Expertise
March has been trusted by key UK industries for decades. We understand the challenges that business faces in terms of productivity, competition, cost control, safety, security and compliance.
Don’t wait for obsolescence to disrupt your operations
Left unchecked, obsolescence can result in unplanned downtime, rising maintenance costs, cybersecurity vulnerabilities, operational risk and difficulties sourcing critical spare parts.
MARCH delivers control system modernisation projects for manufacturers and utility operators through structured engineering, upgrade planning and the replacement of ageing technology.
By replacing unsupported technology with modern, supportable solutions, organisations can:
- Reduce breakdown risk
- Improve maintainability
- Extend asset life
- Maintain operational continuity
- Create a stronger foundation for future improvements
Signs your control system may be becoming obsolete
Many organisations continue operating critical infrastructure long after technology vendors have ended support. Common indicators include:
- PLCs that are no longer supported by manufacturers
- Difficulty sourcing spare parts
- Outdated HMI or SCADA software
- Multiple generations of hardware installed across the same site
- Increasing maintenance costs
- Growing cybersecurity concerns
- Limited ability to expand or improve processes
What obsolescence could be costing you
Ageing and unsupported technology can have consequences beyond engineering challenges. Common business impacts include:
- Production losses due to unexpected failures
- Increasing maintenance and support costs
- Difficulty sourcing critical spare parts
- Compliance and audit challenges
- Reduced operational resilience
- Cybersecurity vulnerabilities associated with unsupported software
- Reliance on a small number of engineers with critical legacy system knowledge, including those approaching retirement
- Delays to improvement, expansion or digital transformation programmes
A structured approach to managing obsolescence
MARCH modernises ageing control and electrical systems for industrial and utility operators through structured upgrade programmes designed to reduce risk, improve supportability and prepare assets for the future.
As partners to Siemens, Rockwell Automation, Schneider Electric and AVEVA, we deliver end-to-end modernisation projects in live operational environments.
Assess
We review existing control systems, identify unsupported technology and assess the risks associated with ageing or obsolete assets.
Engineer
Our multidisciplinary teams develop migration strategies, FEED studies and upgrade roadmaps tailored to operational requirements.
Modernise
We replace obsolete PLCs, deliver control system migration projects and implement SCADA and hardware upgrades using modern, supportable platforms while retaining suitable assets where appropriate.
Commission
Structured testing and commissioning supports a controlled transition, reducing risk and minimising downtime during implementation.
Outcomes
Reduce downtime risk
Address unsupported technology before it impacts operations.
Extend asset life
Maximise the value of existing systems and infrastructure.
Improve supportability
Move towards modern, manufacturer-supported platforms.
Enable future improvements
Create a platform for future upgrades, integration and operational development.
Services that support control system modernisation
Managing obsolescence often involves more than replacing equipment. It can require upgrades to control systems, electrical infrastructure, software platforms and operational technology environments. MARCH integrates these disciplines to reduce risk, extend asset life and support future improvements.
FAQs
What is control system obsolescence?
Control system obsolescence occurs when hardware, software or network infrastructure is no longer supported by manufacturers, making maintenance, upgrades and spare part sourcing increasingly difficult.
How do I know if my PLC is obsolete?
Warning signs can include manufacturer end-of-support notices, limited availability of spare parts, increasing maintenance requirements and difficulty integrating with newer systems. Many organisations also find that outdated PLC platforms limit opportunities for future upgrades and operational improvements.
Should I replace my entire control system?
Not necessarily. A targeted modernisation approach can replace ageing technology while preserving assets that remain fit for purpose. Many projects focus on modernising obsolete components while retaining existing functionality and interfaces wherever appropriate.
How can control systems be upgraded with minimal downtime?
Planning, FEED studies, off-site preparation, structured commissioning and phased migrations can help reduce disruption during upgrades.
What cybersecurity risks can obsolete control systems create?
Unsupported hardware and software may no longer receive security updates, making systems more difficult to protect and maintain. Modernisation programmes can help organisations move towards supported platforms and improve long-term cyber resilience.
How can modernisation help extend asset life?
Modernisation can help extend the life of existing assets by replacing unsupported technology, improving maintainability and introducing modern platforms that support future upgrades and operational improvements.
Which industries can benefit from obsolescence management?
Any organisation that relies on industrial control systems can be affected by obsolescence. This includes manufacturers, utilities, infrastructure operators and other asset-intensive industries where reliability and operational continuity are critical.
Book an obsolescence review
Concerned about ageing control systems, unsupported hardware or increasing maintenance risks?
MARCH can review your existing control environment to identify unsupported technology, spare parts risks, cybersecurity vulnerabilities and practical opportunities to improve reliability, maintainability and future readiness.