The Aging SCADA Problem
Walk into most Indonesian manufacturing plants and you'll find SCADA systems on Windows XP, communicating via RS-485 serial — security vulnerabilities and data islands.
Why You Can't Just Replace Everything
A steel plant's PLC network cannot go offline for a migration project. Modernization must be non-disruptive.
The Three-Layer Approach
Layer 1: Data Collection (Months 1-3)
Install OPC-UA gateways alongside existing PLCs. Read Modbus/DNP3 without interfering with control logic.
Layer 2: Visibility (Months 3-6)
Build a modern SCADA dashboard (Ignition, Grafana) reading from the new data layer. Operators gain modern visualization while legacy remains in control.
Layer 3: Integration (Months 6-18)
Connect operational data to ERP and predictive analytics. Migrate control logic on non-critical systems first.
The Business Case
Modernization projects show ROI through 15–25% OEE improvement and predictive maintenance savings. Payback periods of 18–30 months are typical in Indonesia.