Digitalizing Brownfield Plants: Start Small, Scale Fast

Most factories aren’t greenfield — they’re running on decades-old PLCs, wiring, and SCADA systems. The key to digitalizing brownfield plants is starting small, proving value early, and scaling fast without disrupting production.

1. Start with Data Visibility

Install edge gateways to collect key machine signals (runtime, status, downtime). Focus on one line or cell, not the entire plant. Use open standards like OPC UA or MQTT Sparkplug B for connectivity.

2. Build a Scalable Data Model

Structure data by asset and process, not by tag. This ensures new lines can be added later without redesigning the entire architecture.

3. Integrate Incrementally

• Step 1: Read-only connection for dashboards.
• Step 2: Add alerts and KPIs for maintenance or quality.
• Step 3: Expand to predictive and closed-loop control.

Example

A 1980s automotive plant connected five legacy PLCs via MQTT to a cloud dashboard. Within six weeks, they identified 12% hidden downtime — all without touching control logic.

Related Articles

• Bridging Old PLCs to Modern Data Stacks
• Change Management for Operators: Training That Sticks
• How to Pick Pilots That Become Programs

Conclusion

Brownfield digitalization isn’t about replacing — it’s about connecting. Start small, measure impact, and scale what works.