Legacy automation systems often present significant challenges, from data silos and inefficient processes to scalability limitations and high maintenance costs. Inductive Automation’s highly trusted platform Ignition, for supervisory control and data acquisition (SCADA), human-machine interfaces (HMI), manufacturing execution systems (MES), and the Industrial Internet of Things (IIoT), is transforming automation by providing a centralized, scalable, and cost-effective solution.
In this blog, you will learn how the world’s most innovative SCADA software can revitalize any legacy industrial control system with recent projects from the City of Fort Smith Utility, California American Water, Dublin Airport, Belden, and HMI Glass. Each of these organizations was able to improve outdated systems at their own pace, without replacing all of their legacy equipment, leading to a smooth and simple transition.
Common Pain Points Of Legacy Systems
Many older systems operate in isolated environments with a narrow range of communication protocols. Legacy systems also rely on manual data retrieval and reporting, can’t accommodate modern applications, and have licensing requirements that limit growth. As a result, these systems struggle with cybersecurity, regulatory compliance, scalability, and integrating new technology. Additionally, the cost of maintenance can be substantial with frequent downtime and fees on extra tags, clients, and connections.
Legacy SCADA platforms tend to be less efficient because these platforms are slower and usually built for on-premise use, requiring operators to be physically present to monitor and control the system. These limitations make Ignition a real advantage for growing organizations that are still using legacy systems.
Legacy System Automation Modernization
Older equipment often requires compatibility with certain protocols to function, which is a common excuse for many organizations to keep their outdated systems. However, with Ignition, you don’t need to rip and replace your entire plant floor. Ignition connects to SQL databases and protocols like OPC UA, Modbus, and many more, which enabled the cable manufacturer Belden to continue using the legacy devices in its facility. Belden was also able to use SQL Server to perform cross-database queries and extract data from these connections.
The glass manufacturer, HMI Glass, also achieved manufacturing process optimization benefits with Ignition's interoperability. “A lot of the equipment was legacy equipment, and we had to get creative with the ways that we were able to pool utilization data for the purposes of showing things like OEE and utilization off of machines. We use the Opto 22 groov RIOs attached to some vibration sensors and some additional sensoring to be able to augment an existing piece of equipment with some Industry 4.0 or IIoT capability. So without being able to access the machine data directly, we were able to take advantage of modern-era hardware in combination with some modern-era transmission protocols,” said Remus Pop, Director of Riveron, working with HMI Glass.
Minimizing Cost With A Highly Scalable And Flexible Architecture
By connecting to multiple communication protocols and integrating with legacy devices like at the Belden and HMI Glass facilities, Ignition extends the lifespan of legacy equipment, making it much easier for companies to improve operations while reducing costs. However, Ignition’s unlimited licensing model and easy-to-upgrade architecture also allow organizations to scale operations without incurring additional fees.
With Ignition, there is no limit to the number of tags, devices, connections, and users, making it ideal for both small facilities and large enterprise deployments, which was a big selling point for Dublin Airport. “With Ignition’s open and flexible approach and the low-cost licensing model, we’ve been able to deliver a number of projects that previously would have required a large capital investment,” says Thomas Quinn, Baggage Systems Technical Support for Dublin Airport.
Ignition is web-based and web-managed, which enables you to upgrade your system without any negative effects on OEE. "The way that Ignition handles the upgrade is far superior to any other software I've touched before. It's zero impact on production," says TJ Holt, Team at Lead Flexware, working with California American Water.
Lightning-Fast Reporting
One of the most common issues with many legacy automation systems is, ironically, the lack of automation. Ignition’s tools for creating reports for SCADA, overall equipment effectiveness (OEE), compliance, historical data, and much more enable you to seamlessly build and automate reports to view on any device.
These features make it easier for operators to create custom reports without relying on IT teams, streamlining processes and improving response times. John Guthrie, Project Manager for the City of Fort Smith Utility explains, "In the past, (creating custom reports) would take at least one and a half hours to complete. Now, I can do it from my office in 30 minutes or less."
Industrial Strength Security
Legacy systems were often made before modern cybersecurity threats, and many weren’t even created with cybersecurity in mind because they were not intended to be connected to the enterprise. This isolation does help to keep the system secure, but in the age of Digital Transformation, isolation is an inefficient crutch that holds back your system’s potential.
Ignition can connect your entire enterprise and keep your system extremely secure with TLS technologies, client authentication, built-in system auditing, advanced encryption, and the ability to connect to modern security applications. Ignition also uses role-based user permissions and enables views for different access types. "One of the problems we had previously was to view the SCADA system, it had to be in a secure network. One thing that we were able to do with the Ignition system is make a view-only that doesn't go into the secure side,” said Mike Grondin, SCADA Manager for California American Water.
Centralizing Your Operations
Since Ignition’s modern security features make isolating your legacy system unnecessary, you can securely connect your whole system and even multiple systems across a wide geographic area.
By connecting and consolidating multiple legacy systems into a single, unified platform, you can eliminate data silos, improve information flow across departments and facilities, and provide global real-time access. Lance McAvoy, Director of the City of Fort Smith Utility says, "I can look at all the SCADA with the plants, distribution system, collection system, all from one terminal, as opposed to having to go to individual locations to see each one. We have four treatment plants, and two of them are located in other counties. Now we can jump on a terminal and diagnose remotely if there’s a problem."
Revamp Your Legacy System With Ignition
Ignition is a game-changing platform for legacy automation modernization. By enhancing connectivity, streamlining data collection, and improving operational efficiency, it empowers organizations to scale, minimize costs, and future-proof their operations. With its flexible architecture, advanced security, and open integration capabilities, Ignition is the ideal solution for companies looking to start their Digital Transformation journey and transition into the era of smart manufacturing and Industry 4.0.
Try Ignition’s unlimited free trial and test out Ignition for yourself!
