Consider two machines:
Machine A is twenty-five years old. Its mechanical systems—the frame, the bearings, the gears, the hydraulic cylinders—are in excellent condition. It was overbuilt in an era when steel was cheap and engineers added safety factors of five or more. This machine will probably outlive its operators.
But its control system is a relic. The programmable logic controller (PLC) comes from a manufacturer that went out of business fifteen years ago. The user interface is a monochrome screen with a membrane keypad. There is no data port, no network connection, no way to monitor its performance remotely. Replacement parts for the control system are unobtainable except from scavenged units.
Machine B is brand new. It has a sleek touchscreen interface, cloud connectivity, predictive maintenance algorithms, and energy-optimized servo drives. But its frame is lighter, its bearings are smaller, and its expected service life is ten years—not twenty-five.
Which machine is more valuable?
The answer depends entirely on what you value.
If you need cutting-edge functionality and connectivity, Machine B wins. If you need durability and long-term reliability, Machine A's mechanical bones are superior—but its obsolete brain holds it back.
Retrofitting resolves this paradox. It takes the durable bones of Machine A and gives them the brain of Machine B. The result: a machine that is both durable and modern.
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