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Industrial automation data recovery

Start with the automation data the operation can no longer use.

A stopped machine or line is not automatically a data-recovery case. ADR becomes relevant when the current PLC or HMI project, recipe, historian, MES or ERP record, server volume, database, configuration, or backup is inaccessible from its client-controlled storage source—or when another repair attempt could change the only remaining copy.

Call a recovery technicianDescribe the inaccessible data

Tell us what data is unavailable, where its last usable copy should exist, the affected equipment and software, storage media, exact errors, and every action already attempted.

Failure boundary identifiedEquipment fault or inaccessible data source
Original state preservedMedia, projects, exports, and backups
Recovery by layerStorage, filesystem, database, application
Operational validationBy the authorized automation team

Choose the unavailable business object

The symptom on the plant floor does not always identify the recovery source.

Use the path that names what the operation cannot access. ADR first establishes the source and protects it; equipment correction, logic changes, machine-safety decisions, and production approval remain with the responsible vendor or controls team.

PLC or HMI projectThe current project, recipe, runtime image, or configuration is inaccessible after media failureStop power cycling, formatting, initializing, repair, and writes to the only source.Review PLC and HMI project recovery → MES or ERP recordsProduction, inventory, order, quality, or accounting records are unavailable after storage failurePreserve the complete RAID, VM, database, log, backup, export, and recovered state.Review MES and ERP recovery → Control computer or serverThe host will not boot and required automation data cannot be accessedThe failed host does not have to boot before its storage can be evaluated.Review server recovery → Historian or databaseThe files exist, but the application cannot start, attach, mount, or use the required recordsProtect database files, logs, storage states, backups, exports, and linked repositories.Review database recovery → RAID, NAS, or storageThe volume is degraded, missing, offline, or inaccessiblePreserve member identity, order, controller evidence, and intervention history before reconstruction.Review storage recovery → Robotics and motion systemsRequired programs, calibration data, vision data, logs, or archives are unavailableIdentify the precise client-controlled source before changing the equipment or controller.Review robotics recovery →

What ADR needs first

Describe the missing data before trying to repair the machine around it.

  1. 1

    Name the unavailable data

    Identify the project, recipe, historian, database, configuration, image, document, or production record required.

  2. 2

    Locate every possible source

    Preserve controller media, panels, computers, servers, drives, cards, USB devices, backups, exports, and alternate copies.

  3. 3

    Record the intervention history

    List power cycles, format prompts, repairs, clones, restores, uploads, downloads, firmware changes, and replacements.

  4. 4

    Separate recovery from validation

    ADR recovers the identified data; the authorized automation team validates logic, dependencies, safety, and production suitability.

When the data—not only the machine—is unavailable

Preserve the source and tell ADR what the operation needs back first.

ADR can evaluate the storage source without making the failed controller, panel, computer, server, or array the recovery environment. The correct path depends on where the data resides and whether that source can still be read safely.

Call 1-800-228-8800Start automation-data triage