DCS Migration and Replacement

Distributed control system (DCS) migration can help your plant stay up to date with modern and efficient control systems before the current one becomes obsolete. When you want to undergo DCS migration and need help configuring and implementing a strategy, Malisko is here for you. Our team ensures you have a plan for a seamless system upgrade and a long-term partnership you can rely on.

How DCS Migration Helps You

DCS migration helps companies introduce new technology and control systems to enhance operations and keep the systems updated. Modern Distributed Control Systems offer significant advantages over legacy DCS systems that have been in use for decades. With enhanced processing power, modern DCS provides real-time data analytics and improved decision-making capabilities, allowing for more efficient and precise control of industrial processes. 

Additionally, contemporary DCS feature advanced cybersecurity measures, protecting critical infrastructure from emerging threats. Their scalability and integration with other digital systems enable seamless expansion and upgrades, ensuring long-term viability and reduced downtime. Finally, modern user interfaces and mobility options facilitate better operational visibility and remote management, leading to increased productivity and reduced operational costs.

The DCS migration process involves transferring all the data and functions from the old system to the new one with the added advantage of incorporating new functionality to streamline operations. A smart DCS migration strategy involves switching technologies before the current ones become outdated and no longer supported. By keeping up with the latest control system technology, companies can improve performance and remain efficient to get the best return on investment (ROI).

Undergoing a DCS migration also benefits your firm because the technology helps you:

• Maintain compliance and security: Migrating to a modern DCS is a vital step to get a handle on OT security posture. An updated DCS ensures your plant adheres to the latest security protocols, protecting against cyber threats that legacy systems are often vulnerable to. By incorporating advanced security features such as robust encryption, multi-factor authentication, and continuous monitoring, modern DCS systems safeguard critical infrastructure from potential breaches. Additionally, compliance with industry regulations and standards is streamlined with modern DCS. For instance, adherence to segmentation concepts presented in IEC-62443 helps in creating secure zones and conduits within your network architecture, minimizing the risk of unauthorized access and ensuring the integrity of your operations. This compliance not only protects your company from legal repercussions and fines but also builds trust with customers and stakeholders who prioritize security and reliability.
• Remain scalable and flexible: If you need to make changes to enhance processes or support your plant’s growth, your new DCS can adapt to integrate new technologies or requirements. This is especially true with the integration of modern industrial IT infrastructure leveraging ethernet controls networks, server virtualization, and common IT management tools aligned with stringent change control that is critical to the performance of DCS systems. Whether you’re scaling up production, incorporating advanced automation, or integrating with IoT devices, a modern DCS provides the robust framework necessary to handle these advancements seamlessly.
• Gain an advantage over competitors: Migrating to a modern Distributed Control System (DCS) provides your company with a substantial competitive edge. Leveraging the latest technology means you can harness advanced capabilities such as predictive maintenance, which reduces unexpected downtimes and extends the lifespan of equipment. Enhanced data analytics and real-time monitoring allow for swift and informed decision-making, optimizing processes and increasing overall efficiency. 

An effective and efficient manufacturing facility relies on accurate, automated control of all processes and equipment. A shop’s floor contains many components requiring careful analysis, configuration and deployment for successful production, from analog transmitters and proximity switches to motor control centers and power supplies. To ensure the highest levels of productivity and product quality, plants must implement a modern shop floor control system that communicates with all these components across each manufacturing line.

Shop Floor Control Tools to Modernize Your Facility

The team at Malisko understands that all plant manufacturing components must work together seamlessly to achieve these goals. We’ll work with you to learn about your existing processes and develop a strategy tailored to your operation’s unique goals and objectives.

Our vast experience in developing shop floor control solutions enables us to offer services for the most critical elements of your operation, including:

• Electrical power distribution with monitoring, including main and sub switchgear.
• Electrical and control panel design, including lighting and utility.
• Instrumentation specifications.
• Controllers, such as programmable logic controllers (PLCs) and distributed control systems (DCSs), for processes, utilities and building services.
• Motor control centers (MCCs) and variable frequency drives (VFDs).
• Inline analytical equipment.
• Machine controllers.
• Human-machine interfaces (HMIs), including standalone and distributed.
• Communication networks for controllers, I/O and special-purpose devices.
• Wiring and cabling, including secure remote telemetry (wireless).
• Process and operational data collection, storage and reporting.
• Web-based SCADA (Supervisory Control and Data Acquisition).
• Secure remote system monitoring for troubleshooting and technical support.

As part of our shop floor control offerings, Malisko offers integration services for hardware, software and other equipment to deliver an efficient and cost-effective solution.

Benefits of Shop Floor Control Software

An effective production and shop floor control software solution is one of the most critical aspects of improving your shop’s efficiency. This software lets you connect all your automated equipment and components from your plant’s operations to streamline production and enable successful manufacturing. Implementing high-quality software allows you to control all your most critical manufacturing elements in real-time.

Integrating a software solution tailored to your company’s unique operation enables you to enjoy benefits like:

• Reducing manufacturing costs.
• Improving product quality.
• Ensuring production consistency and minimizing errors.
• Integrating with existing production software.

Frequently Asked Questions About Smart Manufacturing

Still have questions about smart manufacturing? We can answer them.