today, the concept of retrofitting is a common principle in the pursuit of renewing outdated machine tools. The involvement of automation in conventional cutting machine becomes a must. It will improve meantime between failures, mean-time to repair and will save energy as well. The wire cutting and straightening machine is selected to be retrofitted, because the machine is mechanically good. . And the retrofitting is based on a PLC control scheme. The machine used has specified length to suit the required length for the shelves and basket used in air cooler refrigerators plant, so it is a very important machine in the company production line, any failure in any part will cause a considerable delay in the final production line. PLC is a suitable the manufacturing environment [1]. This paper an attempt is made to replace the conventional control system with a PLC system in old machine. The result shows a good improvement in down time. There drop in down time percent from 86% and 23% in years 2014 and 2015 respectively to .0.08% in year 2018 after implementation of PLC.