Heavy Engineering Automation Case Study
Upgrading Obsolete PLC Infrastructure in a High-Risk Industrial Environment
Stratos Control Systems delivered an obsolescence-led PLC upgrade project for a heavy engineering site where failure risk and downtime cost were escalating. By developing a structured migration strategy and executing a phased shutdown plan, the site eliminated obsolete hardware risk and improved maintainability for long-term operational resilience.
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01
The Problem
The site relied on obsolete PLC hardware and custom, undocumented logic, with limited spare part availability and high downtime cost per hour.
Failure risk was increasing year on year, and maintaining system reliability was becoming harder as supportability declined.
02
Scope of Work
Obsolescence Audit & Risk Review
Stratos assessed the control infrastructure to define the upgrade path and reduce shutdown risk.
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This included:
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Obsolescence audit of PLC hardware and spares
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Review of undocumented logic and maintainability risk
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Assessment of downtime exposure and critical failure points
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Definition of phased migration scope and timing
Phase 2 – Migration Strategy
A structured upgrade strategy was created to remove obsolescence risk and introduce supportable standards.
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The strategy included:
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PLC migration strategy and coding standards
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Control panel refurbishment approach where required
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Phased shutdown execution plan to control risk
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Documentation improvements to protect system knowledge
Phase 3 – Implementation
Stratos delivered the upgrade with controlled commissioning and structured handover for long-term support.
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Implementation included:
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PLC platform upgrade and software redevelopment
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Panel upgrades and refurbishment as needed
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Phased cutover aligned to shutdown windows
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Improved documentation and maintainability handover
03
Platforms Used
The project utilised modern automation and control system technologies, including:
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Siemens S7
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Industrial-grade control panels
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Structured PLC coding standards
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These technologies provided improved system reliability, visibility, and maintainability.
04
Outcomes & Metrics
Key outcomes included:
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50% reduction in automation-related downtime
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Improved maintenance documentation and supportability
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Extended asset life by 10+ years
Testimonial
“Stratos delivered a technically sound upgrade while managing shutdown risk carefully. The system is now maintainable and future-ready.”
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Engineering Director
