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At the risk of aging myself, I started my first job after college by manually mapping DCS system I/O points using a process instrumentation diagram (P&ID), a pen, and a piece of paper. But technology has evolved significantly since then. Today, engineers can complete the same task using automatic loading and balancing by scanning P&ID drawings into the DCS system design.
I mention this because organizations across many industries recognize the impact of digital transformation, or digitalization, on their operational technology. Yet many still struggle to implement it effectively. Distributed control systems (DCS) are crucial in this shift by enabling operations to automate non-value activities and reallocate workforce time more efficiently.
Benefit of digital transformation
Digital transformation is set to significantly impact industrial operations over the next two to three years. However, many organizations still lack the tools, talent, and infrastructure needed to successfully deploy autonomous and remote operations at scale.
Earlier this year, Schneider Electric partnered with independent research firm Omdia to analyze how organizations are approaching digitalization across industrial sectors. The findings revealed most organizations are still in the early stages of building a fully optimized digital ecosystem. These insights are explored further in our blog, 3 key findings on how industries utilize digitalization.
Improving productivity with digitalization
Survey respondents across OT segments including energy, chemicals, water and wastewater, and refining highlighted that digitalization is no longer optional but essential for business success. While nearly 80% of IT and OT managers’ report adopting digital initiatives, concerns around cost and opportunity-lost (i.e., possibility of a shutdown) continued to slow full-scale transformation.
The top needs managers identified for implementing a DCS included:
- Reduced IT cost
- Improved scalability
- Greater business continuity
- Enhanced data processing and management process
There is a growing adoption of smart technologies across digital enterprises, as organizations look to modernize operations and improve performance. Migrating a modern DCS helps extend the longevity of continuous applications.
Successfully scaling digital transformation requires partnering with experts to ensure secure, resilient systems. Schneider Electric supports this transition with deep industry expertise, offering structured migration roadmaps, training programs, and scalable deployment strategies. Organizations can confidently adopt digital technologies for a smoother transition to remote and autonomous operations.
Reduce operational downtime
Minimizing downtime remains a top concern for organizations undergoing digital transformation. Many survey respondents cited the risk of shutdowns and limited readiness for deploying new technologies as key barriers.
A proven strategy to address this challenge is the use of “hot cutovers,” where legacy and new systems run in parallel. This approach enables continuous operations during system transitions, significantly reducing downtime risk.
In contrast, traditional “rip-and-replace” methods can take weeks or even months to restore full operations. Phased migration preserves field wiring and maps inputs and outputs directly to new systems. This one-to-one method reduces implementation time and ensures lower-risk DCS migration.
Organizations can further optimize performance and reduce risk by leveraging digital twin technology. By simulating real-time operations, digital twins allow teams to validate changes and demonstrate value before deployment, to ensure smoother transitions and improved operational outcomes.
Considering a DCS upgrade? Ask these five questions to prepare for a successful transition.
Digitalization with end objectives in mind
As many legacy DCS systems approach the end of their lifecycle, companies must turn to supporting digitalization initiatives. In order to incorporate artificial intelligence for a fully autonomous, self-optimizing system.
To fully realize these benefits, organizations need a clear strategy that prioritizes scalable outcomes over short-term proof of concept. This includes evaluating technology capabilities, aligning with experienced partners, and fostering stakeholder buy-in to support the adoption of smart technologies.
Modernizing legacy DCS systems not only enables greater efficiency and profitability but also strengthens cybersecurity. Obsolete systems are increasingly difficult to protect and are more at risk to cyber-attacks, making modernization critical for safeguarding infrastructure and intellectual property.
This is where modern distributed control systems become essential in helping organizations turn digital transformation from a concept into a scalable, practical reality. Explore how DCS migration and updates support your digital transformation journey.
