Metal Forging Industry Solutions

Modernizing process control and automation systems for metal forging operations where uptime is absolute and proprietary process recipes are irreplaceable.

Metal forging operations run continuously under extreme conditions — high temperatures, heavy loads, and tight tolerances. The process control systems that manage furnace temperatures, press sequencing, die positioning, and quality parameters have been refined over decades to produce consistent, high-quality results. These systems are deeply integrated into every aspect of production.

Many forging facilities still rely on legacy VAX, Alpha, and OpenVMS-based control systems originally programmed in FORTRAN and C. The proprietary recipes and process logic encoded in these systems represent millions of dollars in development and cannot simply be easily replicated or replaced. Salem Automation specializes in preserving this critical process knowledge while migrating to modern platforms that are supportable, reliable, and capable of integrating with enterprise systems.

Providing Tangible Value

  • Preserve proprietary forging recipes and process logic with zero knowledge loss during migration 
  • Eliminate production risk from aging hardware with end-of-life components
  • Ensure production operations remain uninterrupted during system transitions through phased Shadow Mode deployment.
  • Enable real-time production tracking, quality data capture, and enterprise reporting 
  • Reduce mean time to repair through modern, vendor-supported hardware and software

Metal Forging Industry — Products, Services & Solutions

Services

  • 24/7 mission-critical support with tiered SLAs
  • OpenVMS system administration and cluster management
  • Legacy SCADA and HMI replacement
  • Proactive remote systems monitoring and management
  • Incident management and root cause analysis
  • Operator training and go-live support
  • Process flow documentation and system asset mapping
  • Process control application maintenance and enhancement

Solutions

  • vtALPHA and vtVAX virtualization of VAX and Alpha systems
  • FORTRAN / C / Pascal to Python and C# code migration
  • Serial RS-232 to Ethernet protocol conversion
  • VAX-to-PLC Ethernet communication (Allen Bradley)
  • Shadow Mode phased deployment with zero downtime

  • Legacy Fibre Channel to modern SAN storage migration
  • OpenVMS cluster consolidation and optimization

Platforms & Technologies

OpenVMS V5.5+

DEC VAX and Alpha servers

vALPHA / vIVAX virtualization

Modern Hypervisor platforms

Modern SCADA

Major PLC hardware families

DEC RdB / SQL databases

FORTRAN, C, Pascal, Python, C#

ABNet communication software

EtherNET/IP industrial networking

Ready to modernize your legacy systems?

Contact Salem Automation to discuss your specific requirements and discover how we can protect your investment.

We use cookies and other tracking technologies to improve your browsing experience on our website, to show you personalized content and targeted ads, to analyze our website traffic, and to understand where our visitors are coming from.