Implementation of Integrated Control Systems Projects in Companies Focused on Industry 4.0: Opportunities and Challenges in Brazil

Abstract

Integrated control systems (Supervisory Control and Data Acquisition–SCADA and Manufacturing Execution Systems—MES) constitute the backbone of Industry 4.0; however, research on their implementation remains scarce. This study analyzes the opportunities and challenges of modernizing these systems within the context of the Brazilian industry. A survey of 101 experts was conducted, with results analyzed via Friedman and Holm–Sidak nonparametric tests to establish a clear hierarchy of factors. Findings reveal that while economic efficiency, productivity gains, and real-time remote access represent the most significant opportunities, they are countered by critical structural challenges: obsolete machinery and inadequate infrastructure. These challenges significantly inflate implementation costs and highlight the reality of technological obsolescence that is typical of emerging economies. By applying the Resource-Based View (RBV), this research frames digital integration as a strategic competitive capability rather than a mere technical upgrade. Practically, the study provides a roadmap for industrial leaders to balance digital agility expectations with pragmatic operational constraints. These insights offer a foundation for successful digital transformation, delivering actionable value for academics, industrial managers, and policymakers.