Why are legacy automation skills becoming rare?

Many experienced engineers are retiring, and fewer new engineers are trained on older systems.

Can modern engineers learn legacy systems easily?

It can be challenging due to outdated tools, lack of documentation and limited training resources.

Is it better to replace or maintain legacy systems?

This depends on risk, cost and system criticality, but many organisations adopt phased modernisation.

How do you reduce reliance on contractors?

By improving internal documentation, standardisation and system simplicity.

What is the automation skills gap?

The automation skills gap refers to the shortage of engineers and technicians with the knowledge needed to maintain, troubleshoot and improve PLCs, SCADA systems, control panels and industrial automation equipment.

How does the automation skills gap affect manufacturers?

It can increase downtime risk, slow fault finding, delay upgrade projects and place more pressure on internal engineering and maintenance teams.

Can better documentation reduce the impact of skills shortages?

Yes. Clear documentation, accurate drawings, consistent labelling and standardised systems make it easier for engineers to understand and maintain automation systems.

How can external automation support help with skills gaps?

External automation support can provide specialist PLC, SCADA, control panel and troubleshooting expertise when internal teams lack the time, resources or specific technical knowledge required.

Difficulty Finding Engineers Who Understand Old and New Control Systems

Engineer who doesnt understand old systems

Engineering teams are under increasing pressure to support both legacy automation systems and modern control platforms.

But finding engineers who understand both is becoming increasingly difficult.

Most industrial sites now operate a mix of older PLC systems and modern automation technologies, creating a growing skills gap that directly impacts downtime, maintainability and long-term system performance.

At Stratos Control Systems, we help engineering teams reduce dependency on specialist knowledge and build systems that are easier to support, standardise and scale.

The Industrial Automation Skills Gap Is Growing

Industrial control systems have evolved significantly over the last 20–30 years.

Older systems often include:

Siemens S5
PLC5
Legacy HMI platforms
Proprietary communication protocols

Modern systems now involve:

Siemens TIA Portal
Allen-Bradley ControlLogix
Modern SCADA platforms
Ethernet/IP and industrial networking
Data integration and remote access

Very few engineers have the capability to operate both current and legacy PLC and SCADA.

Modern Engineers Lack Legacy Experience

Typical issues include:

Missing PLC backups
Outdated electrical drawings
No revision tracking
Inconsistent I/O labelling
Lack of SCADA documentation
Unclear network architecture

These issues reduce visibility and increase dependency on individual engineers.

Legacy Engineers May Not Support Modernisation

Engineers experienced in older systems may lack exposure to:

Modern SCADA platforms
Cybersecurity requirements
Networked automation systems

This slows down upgrade and transformation projects.

Why This Creates Risk for Engineering Teams

Legacy Knowledge Is Disappearing

Engineers who originally built or maintained older systems are:

Retiring
Leaving the industry
Becoming harder to replace

Critical system knowledge is being lost over time.

Modern Engineers Lack Legacy Experience

Newer engineers may not be familiar with:

Older PLC architectures
Legacy communication systems
Obsolete programming tools

This creates support gaps when older systems fail.

Legacy Engineers May Not Support Modernisation

Engineers experienced in older systems may lack exposure to:

Modern SCADA platforms
Cybersecurity requirements
Networked automation systems

This slows down upgrade and transformation projects.

The Operational Impact of the Skills Gap

Longer Downtime During Failures

When engineers are unfamiliar with systems:

Troubleshooting takes longer
Recovery times increase
Production losses escalate

Increased Dependency on External Contractors

Organisations often rely on:

Specialist legacy contractors
OEM support
Third-party programmers

This leads to:

Higher costs
Slower response times
Reduced internal control

Difficulty Supporting Mixed Environments

Most facilities operate a combination of:

Old PLCs
New PLCs
Multiple SCADA platforms

Without cross-skilled engineers, maintaining consistency becomes difficult.

Delayed Modernisation Projects

Upgrades are often delayed because:

Internal capability is limited
Risks are unclear
Systems are not fully understood

What Difficulty Finding Skilled Engineers Looks Like in Practice

Difficulty finding skilled engineers rarely appears as a single gap. It impacts maintenance, troubleshooting, and project delivery, where limited in-house expertise and reliance on a few individuals slow response times and increase operational risk.

Reduce Dependency on Specialist Engineers

Download the Full Skilled Engineer Requirement Guide

Difficulty finding skilled engineers rarely shows as one issue. It affects PLC programming, control systems, and fault finding, where specialist knowledge is required but not always available, leading to delays and inconsistent outcomes.

Download the Specialist Engineer Guide

How Stratos Supports Mixed Automation Environments

Stratos Control Systems helps engineering teams:

Support both legacy and modern systems
Reduce dependency on specialist engineers
Improve documentation and consistency
Deliver scalable automation infrastructure

Reduce Risk and Improve Long-Term Supportability

If your organisation is struggling to support mixed automation environments, the risk will continue to grow.

Stratos helps you build systems that are easier to understand, easier to maintain and easier to scale.

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Industrial engineer maintaining PLC automation system

Frequently Asked Questions