In the manufacturing sector, legacy systems often serve as the backbone of daily operations. These applications are dependable, familiar, and deeply embedded in workflows. While they continue to perform their tasks effectively, relying on outdated operating systems introduces serious security vulnerabilities and compliance challenges.
The dilemma arises when organisations look to modernise their infrastructure. Trusted tools can suddenly become incompatible or unsupported, forcing costly redevelopment, retraining, or operational disruptions. The stakes are high — downtime in manufacturing can cost tens of thousands of dollars per minute when production grinds to a halt.
Take, for example, an automotive manufacturer that depended on testing rigs worth millions of dollars. These rigs were controlled by Windows XP machines running 16-bit applications — software that couldn’t function on modern Windows systems. Replacing the rigs or rebuilding the software was financially daunting. The question wasn’t whether the tools worked, but how to modernise them without disrupting critical operations.
Why outdated infrastructure is a business risk
Many factories still rely on long-standing applications that run on unsupported operating systems. These aren’t simply back-office utilities; they directly control production lines, logistics, and even quality assurance. A single failed upgrade could take a calibration tool offline, potentially halting operations for days. The fallout includes missed deliveries, financial losses, and reputational damage.
Outdated systems also present prime targets for cyberattacks. From proprietary formulas to detailed design specs, the data within these applications is often highly sensitive. A ransomware attack or system failure could disrupt production, compromise intellectual property, or erode customer trust. The impact extends far beyond IT — it strikes at the heart of business continuity.
Why traditional approaches often fail
Legacy applications are notoriously difficult to modernise. Their code is often tied to specific operating systems and hardware environments. Components such as registry settings, system drivers, or hardcoded file paths were never intended to be portable.
Conventional solutions like containerisation or virtualisation work well for newer, modular applications, but they fall short with older tools. Wrapping outdated software in a container or virtual machine doesn’t eliminate risks — it merely relocates them. In many cases, this approach results in unstable performance, limited functionality, or outright failure in complex production environments where uptime is critical.
Modernising without rebuilding
Instead of rewriting code or replacing costly equipment, manufacturers can adopt solutions that preserve both applications and their environment-specific dependencies. This approach allows legacy systems to run on secure, modern operating systems without requiring virtualisation or containers.
For the automotive company mentioned earlier, this strategy was transformative. The critical testing applications were packaged from their original XP setup and redeployed onto current Windows desktops. This not only protected their investment in testing rigs but also enhanced resilience by eliminating the reliance on a single machine. The applications could now be deployed across multiple devices, ensuring greater flexibility and reducing the risk of operational bottlenecks.
Rethinking modernisation
Legacy applications remain indispensable for manufacturers, yet leaving them on unsupported platforms is unsustainable. Modernisation should no longer be seen as a mere IT upgrade — it’s a business-critical strategy. The risks of inaction span financial, operational, and reputational domains, making it a priority for leadership teams.
By redeploying legacy applications to modern platforms without code changes or disruptive rebuilds, manufacturers safeguard uptime, strengthen security, and protect customer trust. True modernisation isn’t about chasing every new technology trend. It’s about ensuring that the systems keeping production alive continue to operate safely, efficiently, and securely.
