Don’t Let Old Servers Halt Your Manufacturing Production
Your MES, ERP, and production systems work fine. But the hardware doesn’t. Stromasys moves them to x86 or the cloud in weeks, without changing legacy code.
90%
reduction in maintenance costs
*Based on real customer deployment
Key Challenges of Legacy Systems
Rising
Costs
Maintenance costs rise as vendors discontinue support, and spare parts disappear. The cost dynamics become even worse with large, power-hungry physical computers in the data center.
Cybersecurity
Vulnerabilities
Old systems lack modern security features like encryption and patching, making them easy targets for ransomware. This also leads to compliance risks with regulations and customer demands.
Downtime Risk and
Operational Disruption
Aging hardware is more likely to fail, halting production for days. Legacy ERP/MES often struggle with real-time scheduling and inventory, causing supply chain delays and missed deliveries.
Integration and
Data Silos
Legacy systems don’t integrate with IoT devices, cloud platforms, or modern ERP/MES. Disconnected systems create data silos, blocking real-time visibility and stalling Industry 4.0 efforts.
Limited Scalability
and Innovation
Old platforms are rigid. Expanding product lines or adding automation requires costly custom engineering. Competitors using AI, robotics, and cloud tools gain an edge in cost and agility.
Absence of
Backup Plans
Legacy systems often lack modern disaster recovery or redundancy options, leaving manufacturers exposed to critical failures. When old hardware fails, finding people to keep things running again can take weeks.
Why Is It Important
Numbers don’t lie! See the real risks and costs of maintaining legacy systems for manufacturers
In 2018, a top Taiwan-based semiconductor manufacturer lost $170 million due to legacy downtime.
According to the National Association of Manufacturers, unplanned downtime costs U.S. manufacturers $50 billion annually.
Stuck with a legacy MES? You’re looking at 37% more downtime and 42% higher defect rates compared to manufacturers with modern systems.
Stromasys: The Ultimate Protector of Your Mission-Critical Workloads
Stromasys Charon replaces aging hardware (SPARC, PA-RISC, VAX, Alpha) with virtualized solutions that keep your legacy software running without code changes. You can move your entire software installation to an industry-recognized modern environment (X86 or Cloud) without making any changes to the operating systems (Solaris, MPE, HP-UX, OpenVMS, True 64).
Eliminated Legacy
Hardware Risks
Outdated hardware is replaced with a virtualized environment that runs on modern, stable systems. This minimizes the risk of sudden failures, long downtimes, and expensive emergency repairs.
Uninterrupted ERP
and MES continuity
Keep your ERP and MES systems operational without rewriting code or disrupting workflows. Charon ensures your critical software runs seamlessly, even as hardware evolves.
Enhanced security
and compliance
Add modern security features like encryption, patching, and network segmentation to protect against cyber threats. Charon also helps meet compliance standards, ensuring audit readiness and customer trust.
Future-ready
scalability
Integrate with IoT, cloud platforms, and Industry 4.0 technologies without replacing your legacy systems. This unlocks real-time data, predictive maintenance, and AI-driven insights to stay ahead of competitors.
Manufacturers lose $695M yearly due to legacy hardware downtime.
See how Stromasys can positively impact the cost dynamics of your on-prem data center.
Trusted by Top Manufacturers Worldwide
How Stromasys Streamlined Disaster Recovery for a Cement Manufacturer
Get Expert Insights Tailored to Your Manufacturing Needs
Tested strategies to extend the life of your mission-critical manufacturing software, such as ERP, scaling operations without replacing legacy OS.
Get the technical details on how Stromasys emulates your legacy hardware on a more modern platform to keep your legacy applications running.
Practical advice for manufacturers tackling legacy hardware headaches, from downtime risks, maintenance hassles, to Industry 4.0 integration.
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