Team 3 Cummins - Controls Development and Training Station

As industrial automation systems grow increasingly complex through the integration of diverse hardware and software, the need for a safe, structured, and modular training environment has become critical. Currently, Cummins relies heavily on on-the-job training, which exposes operators to safety risks, threatens production uptime, and limits the ability to learn in a fully controlled setting.

To address this, the Manufacturing Controls Development & Training Station integrates Allen-Bradley and Siemens PLC platforms into a single, portable workbench. The system features essential control devices-such as sensors, pushbuttons, and I/O modules-alongside critical safety mechanisms like door interlocks and emergency stops. Designed with an emphasis on portability, modularity, and future expandability, the workstation ensures engineers can safely evaluate new hardware and adapt to emerging technologies for years to come.

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Problem Statement/Summary

- Addresses the industrial skills gap by providing a dedicated, hands-on training platform that equips new technicians and transitioning employees with practical experience in an industrial control's environment. ​

​- Enhance safety and reduce production impact by enabling trainees to practice on a safe, offline system which minimizes risks to the trainees and preventing production downtime. ​

- Accelerate workforce readiness for Cummins by delivering a standardized, modular training workbench that speeds up onboarding and strengthens employee competency.