The hard truth is that these legacy systems are no longer sustainable. They may still function day to day, but each year brings increasing maintenance costs, cybersecurity vulnerabilities, and efficiency limitations. Upgrading isn’t just about keeping up with technology. It’s about ensuring operational resilience, reducing long-term costs, and freeing your business from dependence on a dwindling pool of legacy system experts. Here are a few examples of those systems:
Many plants still rely on Ignition SCADA systems, which remain embedded in their operations due to the vast amounts of proprietary logic and plant-specific integrations they contain. These systems are deeply interwoven with PLCs, custom dashboards, and production data. However, upgrading is far from simple. Compatibility issues with outdated hardware and software, custom scripting dependencies, and the fear of disrupting production all create strong resistance to change. The few engineers who understand these systems command high consulting fees, making maintenance an expensive, short-term fix rather than a sustainable solution.
Similarly, Visual FoxPro and FoxPro-based custom applications are still powering inventory management and job tracking systems across smaller and mid-sized manufacturers. FoxPro was discontinued long ago, and the people who once developed and supported it are now a vanishing breed. When a FoxPro database breaks or is corrupted, finding someone capable of repairing it can be nearly impossible. And when you do, the cost of that expertise often exceeds the price of building a modern solution from scratch.
Microsoft Access databases present another common challenge. Once a quick and flexible way to manage reports and workflows, many Access-based systems are now decades old. They weren’t designed for cloud connectivity, secure data handling, or multiuser access, yet they still function as critical “glue” within plant operations. These outdated Access applications frequently lack proper version control, backup protocols, or integration options, leaving companies exposed to security risks and system failures.
Old Microsoft SQL Server editions, like 2000, 2005, and 2008, also remain a backbone for many custom manufacturing applications. While the database engine may still run, the code, triggers, and schemas surrounding it are often so customized that upgrading risks breaking critical functionality. As Microsoft phases out support for these versions, maintaining them becomes a high-cost, high-risk game of patching and workaround engineering.
The situation is no better for systems running Sybase Adaptive Server Enterprise (ASE) or Informix databases. These platforms once provided solid reliability for ERP and process systems, but their decline in market presence has made skilled support rare and expensive. Companies relying on them face increasing modernization pressure, yet the cost and complexity of migration often cause delays that create a cycle of dependency on aging infrastructure that grows riskier each year.
Legacy ERP and MES suites, such as old installations of JD Edwards OneWorld, Baan, Lawson, or even early SAP ECC, persist because of the massive customization and regulatory validation once built into them. Unfortunately, these older systems cannot easily accommodate modern analytics, cloud integration, or AI-driven optimization. As their technical foundations age, the cost of maintenance rises sharply, with every patch or update requiring specialized expertise that comes at a premium.
Finally, custom Visual Basic 6 and early VB.NET applications remain common across factory floors, often serving as the backbone for reporting, scheduling, and machine control. These “homegrown” systems have been patched, modified, and stretched far beyond their intended lifespan. Their dependence on obsolete SQL schemas and flat reporting tables makes them fragile and nearly impossible to extend. Developers capable of maintaining these applications are few, and most are nearing retirement, leaving companies vulnerable to critical skill gaps.
At FocustApps, we specialize in helping manufacturers make this critical transition. Our team can take what you already have: your existing data, workflows, and system logic, and modernize it with custom-built software designed for today’s technology landscape. Whether you need to integrate outdated databases into a cloud environment or completely rebuild legacy applications, FocustApps delivers scalable, future-ready solutions that enhance performance, security, and productivity—without the pain and premium price of maintaining the past. To learn more, call Becky Faith today at 502.465.5104.