Managing Risk in Aging Control Systems

Industry: Food & Beverage

Case Study

Managing Risk in Aging Control Systems

Rapid recovery of a failed HMI system and identification of broader asset risk within aging equipment.

The Situation

Following routine maintenance, a production line failed to restart due to an unresponsive HMI.

Challenge:

Immediate production downtime

Loss of HMI project file

Aging system with unsupported components

No critical spares available on site

Approach:

Conducted immediate remote diagnostics via video call

Identified loss of HMI project as root cause

Restored system using previously secured backup

Assessed broader risks across the aging control system

The Outcome​

Rapid restoration of production with minimal downtime

Avoided extended outage due to backup availability

Identified critical long-term risks within the system

Provided a clear path toward proactive asset management

Utilising the latest technology to develop innovative programming and upgrade existing systems.

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