Automation vendors love to talk about transformation: digital twins, edge computing, predictive maintenance. The promises are slick and the vision is compelling. But for engineers tasked with making it all work, the reality is often far less futuristic.
Most sites across WA, particularly in mining and heavy industry, are built on decades-old infrastructure. DCS and PLC systems still running today were never designed with modern integration in mind. Ethernet/IP might be present in pockets, but much of the backbone still relies on legacy protocols, minimal documentation and hardware that is long past end-of-life.
This is where the concept of the smart plant collides with the reality of site conditions. Engineers are being asked to layer cloud-based analytics platforms over systems that struggle with basic remote access. They are expected to retrofit condition monitoring and cybersecurity frameworks onto equipment that was never designed to be connected in the first place.
This technical burden is significant. It is not just about configuration changes or firmware updates. It often involves rethinking architecture, bridging incompatible systems and introducing middleware to enable even basic data flow. In many cases, engineers are forced to reverse engineer undocumented logic or modify control panels without reliable schematics.
The introduction of even a seemingly simple modernisation can uncover wider issues. Earthing problems, noisy signals or poor segregation can bring new systems to a halt before they even go live. At the same time, compliance requirements around hazardous areas, SIL ratings and cybersecurity continue to tighten.
There is clear momentum behind the shift to smarter, more connected plants. But alongside the new tech, there is a lot of legacy infrastructure that still needs to be navigated. That complexity is easy to underestimate.
The engineers I speak with are not working in clean-slate environments. They are adapting, problem-solving and keeping operations running while the rest of the industry talks about transformation. This is engineering excellence in practice. It’s not just about deploying the latest technology - it’s about the deep understanding and methodical work of integrating it with what’s already there. It’s the skill, experience and ingenuity of engineers that create real-world fit-for-purpose outcomes.
Are you ready to explore the next step in your engineering career? Get in touch with our team today and let us help you find your perfect role or search current engineering job opportunities.
