How Poor Automation Integration Increases Operational Risk Long Before Failures Happen
Industrial automation system integration risk often shows up long before a system fails. It hides in workarounds, outdated parts, and small fixes that stack up over time. For operations leaders, these risks can quietly raise downtime, safety issues, and costs. Many teams do not notice the danger until a critical component breaks and forces a rushed decision.
David Thompson, Automation Manager at Design Solutions and Integration, has seen this pattern for years. With nearly two decades in automation, he helps teams spot risk early and plan smarter upgrades. His insight shows why integration quality matters as much as the equipment itself. When systems grow without a clear plan, risk grows with them. The good news is that teams can address these risks before failures happen.
The Hidden Operational Risk in Poor Automation System Integration
Most operations teams inherit automation systems built over many years. Each upgrade solves a short-term problem. Over time, those choices create hidden weak points. Old hardware must talk to new platforms. Different communication methods compete. Support becomes harder each year.
Thompson explains that older systems often last a long time, but parts do not. When one component fails, the rest may follow. “One piece of the system goes down, the rest could follow,” he said. That reality creates operational risk in industrial automation long before alarms sound.
The challenge grows when experience gaps appear. Teams change. Knowledge walks out the door. New staff may not know why systems were built a certain way. Poor automation system integration makes that learning curve steeper. Risk increases even if production still runs today.
Reducing Industrial Automation System Integration Risk with a Clear Plan
Reducing industrial automation system integration risk starts with stepping back. Teams need a clear view of the full system, not just the failing part. Thompson often helps teams decide whether small upgrades still make sense or if a broader plan is needed.
Incremental upgrades work in some cases. Small systems with limited inputs can often be replaced quickly. Larger systems are different. Hundreds of connections mean every change affects something else. Compatibility matters. Support matters. Future growth matters.
Thompson stresses honest conversations early. “You kind of just have to take a step back and see what they have there,” he said. That review helps teams balance cost, downtime, and long-term flexibility. Strong automation system integration planning lowers risk before it becomes costly.
How Better Automation System Integration Lowers Long-Term Risk
When teams address integration risk early, results follow. Systems become easier to maintain. Downtime drops. Safety improves. Staff spend less time troubleshooting and more time improving processes.
Strong automation system integration also supports growth. Ethernet-based networks, modern PLCs, and standardized designs make future changes easier. Operational risk in industrial automation decreases because systems are built to adapt, not patched to survive.
Another benefit is accountability. Thompson points to integrity as a core value in automation work. Doing the job right the first time builds trust and long-term value. When integration partners stand behind their work, teams gain confidence in every upgrade.
Conclusion
Industrial automation system integration risk does not start with a breakdown. It starts when systems grow without a plan. Small mismatches, aging parts, and lost knowledge all add risk over time. Operations leaders who address these issues early protect uptime and budgets.
David Thompson’s guidance shows the value of stepping back and seeing the whole system. With the right partner and a clear strategy, teams can reduce risk before failures happen. Smart integration choices today create safer, more reliable operations tomorrow.
About the Guest
David Thompson is an Automation Manager at Design Solutions and Integration. He has nearly 20 years of experience working across industrial, municipal, and energy automation systems. His focus is on practical solutions that reduce risk and improve reliability.
About the Company
Design Solutions & Integration (DSI) is a faith based, 100 percent employee-owned company with more than 25 years of experience in the oil and gas industry. With 125 employees and operations across the Bakken and Permian Basin, DSI delivers electrical, automation, fabrication, engineering, and turnkey field services. The company focuses on integrity, long term partnerships, and high-quality solutions built through a vertically integrated model. Learn more at www.relyondsi.com.
