How to Conduct a SCADA System Audit in 2025

09-06-2025
How to Conduct a SCADA System Audit in 2025

Why This Matters

Factories today are not what they were ten years ago.


Machines are smarter. Data is everywhere. But with this growth comes pressure. Pressure to reduce downtime. To control costs. To keep systems safe. And most importantly, to know — is your SCADA system still working the way it should?

Many companies run without checking. Until something breaks.

A SCADA system audit helps you stay one step ahead. It tells you what is working, what is not, and what can go wrong before it actually does.
It is no longer optional. It is a must.

What Is a SCADA System Audit?


A SCADA system stands for Supervisory Control and Data Acquisition.

It is the system that allows factories and industrial plants to monitor, control, and collect data from machines and processes in real time. SCADA connects your physical equipment — like sensors, motors, and valves — to software screens that operators can see and act on.

In simple words. It is the eyes and brain of your plants 

In 2025, this is more important than ever. Why?

  • Cyber attack are rising.
  • Machine need to talk to each other in real time.
  • Manager need fast, accurate data to make decision.
  • old systems are slowing plants down.


A Good Audit Helps You:


  • find small issues before they become big ones.
  • Keep your data clean and correct.
  • Stay ready for audits and certifications.
  • Save money by improving efficiency. 
  • Know when it is time to upgrade or expand.


A quick look at where SCADA Came From 


Before SCADA Systems existed, factories and industrial plants ran by hand. Operators had to press physical buttons, turn knobs, and check readings on analog meters. Everything had to be done manually- often in noisy, complex environments.

As plants grew bigger and spread across larger areas, this manual work become difficult and unsafe. Companies started using relays and timers to control machines from a distance. This helped a little. But these systems were hard to maintain, tough to reprogram, and took up a lot of space.

Then, in the 1950s, computers entered the scene. For the first time, industries could control some processes using digital tools. In the 1960s, the idea of sending data from remote sites to a central system — called telemetry — became popular.

Finally, in the early 1970s, the term SCADA — Supervisory Control and Data Acquisition was born was born.

With the help of microprocessors and control devices like programmable logic controllers, SCADA systems gave companies the power to monitor and manage entire plants — from one place, in real time.

That was the beginning of automation as we know it today.


Three parts of a Good SCADA Audit


1. System Infrastructure Check

This is the base of everything. It includes your machines, cables, servers, and how they connect.

Why it matters : If your foundation is weak, the rest will fail too. Delays, errors or even systems crashes can happen.

What to check: 

  • Your field equipment's and control panels.
  • Network layout and cable health.
  • Backup power and server performance 
  • communication between machines.

How to do it:

Walk through your plant. Check each part physically and through system tools. Make sure your layout is mapped and updated.


2. Software and Data Check

This is the brain of your system. It includes your operators screens, alarms, report and data storage.

Why its matters:

If the software is slow or wrong. Your people will act on bad information. That can cause serious problems.

What to check:

  • Operator screens - are they showing the right values?
  • Alarm system - are you getting the right alarm at the right time?
  • Data - Is it bring stored , backed up, and reported correctly?

How to do it : talk to your operators. See what they struggle with. Run test cases. Use software tools to check for missing or wrong data. 


3. Cybersecurity and compliance check

This protect everything. From your machine to your data and your people. 

Why it matters: One attack can shut down your whole plant. Or leak sensitive business data. Or worse, harm someone. 

What to check: 

  • Who has access to what?
  • Are your passwords strong and updated?
  • Is your software patched and updated?
  • Is your system connected to the internet? Is yes, how is it protected?

How to do it: Run a basic security scam. Change default passwords. Create level of access based on job roles. Keep a long of all system changes. 


What happens If You Do Not Audit?

Many companies wait until there is a breakdown. By than. It is too late.

Here is what can happen if you ignore your SCADA system:

  • Unexpected downtime during peak hours.
  • Machine working on old and wrong setting.
  • Bad data leading to bad business decision
  • High electricity or raw material waste
  • Safety risk for your people 
  • penalties during external audit


How Reckers Automation Helps


At Reckers Automation, We work with every client. No two plants are the same. That is why we do not offer a fixed plan. We listen first.

We have worked with plans in:

  • Automobile 
  • Pharmaceutical 
  • Food Processing
  • Original Equipment manufacturing
  • Large suppliers


We use trusted tools like AVEVA and Teltonika. We check everything in detail - the layout, the software, the data and the risks. Our audit have helped companies.


  • Cut energy use by up to 20 percent
  • Reduce downtime by 30 to 40 percent
  • Catch hidden security risk
  • Decide what to upgrade and when

Our team becomes your extended team -- without the cost of hiring full-time engineers.


Quick Summary


In 2025, a SCADA audit is not just about safety. It is about staying in control of your plant, your people, and your profits.

Act now. Because the best time to prevent failure is before it happens.


FAQs


1. How often should I audit my SCADA system? 
Once a year is a good practice. You should also audit after any major upgrade or issue.

2. Can I do a SCADA audit myself?
You can begin with basic checks. But a full audit needs experience and tools that experts use.

3. Will an audit stop my plant?
No. Most audits are done while systems are running, or during maintenance hours.

4. What does a professional audit cost?
It depends on the size of your plant. But the cost is small compared to the money saved through early fixes.

5. Can this help with digital transformation? 
Yes. A good audit shows you what is outdated and what can be automated or improved.





 





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