A High‑Risk Control System Upgrade that Protected Production
A major manufacturing facility was operating on an outdated, unsupported control system, an approach that left the site vulnerable to extended downtime if even one component failed. With production demand rising and outage windows shrinking, the facility needed a way to modernize without jeopardizing safety or output.
By applying advanced modernization tools, including full offline simulation and a strategy that reduced rewiring and key risk points, the project finished an entire week early. That early restart enabled 27 additional batches, delivering $37.56 million in added revenue while eliminating the ongoing risk of running on an obsolete platform.
By applying advanced modernization tools, including full offline simulation and a strategy that reduced rewiring and key risk points, the project finished an entire week early. That early restart enabled 27 additional batches, delivering $37.56 million in added revenue while eliminating the ongoing risk of running on an obsolete platform.
