A single failure of your Delphi or Access software can turn into the most expensive production downtime of the year in a matter of minutes.
Many production systems have been running on Delphi or Access applications for years, reliably controlling machines and delivering data to ERP or MES. But this stability is deceptive: in many cases, these are systems that have grown over decades.
Risks remain invisible until it is too late. A failure of production software does not just mean IT problems. It directly jeopardizes delivery capability, product quality, and the entire value chain. It is therefore crucial for production managers to be aware of these risks and actively manage them.
According to the ABB study «Value of Reliability,» unplanned downtime costs German industrial companies an average of EUR 147,000 per hour. A two-hour outage can quickly result in costs in the hundreds of thousands or even millions, depending on the machinery, production value, and product line. If your production is down for 10 hours, the cost would be approximately EUR 1.47 million. That’s just for the outage itself, without follow-up costs such as scrap or delays.
Robert Schmuck, CTO soxes AG
Delphi and Access applications were often developed for stable processes, not for dynamic production environments. As soon as interfaces to ERP or MES become unstable or a faulty update is installed, the entire line can come to a standstill.
Such downtime causes high production downtime. Depending on the industry and production volume, each hour can mean losses in the five- to six-figure range.
A production stoppage is expensive, but the follow-up costs are often even higher. If an Access application that transfers production data to the ERP fails, incorrect or missing entries occur. This leads to manual corrections, special transports, and overtime.
In modern production systems, automated testing and monitoring ensure that incorrect data or process deviations are detected immediately. This level of security is lacking in old Delphi or Access systems.
An incorrect parameter, an incomplete data record, or an interface error can render entire production batches unusable. This not only means high material and disposal costs, but also direct damage to the trust of customers and auditors.
Today’s production systems are closely linked to the supply chain. If data from a Delphi or Access application is not reliably transferred to the ERP or MES, the entire delivery planning process is thrown into disarray.
This can result in delayed deliveries, contractual penalties, or even the loss of important customers.
Further development is often only possible with great effort, if at all. This creates a competitive disadvantage: while other companies are digitizing and optimizing their production, your own system remains static. Competitiveness declines and costs rise.
The number of experts who are proficient in Delphi or Access is dwindling. Every adjustment takes longer, costs more, and depends on a few individuals.
When a developer leaves the company, valuable know-how is left unsecured. Without targeted knowledge and documentation, there is a risk of complete standstill as soon as a small adjustment is necessary.
soxes is your partner for legacy software support and combines Delphi expertise with .NET, Python, PostgreSQL, and cloud solutions for companies from various industries.
How can I avoid downtime in production?
Downtime can be significantly reduced through code review, monitoring, and a clear modernization plan.
Can an Access database be integrated into a modern ERP or MES?
Yes, this is technically possible, but often unstable and prone to errors. In the long term, it makes more sense to plan a clean interface or migration to avoid data loss and downtime.
How long can a Delphi or Access application still be operated?
As long as the systems run stably and the interfaces function, continued operation is possible. It becomes critical when security updates are missing, interfaces become fragile, or skilled personnel are no longer available.
How much does it cost to modernize production software?
The costs depend on size and complexity. Many companies start with a risk check in the five-figure range and then decide whether to modernize individual modules or redevelop the entire system.
Which modules should be modernized first to reduce downtime?
Start with interfaces to ERP and MES, central data objects, and error-prone automations. This is the fastest way to reduce the risk of failure.
What security vulnerabilities are typical in old Delphi applications?
Current TLS versions, secure password storage, and regular security updates are often missing. A code review reveals these gaps.
When does switching from Access to SQL Server pay off?
As soon as data volumes grow, more than 10–15 simultaneous users are working, or performance bottlenecks occur, SQL Server reduces operating costs in the long term.
Who provides maintenance and support for old Delphi applications in Switzerland?
soxes AG is a service provider specializing in legacy software. We offer long-term support, code reviews, and targeted upgrades to keep systems running smoothly.
Instead of ignoring these risks, we recommend a structured risk check. This will give you a clear analysis of your production software and a plan of action for the coming years.
You reduce risks, ensure the stability of your production, and gain time to implement a planned modernization based on .NET, Python, cloud, or modern ERP/MES interfaces.
A manufacturing company had been working with an outdated Delphi-based MES solution for over 15 years, which was only supported by a single developer: an increasing risk for ongoing operations.
The developer left the company, and the existing software was technically obsolete, poorly documented, and difficult to maintain. In addition, there was no clear separation between legacy systems, data flows, and modern interfaces.
soxes developed a new MES platform based on modern web technologies such as C#, with a clear architecture, tested interfaces, and flexible connection to ERP and machines.
The new solution reduces dependency risk, ensures technological future-proofing, and enables controlled implementation without interrupting production.
Identify hidden vulnerabilities before they cause costly production downtime.
Sofia Steninger
Solution Sales Manager
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