Welcome to our new weekly series, The Industrial Revival. Over the next four weeks, we will publish research-based reports examining the intricate and often overlooked realm of industrial machinery. Our objective is to equip non-engineering professionals—particularly those engaged in procurement and management—with the knowledge required to make informed, strategic decisions.
The Unseen Story of Your Machinery
Every used machine carries a unique history. This history is reflected not only in visible signs such as rust or the sound of its gears but also in its very foundation—the control and automation systems. For many enterprises, acquiring a used machine is considered a prudent financial decision, offering a high-value asset at a fraction of the cost of new equipment. However, beneath the surface of such transactions can lie latent risks—hidden costs that gradually erode operational efficiency and profitability.
This is the central focus of the initial phase of our series: unveiling the concealed financial and operational burdens associated with obsolete control systems. We will demonstrate why the purchase price is often merely the starting point of a machine’s overall cost.
The Agenda for Weeks 1–4
Week 1: The Hidden Cost of Old Machinery – More Than Just the Purchase Price
This opening report will challenge conventional perceptions of machinery cost by introducing the concept of Total Cost of Ownership (TCO). We will analyse how unplanned downtime, costly repairs, and reduced operational efficiency can transform an apparent bargain into a financial liability.
Week 2: Is Your Machine Speaking a Dead Language? – Decoding Obsolete Control Systems
This report will examine the pivotal role of control systems, distinguishing between outdated, unsupported models and modern, integrated solutions. We will illustrate how obsolete systems hinder interoperability with contemporary machinery and how lack of manufacturer support can leave operations vulnerable.
Week 3: Why the Best Operator Cannot Overcome a Flawed System – The Bottleneck of Outdated Controls
Through an in-depth case study, we will demonstrate how the mechanical potential of a machine can be significantly limited by antiquated control systems, regardless of operator expertise.
Week 4: The Unseen Risk – How Obsolete Systems Impact Safety and Compliance
The concluding report in this segment will address the critical safety and regulatory implications of using machinery equipped with outdated systems. We will outline how such systems often fall short of current safety standards, placing both personnel and organisational compliance at risk.
We invite you to engage with this series and deepen your understanding of the machinery that drives your operations. Each report will empower you to evaluate equipment beyond its purchase price, ask the right questions, and make decisions that safeguard both performance and profitability.
About the Author
Byron Nyasha is an Automation and Control Engineer with a Bachelor’s degree in Electronic Engineering from National University of Science and Technology (NUST) Zimbabwe. With over a decade of professional experience in the mining and manufacturing sectors, he specialises in the design, implementation, and maintenance of industrial automation systems. His competencies extend to project management, pre-sales, and after-sales support, with a particular emphasis on sustainable solutions tailored to the needs of developing economies. He can be reached at +263 775 769 903.