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Situation 03 / 08 — Platform risk

Aging automation and control systems

The line runs fine. The software driving it stopped being supported years ago.

Salem’s automation work sits at Level 2 and above — human-machine interface, data acquisition, supervisory control and data acquisition, data historian, and manufacturing execution. Companies call when the control layer still does its job but can no longer be supported, upgraded, or connected to anything the business wants to use.

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Sound familiar

  • Human-machine interface or supervisory control software is several major versions behind support
  • The original integrator is gone and no one will take responsibility for the control system
  • Process data is collected but never historized, or sits in a historian nobody can query
  • Production reporting happens in spreadsheets because there is no manufacturing execution layer

How Salem approaches it

01

Document the control and information layers as they run today

Salem maps the input and output points, tag structure, screens, alarm logic, and every interface reaching up toward the business systems. Undocumented control systems are the norm, not the exception, and the map determines what can safely change.

02

Modernize the layer that is holding the others back

Sometimes the constraint is a supervisory control platform at end of life. Sometimes it is a historian with no usable interface, or a missing execution layer. Salem upgrades or replaces the specific layer causing the problem rather than proposing a full rebuild.

03

Connect the plant floor to the systems above it

Once the control and information layers are current, production data reaches quality, planning, and reporting without anyone exporting a file by hand.

Related services

SCADA modernization

Industrial automation

What does the control system already know that nobody can see?

Most plants are collecting far more than they can use.

Describe the control layer — platforms, versions, and what the business is asking it to produce. Salem will tell you which layer to modernize first.

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Oracle Rdb on OpenVMS: Three Paths Forward

Join us on Wednesday, October 7, 12:00 PM – 1:00 PM for a practical webinar exploring three paths forward for Oracle Rdb and OpenVMS environments.

Salem Automation, PARSEC Group, and CONNX will cover emulation, bridging Rdb data into modern business processes, and migrating the database and supporting functionality to a new platform.

Discover how to modernize while reducing migration risk and keeping critical legacy systems supported.

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