A SCADA (Supervisory Control and Data Acquisition) system is a computer-based system for visualizing, analyzing, and controlling process data. It belongs to operational technology (OT) and, unlike traditional process control systems, is designed to centrally manage widely distributed plants. As part of the management level, SCADA connects the process level with IT and creates a continuous data flow along the automation pyramid.
The heart of the system is SCADA software, which links all automation levels together. At the field level, sensors and actuators continuously collect process data such as temperature, pressure, or fill level. This data is forwarded to the control level—usually to programmable logic controllers or regulators.
Standardized communication protocols such as OPC UA or Modbus ensure that the recorded data is transferred to the control level, where it is visualized, analyzed, and archived in real time. This provides a clear picture of the current plant status, including all relevant measured values, warning messages, and time series.
SCADA systems are traditionally operated via local control devices such as human-machine interfaces (HMIs), which are located directly on site at the plant, or automation systems with touch panels. Modern SCADA solutions increasingly offer web-based access options, allowing operators to access the visualization and control of the systems via common Internet browsers or specialized web clients.
This flexibility not only enables access from various end devices such as PCs, tablets, or smartphones, but also secure remote access from external locations. This requires appropriate security measures such as encrypted connections, VPNs, and access controls to ensure the integrity and confidentiality of the process data.
SCADA systems offer a variety of advantages that relate to both technical and economic aspects. These include:
One of the biggest advantages of a SCADA system is the continuous monitoring of all connected processes and systems—in real time and from a central control station. Operating states, measured values, alarms, and events are continuously recorded, visualized, and documented. This enables operating personnel to respond early to deviations, errors, or safety-related events before they have a negative impact on operations. Downtime, production losses, or damage to machines can thus be minimized and plant availability increased.
SCADA systems record and archive large amounts of process data over defined periods of time. This history is a valuable basis for downstream analyses – for example, to investigate the causes of errors, optimize energy consumption, or improve production processes. In addition, many SCADA solutions support export to formats that can be easily integrated into business intelligence tools or management systems such as MES or ERP.
A SCADA system can usually be easily integrated into existing automation structures. It communicates with a wide variety of controllers, sensors, or field devices via standardized protocols (such as OPC?UA, Modbus, or SPE), even if these come from different manufacturers. This creates a consistent, interoperable overall system without having to completely replace the existing infrastructure.
Thanks to extensive diagnostic and alarm functions, a SCADA system helps to increase operational reliability. Critical conditions—such as limit value exceedances, pump failures, or communication errors—are automatically detected and reported to the responsible parties. In conjunction with redundancy concepts and user roles, security requirements and access controls can also be implemented efficiently.
A well-planned SCADA system has a modular structure and can therefore be flexibly expanded for digital transformation. New machines, sensors, or entire plant components can usually be integrated without great effort. This makes the solution future-proof, especially in times of growing demands from Industry 4.0 or IoT. As SPS-MAGAZIN reported back in 2014, modern SCADA systems are considered the backbone of digitally networked production processes.
Many modern SCADA systems also enable secure access to process data via VPN or web clients. This is particularly advantageous for companies with multiple locations or for plants that are operated across different geographical areas (e.g., in the energy or water industry or smart city mobility). Service personnel can thus perform diagnostic functions remotely or intervene at short notice without having to be on site.
All events, status changes, and operator interventions are automatically logged. This ensures complete traceability in terms of quality assurance, auditing, or regulatory requirements—for example, in the areas of food safety, energy supply, or environmental technology. Even in the event of errors or accidents, it is possible to reconstruct exactly what happened and when.
SCADA systems and cloud-based solutions pursue similar goals—such as monitoring, controlling, and analyzing technical processes—but differ fundamentally in their architecture, application, security, and flexibility. Nevertheless, they are not direct competitors, but increasingly complement each other.
In 2024, SCADA technology was valued at $41.75 billion according to market research company Fortune Business Insights. This development is being accelerated by technological advances and ongoing digitalization.
The future of SCADA systems lies in modular, intelligent platforms that are closely networked with IIoT, cloud technologies, edge computing, and AI applications. Modern SCADA solutions no longer function solely as visualization and control tools, but as central data hubs for real-time analysis, remote access, predictive maintenance, and adaptive process optimization.
At the same time, openness (e.g., via OPC UA or MQTT), interoperability, and cybersecurity are becoming more important, for example, through the implementation of established security standards such as IEC 62443. In many industrial applications, companies are therefore increasingly relying on hybrid architectures. While SCADA remains responsible for real-time control locally, cloud-based systems take over higher-level data analysis, AI-based optimization, or mobile visualization.
The introduction of a SCADA system typically takes place in several coordinated phases—from the initial needs assessment to final commissioning. In order for such a project to be successfully implemented, a structured approach and consultation with a SCADA system specialist are essential.
The requirements analysis defines the specific objectives and framework conditions of the project. This includes questions such as which processes are to be monitored and controlled, which data points are to be recorded, which response times are required, and whether existing automation systems (such as PLCs or RTUs) need to be integrated. Requirements for security, availability, redundancy, and user rights are also included in the analysis. The results of this phase are recorded in a detailed specification sheet, which serves as the basis for all further planning steps.
Based on the defined requirements, a SCADA platform is selected that fits the existing infrastructure, is scalable, and provides all necessary functions. In addition, the control hardware (such as programmable logic controllers or remote terminal units), network components (e.g., switches, gateways, or firewalls), and the servers and operating devices for visualization and data storage are selected. The licensing model, maintenance contracts, and possible interfaces to existing IT systems (such as ERP or MES) are also taken into account in this phase.
Here, the entire structure of the SCADA system is designed – from the network topology and server and client structure to redundancy strategies, security concepts, and the integration of external systems. It is precisely defined which devices are connected at which points, how communication takes place, and how the system should respond to errors or failures. In addition, a project schedule with milestones, resource requirements, and responsibilities is created.
During the engineering phase, the previously defined system structure is implemented. The SCADA software is configured, data points are created, communication protocols are implemented, and visualizations are created—such as process images, flow diagrams, alarm cascades, and dashboards. User management with different access rights is also set up. If necessary, scripts are programmed to implement automated processes or calculations.
Software configuration is followed by system integration, i.e., the connection of the SCADA platform with the real field devices and controllers. This involves checking whether communication with sensors, actuators, and PLCs is working correctly. The connection between the control level and the management level is tested, data is transmitted live, commands are passed on correctly, and feedback is checked. Minor technical problems often occur during this phase, such as incorrect addressing or time delays in data transmission, but these can usually be quickly resolved.
Here, the entire SCADA system is tested under real conditions. Functional tests ensure that all visualizations are working correctly and that control elements are functioning as planned. Alarms are simulated to see if they are triggered and forwarded. Performance is also tested, for example, under high data loads or in redundancy scenarios. The test phase is crucial for operational safety and should be carefully documented. Only when all functions are running stably is commissioning carried out, usually first in observation mode, before the system goes into productive operation.
The operation of a SCADA system does not end with commissioning. In addition to training personnel and creating documentation, continuous maintenance is necessary to ensure long-term system stability, security, and performance. This includes regular software updates, checking communication with field devices, backing up data, and adapting to changing process requirements. Errors and errors are analyzed and corrected promptly to minimize downtime. In addition, the system is checked for security vulnerabilities through regular audits to protect it from cyberattacks and data loss.