Real Missouri industrial clients. Real engineering challenges. Real results.
The challenge: A St. Louis metal stamping and fabrication company with 6 production lines had been running a Windows XP-based SCADA system since 2004. The system was running on hardware with end-of-life support, the vendor had been acquired and no longer supported the platform, and the plant's IT security team had flagged the unpatched industrial systems as an unacceptable cybersecurity risk. Production stoppages from SCADA-related issues had increased 40% year-over-year. Any unplanned shutdown of this facility represented a direct financial impact of $28,000 per hour.
What StableCore delivered: Complete CoreVision SCADA replacement across all 6 production lines — executed over three sequential weekend shutdowns to maintain production Monday through Friday throughout the migration. New CoreNet OT network infrastructure with ISA/IEC 62443 Zone-Conduit architecture. Full ISA-18.2 alarm rationalization that reduced nuisance alarms by 34%. Integration with SAP production planning module. Complete documentation package and operator training program delivered alongside the technical project.
The result: Zero unplanned downtime attributable to SCADA system since commissioning. 34% reduction in alarm activations requiring operator response. $890K in measurable annual production efficiency improvements from improved process visibility and the alarm management improvements that allow operators to focus on the process rather than managing alarm floods.
The challenge: A Missouri regional water and wastewater utility serving 84,000 customers needed to comply with the America's Water Infrastructure Act (AWIA) of 2018 cybersecurity requirements. Their existing SCADA and telemetry system — installed in 2009 — had no meaningful cybersecurity controls, used default vendor passwords on most field devices, had no network segmentation between OT and IT systems, and had remote access configurations that an external audit had characterized as "immediately exploitable by a moderately skilled threat actor."
What StableCore delivered: Complete SCADA and telemetry upgrade across 18 pump stations and 2 water treatment facilities. CoreVision SCADA replacing legacy system with full ISA/IEC 62443 SL-2 security posture. CoreNet OT network architecture with DMZ, VLAN segmentation, and continuous network monitoring via Claroty. Cellular remote access replacement using Tosibox encrypted appliances. Full AWIA Risk and Resilience Assessment documentation delivered alongside technical project.
The result: AWIA compliance achieved and certified by third-party auditor. 99.98% system uptime in first year post-commissioning. EPA and state regulator audit completed with zero findings. Total project cost 40% below competing bid from national integrator, delivered in 18 months vs. competitor's 24-month schedule.