Reliable production starts with a clear understanding of what is installed in the plant. Machines, automation components, spare parts, lifecycle status and obsolescence risks all have a direct impact on uptime, maintenance planning and future investments.
The IBE – Installed Base Evaluation service by Rockwell Automation helps industrial companies build a structured and accurate overview of their installed base, turning fragmented technical information into actionable insights for maintenance, engineering and management teams.
Because when production depends on assets you do not fully know, risk management becomes a guessing game. And guessing, in an industrial environment, is not exactly a best practice.
What Rockwell Automation Installed Base Evaluation is
The Installed Base Evaluation is a structured service designed to analyse and assess the industrial assets installed within a production facility.
Through field data collection, classification and technical analysis, the service helps identify and catalogue key automation assets across the plant, including:
- PLCs and controllers;
- HMIs and supervision systems;
- drives, inverters and motion control components;
- industrial switches and network infrastructure;
- industrial PCs;
- safety devices;
- sensors and field-level components;
- spare parts stored on site.
The final output is a detailed report that provides a clear view of the installed assets, highlights critical equipment, identifies potential lifecycle risks and supports the planning of actions aimed at improving reliability, availability and plant continuity.
Why an installed base assessment matters
Production plants rarely remain unchanged. Over time, they evolve through new lines, machine upgrades, partial replacements, revamping activities, expansions and technical modifications carried out by different teams and suppliers.
This often creates a gap between technical documentation and the real configuration of the plant. Spare parts may no longer match actual operational priorities, while critical components may be missing, insufficient or difficult to source. At the same time, devices that are still working may already be discontinued, approaching end of support or exposed to obsolescence risk.
IBE helps companies bring clarity to this complex scenario and answer essential operational questions:
- Which automation components are installed on each production line?
- Which assets are still active, available or supported?
- Which devices are obsolete or approaching obsolescence?
- Is the spare parts inventory aligned with the real criticality of the plant?
- Where are the most relevant downtime risks located?
- Which modernization activities should be prioritised?
For this reason, the service goes beyond a simple asset inventory: it becomes a practical decision-making tool for industrial operations.
From emergency response to planned asset management
When the installed base is not properly mapped, maintenance activities often remain reactive. Problems are addressed only when they occur, usually under time pressure and with limited options available.
Installed Base Evaluation supports a different approach. Assets are assessed according to technical criteria, lifecycle status, operational criticality and risk exposure. This allows maintenance and engineering teams to plan interventions, optimise spare parts and define modernization roadmaps based on real plant priorities.
The difference is substantial:
Reactive approach
- Action after a failure occurs
- Limited visibility of installed assets
- Spare parts managed without full risk alignment
- Decisions made under pressure
- Higher exposure to unplanned downtime
IBE approach
- Early identification of critical issues
- Structured visibility of the installed base
- Spare parts aligned with asset criticality
- Planned technical and budget decisions
- Lower operational risk
How the IBE service is carried out
The IBE service follows a structured process designed to collect accurate data, analyse plant assets and convert technical information into clear operational recommendations.
1. On-site data collection
The first step consists of collecting data directly at the production facility. During the site visit, information is gathered on electrical, mechanical and automation assets installed across the plant.
The assessment can include Allen-Bradley and Rockwell Automation components, as well as devices from other manufacturers. This broader approach helps create a more realistic and complete view of the actual installed infrastructure.
2. Asset analysis and classification
The collected data is processed and analysed using dedicated tools, allowing assets to be classified according to:
- plant location;
- area, line, machine or panel;
- lifecycle status;
- operational criticality;
- obsolescence exposure;
- spare parts availability and consistency.
This step transforms the asset inventory into a practical risk map, helping identify where action is most urgent or strategically relevant.
3. Final report and recommended actions
At the end of the evaluation, a detailed report is delivered. Depending on the scope of the assessment, it may include:
- overview of the installed base;
- asset lifecycle analysis;
- risk assessment by line, machine or catalogue number;
- spare parts recommendations;
- identification of active, excess or no longer strategic components;
- areas with higher downtime exposure;
- modernization recommendations;
- tools to support lifecycle planning.
The purpose of the report is not simply to document the current situation. Its value lies in helping the company decide what to replace, what to maintain, what to keep in stock and what to include in future investment plans.
Spare parts management based on real plant priorities
One of the most tangible benefits of IBE is the optimisation of spare parts.
In many facilities, storerooms contain both excess components that tie up capital and missing critical parts that can increase downtime risk. This imbalance often remains hidden until a failure occurs.
Installed Base Evaluation helps assess spare parts according to the actual criticality of the installed assets. The service can highlight redundant stock, inactive components, missing spare parts and stock levels that should be adjusted to better support production and maintenance needs.
The result is a more efficient spare parts strategy: lower inventory waste and greater availability of components that are truly relevant to operational continuity.
Obsolescence management and modernization roadmap
Obsolescence does not usually appear overnight. It develops progressively and becomes critical when it is not monitored in time.
IBE helps identify components that may still be operational but are exposed to lifecycle risk because they are discontinued, approaching end of support or no longer fully available. This gives companies the opportunity to plan modernization actions before urgency dictates the agenda.
In this perspective, the service becomes a strategic support tool for building a technical roadmap, reducing emergency replacements and defining priorities based on objective plant data.
How Edge Greece supports industrial companies
Edge Greece supports industrial companies in the adoption of Rockwell Automation solutions and services, helping customers evaluate their technical needs, understand operational priorities and identify practical paths to improve reliability, efficiency and production continuity.
The IBE service is a valuable starting point for building a data-driven maintenance and modernization strategy. It is not just a technical snapshot of the plant, but a decision-making foundation for planning interventions, investments and risk mitigation actions.
Knowing your assets to plan the future of your plant
Modern industrial environments are increasingly connected, complex and dependent on the availability of automation assets. A clear view of the installed base helps reduce uncertainty, anticipate lifecycle risks and plan future activities with greater accuracy.
With Rockwell Automation Installed Base Evaluation, companies can transform asset information into a strategic tool for maintenance, operational continuity and plant modernization.
Contact our experts
Edge Greece is available to provide more information about the IBE service and evaluate the most suitable approach for the needs of your production facility.
Fill in the form to start a technical discussion about your plant.
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