Industrial Automation Modernization Moves Toward Service-Based Models
Industrial companies are facing increasing pressure to upgrade aging automation infrastructure while maintaining continuous production. Many factories still depend on traditional PLC, DCS, and proprietary control systems that were installed decades ago.
However, replacing an entire automation platform remains expensive and risky. Production downtime, engineering resource limitations, cybersecurity concerns, and compatibility issues often slow modernization projects.
Schneider Electric and HPE have introduced a new service-based approach called Industrial Automation Modernization as a Service. The solution combines Schneider Electric’s EcoStruxure Automation Expert (EAE) platform with HPE SimpliVity hybrid cloud infrastructure to support gradual automation transformation.
This approach allows manufacturers to modernize their industrial automation environment step by step instead of replacing existing systems immediately.
Software-Defined Automation Supports PLC and DCS Modernization
The foundation of this offering is software-defined automation (SDA), which separates automation functions from dedicated hardware platforms.
Traditional factory automation often depends on specific PLC hardware, proprietary controllers, and fixed architectures. SDA introduces more flexibility by allowing control applications to run on standardized computing infrastructure.
Schneider Electric’s EcoStruxure Automation Expert follows the IEC 61499 standard and supports a more open automation architecture. Therefore, industrial users can develop, manage, and deploy automation applications with fewer hardware limitations.
From an engineering perspective, this model provides a practical migration path for factories that cannot immediately replace existing PLC and DCS systems. Operators can maintain current production assets while introducing modern automation capabilities.
HPE Infrastructure Provides Industrial Computing Foundation
Industrial automation modernization requires more than software innovation. Manufacturing environments also need stable computing platforms, data protection, and secure infrastructure.
The Industrial Automation Modernization as a Service offering integrates HPE SimpliVity technologies to provide computing, storage, and data management capabilities for industrial workloads.
Moreover, edge computing has become increasingly important in modern factories. Production facilities require faster data processing close to machines, sensors, and control systems.
By combining industrial automation software with hybrid infrastructure, the solution supports applications such as real-time analytics, digital twins, manufacturing intelligence, and AI-based optimization.
Addressing Aging Control Systems and Industrial Cybersecurity Challenges
Many industrial organizations operate legacy control systems that remain functional but face increasing maintenance challenges.
Older PLC, DCS, and SCADA platforms may have limited connectivity, outdated cybersecurity features, and difficulty supporting modern data applications.
Therefore, modernization strategies must balance innovation with operational continuity.
Schneider Electric and HPE designed this service model to help companies protect existing automation investments while gradually introducing open technologies.
In practical industrial projects, engineers often prefer phased migration because complete system replacement can interrupt production schedules and increase commissioning risks.
Three-Layer Architecture Supports Factory Automation Transformation
The Industrial Automation Modernization as a Service model includes three major technology layers.
Infrastructure Layer for Industrial Computing and Data Protection
The first layer provides the hardware foundation. It uses HPE computing, storage, and protection technologies to support industrial applications.
This infrastructure layer helps factories manage automation workloads, production data, and operational applications within secure environments.
It also supports different deployment models, including local industrial edge systems and private cloud architectures.
Automation Software Layer for Open Control Applications
The second layer focuses on automation software and control services.
EcoStruxure Automation Expert enables software-defined control applications based on open automation principles. This architecture reduces dependence on specific controller hardware.
As a result, manufacturers can improve application portability and simplify future automation upgrades.
For factories with mixed environments, including Siemens, Rockwell Automation, ABB, Honeywell, or Schneider Electric control systems, open architectures can support long-term modernization strategies.
Lifecycle Service Layer for Migration and Optimization
The third layer provides engineering and operational services.
These services include automation assessments, migration planning, cybersecurity improvement, managed operations, and continuous system optimization.
Moreover, lifecycle support helps industrial teams address workforce challenges caused by the shortage of experienced automation engineers.
Open Standards Become a Key Trend in Industrial Automation
Open automation standards are becoming increasingly important across the manufacturing sector.
Schneider Electric and HPE participate in UniversalAutomation.org, an organization focused on advancing IEC 61499-based software-defined automation.
Compared with traditional automation models, open architectures provide greater flexibility for system integration.
Industrial users can combine automation software, industrial PCs, cloud platforms, and digital services from different technology providers.
From my experience working with PLC and DCS modernization projects, open standards can reduce long-term dependency on proprietary hardware. However, successful implementation still requires careful engineering planning, cybersecurity management, and process validation.
Supporting Edge, Private Cloud, and Distributed Control Architectures
Modern factories require flexible deployment options because production environments differ significantly.
Industrial Automation Modernization as a Service supports multiple architectures, including on-site control systems, private cloud platforms, and distributed automation environments.
For example, a large manufacturing plant may keep critical control loops near production equipment while moving data analytics and optimization applications to edge or private cloud environments.
This approach helps maintain control system availability while improving data utilization.
Industry Perspective: Modernization Will Focus on Incremental Transformation
The industrial automation market is moving from traditional hardware replacement toward software-driven modernization.
Manufacturers increasingly need automation platforms that support cybersecurity, artificial intelligence, industrial data analytics, and flexible production models.
The Schneider Electric and HPE partnership reflects this market direction. Instead of replacing all PLC and DCS equipment, companies can gradually introduce software-defined automation capabilities.
However, industrial organizations should evaluate modernization projects based on process requirements, safety standards, existing control architectures, and lifecycle costs.
A successful automation upgrade is not only a technology decision. It requires coordination between operations teams, automation engineers, IT departments, and cybersecurity specialists.
Application Scenarios for Industrial Automation Modernization
1. Process Industry DCS Modernization
Chemical, oil and gas, and power industries can use this approach to extend the lifecycle of existing DCS platforms while introducing modern computing and analytics capabilities.
2. Smart Manufacturing Factory Upgrades
Automotive, electronics, and machinery manufacturers can combine existing PLC systems with new software-defined automation applications.
3. Energy Management and Industrial Digitalization
Factories can use edge computing and automation data platforms to improve energy efficiency, predictive maintenance, and production visibility.
4. Multi-Vendor Automation Environments
Large industrial sites with mixed PLC and DCS platforms can adopt gradual modernization without immediate replacement of existing controllers.
Conclusion
Industrial Automation Modernization as a Service represents a shift toward flexible, software-driven factory automation models.
By combining Schneider Electric EcoStruxure Automation Expert with HPE SimpliVity infrastructure, industrial organizations gain a pathway to modernize control systems while protecting existing investments.
For manufacturers planning future automation upgrades, incremental modernization, open standards, and lifecycle services will become increasingly important factors in building resilient industrial operations.