Not to step on anybody's toes..... but the Idec PLC you mentioned already HAS a port for an HMI. Did you already buy the PLC?
If you're going to add an HMI, the inputs you need will be reduced to almost NONE. I know you only need 4 outputs to signal the mac 3000.
If you just want to see 8 lines of info, each line for a slot in the stack and the wash assigned to it, and to be able to add a car as it arrives, make changes up till the car hits the photo eye, and output 1 of 4 outputs for a second or so to the mac 3000, I think you should "Private Message" me.
The only concern I have is that you mentioned something about a "deadline"?
Stationmaster