The Clock is Ticking: Tips for Minimizing Downtime During Control System Migrations

Working on a machine that’s down can feel like a high-stakes balancing act, where thorough engineering is needed, but every minute of downtime translates to lost revenue for the customer. An industry study suggests that unplanned downtime can cost manufacturers up to $260,000 per hour – a staggering number! 

In our line of work, we see a lot of custom-built machines that companies have been relying on for years. As the machine ages, you can get away with replacing a component here or there. But at some point, stakeholders start to think about how and when they need to migrate the control system, especially if the machine has an obsolete PLC, HMI, or motion control system. That’s where we come in. Our customers rely on us to understand the nuances of the machine and hardware, when they don’t have that ability in-house. In this article, we’ll discuss some of our strategies for minimizing downtime during these projects.  

Look for Temporary Solutions 

There are cases where you need to take immediate action, especially if a machine in production isn’t operating.  Usually you can find temporary solutions that will allow you to maintain operational continuity while a larger migration project is underway. We recently had a project where the HMI was failing on an aging machine, and the customer was afraid that the control system was close behind. We were able to provide a cost-effective, temporary HMI solution to keep the machine operational while we worked on the overall control system upgrade.  

Take the Time to Plan 

Before diving into the technical details of the machine, work with your stakeholders to get the bigger picture. Gather all available documentation, learn about the workflow, look at the machine code, and talk with the operators about their wants and needs. This allows you to provide options, create documentation where there is none, anticipate challenges and think of creative solutions.  

When it comes to the actual commissioning – have a plan. Use checklists, simulate your code, do whatever you can to have utmost confidence that the commissioning will go smoothly.  

Keep What You Can 

Not every upgrade requires a complete overhaul. There are a lot of circumstances where you can preserve functioning mechanical components which are at low risk of failure or are quick to replace if they did fail. By leveraging existing infrastructure and parts, you can reduce both costs and downtime.  

Propose Upgrades to Improve Future Uptime 

Replacing the controls with a modern system will open new opportunities that weren’t possible with the prior hardware. For example, updating alarming can improve the operator’s ability to troubleshoot the system. Improving machine ergonomics can reduce operator time to complete tasks and make their day-to-day work more comfortable and efficient. And adding visualizations to display machine overviews, key performance indicators, and trends can help operators make meaningful decisions and train other operators who might not be familiar with the machine.  

If the business wants to strive for zero unplanned downtime, there are other solutions available. You can implement predictive maintenance with monitors and software, which allow you to anticipate when maintenance is required or when parts will fail. You can even develop digital twins to simulate the system in a virtual environment.  

Conclusion: Practical Insights for Successful Integration 

Successful system integration requires a holistic approach that extends beyond technical implementation. The most important thing is to prioritize communication with your stakeholders. You need to ensure that you have all of the information you need, that you’re providing the best solution for your customer’s circumstances, and that everyone is in alignment with the overall strategy and potential impacts. If you didn’t start with comprehensive documentation, make sure you leave your customer with comprehensive documentation. It will become their biggest asset for reducing future integration challenges and create a clear record of the evolution of the system.  

Businesses must approach system integration as an ongoing process of continuous improvement rather than a one-time event. This means investing in team training, keeping scalability in mind, and maintaining a forward-thinking perspective. 

Migrations are more than a necessity- they’re an opportunity to create more efficient machines and operational environments.  By focusing on strategic implementation, minimizing downtime, and maintaining a proactive approach, businesses can convert potential disruptions into powerful catalysts for growth and innovation  

Ready to migrate or upgrade your control systems with minimal disruption? Let's start a conversation.