Modern Controls. Reliable Production. Clear Data.
Ageing PLCs and HMIs are among the biggest hidden risks in Australian manufacturing. MACH specialises in migrating legacy control systems to modern platforms — with zero production loss and full data continuity.
Legacy PLC systems from the 1990s and 2000s are still running critical production lines across Australia. When parts become unavailable and vendor support ends, the risk becomes a ticking clock. MACH has migrated hundreds of control systems — from Modicon, GE Fanuc, Siemens S5, and Allen-Bradley PLC-5 platforms — to modern equivalents, often adding production data visibility that never existed before.
Common Challenges We Solve
- Obsolete PLC platform with no spare parts availability
- HMI screens are failing and replacements are unavailable
- No production data or OEE visibility from existing controls
- Legacy SCADA software on unsupported operating systems
- Control system complexity understood only by one person
- Integration with ERP or MES systems is impossible on legacy platform
How We Approach It
System Audit & Risk Assessment
Document existing logic, I/O maps, and sequences. Identify the highest-risk components and create a migration priority list.
Platform Selection
Recommend the right PLC, HMI, and SCADA platform based on your infrastructure, support requirements, and future connectivity needs.
Logic Migration & Enhancement
Translate existing logic to the new platform, rationalising and improving it in the process. Add alarming, data logging, and reporting.
Parallel Testing
Where possible, test the new system in parallel with the existing one before cutover, eliminating risk on changeover day.
Cutover & Commissioning
Plan and execute the final cutover during a scheduled shutdown, with MACH engineers on site until production is confirmed stable.
What You Can Expect
Eliminate Spare Parts Risk
Replace obsolete cards, processors, and displays with fully supported, locally stocked components.
Modern HMI Interfaces
Replace legacy text panels and CRT displays with modern touchscreen HMIs that operators find intuitive and informative.
Production Data & OEE
Add real-time production rate monitoring, shift reporting, downtime categorisation, and OEE dashboards.
Remote Access & Diagnostics
Enable secure remote access for your maintenance team and MACH engineers — reducing emergency response time significantly.
ERP / MES Integration
Modern PLC platforms make it straightforward to connect your production data to ERP systems, scheduling tools, and MES platforms.
Documented & Maintainable
New systems are fully documented — logic comments, I/O naming conventions, and as-built drawings — so any qualified engineer can maintain them.
Who We Work With
Frequently Asked Questions
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