Top Causes of Industrial Automation Downtime (And How to Prevent It)
- Mar 9
- 3 min read
Updated: Apr 8
Why Industrial Automation Systems Fail, and How to Reduce Downtime
Unplanned downtime in industrial automation systems can be costly, disruptive, and difficult to diagnose.
Whether caused by PLC faults, outdated control systems, or poor system design, automation failures can quickly impact production, safety, and efficiency.
Understanding the main causes of industrial automation downtime is the first step to reducing risk and improving system reliability.
What Causes Industrial Automation Downtime?
Downtime in automation systems is rarely caused by a single issue. It is typically the result of:
Outdated or obsolete equipment
Poorly structured PLC programming
Inadequate maintenance
Communication failures between systems
Lack of system visibility
Below are the most common causes, and how to prevent them.
PLC Faults & Programming Issues
PLC systems are at the heart of industrial automation. When they fail, production stops.
Common issues:
Poorly structured control logic
Undocumented or legacy code
Software bugs or logic errors
Communication failures with other systems
How to prevent it:
Use structured, well-documented PLC code
Regularly review and optimise control logic
Upgrade outdated PLC hardware and software
Many downtime issues can be avoided with professional PLC programming services
Electrical & Control Panel Faults
Control panels are critical to system operation. Faults here can be difficult to trace and resolve.
Common issues:
Loose or damaged wiring
Poor panel layout
Obsolete components
Lack of clear labelling
How to prevent it:
Maintain clear, structured panel layouts
Replace ageing components
Ensure panels meet current standards
Well-designed control panel systems significantly reduce downtime
Outdated or Obsolete Automation Systems
Legacy systems are one of the biggest causes of automation downtime.
Common issues:
Unsupported PLC hardware
Limited availability of spare parts
Compatibility issues with modern systems
Increased failure rates
How to prevent it:
Upgrade or modernise legacy systems
Replace obsolete components
Improve system integration
Strategic control system upgrades and refurbishment can extend system life and improve reliability
Communication & Network Failures
Modern automation systems rely on communication between PLCs, SCADA systems, and devices.
Common issues:
Network configuration errors
Protocol mismatches
Hardware failures
Data loss or delays
How to prevent it:
Use reliable industrial communication networks
Regularly test and monitor system connections
Ensure compatibility between systems
Lack of System Visibility (SCADA Issues)
Without proper monitoring, faults go unnoticed until they cause downtime.
Common issues:
No real-time system monitoring
Poor alarm management
Limited data visibility
How to prevent it:
Implement SCADA monitoring systems
Improve alarm and event tracking
Use data to identify early warning signs
SCADA and HMI systems provide visibility and control across your operation
Poor Maintenance & Lack of Preventative Support
Reactive maintenance leads to repeated failures.
Common issues:
No preventative maintenance strategy
Delayed response to minor faults
Lack of system inspections
How to prevent it:
Implement regular system maintenance
Conduct routine inspections
Address minor issues before they escalate
Proactive fault finding and maintenance support reduces long-term downtime.
Poor System Design & Integration
Poorly designed systems are harder to maintain and more prone to failure.
Common issues:
Inconsistent control logic
Lack of standardisation
Poor integration between systems
How to prevent it:
Use structured, standardised design approaches
Ensure systems are properly integrated
Work with experienced automation engineers
How to Reduce Industrial Automation Downtime
Reducing downtime requires a proactive, structured approach:
Upgrade outdated systems
Modernise PLCs, control panels, and SCADA systems to improve reliability
Improve system design
Ensure systems are clear, structured, and easy to maintain
Implement preventative maintenance
Identify issues early before they cause failure
Improve monitoring and visibility
Use SCADA systems to track performance and detect faults
Use experienced automation specialists
Ensure systems are properly designed, programmed, and maintained
Key Causes of Automation Downtime
PLC faults and programming issues
Electrical and control panel failures
Outdated or obsolete systems
Communication and network issues
Lack of system visibility
Poor maintenance practices
Poor system design and integration
Frequently Asked Questions
What is the biggest cause of industrial automation downtime?
The most common causes include PLC faults, outdated systems, and poor maintenance practices.
How can automation downtime be reduced?
Downtime can be reduced through system upgrades, preventative maintenance, and improved monitoring.
How do PLC faults cause downtime?
PLC faults can stop machines, disrupt processes, and prevent systems from operating correctly.
Why do legacy systems cause downtime?
Legacy systems are more prone to failure, harder to maintain, and often lack support and spare parts.
How can SCADA systems reduce downtime?
SCADA systems provide real-time monitoring, allowing issues to be identified and resolved before they cause failure.
Need Help Reducing Automation Downtime?
If downtime is affecting your operations, Stratos Control Systems can help identify the root cause and implement reliable solutions.
