Industrial automation engineers, systems integrators, plant managers, and those responsible for implementing Industrial Internet of Things (IIoT) solutions in manufacturing environments will find this episode both informative and practical. Hosts Phil Seboa and Ed Fuentes sit down with Jarith Fry, SCADA and Systems Engineering Manager at Highland Pine Products, to discuss the real-world steps involved in upgrading legacy automation systems, leading technology-driven change among long-serving staff, and building a collaborative, knowledgeable technical community. Key topics include the process of migrating outdated PLCs and drives to a scalable SCADA platform, strategies for upskilling a traditional workforce, and the importance of sharing innovation beyond company walls.
Modernizing Legacy Equipment: Bringing Manufacturing into the 21st Century
Highland Pine Products operated for decades on outdated PLC 5s, SLC 500s, and legacy drives. Jarith Fry explains the necessity and challenge of moving away from end-of-life controls: “Most of our equipment is still running off of old PLC 5s and 1336 drives... all equipment that have been deemed end of life by their manufacturer.” To address reliability and scalability, Fry led a migration to the Ignition SCADA platform, which allowed for improved data acquisition, easier operator training, and more robust diagnostic capabilities.
The modernization went beyond replacing a few components. The upgrade involved a complete overhaul of critical process areas, as Fry recounts: “We put in what’s called an extended length infeed that has scanning and optimization solutions to it, but also runs through our giant quad band saw.” By deploying new Allen-Bradley PowerFlex 755TS drives, they not only improved machine control but also enabled predictive maintenance and greater transparency into production. As a result, the company gained deeper operational insights and better positioned itself for future growth and efficiency.
Upskilling Traditional Workforces: Managing Change and Building Confidence
Technology upgrades rarely succeed without organizational buy-in. Fry describes the reality of introducing new tools to staff who are deeply familiar with the status quo: “Electricians… have been here thirty years. They know these old devices. They know how they work. They know how to set them up. They’ve been trained on them, and so they feel comfortable with it. And when you start introducing those new concepts… it starts to scare them.”
Recognizing this, Fry invested in regular, accessible training—leveraging both proprietary and community-developed resources. By involving electricians and operators in code reviews, troubleshooting, and workflow revisions, Highland Pine has gradually shifted attitudes from skepticism to engagement. “As we’ve started to implement more regular training with them… Those companies have produced online training that we can assign to our electricians. So when they’re not dealing with breakdowns, they can actually sit in a room and go through the online training and get their own benefit from that,” Fry points out.
A key tool in this process has been Copia, a Git-based revision control for PLCs, which empowers staff to see what changed and why, strengthening both confidence and collaboration: “It actually allows us to see side by side what’s changed from day to day. So if electricians are getting in and changing things inside the code, we know everything went to crap on Tuesday. Why?”
Community Sharing and Open Technical Innovation: Making Progress Together
Fry firmly believes technical progress is most effective when innovations are shared. After building a downtime tracking and event management system suited to Highland Pine’s needs, Fry began preparing the tool for public release as a module for Ignition, helping others avoid “reinventing the wheel.” He emphasizes the value of community-driven development, saying, “I’m currently in the process of taking this project and developing a module for it so we can release it into the community more easily… I think it’s more important that we have developers that have really good experience and good programming practices coming into the community.”
Fry’s philosophy extends beyond code. He encourages open communication—linking up with peers via LinkedIn, forums, and technical groups to share tips and practical resources. According to Fry, this is especially important for smaller plants or mills with limited resources. “They’re the guys that need the most help, because it’s usually one controls or systems engineer on-site trying to take care of an entire mill all by themselves, and they don’t have the time to go and make this stuff.”
Key Quote From The Episode
“It gives us an opportunity to upskill them and bring them into the new era.” – Jarith Fry
Key Takeaways
Legacy equipment upgrades driven by necessity can spur significant improvements in data visibility, predictive maintenance, and reliability.
- Training and incremental engagement are essential for easing veteran staff into new tools and workflows—combining technical resources with day-to-day support.
- Contributing code modules and practical solutions to the community shortens the learning curve for others and creates a useful network of innovation, especially for smaller operators.
Wrap Up
The experience at Highland Pine Products illustrates that meaningful technology upgrades in industrial settings call for foundational changes both in hardware and in how people work. Moving from outdated PLCs and drives to a scalable, modern SCADA platform opens the door to improved reliability, data-driven decisions, and streamlined maintenance. Achieving these gains depends on equipping staff for new workflows and fostering collaboration rather than resistance. Finally, technical progress on the shop floor multiplies its value when shared—open-source tools, practical modules, and peer support make modernization realistic for resource-constrained sites.
For readers interested in similar progress, consider:
- Conducting risk assessments of your legacy control assets.
- Prioritizing continuous staff education, pairing formal training with hands-on involvement.
- Engaging with IIoT and automation forums to access, share, and request practical resources.
- Considering ways your team's innovations might help the broader community.
About the Guest
Jarith Fry is SCADA and Systems Engineering Manager at Highland Pine Products, based in Oberon, New South Wales. With a background in mechanical engineering and robotics from Eastern Washington University, Fry has moved from integration roles in the US to leading modernization projects for end users in Australia. He contributes technical solutions and support to the global engineering community, emphasizing practical learning and collaborative progress.
