Difficulty Finding Engineers Who Understand Old and New Control Systems
Engineering teams are under increasing pressure to support both legacy automation systems and modern control platforms.
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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.
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At Stratos Control Systems, we help engineering teams reduce dependency on specialist knowledge and build systems that are easier to support, standardise and scale.
Legacy Control SystemFAQs
Why is it difficult to find engineers for legacy and modern control systems?
It is difficult because industrial automation has evolved rapidly, while legacy systems are still widely used. Older systems require specialised knowledge that is becoming rare, while newer engineers are typically trained on modern platforms.
This creates a gap where very few engineers can confidently support both environments, increasing operational risk.
How does the automation skills gap affect downtime?
The skills gap increases downtime because engineers may not fully understand the systems they are troubleshooting. This slows diagnosis, increases recovery time and can lead to temporary fixes rather than permanent solutions.
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In mixed environments, this problem becomes more severe as each system requires different expertise.
Can legacy control systems still be supported effectively?
Yes, legacy systems can still be supported, but it requires structured documentation, standardisation and a clear strategy for knowledge transfer.
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Without these, organisations become dependent on a small number of specialists, increasing long-term risk.
What is the best way to reduce dependency on specialist engineers?
The best approach is to simplify and standardise systems while improving documentation. This makes systems easier to understand and reduces reliance on individual expertise.
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Over time, modernisation and consistency reduce the need for highly specialised legacy knowledge.
The Industrial Automation Skills Gap Is Growing
Industrial control systems have evolved significantly over the last 20–30 years.
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Older systems often include:
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Siemens S5
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PLC5
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Legacy HMI platforms
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Proprietary communication protocols
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Modern systems now involve:
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Siemens TIA Portal
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Allen-Bradley ControlLogix
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Modern SCADA platforms
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Ethernet/IP and industrial networking
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Data integration and remote access
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Very few engineers have experience across both generations of technology.
Modern Engineers Lack Legacy Experience
Typical issues include:
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Missing PLC backups
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Outdated electrical drawings
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No revision tracking
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Inconsistent I/O labelling
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Lack of SCADA documentation
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Unclear network architecture
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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:
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Modern SCADA platforms
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Cybersecurity requirements
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Networked automation systems
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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:
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Retiring
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Leaving the industry
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Becoming harder to replace
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Critical system knowledge is being lost over time.
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Modern Engineers Lack Legacy Experience
Newer engineers may not be familiar with:
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Older PLC architectures
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Legacy communication systems
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Obsolete programming tools
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This creates support gaps when older systems fail.
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Legacy Engineers May Not Support Modernisation
Engineers experienced in older systems may lack exposure to:
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Modern SCADA platforms
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Cybersecurity requirements
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Networked automation systems
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This slows down upgrade and transformation projects.
The Operational Impact of the Skills Gap
Longer Downtime During Failures
When engineers are unfamiliar with systems:
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Troubleshooting takes longer
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Production losses escalate
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Increased Dependency on External Contractors
Organisations often rely on:
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Specialist legacy contractors
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OEM support
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Third-party programmers
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This leads to:
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Higher costs
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Slower response times
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Reduced internal control
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Difficulty Supporting Mixed Environments
Most facilities operate a combination of:
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Old PLCs
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New PLCs
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Multiple SCADA platforms
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Without cross-skilled engineers, maintaining consistency becomes difficult.
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Delayed Modernisation Projects
Upgrades are often delayed because:
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Internal capability is limited
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Risks are unclear
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Systems are not fully understood
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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.
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.
How Stratos Supports Mixed Automation Environments
Stratos Control Systems helps engineering teams:
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Support both legacy and modern systems
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Reduce dependency on specialist engineers
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Improve documentation and consistency
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Deliver scalable automation infrastructure
