate 24/7, where any system failure can have immediate and substantial impacts.

Furthermore, the responsibility of ensuring that all automated systems function correctly and efficiently at all times can be a significant burden, potentially leading to long hours and high-stress levels.


High Responsibility for Safety and System Reliability

PLC Programmers carry a high level of responsibility when it comes to safety and system reliability, as they develop and maintain the systems that control important machinery and processes.

A single error in a PLC program can cause catastrophic failures, which may lead to dangerous situations, damage to the machinery, and loss in productivity or profit.

This pressure to ensure optimal functioning and safety can be stressful and demanding.

Additionally, they are often on call for emergencies or system failures, which can lead to unpredictable work hours and situations.

However, it also means that PLC programmers play a crucial role in ensuring the smooth operation of various industrial and manufacturing processes.


Managing Complex Problem-Solving Under Time Constraints

PLC Programmers are often tasked with managing and resolving complex system issues within a limited timeframe.

They are regularly required to diagnose and fix intricate problems to ensure that the automated processes and machinery of a manufacturing or production line continue to function smoothly.

This can involve a high level of stress and pressure as any delay or downtime can result in significant financial losses for the company.

Moreover, this role often demands immediate response and solutions, which can lead to long working hours and a disrupted work-life balance.

The complexity of the problems also requires an advanced understanding of PLC programming and system troubleshooting, which can be challenging and demanding.


Working in Industrial Environments With Potential Hazards

PLC Programmers often work in industrial settings where they interact with heavy machinery and potentially hazardous equipment on a daily basis.

These environments can pose various safety risks and require constant vigilance and adherence to strict safety protocols.

Working in such environments may also expose them to conditions like noise, dust, heat, or cold, which can be challenging and uncomfortable.

Additionally, the possibility of encountering electrical hazards due to the nature of their job is also a significant risk.

These factors can contribute to a stressful work environment, requiring PLC programmers to maintain a high level of concentration and caution at all times.


Adhering to Strict Industrial Regulations and Standards

PLC Programmers are required to adhere to strict industrial regulations and standards.

They are responsible for creating programs that control the automation of industrial machinery and processes.

This means they must have a deep understanding of safety standards and regulations related to automation.

Failure to adhere to these standards can lead to serious consequences such as damage to machinery, injury to workers, or significant financial losses due to non-compliance penalties.

This responsibility can create a high-stress environment and require constant vigilance to ensure all programs are compliant and safe.

This also means they need to constantly stay updated with any changes in the rules and regulations, which can be time-consuming and challenging.


Necessity to Understand a Broad Range of Industrial Equipment

As a PLC Programmer, it is necessary to have a comprehensive understanding of a wide array of industrial equipment.

This can include, but is not limited to, various types of machinery, electronic components, and control systems.

Furthermore, each piece of equipment may operate differently, necessitating extensive knowledge on the functional aspects of each one.

This can make the role quite complex and demanding, as it requires constant learning and adaptation to new technologies.

Not only does this require a significant time investment, but it can also be challenging to keep up with the rapid pace of technological advancements in the field.

This constant need for learning and development can be stressful and demanding, potentially leading to burnout if not managed properly.


Maintaining Legacy Systems Alongside New Technologies

PLC Programmers often face the challenge of maintaining and updating legacy systems while trying to keep up with the ever-evolving field of new technologies.

Older PLC systems may not have the same capabilities or compatibility with newer technologies, making it difficult to integrate them seamlessly.

This may require the programmer to have a deep understanding of both old and new systems, which can be time-consuming and complex.

Furthermore, legacy systems might lack documentation or support, making troubleshooting and maintenance a daunting task.

This constant juggle between old and new can put a strain on the productivity and efficiency of a PLC programmer.


Risk of Obsolescence of Specific Programming Skills

PLC programmers are required to have a deep understanding of specific programming languages and technologies.

The field of automation is constantly evolving, with new programming languages, tools, and techniques emerging regularly.

This means that the specific programming skills that a PLC programmer has today might become obsolete in the future.

In order to stay relevant in their field, PLC programmers must continuously learn and adapt to new technologies.

This can be stressful and time-consuming, especially if the programmer is working full time.

Furthermore, the risk of obsolescence can also impact job security if a programmer’s skills become outdated.


Potential for Long Hours During Critical Project Phases

PLC Programmers, particularly those involved in the creation or modification of complex control systems, may find themselves working well beyond the typical 40-hour workweek during critical stages of a project.

This could include times when a production line is about to go live, during system upgrades, or when troubleshooting issues arise.

This may mean working late into the night or over weekends to meet project deadlines or to minimize production downtime.

While this can be rewarding in terms of problem-solving and project completion, it can also lead to a work-life imbalance, especially during these critical periods.


Limited Recognition for Behind-the-Scenes Work

PLC Programmers often perform their duties behind the scenes, ensuring the smooth operation of automated manufacturing systems.

Their work is critical in keeping production lines running and avoiding costly downtime.

Despite this, their efforts are not always recognized or appreciated at the same level as more visible roles within an organization.

They may not always receive the credit they deserve for their contributions to the company’s bottom line.

This can lead to dissatisfaction and a feeling of being undervalued, despite the critical role they play in the company’s operations.


Competition in the Field Due to Global Sourcing

PLC programming is a role that is no longer restricted by geographical boundaries.

With the evolution of technology and the internet, companies are now able to source PLC programmers from across the globe.

This means that local PLC programmers are not only competing with each other but also with international candidates.

While this offers companies a wider talent pool to choose from, it can make it more challenging for individual programmers to secure jobs or negotiate higher salaries.

The increasing trend of outsourcing and offshoring in many industries can also make it difficult for PLC programmers to find stable, long-term employment opportunities.


Difficulty in Demonstrating Value to Non-Technical Stakeholders

PLC Programmers often face the challenge of demonstrating the value of their work to non-technical stakeholders.

They work with complex programming codes and automation systems, the intricacies of which are not easily understood by those without a technical background.

This can make it challenging to communicate the necessity and impact of their work to others in their organization who may not understand the complexity or value of PLC programming.

This may lead to underappreciation of their role and potential difficulties in securing necessary resources or support for their projects.

Additionally, the intangible nature of software programming can sometimes make it difficult to demonstrate concrete results, unlike physical products or services.


Cognitive Strain From Intense Concentration Over Long Periods

PLC Programmers are often required to maintain extreme levels of concentration for extended periods of time.

They must continually monitor and adjust programming to ensure that automated systems and machinery function correctly.

This constant attention to detail can lead to mental fatigue and cognitive strain.

This role also necessitates a high level of problem-solving skills, as PLC programmers must be able to quickly identify and rectify any issues that arise.

Over time, this constant mental exertion can lead to stress, burnout, and potential impacts on overall health.

It’s a job that demands a lot mentally, without much room for error, which can be a significant disadvantage for some people.


Need for Efficient Code Optimization and Resource Management

PLC programmers are tasked with the complex job of writing and optimizing code for Programmable Logic Controllers (PLCs).

This job requires a high level of technical knowledge and understanding of both the hardware and software involved.

Efficient code optimization and resource management is crucial in this role.

If the code written is inefficient or not optimized, it can lead to poor system performance, increased energy consumption, and even system failures.

This means that PLC programmers must not only be skilled in writing code but also in analyzing and optimizing it to ensure it runs as efficiently as possible.

Furthermore, PLC programmers often need to work with limited resources, such as memory or processing power.

This calls for careful planning, testing, and reiteration, which can be time-consuming and demanding.

The constant need for efficient code optimization and resource management can make this role particularly challenging and stressful.


Balancing Factory Requirements With Technological Capabilities

PLC Programmers often face challenges in trying to balance the requirements of the factory floor with the capabilities of the technology.

This is because the needs of a manufacturing plant can be dynamic and complex, requiring constant adjustments and fine-tuning of the PLC programs.

On the other hand, the technology, including the PLCs and associated software, have their own limitations and may not always be able to keep up with the changes in the production lines.

This constant tug-of-war can make the job of a PLC programmer difficult and stressful.

Additionally, this can lead to long working hours, including nights and weekends, to ensure that production continues uninterrupted.


Requirement to Provide User Training and Documentation

As a PLC programmer, one of the demands of the job is providing user training and creating documentation for the systems they’ve developed.

This can be quite tedious and time-consuming as the programmer must translate complex programming language into simple, easy-to-understand instructions for non-technical staff members.

This requires not just programming skills, but also strong communication and teaching abilities.

The creation of detailed manuals, guides, and other documents also requires significant time and effort and can be a daunting task, especially if the systems are complex.

This part of the job may divert time from the core programming tasks, thereby extending the time it takes to complete projects.


Keeping Up with Rapid Advances in Automation Technologies

As a PLC programmer, one of the major challenges is keeping up with the constant and rapid advances in automation technologies.

As businesses increasingly turn to automation to improve efficiency and productivity, the technologies and software used in PLC programming are constantly evolving.

This means that PLC programmers need to continuously learn new programming languages, techniques, and tools.

This can be overwhelming and time-consuming, as it often requires extensive research, additional training, and even certifications to stay up-to-date with the latest technologies.

It also means that what you learn today might become obsolete in a few years, making lifelong learning a necessity in this field.


Dealing With Integration Challenges of Different Systems

As a PLC programmer, you are likely to encounter systems from different manufacturers or even different generations of the same system.

These systems may not always be compatible with one another, creating integration challenges.

You will need to find solutions to make these systems work together seamlessly, which can be a time-consuming and complex process.

In some cases, you may need to upgrade or replace hardware, which can be costly.

Additionally, learning to work with each system can require a significant investment of time and effort.

Despite these challenges, the experience of solving complex integration problems can be rewarding and can help you expand your skills.


Stress From Ensuring Zero Errors in Safety-Critical Applications

PLC Programmers are often tasked with creating and maintaining automated systems for industrial applications, many of which are safety-critical.

This means that any error in the programming could potentially lead to a dangerous situation, causing harm to people or damage to machinery.

This responsibility can cause a significant amount of stress, as the programmer must ensure that their code is perfect.

It requires meticulous attention to detail and rigorous testing to ensure that all scenarios have been considered and that the system will respond appropriately in each case.

The pressure to prevent any kind of mishap can be quite overwhelming and can lead to long hours and high stress levels.


Difficulty in Achieving Work-Life Balance Due to Project Deadlines

PLC Programmers often face challenges in achieving a healthy work-life balance due to the demanding nature of their job.

They are frequently required to meet tight deadlines, which can lead to long hours and even working over the weekend.

The unpredictability of project timelines can also lead to irregular working schedules, making it difficult for them to plan personal time or family commitments.

Additionally, PLC Programmers may sometimes be required to be on call outside of normal working hours to troubleshoot and fix urgent issues that arise, further disrupting their personal time.

This demanding schedule can lead to stress and burnout if not properly managed.


Coping With Rapid Shifts in Industry Best Practices

As the field of PLC programming is rapidly evolving, professionals in this role often face the challenge of keeping up with emerging industry standards and best practices.

Unlike some professions where the fundamentals may remain relatively static, PLC programming requires continuous learning and adaptation.

This can be particularly challenging when a project is mid-way through, and a new industry standard emerges that requires significant changes to the programming approach or the code itself.

This means that PLC programmers must be prepared to invest considerable time into self-education and professional development to stay current, which can lead to long working hours and potentially high levels of stress.


Managing Software Licensing and Updates for Development Tools

PLC programmers are often responsible for managing the software licensing and updates for their development tools.

This means that they need to keep track of when licenses need to be renewed to avoid any interruptions in their work.

They also need to stay up to date with the latest software updates and patches, which can be time-consuming.

Furthermore, dealing with software licensing and updates can be a complex and frustrating task, especially when dealing with multiple licenses and vendors.

It is a necessary part of the job that doesn’t directly contribute to programming tasks, but it is crucial to maintain the smooth operation of the development environment.


Vulnerability to Cybersecurity Threats in Industrial Control Systems

As a PLC programmer, you are tasked with managing the programming of industrial control systems that run crucial machinery in factories, power plants, and other industrial settings.

However, these systems are increasingly connected to the internet, which makes them vulnerable to cybersecurity threats.

If a hacker were to gain access to these control systems, they could potentially disrupt or even halt production.

In worst-case scenarios, they could cause physical damage to the machinery or create unsafe working conditions.

As a PLC programmer, you would need to be constantly vigilant and knowledgeable about the latest cybersecurity threats and countermeasures, which can be a stressful and demanding aspect of the job.


Coordinating With Multiple Departments for System Implementation

As a PLC Programmer, one of the main challenges can be the need to coordinate with multiple departments during the system implementation process.

This role often requires working closely with engineering, manufacturing, maintenance, and sometimes even sales and marketing teams.

This could mean dealing with conflicting schedules, varied communication styles, and different priorities.

It can be a challenge to manage differing perspectives and ensure everyone is on the same page.

Additionally, it may also be time-consuming to keep everyone updated about progress and changes, which could potentially delay the project timeline.

This constant coordination can result in stress and can be a significant disadvantage for people preferring to work independently or in a smaller team.



And there we have it.

A raw, unfiltered view of the disadvantages of being a PLC programmer.

It’s not just about coding and automation.

It’s demanding. It requires commitment. It’s maneuvering through a maze of complex programming and technical challenges.

But it’s also about the satisfaction of seeing a machine work perfectly.

The joy of problem-solving and creating efficient systems.

The thrill of knowing you played a part in the smooth operation of an industry.

Yes, the path is challenging. But the rewards? They can be remarkable.

If you’re nodding along, thinking, “Yes, this is the challenge I’ve been seeking,” we’ve got something more for you.

Dive into our expert guide on the reasons to be a PLC programmer.

If you’re ready to embrace both the peaks and the valleys…

To learn, to evolve, and to flourish in this dynamic profession…

Then perhaps, just perhaps, a career in PLC programming is for you.

So, take the leap.

Explore, engage, and excel.

The world of PLC programming awaits.

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