Replace WinCC
Replacing or modernising an ageing Siemens WinCC installation with a web-based system that connects to your existing PLCs, cloud or IoT platforms. Appfront builds the new visualisation, integration and data management layer while your existing control system stays intact, phased in and running in parallel with the old system for as long as needed.
What does replacing WinCC involve?
Siemens SIMATIC WinCC is SCADA/HMI software used to visualise and operate industrial processes, from production lines to process plants. Many companies still run an older variant such as WinCC Classic or WinCC flexible, often configured years ago to order by an integrator who is no longer available.
Older systems are replaced for a few concrete reasons: knowledge of the specific scripts and configuration becomes scarce, extending or changing them takes more and more time, and integration with modern cloud or IoT platforms is difficult or impossible with the original architecture. Siemens offers a newer platform itself with WinCC Unified, but a move is also the moment to choose a fully custom visualisation layer that fits exactly how your organisation works, rather than being tied to a single supplier again.
Replacing WinCC belongs to the same family as other legacy migrations we carry out, such as modernising Delphi applications, replacing COBOL systems and replacing AS400 platforms: different systems, the same careful approach of inventorying, rebuilding and migrating in phases.
Outdated visualisation
WinCC Classic and flexible are no longer the current standard, and adding new functionality is becoming increasingly cumbersome.
Scarce knowledge
Specialists who still know the original configuration are becoming harder to find, which makes maintenance risky.
Limited cloud integration
The original architecture was often not built for integration with modern cloud or IoT platforms.
How we approach a WinCC replacement
We always start with a thorough inventory of what is running now, so nothing is overlooked during the transition.
We map the current screens, tags, alarms and integrations with PLCs and other control systems, including what is hidden in scripts and configuration.
We design the new visualisation layer and the integration with your PLCs, usually via open protocols such as OPC UA or Modbus, and decide where data is stored and exposed.
We build the new system and, where possible, run it in parallel with the existing WinCC system, so operators can get used to it and measurements can be verified.
After verification, we switch over to the new system in phases and decommission the old WinCC system, with documentation and handover to your own team.
What we deliver in a WinCC replacement
The exact scope depends on your current installation and requirements; below are the components that almost always come up.
Web-based visualisation
A modern, responsive visualisation layer that can be consulted on the shop floor and remotely, without installation on every workstation.
PLC integration
Integration with your existing PLCs via open protocols such as OPC UA or Modbus, so the control hardware stays unchanged.
Historical data & trends
Measurement values are stored and made accessible as trends and reports, usable for analysis beyond the shop floor.
Alerting
Alarms with prioritisation and notifications, so deviations on the shop floor are noticed and followed up in time.
User roles & permissions
Access to screens and control functions based on role, so operators only see and do what their task requires.
Cloud or on-premise
You choose whether the new system runs fully on-premise, in the cloud, or hybrid, in line with your IT policy and network requirements.
Who replacing WinCC is relevant for
Mainly for organisations where the current system has become a growing risk or constraint.
Manufacturing and process industry
Companies with ageing WinCC installations on production lines or process plants that are due for replacement.
Companies that want to move to the cloud
Organisations that want to connect production data to cloud or IoT platforms, which is difficult with the original WinCC architecture.
Organisations with scarce WinCC expertise
Companies where the specialist who originally configured the system is no longer available, making maintenance risky.
Companies that want to reduce vendor lock-in
Organisations that prefer an independent, maintainable visualisation layer rather than being tied to a single supplier again.
Technology in a WinCC replacement
We prefer open, vendor-independent protocols, so you don't get locked into a single ecosystem again.
Why Appfront for replacing WinCC?
We start with a thorough inventory of your current installation, so nothing is overlooked: screens, tags, alarms and the integrations that keep your process running.
We build the new layer with open protocols and clear documentation, so your own team or a future partner can understand and manage the system. No black box, but an architecture you can explain yourself.
See also our approach to other legacy migrations: modernising a Delphi application, replacing a COBOL system and replacing AS400, or our wider custom software development.
- Thorough assessment before development
- Integration via open protocols such as OPC UA and Modbus
- Parallel running possible during the transition
- Experience with other legacy migrations (Delphi, COBOL, AS400)
- Clear documentation for your own team
- Cloud, on-premise or hybrid options
Securing your OT environment
A SCADA/HMI system connects directly to your production process, so security is addressed from the design stage: network segmentation between IT and OT, role-based access to control functions, and an architecture that can be patched without disrupting the process.
You can read more about our approach to information security in our information security policy. Discuss your situation with no obligation via our contact form.
- Network segmentation between IT and OT
- Role-based access to control functions
- Patchable architecture without process disruption
- Logging of changes and access
Frequently asked questions about replacing WinCC
Answers to the questions we are asked most often.
WinCC is Siemens' SCADA/HMI software for visualising and operating industrial processes. Businesses replace older versions such as WinCC Classic or WinCC flexible because knowledge of the old configuration becomes scarce, maintaining custom scripts is expensive, and integration with modern cloud or IoT platforms is difficult with the original architecture.
It can be phased. We first inventory which screens, tags and integrations are most critical and build those first. The new system can run alongside the old one for a while, so you can compare before fully switching over.
Yes, that's the starting point. We rebuild the integration with your PLCs, usually via open protocols such as OPC UA or Modbus, so the new visualisation layer keeps communicating with the same control hardware.
This page is specifically about WinCC, but we modernise legacy systems more broadly. See also our pages on modernising Delphi applications, replacing COBOL systems and replacing AS400 platforms: different systems, the same approach of careful assessment and phased migration.
Yes. We usually deploy the new visualisation in parallel with the existing WinCC system first, so operators can get used to it and you can verify that measurements and control are correct before the old system is phased out.
Yes. A modernisation is often the perfect moment to also make production data available for dashboards, reporting or analysis beyond the shop floor, via a cloud or on-premise integration that fits your IT policy.
We build custom software around your existing installation and PLCs. We are not a Siemens licence reseller; our work is designing and building the replacement visualisation, integration and data management layer.
Ready to replace your WinCC system?
Tell us what your current WinCC installation looks like: which PLCs, which screens and which integrations. We'll help you plan a phased transition to a modern, maintainable visualisation layer.