Industrial Automation Challenges & Modernisation
Industrial control systems rarely fail overnight.
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Performance declines gradually, through obsolete PLC hardware, inconsistent standards, limited diagnostics, and fragile integrations.
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At Stratos Control Systems Ltd, we help organisations reduce risk, improve reliability, and modernise automation systems in a structured, low-disruption way.
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Below are the most common control system challenges we resolve.
Reduce Downtime Caused by Control Systems
Unplanned downtime is rarely caused by a single component failure.
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It is often prolonged by:
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Inconsistent PLC structure
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Hidden interlocks
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Weak recovery logic
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Limited system state visibility
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Downtime reduction requires architectural clarity, not just reactive maintenance. Learn how to reduce downtime caused by control systems through structured fault analysis and system review.
Identify control weaknesses that extend fault duration and increase production loss.
Replace Obsolete Systems
Legacy PLCs and unsupported platforms increase operational risk.
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Common symptoms include:
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Spare part scarcity
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Unsupported firmware
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Dependency on retired engineers
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Rising downtime impact
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Modernisation does not always require full replacement, structured refurbishment and phased PLC upgrades reduce risk without major disruption.
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Upgrade diagnostics, alarm clarity, and system insight to reduce downtime and restore operational confidence.
Improve Fault Finding & Maintenance
Poor diagnostics extend downtime. Improving fault finding and maintenance processes reduces mean time to repair and strengthens engineering confidence.
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Typical issues include:
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Generic alarms
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No root cause identification
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Inconsistent naming conventions
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Poor documentation
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Limited trend data
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Improving diagnostics with SCADA upgrades reduces mean time to repair and strengthens maintenance confidence.
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Improve alarm structure, fault localisation, and system visibility.
Standardise Control Panels & PLC Architecture
Mixed PLC styles and inconsistent panel layouts increase complexity. Standardising control panels and PLC architecture simplifies maintenance and future upgrades.
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This creates:
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Increased training burden
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Complex troubleshooting
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Inconsistent safety implementation
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Long-term support dependency
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Standardisation of control panel design reduces complexity and simplifies future upgrades.
Simplify support, reduce risk, and future-proof your control systems.
Modernise Automation Without Disruption
Delaying upgrades increases risk. A structured plan to modernise industrial automation systems reduces technical debt and protects operational continuity.
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The perceived risk of change often outweighs the perceived risk of staying still.
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This results in:
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Growing technical debt
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Increased exposure to failure
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Reduced scalability
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Emergency replacement scenarios
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Structured PLC upgrades and phased modernisation reduces risk while maintaining throughput.
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Upgrade safely, strategically, and without unnecessary downtime.
Gain Visibility with SCADA & System Monitoring
Without clear system insight, recovery becomes reactive. Implementing SCADA and system monitoring solutions improves operational visibility and proactive maintenance.
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Common visibility gaps include:
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No bottleneck insight
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No accumulation mapping
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No downtime categorisation
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Limited historian data
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Poor alarm clarity
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Modern SCADA systems and monitoring solutions restore operational insight.
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Implement SCADA and monitoring systems that support proactive decision-making.