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Applied Control Solutions (ACS)
Two engineers walking a plant pipe rack, one pointing out a field instrument

Control-system risk · Critical infrastructure

Most serious control‑system events aren’t cyberattacks.

Many of the incidents that injure people, damage equipment and interrupt operations begin as automation failures in sensors, actuators, control logic, calibration, communications and process behavior. ACS helps organizations recognize those incidents and learn from the patterns others miss.
  • 20+ years

    tracking automation incidents

  • World's largest

    record of ICS automation incidents

  • Licensed PE

    engineering-led analysis

  • U.S. Congress

    Joe Weiss has testified before Congress

Automation vs. cybersecurity

Cyberattacks are real. They are not the whole control‑system risk picture.

The gap

The category most organizations are not tracking.

Automation incidents rarely look like incidents: they show up as equipment failures, unexplained downtime, recurring process problems, or root-cause findings that never quite close.

30,000+
deaths linked to control system incidents worldwide
$100B+
in direct impacts

Source: ACS incident research.

Read the full breakdown

Automation incident

What it is
Sensors, actuators, control logic, calibration and setpoints: engineering causes that change how the physical process behaves.
Usually seen as
Equipment failures, unexplained downtime, recurring process problems.
Needs
Engineering-led investigation.

Network cybersecurity incident

What it is
Malware, ransomware, credentials and remote access: unauthorized or malicious activity through networks.
Usually seen as
Alerts from network monitoring and security tools.
Needs
Cyber incident response.
What ACS does

Turn hidden incidents into operating knowledge.

See how the Workshop and Annual Service fit together
  1. 01Recognize

    Identify the automation incidents your organization may have filed as equipment failures or unexplained downtime.

  2. 02Compare

    Put your experience in context using ACS incident knowledge across sectors and geographies.

  3. 03Stay current

    Receive relevant incident intelligence, notifications, reviews and expert access all year.

Where to start

From first findings to year-round intelligence.

The Workshop can stand alone. The Annual Service begins with it, then keeps your organization current all year.

Cross-functional plant team studying a piping and instrumentation diagram together
01

Start here

Incident Identification Workshop

Find what you’ve been missing.

Lower initial commitment. An on-site, train-the-trainers engagement that helps operations, engineering, safety and security personnel recognize and classify automation incidents in their own experience.

  • On-site, train-the-trainers
  • Patterns in sensors, actuators, calibration, control logic and communications
  • Book it on its own, or as step one of the Annual Service
Operator at an HMI workstation in a bright industrial control room
02

Continue all year · Includes the Workshop

Annual Service

Begin with the Workshop, then continue all year.

The complete recurring service. It begins with the Workshop, then adds annual incident intelligence, sector comparison, notifications, periodic reviews and access to ACS expertise throughout the year.

  • The Incident Identification Workshop, as onboarding
  • The ACS annual incident report and sector comparison
  • Notifications, periodic reviews and year-round expert access
Sectors we serve

Automation incident intelligence, by sector.

  1. 01Oil & Gas
  2. 02Utilities
  3. 03Water & Wastewater
  4. 04Chemical
  5. 05Manufacturing
  6. 06Transportation
  7. 07Nuclear
  8. 08Food & Beverage
  9. 09Pharmaceutical
Pneumatic control valve with actuator and positioner, a Level 0 field device
Case study

Identifying Automation Incidents Behind a 3% Productivity Opportunity at a Major Industrial Facility

The most significant sources of operational loss were ICS automation issues, not cyberattacks.

Problem
A facility producing about $1 billion a year had unexplained downtime, inconsistent throughput and recurring equipment issues.
Finding
Monitoring raw sensor signals surfaced inoperable and uncalibrated sensors, improperly ranged instruments and controller tuning errors that operators could not see.
Consequence
Those automation incidents added up to an estimated 3% of lost production: tens of millions of dollars in potential additional output.

Every facility is different, and not every site will find the same opportunity.

Joe Weiss, Managing Partner of Applied Control Solutions
About ACS

Joe Weiss

Managing Partner, Applied Control Solutions

Licensed PE / CISM / CRISC / ISA Fellow / IEEE Sr. Member / Testified before Congress / Process Automation Hall of Fame

Joe Weiss was among the first to show that serious control-system events are routinely filed as equipment failures, so their automation causes are never investigated. Over more than 20 years he built the incident record that documents it, working from the engineering realities of operational technology rather than an IT-security playbook. That perspective is what makes ACS’s authority founder-led, not certification-led.

The ACS Annual Service puts that incident record, and direct access to Joe, to work for your organization.

Protecting Industrial Control Systems from Electronic Threats by Joseph Weiss

Author of Protecting Industrial Control Systems from Electronic Threats

FAQ

Common questions.

How is an automation incident different from a cyberattack?

An automation incident is a control system failure whose root cause is engineering (sensors, actuators, control logic, calibration, or setpoints), not an attacker on the network. A cyberattack is unauthorized activity through networks, credentials, or malware. Most control system harm comes from the former, and is routinely misread as equipment failure.

Why do organizations miss these incidents?

Automation incidents rarely look like incidents. They show up as equipment failures, unexplained downtime, recurring process problems, or root-cause findings that never quite close. Operators see that something is wrong but aren't trained to classify it, and security teams know networks, not normal process behavior.

Should we start with the Workshop or the Annual Service?

Start with the Incident Identification Workshop if you want a lower-commitment way to test the ACS approach. The same Workshop is the onboarding component of the Annual Service, which then keeps you current all year. If you're not sure, a 20-minute Incident Review will tell you which fits, or whether neither does.

How much does the Annual Service cost?

Pricing is based on the size of your organization. Request an Incident Review for a quote. The Annual Service begins with the Incident Identification Workshop, then adds the ACS annual incident report, comparison with your sector and geography, significant-event notifications, periodic reviews, and year-round availability by phone, email, and video.

Does ACS replace our cybersecurity team?

No. ACS makes your engineering and security teams better at recognizing the automation incidents that network monitoring misses. It complements your cybersecurity program; it doesn't replace it.

Is incident data shared confidentially and non-punitively?

Yes. ACS turns what it learns into trusted, non-punitive information sharing that helps the whole sector improve, without exposing the organizations involved.

20-minute Incident Review

Request a 20-minute Incident Review.

Tell us what you're seeing. ACS will reply within one business day to set up a short conversation, and help you decide whether the Workshop, the Annual Service, or neither is the right fit.

Preferred next step
ACS replies within one business day.

What happens next

  1. 01

    We reply

    ACS reviews your request and replies within one business day.

  2. 02

    You pick a time

    Choose a slot for the 20-minute conversation, right after you submit or from our reply.

  3. 03

    You get a clear answer

    Leave knowing whether the Workshop, the Annual Service, or neither fits, and what the next step would be.

Prefer to talk now? Call (408) 253-7934