Complexity in Automation and Industrial Projects
Historical precedent is not an argument—it is a cost factor
In many automation and industrial projects, complexity is tacitly accepted. “That’s just how it’s always been” is often cited as an explanation—but not as a solution. In fact, the accumulated complexity of systems is one of the biggest hidden cost factors in production and retrofit projects.
Custom solutions, proprietary interfaces, and legacy workarounds often seem harmless in day-to-day operations. However, their true impact becomes apparent with every expansion, disruption, or modification. That is precisely when it becomes clear just how resilient—or how complex—a system landscape really is.
The result of unnecessary complexity:
- Longer project durations
- Higher maintenance and operating costs
- Growing Interdependencies Between IT and OT
- Increasing administrative burden
- Increased Risk When Changes Are Made
This becomes particularly clear in retrofit projects. It is rarely the existing system itself that hinders modernization efforts. Much more often, it is the system landscape that has evolved over time—lacking a clear structure, defined responsibilities, and standardization.
The crucial question, therefore, is not:
Why did we used to do it that way?
Rather:
What does this complexity cost us today—and what will it prevent tomorrow?
Complexity is no accident—it is man-made
System landscapes that have evolved over time often remain stable for a surprisingly long time. Problems only come to light when changes become necessary:
- A new machine is to be integrated
- A wayfinding system is being modernized
- Security requirements are increasing
- Production processes must be adjusted
Suddenly, enhancements take longer than planned, dependencies are unclear, and every change becomes a risk. Not because the technology fundamentally fails—but because there is a lack of transparency and structure.
The Reality in Many Industrial Companies
- Complexity arises gradually and unintentionally
- Changes are the true stress test for systems
- A lack of transparency costs time, money, and resources
- Retrofit projects rarely fail because of the equipment—but rather because of organizational structures
If you want to remain competitive in the long term, you don’t need additional complexity—you need manageable, scalable system architectures.
Our Response to Increasing Complexity
The ROTH Group does not rely on radical replacement or complete reimplementation. Instead, we bring order to existing systems —in a structured, transparent manner, and without disrupting ongoing operations.
Our Approach to Sustainable System Modernization:
- Analysis of existing system landscapes:
Transparency regarding dependencies, interfaces, and responsibilities as the basis for every decision. - Clear Roles Between IT, OT, and Control Systems:
Clearly defined responsibilities reduce friction and coordination efforts. - Reducing and standardizing interfaces:
Less complexity means greater stability, better maintainability, and faster adaptations. - Step-by-Step Modernization During Operation:
No unnecessary downtime—just a controlled transformation with predictable risk.
From an Organic System to a Manageable Structure
Complexity doesn’t just go away on its own. But it can be structured, reduced, and strategically managed.
This transforms a system landscape that has evolved over time back into a transparent, scalable, and future-proof system—with clear responsibilities and changes that can be planned.
The key question for your company is:
What is holding you back more when it comes to change—legacy technical issues or a lack of clarity in your system architecture?
If you want to actively shape—rather than simply manage—increasing complexity, please contact us.
