Why Scalability in Control Systems Software Became Essential

Aug. 14, 2025
Legacy control systems can’t keep up with current manufacturing demands. However, scalable, AI-enabled platforms with flexible licensing and deployment options are reshaping operational control across industries and facility sizes.
  • Manufacturers need scalable platforms that support real-time visibility, flexible deployment and seamless integration across machines, lines and facilities regardless of operation size. 
  • Modern control systems offer user-based and subscription licensing, enabling cost-effective scaling and easier planning compared to traditional tag- or server-based licensing models. 
  • Advanced analytics, machine learning and generative AI embedded in modern control systems software deliver predictive insights and intuitive visualizations while genAI smart assistants accelerate development and improve operational decision-making. 

 

Imagine you're overseeing a production site. Maybe it's just one line, or perhaps it's hundreds of machines across multiple facilities. Your goal is the same in each case: keep operations running optimally.

In reality, this goal is complicated and can be difficult to achieve — whether that’s down to ill-matched software, machines that don’t talk to each other or systems that weren’t built to grow with the operations.

For decades, control software has been chosen primarily based on project size. Small installations got one type of tool, while bigger enterprises got more complex solutions. This seemed like a reasonable approach until companies were confronted with a barrage of compatibility, scalability and cost issues.

That’s why this old model for selecting control software no longer fits the purpose. Every operation — no matter the size — needs flexibility, real-time visibility and the ability to evolve with the times. This need for unified, scalable control impacts everyone in manufacturing, whether you're a shop floor operator, maintenance technician, engineer or company director.

Key facets of suitable control software

The changes that have taken place across manufacturing economies globally require manufacturers to go beyond basic HMI or SCADA to achieve full-scale visibility and control.  But what does this look like?

Smart assistants can guide users through development tasks, provide training and simplify access to documentation — all within the same platform.

It can mean implementing integrated components, such as historian databases, alarm management, reporting, analytics, workforce collaboration and cloud connectivity. These technologies can work together to support daily workflows and long-term growth. It’s also important to select an industrial software platform purpose-built to support all stakeholders. 

By implementing a consistent architecture and development environment, teams can avoid the inefficiencies and risks of juggling multiple systems and vendors.

Clear licensing for scalable growth

One of the biggest roadblocks to a control system’s ability to scale with a company is the traditional licensing process based on tag counts or server limits. This often makes planning difficult and scaling expensive. Fortunately, manufacturers now have more options to access modern platforms that offer flexible user-based or subscription models that align with real-world usage and budgeting needs.

This kind of licensing allows users to scale applications up or down as needed. For example:

  • Edge licenses: These are ideal for frontline teams needing local HMI and Industrial Internet of Things (IIoT) connectivity for individual machines or production lines. 
  • Supervisory licenses: These are perfect for centralized SCADA across multiple sites, promoting visibility and standardization across departments. 

As systems expand, these licenses can adapt to preserving past development efforts while enabling new functionality.

Easier deployment is the new standard

Deployment should be as flexible as the software itself. Whether running at the edge, in the control room, on mobile devices, in the cloud or all of the above, modern software should support any combination without added complexity.

With vendor-hosted cloud options, users benefit from simplified updates, enhanced security and a reduced maintenance burden. In addition, integration with systems like ERP (enterprise resources planning) or MES (manufacturing execution systems) ensures that data flows smoothly throughout the organization, bridging the gap between operations and enterprise systems.

Richer visualization for smarter operations

While traditional HMI/SCADA capabilities, such as trends and graphics, remain important, they’re now considered standard. The real value lies in the data and what teams can do with it.

Integration with ERP or MES ensures that data flows smoothly throughout the organization, bridging the gap between operations and enterprise systems.

Modern platforms enable access to analytics, machine learning and generative AI (genAI) tools that provide predictive insights, identify inefficiencies and recommend actions. These features let users reduce downtime, optimize performance and make informed decisions fast.

With features such as self-service visualization tools and pre-configured dashboards, even non-technical users can intuitively interact with complex data.

For example, users can apply animations to holistically visualize complex interactions and incorporate a combination of AI and analytics in their applications, enabling them to reduce production costs, predict potential equipment failure and rapidly locate any information within their systems within seconds. A proven operations control software suite enables users to rapidly prototype, test and iterate before scaling to production.

GenAI assistance and workforce empowerment

Emerging technologies like genAI can transform the way your teams interact with software. Smart assistants can guide users through development tasks, provide training and simplify access to documentation — all within the same platform.

This kind of built-in intelligence accelerates project development, supports knowledge transfer and enables workers of all skill levels to contribute effectively.

Instead of relying on custom-built tools or scattered documentation, teams benefit from a centralized system that encourages collaboration, continuous learning and quick troubleshooting.

Rashesh Mody is executive vice president, business strategy and realization, Aveva.

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