Industrial Automation
Modernize aging PLC, DCS, SCADA, and HMI systems with a phased approach that addresses obsolescence, migration risk, production constraints, backups, and long-term supportability.
Why Direct
Aging control systems rarely become a problem all at once. Risk builds through unsupported hardware and software, limited spare parts, missing source code, outdated documentation, and hidden dependencies. Direct evaluates those risks before the upgrade begins, then plans the migration around production requirements, recovery options, and long-term support.
Our Capabilities
From lifecycle assessment and migration planning through testing, cutover, commissioning, and handoff, Direct Automation manages control system modernization with uptime, recoverability, and long-term support in mind.
We review aging hardware, software, and firmware support, hard-to-source parts, licensing, documentation, backups, source-code availability, and system dependencies. The result is a clearer view of lifecycle risk and a prioritized roadmap for what should be maintained, upgraded, or replaced.
Direct Automation plans PLC, DCS, SCADA, and HMI upgrades and retrofits around existing infrastructure and outage windows. Hardware, software, I/O, communications, network dependencies, and operator interfaces are coordinated so older platforms can be replaced with less disruption.
Our engineers build migration plans around sequencing, backups, rollback paths, testing, and validation before cutover. FAT and SAT are used when required to confirm programming, communications, interfaces, alarms, and operating sequences before changes move into production.
We coordinate shutdown planning, cutover, field verification, commissioning, startup, and handoff to keep the transition controlled. Updated backups, configuration records, drawings, and documentation leave the plant with a clearer recovery path and a system that is easier to support.
A successful upgrade should reduce lifecycle risk without creating unnecessary downtime, recovery gaps, or support challenges. Better planning helps protect production while leaving the plant with a more reliable, supportable control environment.
Support status, spare availability, software dependencies, backups, and plant priorities help focus upgrades where aging systems create the greatest operational exposure.
Testing, rollback paths, cutover steps, and shutdown windows help keep the migration controlled while reducing production disruption.
Current backups, documentation, and standards give maintenance teams a clearer recovery path and a more supportable system.
Connect With Direct
Tell us what you’re working on, and our team can help identify the right next steps for lifecycle assessment, migration planning, phased upgrades, cutover, or ongoing support.
(866) 583-3377
3405 N Louise Ave, Sioux Falls, SD 57107
info@directcompanies.com
Ready to Move Forward
Have aging equipment, unsupported controls, missing backups, or a migration on the horizon? Our engineers can help build a modernization plan around uptime, lifecycle risk, and your existing system.
Instant access after submission.
Instant access after submission.
Instant access after submission.
Instant access after submission.
Instant access after submission.
Download the Emerson white paper on tank gauging accuracy, safety compliance, and modernization.
