At a Glance
2026 brings rising lifecycle pressure, tighter cybersecurity expectations, leaner teams, and shifting supply chains—making targeted upgrades more important than ever.
Industrial automation evolves every year, but 2026 introduces a level of change that teams can’t overlook. Not because of new product launches, but because several longstanding pressures—lifecycle limits, cybersecurity expectations, leaner staffing, and supply chain constraints—are converging in ways that directly influence how plants operate and plan for the future.
Over the past two years, several control platforms have reached key stages in their lifecycle, and spare parts for aging systems remain scarce as vendors focus on modern hardware. Meanwhile, changes in Windows support and stricter IT/OT cybersecurity standards mean that older control system versions might no longer meet baseline requirements, prompting earlier upgrade discussions.
With leaner teams and rising expectations for plantwide visibility, many organizations are reevaluating whether their current systems can support long-term reliability.
This post highlights the key industrial automation trends of 2026 and what they mean for reliability, staffing, and modernization planning—so you can direct your efforts where they will have the greatest impact.
Trend 1: Lifecycle Pressure Finally Reaches a Tipping Point
For years, end-of-life notices have been easy to delay. But in 2026, lifecycle pressure shifts from being theoretical to practical.
What’s Driving the Shift
- Legacy hardware availability is becoming more limited. Long-established PLCs, I/O families, and HMIs are more difficult to source as inventories shift to newer platforms.
- Multiple platforms are reaching key milestones in their lifecycles.
Siemens S7-300/ET 200M phaseout and Rockwell discontinuing RSLogix 5 licensing are examples of pressure points now impacting the plant floor. - Aging systems now pose a greater risk of downtime.
With limited spares, a single failure can trigger unplanned migration.
Why This Matters to Plant Leaders
Lifecycle pressure affects outage planning, spare strategies, compliance, and the speed at which teams can recover from failures.
What to Do Now
Identify systems where a single failure would halt production and verify spare availability. Rising lead times and inconsistent inventory signal modernization priorities for 2026
Trend 2: Cybersecurity Now Drives Modernization Decisions
Cyber requirements have become a primary factor in upgrade timing. Older control systems often can’t meet today’s security expectations without modernization.
What’s Changing
- Unsupported Windows versions are no longer viable. Many legacy HMIs and servers run OS versions that reached end of support in 2023–2024.
- Stricter IT/OT standards are being enforced. Expectations around patching, MFA, and supported software now apply to control systems.
- Older platform versions can’t keep up. Many legacy releases cannot run on supported OS baselines.
Why This Matters to Plant Leaders
Unsupported systems create security and compliance gaps, and IT may require upgrades during audits.
What to Do Now
Map system versions to your site’s security requirements. Any mismatch becomes a priority for 2026 planning.
Trend 3: High-Availability and Modular Architectures Move to the Mainstream
Modern architectures are now a practical response to reliability and staffing pressures—not just a premium option.
What’s Changing
- Redundancy is more accessible. Modern PLC and DCS families simplify high-availability configurations.
- Modular I/O reduces downtime risk. Distributed designs make it easier to isolate issues and replace hardware quickly.
- Mixed-vendor environments are easier to support. Open protocols improve interoperability without heavy integration work.
Why This Matters
These architectures reduce single points of failure, improve recovery time, and make phased modernization feasible.
What to Do Now
Flag areas where a single failure would cause extended downtime and evaluate modular or redundant alternatives.
Trend 4: Workforce and Resourcing Shifts Are Reshaping Modernization Strategy
Plants are moving into 2026 with smaller teams and fewer in-house specialists. This directly impacts modernization priorities.
What’s Changing
- Teams are operating with fewer technical personnel. Maintaining complex legacy systems is increasingly challenging.
- More work depends on outside support. Plants rely more on integrators for updates, troubleshooting, and lifecycle planning.
- Modern architectures reduce support burden. Simpler, standardized platforms are rising to the top of upgrade roadmaps.
Why This Matters
Lean teams require systems that are easier to support. Phased, standardized upgrades help prevent overwhelming internal resources.
What to Do Now
Utilize each upgrade to streamline architectures and unify controls so current and future teams can support them confidently.
Trend 5: Supply Chain Realities Favor Modern Platforms
Supply chains have become more stable in some areas, but legacy hardware still remains unpredictable.
What’s Changing
- Distributors are stocking fewer legacy components. Older PLC modules, I/O cards, and HMIs continue to decline in availability.
- Lead times for older parts remain inconsistent. Modern families are better supplied, but legacy components are not.
- Failing legacy hardware creates unplanned risk. Parts scarcity can turn minor failures into extended downtime.
Why This Matters
Spare strategy turns into a risk-management activity. Plants are increasingly focusing on upgrades to lessen reliance on hard-to-source hardware.
What to Do Now
Review spare-part strategies and flag components with long or uncertain lead times. These systems are prime candidates for phased modernization.
A Clearer Path Forward in 2026
The factors shaping 2026 are practical and immediate. While no plant can modernize everything at once, small, focused improvements can effectively reduce risk and enhance reliability. Updating a key component, simplifying an architecture, or planning a phased migration all help build the foundation for long-term stability.
If you’re exploring how these trends affect your facility, Pigler can help you understand options, compare pathways, and plan upgrades that meet real-world constraints. The aim isn’t perfection—it’s confidence, clarity, and a solid foundation for the years to come.
Let’s Solve Your Automation Challenges Together
Whether you’re planning upgrades, tackling system issues, or looking for clarity on your next steps, we’re here to help.
Let’s Solve Your Automation Challenges Together
Whether you’re planning upgrades, tackling system issues, or looking for clarity on your next steps, we’re here to help.
