In manufacturing, legacy software imposes fundamental operational limitations. Outdated ERP and MES systems tend to create data silos, limit operational visibility, and complicate integration with other tools and IoT devices by enforcing rigid data structures. They can also create dangerous latency in quality control and equipment monitoring as a result of batch data processing, sometimes with intervals of several hours.
Combined with a reliance on spreadsheets, this ecosystem falls short of meeting the real-time, data-driven demands of modern manufacturing.
The data silos, lack of transparency, and integration difficulties also contribute to the “reality gap", the discrepancy between the assumptions of a legacy planning system and the realities of production.
Legacy planning systems often operate on flawed assumptions, fixed lead times, zero equipment failures, and a fully staffed, fully efficient workforce. In contrast, real production environments are complex and messy: machines break down, employees call in sick, and numerous variables cause delays and inefficiencies.
Over time, the reality gap grows as planners create unrealistic expectations without experiencing the consequences of their actions. Teams struggle to complete initiatives and often feel they’re spread too thin when their planned outcome is tied to an equation where everything works perfectly.
This undermines morale and creates tension between departments, ultimately affecting the ability to deliver high-quality results over time.
Along with creating a false sense of reality, legacy systems also hinder the agility of manufacturers and their Industry 4.0 transformation.
At the core of this problem lies poor data utilization. When legacy systems leave manufacturers with incomplete, outdated, or siloed data, it becomes challenging to act quickly or confidently.
This is a widespread challenge:
Transitioning to Industry 4.0 presents manufacturers with complex challenges, encompassing both technological and organizational aspects. The limitations of existing legacy software systems amplify these challenges:
To effectively transition to Industry 4.0 manufacturing, real-time data exchange and automated process coordination are essential for successful implementation.
By replacing traditional systems with modern digital management platforms that provide real-time visibility, you can prevent reality gaps and overcome organizational silos.
One of our clients, Fläkt Woods, realized they had communication gaps across their organization, with relevant data sometimes going unused for up to 24 hours. Chris Mousley, Manufacturing Improvement Manager at Fläkt Woods, shared:
“There were endless pieces of paper being printed out from daily to weekly activities, and inevitably, there was much outdated information.”
One key challenge was the difficulty in communicating issues quickly and efficiently from the shop floor to the management team.
To address this, Fläkt Woods implemented Mevisio’s digital board software to modernize communication and streamline issue escalation across teams and departments. As a result, they now track issues more effectively and have successfully applied lean methodologies to support continuous improvement efforts. The improved transparency has also helped the team better understand how their work contributes to the bigger picture.
“There is a solution available to take over from the traditional lean gemba walk and visual planning management boards that ticks all the boxes that lean requires. For me, the future of it all is in Industry 4.0, and technology is the way forward”, Mousley said after implementing Mevisio.
Read the Fläkt Woods case: Fläkt Woods leverages Mevisio to enhance daily & lean operations