Where Technology Meets the Shop Floor – Unscripted With SST Episode Eight

In this episode of Unscripted with SST, the team tackles a critical issue facing small and mid-sized manufacturers: how to manage IT when your business depends on equipment that may have been running for decades. Host Tracy Elston is joined by SST COO Beau Elston and Centralized Services Engineer Ryan Gallenberg to explore the unique technology challenges that manufacturers face and how to turn potential vulnerabilities into competitive advantages.

The Legacy System Reality

Manufacturing environments present a unique IT challenge that most other industries don’t face. While a typical business might refresh computers every 3-5 years, manufacturers often rely on CNC machines, industrial control systems, and production equipment that has been running for 10, 15, or even 20 years.

These systems weren’t designed with modern cybersecurity in mind. They often run on outdated operating systems like Windows XP or Windows 7, and they can’t be easily upgraded without risking production downtime or compatibility issues. Yet these same systems are often connected to the network, creating potential security vulnerabilities.

The challenge isn’t just technical—it’s operational. These machines are the backbone of production, and any downtime directly impacts revenue, customer relationships, and competitive positioning.

The Hidden Costs of “If It’s Not Broken, Don’t Fix It”

Many manufacturers operate under the assumption that as long as production is running, IT is working fine. But this reactive approach creates several hidden risks:

Operational Risk: Legacy systems are more prone to unexpected failures. When a critical production system goes down, the cost isn’t just the repair—it’s the lost production time, missed shipments, and potential customer relationships.

Security Risk: Older systems often can’t run modern security tools, making them attractive targets for cybercriminals. A successful attack doesn’t just threaten data—it can shut down entire production lines.

Compliance Risk: As supply chain security requirements become more stringent, manufacturers may find themselves unable to meet customer or regulatory compliance standards without proper IT controls in place.

Visibility Gaps: Without proper monitoring and documentation, manufacturers often don’t know what systems they have, how they’re connected, or what would happen if they failed.

The Documentation Dilemma

One of the most common issues the team encounters is the lack of proper IT documentation and inventory. Over time, manufacturers add equipment and systems without thinking about how they integrate with the existing technology environment. This creates “islands” of technology that may not communicate well with each other and are difficult to monitor or secure.

Understanding what systems exist, how they’re connected, and which ones are truly critical to operations is the first step in building a strategic IT approach.

Modernization Without Production Interruption

The good news is that modernization doesn’t require replacing expensive production equipment. Strategic IT planning can help manufacturers:

• Implement network segmentation to isolate legacy systems while maintaining functionality
• Deploy monitoring tools that work with older systems to provide visibility and early warning of issues
• Create business continuity plans that minimize the impact of system failures
• Establish compliance frameworks that satisfy customer and regulatory requirements

The key is taking an intentional, phased approach that prioritizes the most critical systems and highest-risk areas first.

What Good IT Looks Like for Manufacturers

Effective IT for manufacturers goes beyond just keeping systems running. It includes:

• Complete visibility into all systems and their interdependencies
• Proactive monitoring and maintenance to prevent unexpected failures
• Security controls appropriate for both modern and legacy systems
• Business continuity planning that considers operational realities
• Compliance frameworks that prepare for evolving requirements
• Strategic roadmaps that align technology investments with business goals

Most importantly, it requires understanding the business impact of technology decisions, not just the technical requirements.

The Cost of Planning vs. The Cost of Reacting

The manufacturing industry provides a clear example of why proactive IT planning matters. The cost of planned downtime for maintenance or upgrades is predictable and manageable. The cost of unplanned downtime from system failures, security incidents, or compliance issues can be devastating.

Manufacturers who invest in strategic IT planning report fewer surprises, more predictable operations, and better relationships with customers who depend on reliable delivery schedules.

Time to Get Strategic About Manufacturing IT

If your manufacturing business is still treating IT as an afterthought, you’re operating with unnecessary risk. The goal isn’t to replace every piece of legacy equipment—it’s to understand your environment, manage your risks, and create a technology foundation that supports reliable operations and future growth.

Manufacturing IT requires specialized knowledge of both business operations and industrial technology. The right IT partner understands that production can’t stop, compliance requirements are evolving, and every system failure has real business consequences.

SST specializes in helping manufacturers navigate these unique challenges. From inventory and risk assessment to strategic planning and ongoing support, we help turn IT from a source of worry into a competitive advantage.

Ready to take control of your manufacturing IT environment? Let’s discuss how strategic planning can reduce your risks and support your operational goals.