Most failures in controls and automation don’t start with sparks, alarms, or flashing lights. They start quietly, with something missing.
When One Small Oversight Becomes a Full-Scale Crisis
Not long ago, a Perceptive Controls customer called us in a panic.
Their PLC had failed unexpectedly. Production was down. Operators were waiting. Management was asking questions. And then came the realization that made the situation far worse than it ever needed to be:
There was no backup.
Not on their servers.
Not on a USB drive.
Not with their original automation provider.
The PLC program, the brain of their operation, was simply gone.
That single oversight eliminated any path to a fast recovery. What could have been hours of downtime turned into days of reverse engineering, stress, and lost production. And the hardest part? This situation is far more common than most people realize.
The Invisible Risk in Industrial Automation
In controls and automation, backups aren’t flashy. They don’t improve cycle times or boost throughput. They sit quietly in the background, until the day everything goes wrong.
That’s why they’re often overlooked.
But losing a PLC, HMI, or SCADA system without a current backup can mean:
- Extended production downtime
- Emergency service costs
- Lost process knowledge
- Increased safety risk
- Pressure on operators and maintenance teams
- Management scrambling for answers
And once the program is gone, there is no “undo” button.
Why Backup Plans Must Be Non-Negotiable
At Perceptive Controls, we treat backup and disaster recovery planning as a responsibility, not an optional add-on.
Every project we deliver includes:
- A complete copy of the PLC, HMI, or SCADA program sent directly to the end user
- A secure copy stored on our internal network for safekeeping
- Clear documentation to support future troubleshooting and recovery
Why? Because when a failure happens, and eventually, it will, the worst time to think about a backup plan is after the system is already down.
Ask Yourself This Before the Next Failure
Take a moment and be honest:
- What would happen if you lost a PLC today?
- Do you have a verified, restorable backup?
- Is it stored somewhere safe, and accessible?
- Does your automation provider have their own disaster recovery plan?
If you can’t answer “yes” with confidence, you’re carrying an invisible risk.
Backup Planning Isn’t About System Size
I often hear, “Our system isn’t that big.”
That doesn’t matter.
Whether your automation system is complex or compact, every operation depends on software that cannot be easily recreated under pressure.
A proper controls and automation disaster recovery plan should include:
- Regular PLC, HMI, and SCADA program backups
- Off-machine storage (not just on the device itself)
- Version control and documentation
- A trusted automation partner who can respond during a crisis
The Difference a Prepared Partner Makes
When things go wrong, and they always do eventually, the question becomes:
Who is ready to help you recover?
At Perceptive Controls, we design automation systems with the understanding that failure is not a matter of if, but when. Our job is to make sure that when that moment arrives, you’re not starting from zero.
Because in controls and automation, backup plans aren’t about paranoia.
They’re about professionalism.
They’re about responsibility.
And they’re absolutely non-negotiable.
Larry West
Perceptive Controls, Inc.
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