A focused on-site OT assessment that delivers a complete asset inventory, prioritized recommendations, and a phased modernization roadmap. Weeks, not quarters.
Plants our engineers have stood on
You know the bottleneck is somewhere on Line 3. You know maintenance is reactive. You know there is data trapped inside legacy PLCs that nobody on your team can actually get to.
But you can't prove any of it. Not with numbers. Not in a way the P&L will respect. That is because most plants have no real OT foundation underneath them.
What is missing today
What the assessment changes
You can't fix what you can't see. And you can't see what third-party integrators are sitting on.
Not a slide deck. Three artifacts you can hand to corporate, to your cyber team, and to whoever signs the capital request.
Inventory
Every PLC, drive, sensor, and network asset documented. IT/OT topology mapped. Gaps and risks flagged. The artifact your engineering and maintenance teams have never had on paper.
Recommendations
Prioritized actions ranked by impact and effort. What to fix this quarter. What to plan for next year. What to leave alone — because not every finding is worth a project.
Roadmap
A phased modernization plan that moves you from no real-time visibility to predictive maintenance, real-time OEE, and OT data flowing into your ERP — in a sequence your floor can absorb.
The method is built on 30+ years of controls engineering and 1,900+ automation projects across Fortune 500 industrials and regional manufacturers. It runs in the same order every time, because the order is what makes it safe.
The foundation
We start with what is already on your floor. Segment your OT network. Inventory every asset. Stand up read access into PLCs over OPC UA and MQTT. Layer in Opto 22 RIO sensors for vibration, current, and temperature where you are flying blind.
The visibility
Ignition and on-prem SQL become the data layer your team owns. Real-time OEE. Downtime analysis. Condition monitoring. Operator dashboards that show the floor what the floor is actually doing.
The outcome
Predictive maintenance driven by data, not the calendar. Bottleneck targeting and cycle-time reduction. Multi-site rollouts built from templates, not snowflakes. OT data flowing into ERP, finance, and S&OP.
How we stood up a complete monitoring solution at Batesville Casket's Vicksburg plant — three shifts, running on paper, with the PLCs owned by somebody else.
The situation
No real-time visibility. No downtime analysis. No predictive signals. Data was locked inside legacy PLCs managed by third-party integrators. Plant leadership had no real access beyond the machine itself.
The complication
There was no enterprise OT foundation to build on. No asset inventory. No IT/OT segmentation. No standard for adding equipment. No platform their own team owned.
The resolution
A segmented OT network built with Dynex. Ignition plus on-prem SQL over OPC UA. Opto 22 RIO sensors on two saws monitoring vibration, current, temperature, photo-eye, and e-stop. Live within one week of equipment arrival.
$50–100K
avoided when vibration data caught a failing bearing
1 week
from equipment arrival to live monitoring
Low risk. Defined scope. You get a complete picture of your plant without signing a six-figure software contract first.
Weeks, not quarters. We are on the floor, in your network, and delivering recommendations on a timeline that matches plant reality.
A fixed fee quoted against a written scope, with labor and travel broken out line by line before you sign. No open-ended discovery, no surprises.
We are not a SCADA vendor trying to sell you more SCADA. We are not a strategy deck. We are plant operations people, controls engineers, and integration architects who have stood on the floor at Trane, Abbott, MacLean-Fogg, and Ajinomoto.
Magic Consulting, Magic Engineering, and Magic Integration are divisions of Magic Software Americas under one P&L. The OT engineering, the enterprise integration, the application work and the operational strategy are all in-house. No layer of this gets subcontracted, so there is no seam for a problem to hide in.
The combined group
15,000+
professionals
6,000+
customers
50+
countries
1,000+
business partners
1,900+
automation projects
1983
in business since
Credentials on the floor
CESMII is the U.S. Department of Energy-backed Smart Manufacturing Institute. Its CEO, John Dyck, described the Magic-Axiom collaboration as “the kind of partnership needed to drive the industry forward,” citing its potential to bring scalable and sustainable innovation to U.S. manufacturing.
Magic Software press release, July 15, 2025.
OT Assessment
Fixed fee, quoted to scope
Labor and travel broken out before you sign. Priced per plant.
Includes:
Need ongoing support across multiple sites? Ask about pre-funded support agreements with response-time SLAs and dedicated capacity.
Typical engagements run four to six weeks from kickoff to final roadmap delivery, including on-site time at your plant.
Better. We are platform-agnostic and build on what works. The assessment will tell you what to keep, what to extend, and what to retire.
No. The assessment is independent, and so is the recommendation. We recommend the right tool for your floor, not necessarily one of ours. The findings are yours to act on however you choose — with us or with someone else.
You get a roadmap. From there, most plants choose to engage us on Phase 1 implementation, but you are under no obligation. Some move to a pre-funded support agreement for multi-site work.
No. The assessment is read-only and non-invasive. We are inventorying and observing — not touching control logic.
Where this leads
Understand
Real-time OEE, downtime analysis, and condition monitoring on a data layer your team owns.
Read itConnect
When corporate IT needs segmentation, patch management, and an audit trail that reaches past the IDF.
Read itOutperform
Tie machine events to production, quality, and the ledger so finance can see true cost per part.
Read itThirty minutes to scope your assessment. Bring the line that keeps surprising you and whatever documentation you already have — we'll tell you what the on-site week would cover and what it would cost.
Prefer to pick a time yourself? Book a call directly.
