What is OT cybersecurity and why does it matter for UK manufacturers?

OT (Operational Technology) cybersecurity protects the PLCs, SCADA, HMIs and control networks that run production. It matters because OT cyber incidents have cost UK manufacturers £44 billion in the last five years. Most attacks succeed against legacy PLCs and unsegmented networks - exactly what 56% of UK manufacturers still operate. The relevant standard is IEC 62443.

What is IEC 62443 and do we need to comply?

IEC 62443 is the international standard for industrial automation and control systems cybersecurity. It is increasingly required by major customers (especially in automotive, aerospace, energy and defence supply chains) and by cyber insurers. We assess your current state against IEC 62443 and produce a phased compliance roadmap aligned to production windows.

Can you upgrade legacy PLCs without disrupting production?

Yes. We work in phased shutdowns aligned to your planned maintenance windows. The methodology is: full automation mapping; detailed functional specifications and migration plans; FAT/SAT testing in our workshop or yours before installation; site commissioning during a planned outage; full operator training and handover documentation.

What PLC and SCADA platforms do you work with?

Our team is multi-platform: Siemens (S7-300, S7-1500, TIA Portal, WinCC), Rockwell (ControlLogix, FactoryTalk View), Schneider (Modicon, Wonderware/AVEVA), Beckhoff (TwinCAT) and Mitsubishi. We are platform-agnostic - we recommend the right kit for your needs and your existing skills, not the platform we have a sales target on.

How do you address the UK skills gap in automation?

Two ways. First, we standardise your control code to libraries based on ISA-88 and ISA-95, which makes it easier to recruit and onboard engineers because the code is readable and consistent. Second, we provide ongoing support and training so your existing team can maintain the systems we deliver, rather than being permanently dependent on specialist contractors.

What is OT cybersecurity and why does it matter for UK manufacturers?

OT (Operational Technology) cybersecurity protects the PLCs, SCADA, HMIs and control networks that run production. It matters because OT cyber incidents have cost UK manufacturers £44 billion in the last five years. Most attacks succeed against legacy PLCs and unsegmented networks - exactly what 56% of UK manufacturers still operate. The relevant standard is IEC 62443.

What is IEC 62443 and do we need to comply?

IEC 62443 is the international standard for industrial automation and control systems cybersecurity. It is increasingly required by major customers (especially in automotive, aerospace, energy and defence supply chains) and by cyber insurers. We assess your current state against IEC 62443 and produce a phased compliance roadmap aligned to production windows.

Can you upgrade legacy PLCs without disrupting production?

Yes. We work in phased shutdowns aligned to your planned maintenance windows. The methodology is: full automation mapping; detailed functional specifications and migration plans; FAT/SAT testing in our workshop or yours before installation; site commissioning during a planned outage; full operator training and handover documentation.

What PLC and SCADA platforms do you work with?

Our team is multi-platform: Siemens (S7-300, S7-1500, TIA Portal, WinCC), Rockwell (ControlLogix, FactoryTalk View), Schneider (Modicon, Wonderware/AVEVA), Beckhoff (TwinCAT) and Mitsubishi. We are platform-agnostic - we recommend the right kit for your needs and your existing skills, not the platform we have a sales target on.

How do you address the UK skills gap in automation?

Two ways. First, we standardise your control code to libraries based on ISA-88 and ISA-95, which makes it easier to recruit and onboard engineers because the code is readable and consistent. Second, we provide ongoing support and training so your existing team can maintain the systems we deliver, rather than being permanently dependent on specialist contractors.

The Challenge

What We Deliver

How We Work

What You'll Achieve

Resources

Industrial automation, PLC and SCADA modernisation for UK manufacturers - IEC 62443 compliant

Industrial Automation UK: PLC, SCADA and OT Modernisation

Control systems run your production lines — PLCs, SCADA, HMI panels, and DCS networks. We help manufacturers upgrade and standardise their PLC, SCADA, and HMI systems — reducing unplanned downtime, improving product quality, and strengthening OT cybersecurity.

The Automation Challenge

Many manufacturers rely on ageing control systems that are difficult to maintain, hard to recruit for, and increasingly vulnerable to cyber threats — while production demands grow.

56%

Legacy OT Systems

Of UK manufacturers still operate critical processes on legacy OT systems over 15 years old — Make UK Reports

£44B

OT Cyber Cost to UK

Cybersecurity lapses in operational technology environments have cost UK firms £44 billion over the past five years — ABC Money

35%

Control Skills Gap

Of UK manufacturers report difficulty recruiting PLC and SCADA engineers, with average vacancies open 6+ months — IET Skills Survey 2025

What We Deliver

We modernise and standardise your automation infrastructure — from individual PLCs to enterprise-wide SCADA and control networks.

PLC Implementation

Upgrade legacy PLCs to modern, maintainable platforms with standardised code libraries and documentation.

Legacy PLC migration and upgrade paths
Standardised control code libraries (ISA-88/ISA-95)
Reduced dependency on specialist contractors

SCADA & HMI Upgrades

Replace outdated SCADA and HMI systems with modern, web-based platforms that improve operator experience and data access.

Modern HTML5 HMI design and deployment
Centralised SCADA for multi-site visibility
Alarm rationalisation and management

Secure Remote Access

Secure your operational technology infrastructure against emerging threats while enabling safe remote monitoring and support.

OT network segmentation and hardening
Secure remote access for monitoring and support
IEC 62443 compliance assessment and implementation

How We Work

A structured methodology to connect your systems without disrupting operations.

Automation Mapping

Survey your existing control systems and network architecture. Identify risks, obsolescence, and priority upgrades.

Design & Specification

Create detailed functional specifications, hardware schedules, and migration plans aligned to production windows.

Commission

Implement upgrades in phased shutdowns with full FAT/SAT testing, operator training, and handover documentation.

Validate & Support

Establish ongoing monitoring, preventive maintenance schedules, and continuous improvement programmes.

What You'll Achieve

Operational Outcomes

Uptime & Performance

Reduced unplanned downtime through modern and reliable systems
Improved OEE with standardised automation across production lines
Faster fault diagnosis with modern HMI and alarm management

Business Value

Security & People

Strengthened OT cybersecurity posture meeting IEC 62443 standards
Reduced dependency on specialist contractors
Safer operator experience with modern HMI and safety system upgrades

Ready to Modernise Your Control Systems?

Schedule a free consultation to discuss automation infrastructure and build a prioritised upgrade roadmap.

Industrial Automation UK: PLC, SCADA and OT Modernisation