By Seth Rang, PE
Project Manager
Water & Environment
In today’s rapidly evolving industrial landscapes, the demand for skilled professionals in Programmable Logic Controllers (PLCs), Human Machine Interfaces (HMIs), Supervisory Control and Data Acquisition (SCADA) systems, and industrial automation is growing. However, an alarming trend is emerging where the number of qualified personnel familiar with these critical systems is steadily declining. This skills gap presents significant challenges for industries relying on automation for efficiency, reliability, and safety.
The Growing Skills Gap in Industrial Automation
There are several factors contributing to the shortage of professionals skilled in automation and control systems:
- Aging Workforce – Many experienced engineers and technicians who have built their careers around industrial automation are retiring, leaving behind a knowledge vacuum that younger professionals have yet to fill. This loss of institutional knowledge makes it difficult for organizations to maintain their systems efficiently, as replacing decades of expertise is no easy task. Additionally, this retirement wave is happening faster than industries can train and onboard new talent, exacerbating the skills shortage.
- Declining Enrollment in Technical Trades – The push toward four-year degrees has led to a decrease in enrollment in technical and vocational programs that traditionally have produced automation specialists. Many high schools and community colleges have reduced their focus on industrial trades, leaving fewer opportunities for students to develop hands-on experience with automation technologies. As a result, the pipeline of new automation professionals entering the workforce is insufficient to meet future industry demand.
- Evolving Technology – Rapid advancements in industrial automation require continuous learning. However, many organizations struggle to provide adequate training to keep their workforce updated. Traditional controls systems are being integrated with newer technologies such as Industrial IoT, AI-driven analytics, and cloud-based monitoring, making it crucial for professionals to stay ahead of the learning curve. Organizations that fail to invest in ongoing training risk falling behind in efficiency and reliability due to experiencing longer downtimes.
- Competition from Other Industries – With the rise of digital transformation, automation professionals are frequently being recruited into IT, AI, and other high-tech fields, reducing the available workforce for industrial sectors. Industries such as software development, cybersecurity, and data science offer attractive salaries and opportunities, drawing talent away from traditional industrial automation roles. This competition for skilled workers further intensifies the challenge of maintaining a reliable workforce in areas such as manufacturing, utilities, and other industrial sectors.
The Impact on Industrial Operations
The decline in skilled personnel directly affects operational efficiency, safety, and system reliability. Manufacturing plants, water and wastewater facilities, and energy companies are experiencing increased downtime, delays in troubleshooting, and rising costs due to the lack of experienced automation professionals.
Without proper expertise, companies risk misconfigurations, ineffective programming, and unstable quick fixes in their control systems. This can lead to serious operational consequences, including compliance issues, environmental risks, and production inefficiencies.
How KCI Can Help
As industries struggle to find qualified professionals to maintain and optimize their automation and control systems, our firm stands ready to bridge this gap. We offer:
- Troubleshooting – Our experienced staff can quickly diagnose and resolve system issues, minimizing downtime and keeping systems operational. We work with a variety of systems and configurations and can confidently handle complex challenges.
- Programming and System Optimization – We provide skilled programming for PLC, HMI, and SCADA systems, to keep your processes running efficiently and securely. Whether it’s modifying existing code, creating new automation logic, or optimizing system performance, our specialists bring solutions tailored to your unique operational needs.
- Training and Knowledge Transfer – To address the skills gap, we can offer customized training programs for in-house personnel to help organizations build internal expertise. Our training sessions can be customized to range from beginner-level introductions to advanced troubleshooting techniques based on the existing level of experience of the personnel.
- On-Demand Support – Our team is available for emergency troubleshooting, upgrades, and consulting services to ensure our clients’ automation systems remain robust and reliable. We can provide remote or on-site assistance, reducing interruption and maintaining operational continuity.
- System Upgrades and Migration – With the constant evolution of industrial technology, we assist companies in upgrading outdated control and monitoring systems, allowing them to remain compatible with modern requirements. Our migration strategies minimize disruptions while enhancing system capabilities.
Future-Proofing Industrial Automation
To combat the ongoing shortage of skilled professionals, industries and organizations must take proactive steps, including investing in training, partnering with automation experts, and embracing new technologies that streamline operations. By leveraging external expertise, companies can maintain efficiency and reliability while working to develop the next generation of automation professionals.
KCI is committed to supporting industries through these challenges. With a team of highly skilled engineers and automation specialists, we provide critical solutions that keep operations running smoothly. Contact us today to learn how we can help your organization navigate the evolving landscape of industrial automation.
