Open Automation Is Rewriting the Rules of Industrial Efficiency

Open Automation Is Rewriting the Rules of Industrial Efficiency

At Automate Show 2025, one of the most compelling conversations wasn’t about new products—it was about a shift in mindset that’s quietly transforming the way industrial facilities operate: open, software-defined automation.

In a discussion with Fabrice Meunier, Vice President – Industrial End User, System Integrator and Software Business, Schneider Electric, several core themes emerged around the adoption of open systems in industrial environments. These insights have far-reaching implications for manufacturers seeking agility, efficiency, and long-term scalability.

1. Engineering Efficiency Is the Hidden ROI

One of the most impactful but often underestimated benefits of moving to open automation is the gain in engineering efficiency. In today’s plants—many of which run hundreds of PLCs from different vendors—engineers often spend weeks rewriting similar logic for each system. With an open architecture, that logic can be reused and deployed across multiple platforms, saving up to 25–30% of engineering time.

This not only speeds up development cycles but also frees up teams to focus on optimization, rather than repetition.

2. Legacy Equipment Can Be Modernized—Without Ripping and Replacing

Industrial operators face a well-known dilemma: how to modernize aging equipment without halting production or investing in complete overhauls. Open automation offers a bridge between brownfield and greenfield environments.

Facilities can repurpose existing assets by decoupling software from hardware, avoiding the traditional “start from scratch” model. This makes it possible to reconfigure production lines on the fly—especially valuable when demand shifts unexpectedly.

3. Vendor Lock-In Is Fading—And That’s by Design

Closed systems have long dominated industrial automation, locking operators into specific ecosystems and making upgrades expensive and time-consuming. Open systems now allow code and logic to move freely across platforms, without reengineering everything.

This shift enables manufacturers to be more flexible with future tech adoption—no more throwing out hardware every time an upgrade is needed.

4. Turning Disconnected Data into Real-Time Action

Disjointed data remains a widespread pain point in industrial operations. Open automation offers a way to connect and contextualize information, allowing real-time decision-making. It’s a fundamental evolution from the legacy of traditional PLCs, which were designed decades ago as closed, hardware-bound systems.

Now, control logic and data handling can adapt fluidly across environments, giving teams better tools for responsiveness and optimization.

5. Change Management Is the Real Hurdle

While the technology is ready, what often holds companies back is internal alignment. To fully benefit from open automation, organizations need an end-to-end transformation mindset. One person or one department cannot drive it alone—success depends on buy-in from across operations and leadership.

Change management is no longer an afterthought; it’s central to scaling the benefits of open systems.

Sponsored by Schneider Electric