In the industrial manufacturing sector, the term “automation” often raises concerns about job security. However, when done properly, modernizing your facility is more about empowering your workforce than replacing them. By implementing a strategic controls migration, you can enhance your processing capabilities to meet your company’s goals without harming team morale. A successful migration shifts the focus from outdated, frustrating equipment to intuitive, flexible systems that make daily tasks safer and more efficient.
Here are five ways to elevate your automation strategy while keeping your workforce engaged and confident.
1. Eliminate the Frustration of Rigid Legacy Systems
Nothing kills morale faster than struggling with malfunctioning tools. Many manufacturers are stuck with rigid architectures that can’t meet customer demands.
For a global producer of specialty additives, an outdated legacy Distributed Control System (DCS) limited their agility. The system was inflexible and depended on a small group of service providers, which conflicted with their need to adapt formulations rapidly. By focusing on migrating controls, they transitioned to a modern platform that eliminated these daily issues. When you equip your team with tools that support their workflow rather than hinder it, satisfaction naturally increases.
2. Treat Expansion as a Modernization Opportunity
Sweeping changes can be overwhelming for staff. Instead of overhauling an entire plant overnight, look for natural opportunities to introduce new technology.
When the additives manufacturer needed a new reactor, Magnum took it as an opportunity to introduce a Rockwell Automation FactoryTalk Batch solution. This specific controls migration became the foundation for the future without disrupting the entire facility at once. This approach lets your team get comfortable with new technology in a controlled environment before it rolls out plant-wide.
3. Focus on Usability and Safety to Build Confidence
New systems should make operators feel safer and more capable, not confused. Modern platforms improve usability, allowing you to train a broader range of operators with confidence that safety remains intact.
Jordan Stoltz, Engineering Director at Magnum Systems, notes the impact of this approach:
“Beyond the adaptable technology, the new platform enhances usability and operational safety for workers. The system allows them to train a wider array of operators with confidence that neither output nor safety will be compromised. This is especially helpful as experienced users leave the workforce and the client is forced to adapt.”
When employees see that controls migration directly invests in their safety and skill development, their buy-in increases significantly.
4. Adopt a Scalable, Phased Approach
Automation doesn’t have to be “all or nothing.” A phased migration lets your team adopt changes gradually. Since the initial implementation for the global manufacturer, the system has been expanded multiple times, increasing automated control in previously manual areas and migrating nearby hardware as schedules permitted.
Mark Randall, a project manager at Magnum Systems, describes the advantages of this ongoing relationship:
"Since the initial deployment, projects have ranged from smaller to more complex efforts, all of which are easy to execute on the revised system.
Breaking the controls migration into smaller projects reduces the stress of change and lets your team celebrate small wins along the way."
5. Use Simulation to Lower Anxiety
Uncertainty significantly lowers morale. “Will this work?” and “Will I break it?” are common fears during an upgrade. Digital twin technology helps reduce this worry by enabling code to be written, tested, and validated before deployment.
“We will leverage our digital twin technology for this project, which allows us to deploy the update with the highest efficiency and least risk,” says Randall regarding the manufacturer’s recent loadout expansion.
Using tools like Rockwell Automation’s Logix Echo software creates a safe sandbox environment.
“Clients can also train on the systems beforehand, which further allows them to experience the new solutions faster and with greater confidence,” Randall adds.
When operators practice on the new system before it goes live, fear turns into mastery.
Ready to Modernize Your Operations?
Modernizing your facility isn’t just about hardware; it’s about preparing your team for success. By migrating controls to replace rigid legacy systems with flexible, safe, and testable solutions, you ensure your technology evolves alongside your workforce, not against it. The outcome is a facility that is adaptable, efficient, and run by a confident team ready for the future.
Your facility’s potential shouldn’t be held back by outdated technology. If you’re aiming to boost agility and empower your workforce with future-ready systems, we’re here to listen.
Contact Magnum Systems today to discuss your specific needs and explore how we can help you scale with confidence.
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