Industrial automation professionals, systems integrators, and plant managers tuning into Unplugged: An IIoT Podcast will find Vladimir Romanov’s conversation with host Phil Seboa relevant and practical. This episode focuses on managing legacy systems on the plant floor, the importance of upskilling personnel, and the challenges and strategies for integrating data-driven solutions in manufacturing.

Bridging the Gap Between Legacy Systems and Modern IIoT

Vladimir Romanov points out that working with legacy equipment is a reality for many manufacturers. Before any advanced analytics or optimization, there’s often a considerable effort required just to get reliable data out of outdated hardware and software. “The reality is… you need to spend a lot of time contextualizing the data, but ultimately upgrading the equipment to be even able to communicate the data out,” Romanov notes. He describes visiting sites still reliant on technologies like Windows 98 or PLCs that are long obsolete. The first step is conducting detailed on-site assessments, prioritizing upgrades based on risk and budget, and ensuring any investment genuinely improves communication and reliability. These incremental improvements pave the way for future digitalization.

Upskilling the People Behind the Technology

Romanov emphasizes that technical challenges are matched—often surpassed—by workforce development issues. “Almost every factory I go to is hiring for control systems engineers. Right? So there's a clear lack of… just people… to maintain the plant running, but ultimately slowly improve the plant as well,” he explains. He stresses that technology alone can’t drive manufacturing forward without staff who understand both the hardware and the new software tools being added. Compounding the challenge is the difficulty of quantifying return on investment from new data solutions up front, making management buy-in and employee training essential for successful modernization projects.

Turning Data Into Actionable Plant Improvements

Collecting data is only part of the process. Romanov observes that even as plants install SCADA, MES, and historian systems, staff on the floor may not always know how to interpret the new data or what actions to take. “I still see a lack of plant floor understanding of data… dashboards that give you high level insight,” he explains. Many teams struggle to move beyond monitoring to using information for decision-making and improvement. Romanov suggests that change management, ongoing education, and involving frontline employees in solution design are needed to realize real manufacturing gains from digital solutions.

Key Quote From The Episode

“I think the people challenge is even greater than the technical challenge.” – Vladimir Romanov

Key Takeaways

• [00:11:37] Many plants require careful, phased approaches to replace or upgrade legacy systems—big-bang modernization is rarely possible.
• [00:16:17] Upskilling is critical: There’s a shortage of controls engineers, and without investment in people, technology upgrades fall short.
• [00:32:35] Having data doesn’t guarantee improvement—success depends on team members understanding how to interpret and act on this information.

Wrap Up

Manufacturers looking to improve operations must balance legacy equipment realities, invest in workforce capabilities, and support change management to translate data into real improvements. Readers should start with targeted assessments of plant infrastructure, plan for incremental upgrades, and prioritize team training and engagement throughout technical shifts. Partnering with professionals who understand both equipment and organizational culture will accelerate successful outcomes.

About the Guest

Vladimir Romanov is a leader in industrial automation and digital transformation. Having worked with Procter & Gamble, Kraft Heinz, and in IT-focused startups, he brings deep hands-on experience bridging operational and data-driven solutions. Romanov is also known as a co-host of Manufacturing Hub and founder of SolisPLC, where he is an advocate for ongoing learning in the manufacturing sector.

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