The Industrial Guide to The End of XP · 2013. 8. 20. · which a typical 32-bit Windows XP operating system is unable to address. A 64-bit install of Windows 7 allows full exploitation

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The Industrial Guide to

The End of XP

Sponsored by:

Comprehensive Computer Solutions

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Industrial Guide to The End of XP Comprehensive Computer Solutions

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Table of Contents

Chapter 1 What is the End of XP?

Chapter 2 Why an Industrial Guide?

Chapter 3 Scenario One: The End User

Chapter 4 Scenario Two: The OEM Ready to Upgrade

Chapter 5 Scenario Three: The OEM Who Can’t Upgrade (Yet)

Chapter 6 Conclusion


Industrial Guide to The End of XP Comprehensive Computer Solutions0 1

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Chapter One

What is the End of XP?On April 8, 2014, Microsoft® will end extended support for Windows® XP. This means that no additional patches, bug fixes, or service packs will be released, and that users will no longer have access to free or paid technical support. Systems running XP won’t suddenly stop working on April 8, but they will become increasingly vulnerable and the source of additional problems...

Security“The sudden absence of support for XP leaves a void that will likely be filled by a slew of old and/or soon-to-be-discovered vulnerabilities and subsequently give rise to a new crop of security exploits that specifically target these legacy systems, which are now devoid of security updates or support. … older operating systems typically have more exploit activity due to the fact that myriad exploit kits and existing malicious code have had ample time to mature and circulate.”

- Source: http://blog.fortinet.com/old-operating-systems-present-new-security-challenges/

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Average Infection Rate

Windows XP Windows 7SP3 SP1

January - June 2012

32-Bit

9.5

32-Bit

4.9

64-Bit

3.1



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Cost“Simply stated, older technology has a higher maintenance cost. This is exacerbated when organizations keep PCs in use for extended periods of time (beyond a typical three- to four-year life cycle).”

Operational Expenses

- Source: IDC White Paper sponsored by Microsoft Corporation, Mitigating Risk: Why Sticking with Windows XP is a Bad Idea, Doc #234690, May 2012.

Performance“Most new PCs have features that were nonexistent, or immature, when service pack enhancements for Windows XP were discontinued. Today’s PCs include features such as integrated WiFi and Bluetooth, faster USB ports, and high-resolution monitors and touchscreen capabilities. Many of these capabilities are either poorly supported or not supported by Windows XP Professional. Further, today, most PCs ship with a minimum of 4GB of memory, which a typical 32-bit Windows XP operating system is unable to address. A 64-bit install of Windows 7 allows full exploitation of that memory.”

- Source: IDC White Paper sponsored by Microsoft Corporation, Mitigating Risk: Why Sticking with Windows XP is a Bad Idea, Doc #234690, May 2012.

Windows XP

*cost per PC per year *cost per PC per year

Windows 7

Windows 7 Provides

Better Driver Stability

Improved Wi-Fi

USB 3.0

Improved 64-bit Support

Support for more RAM on 64-bit systems



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SustainabilityWindows 7 is the last downgrade path to Windows XP. When it goes “end of life” there will be no way to purchase new computers or licenses that can revert to Windows XP.

“According to a survey of 200 IT directors and CIOs, 80 per cent are concerned that Windows XP’s end date in 2014 will leave them with a large amount of unsupported business critical applications, while 43 per cent have not introduced strategies to migrate any of the legacy Windows XP apps.”

- Source: (UK) http://www.scmagazineuk.com/windows-xp-applications-slowly-cause-fear-for-businesses/article/279319/

Windows XP Windows 7 Windows 8

October 2014*

- *Estimate based on historical data. Microsoft has not announced an official date.



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Retail vs. Embedded Operating System Lifecycles

Product Distribution End Date

Mainstream Support End Date

Extended Support End Date

Windows XP 10/22/2010 4/14/2009 4/8/2014

Windows Embedded Standard 2009 1/8/2024 1/14/2014 1/8/2019

Windows 7 10/26/2014* 1/13/2015 1/14/2020

Windows Embedded Standard 7 7/27/2025 10/13/2015 10/13/2020

- *Estimate based on historical data. Microsoft had not announced an official date at time of publishing.

Why Windows 7? Although Microsoft released Windows 8 in October 2012, CCS-Inc. currently recommends Windows 7 as the preferred upgrade path from XP. Having deployed Windows 7 PCs in many industrial applications, we believe that this operating system is well-suited for a marketplace that values stability and prefers mainstream technology to the cutting edge.

Why Windows Embedded Standard 2009?For those companies who must continue to rely on XP dependent hardware or software, CCS-Inc. suggests moving to Windows Embedded Standard 2009 (WES). Other XP embedded operating systems exist but have the same end of extended support date. WES is supported until January 8, 2019.

“If enterprises are holding off on Windows 8, they are still embracing Windows 7 as an upgrade solution,” Microsoft (NSDQ:MSFT) CFO Peter Klein said Thursday. This quarter we saw continued progress from the transition of Windows XP to Windows 7. Now, two-thirds of all enterprise desktops are running Windows 7,” Klein said on a conference call with analysts Thursday after the company reported its third-quarter earnings.

- Source: http://www.crn.com/news/applications-os/240153238/despite-%20%20%20%20windows-8-availability-enterprises-transitioning-from-xp-to-7.htm



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Chapter Two

Why an Industrial Guide?Microsoft operating systems support a myriad of applications, businesses, and users all over the world, but we found that most of the information available regarding the transition from Windows XP to 7 focused on traditional office environments. We wanted to provide some archetypical examples of industrial organizations and how they might effectively address the end of XP.

Which one sounds most like you?Scenario One: The End User

This scenario describes a company who uses Windows XP computers to control its plant floor operations. Learn why they decide to move to Windows 7 and how they do it through replacement PCs and upgrade disks. Page No. 6

Scenario Two: The OEM Ready to Upgrade

Read this story if you provide a solution that currently includes an XP computer and uses commercially available software and hardware. This company decides to upgrade to Windows 7 when they face a hardware availability issue. Page No. 10

Scenario Three: The OEM Who Can’t Upgrade (Yet)

If you have developed proprietary cards or software that are part of your XP based solution, this example highlights how an embedded operating system may offer more lifecycle control and customization. Check it out if you know you don’t have time to develop Windows 7 compatible versions before XP support ends. Page No. 14



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Chapter Three

Scenario One: The End UserCompany ProfileWidget Makers International (WMI) is a mid-size company that operates a large manufacturing facility in Duluth, MN. In the mid-2000s, WMI invested heavily in automation systems to improve quality and efficiency. The company has grown steadily since that time and recently expanded its capacity by 25%.

Hardware + XP SituationWMI’s plant floor IT infrastructure now consists of 400 computer nodes – 200 industrial PCs of various form factors used for embedded control functions, 50 fully-enclosed panel PCs that serve as production line HMIs, and 150 commercial desktop HMIs in the control room – all running Windows® XP. They are networked as part of the MRP and automation systems, as well as to the corporate offices, but are not directly connected to the internet.

With 75% of Widget Makers’ computer equipment dating back 7+ years, they have begun to experience in-field failures. In fact, they have had to repair or replace twenty units in the past six months.

Security

The network described here is pretty typical. Since the plant floor PCs aren’t connected to the Internet, WMI assumes they’re safe. They have bought into the myth of “air-gapping.” An air gap describes a physical separation between networks that prevents data transfer. But in this case, the corporate network is connected to the plant floor for monitoring, so the HMIs are actually exposed to external threats.

Since WMI regularly applies patches, updates, and service packs to its OS, automation software, and antivirus package, security hasn’t been an issue. If they are still running Windows XP



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past April 8, 2014, though, it could become one. Widget Makers will have no defense against vulnerabilities that are discovered past that date.

Cost

Everybody knows that time is money. While not all of WMI’s PC failures caused downtime, a few of them did. In a May 2012 report by Stratus Technologies and IndustryWeek, surveys revealed that an average manufacturing downtime incident costs $18,286. WMI literally can’t afford to keep using its old hardware much longer, but some members of management seem more willing to risk the downtime than incur the capital expense to upgrade or replace all 400 systems.

During its recent expansion, WMI purchased approximately 80 new computers. They noticed a line item on each unit charging 30 minutes of labor to downgrade from Windows 7 to XP. The prices of some legacy components (required to run XP) have also started to creep up as supply dwindles in favor of newer models and operating systems. By continuing to use XP, WMI is actually paying more for systems that are well behind mainstream technology and capabilities.

Performance

In the world of computing, nothing lasts forever. In addition to out-and-out failures in its older systems, WMI is also experiencing more support incidents and required reboots. But even if every computer was working at 100% capacity, they would still be missing out on functionality available on Windows 7 platforms. Through multi-core processing and utilization of more RAM, they would experience speed improvements on the plant floor. Widget Makers would also benefit from a management dashboard, report generator, and enhanced operator screens not offered in the XP compatible version of their automation software.

Sustainability

The longer WMI continues to depend on Windows XP, the more sourcing and support challenges they are going to face. Finding XP compatible replacement parts is time-consuming. Since some vendors have already discontinued these products, WMI often resorts to online resellers and auctions. They have also been warned by their system builder that downgrading to commercial XP licenses will not be an option much longer. Whenever Microsoft® stops selling Windows 7 OEM licenses, there will be no downgrade path. They would have to switch to a volume licensing structure and sign an agreement directly with Microsoft. Additionally, they



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have heard rumors that their automation software vendor wants to end support for the XP compatible version they are currently using. WMI recognizes that it must do something to ensure the operational future of its production line.

The Tipping Point

WMI has been putting off an OS upgrade for some time because, until recently, Windows XP has been such a reliable platform. But increasingly frequent system failures have them worried about uptime, and they know they need a contingency plan. Rather than fight the rising costs and sourcing issues associated with XP and legacy hardware, WMI is ready to transition to a Windows 7 deployment.

XP to 7 – Upgrades and ReplacementsWMI first contacts the control system integrator who coordinated its manufacturing automation project several years ago. The integrator assures them that they will be very pleased with the newer version of their automation software and that, with proper planning and training, they will start recouping the costs of the upgrade through higher productivity almost immediately.

To ensure compatible hardware purchases, the integrator documents the necessary I/O and communication protocols that the new platforms will need to support and recommends a company they have worked with previously. The computer partner has over 20 years of experience delivering Microsoft® based solutions to the industrial market. Since most of WMI’s IT staff comes from enterprise and small business computing backgrounds, they decide that working with a specialized third party is a good idea.

The partner begins by gathering information about WMI’s application, operating environment, and current hardware setup. They then propose a combination of upgrades and replacements. They will replace the aging computers with new hardware but comparable form factors. The partner will design in long lifecycle components wherever possible. They will also create an image for each functional group (embedded control and HMI) based on the Windows 7 operating system. Images will include appropriate software applications and custom settings. The partner will ship all new systems in ready-to-use condition.

After confirming that WMI’s recently purchased units (downgraded from Windows 7 to XP) are in good condition, the partner decides to create an upgrade kit. They will develop and supply



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wizard-driven image disks for these 80 PCs that will help technicians quickly and consistently upgrade them to Windows 7. This will bring all 400 computers up to a common operating system and the new version of the automation software.

Satisfied with the proposal, the lower costs of using mainstream hardware and OS licenses, and a smooth transition for its newer PCs, Widget Makers places an order for several first article units and the upgrade kit. They work with their control system integrator to setup a test network and run the computers through representative scenarios which reveal some exciting performance improvements. WMI then orders the remainder of the systems and schedules the rollout for the week of its summer holiday shutdown.

Up and running for several months now, Widget Makers has been impressed with the reliability of its new computers and pleasantly surprised by their lower power consumption. The IT department is happy to support the same operating system in the production environment as it has been for some time in the corporate offices, especially since they will now be on the same security update cycle. And the installation group liked that the systems were “plug-and-play” because it significantly expedited deployment. All in all, the transition was a huge success.



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Chapter Four

Scenario Two: The OEM Ready to UpgradeCompany ProfileSawmill Suppliers designs and manufactures large industrial equipment for lumber processing. Their current product line (released in 2008) sells about 300 machines per year, and they are working to introduce all new models in late 2015.

Hardware + XP SituationEach piece of equipment Sawmill sells includes a custom panel PC operator interface. The engineering team designed these computers in-house. They work with a local metal shop for the custom chassis and source the boards and other hardware components from various distributors. After production technicians assemble the computers, install Windows® 7 and downgrade to XP, and load third-party control software, they integrate the units into the machines for inspection and shipment.

Because of the rigorous testing that happens prior to product launch, they have made only minor modifications to the machine designs and haven’t touched the operator interfaces in approximately five years. Sawmill’s purchasing department recently alerted product engineers to a sourcing issue that will require them to take a second look. The buyers just received an end-of-life (EOL) notification for the boards that are used in every system. With the new product line not scheduled for completion for two years, Sawmill must make a large last-time-buy of the boards to keep up with demand for its current models, find a suitable replacement, or redesign the panel PCs.



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Security

When Sawmill ships its products, they make sure that the operating system and control software is fully patched and updated. They have very little visibility into how their customers maintain security onsite, though. The small number of support calls involving infections leads them to believe that most perform regular system maintenance or use the machines in a truly offline environment. Patch management is streamlined significantly in Windows 7, which already experiences fewer than half as many infections as XP, so Sawmill could tout an OS upgrade as a product security enhancement.

Examples of OS HardeningWhen using a retail version of a Microsoft operating system for a specialized, industrial application, tailoring the image can increase security and improve operator efficiency. Here are some common customizations.

Remove consumer-based Windows features and programs, such as:

• Games

• Media Player

• Media Center

• Home Group

• Access to web browsers

• Universal plug-and-play

Create role-based permissions.

For instance, create an Operator Account that can’t:

• Open the Control Panel

• Access physical drives in My Computer

• Change screen settings



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Cost

Cash flow has been an issue for Sawmill before, so they are not interested in purchasing a large volume of boards that they may or may not use before the new product line (with new interfaces) hits the market. The quote they received for QTY: 500 totalled $450,000. They would prefer to find a replacement board that they can order as-needed or in limited quantities.

Sawmill has identified computer assembly and configuration as a disproportionately time-consuming piece of its production process. Now that they are also facing a possible redesign, they worry that they will have to devote some of their valuable engineering resources to the operator interface rather than to improving the cutting edge lumber processing technology for which they are known. They know that they have to something to address the EOL part, but they do not want to give up market share to do it.

Performance

Operating system and software performance has never been an issue for Sawmill Suppliers’ customers, but they have experienced hardware failures during operation. Sawmill offers drop-in replacement units when this happens, but have not performed enough root cause analysis to determine how to prevent it. A redesign would provide an occasion to do so and thus improve product reliability.

Sustainability

To continue providing product, Sawmill must find a way to sustain its panel PC supply chain. Unfortunately, all the comparable boards – same form factor, XP compatible, etc. – have similar EOL dates. Sawmill realizes it will probably have to upgrade not only the hardware, but also the OS and control software, since newer boards don’t support XP.

The Tipping Point

Sawmill has reached an impasse. Although the timing isn’t ideal, they recognize that this is an opportunity to make updates to the operator interfaces that will carry through to next generation equipment. They decide to outsource the project in hopes of streamlining their R&D efforts.



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XP to 7 – Designing a New SystemSawmill chooses a system builder partner with experience designing and manufacturing Windows based, custom, industrial computers. Since the physical dimensions of the system are predefined by the existing cutout, the partner moves on to identifying environmental specifications. By reviewing failure data from past and current customers, they determine that improving vibration isolation and power distribution in the new design will increase the MTBF. Sawmill will benefit from the partner’s team of computer, mechanical, and electrical engineers as well as its experience qualifying and selecting industrial hardware components.

As expected, the computer company recommends migrating to a Windows 7 installation. They ensure Sawmill that the OS has proven to be even more stable and reliable than XP, and that it will be available from and supported by Microsoft® for years to come. Upgrading to 7 will also allow use of more mainstream hardware and the newest version of their control application. By “hardening” the OS, or removing unnecessary components and disabling certain settings, they will be able to reduce operator error and simplify support. The partner will even be able to provide better branding by incorporating Sawmill logos and pictures on the desktop and boot screen. All of these customizations will be built into the image the partner creates, and will be applied consistently to each system before shipping to Sawmill.

The partner begins by prototyping the software setup and then develops an electrically functional prototype. They work with Sawmill to make tweaks where necessary and firm up requirements. Next, they build and test pilot systems internally before sending to Sawmill for field-testing.

Now in full-scale production, Sawmill is happy with its decision A) to upgrade its platforms to Windows 7 and B) to let a partner computer company handle the transition, development, and production. They were able to position the changes as a product line enhancement due to increased stability and security. They have more time and resources available to dedicate to new product development. And, they won’t have to worry about interface changes for quite some time. In addition to the extended lifecycle of Windows 7, the partner company will now manage all EOL component issues and help Sawmill plan for future upgrades.



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Chapter Five

Scenario Three: The OEM Who Can’t Upgrade (Yet)Company ProfileBeyond Precision Instruments (BPI) develops non-destructive test equipment for aerospace and defense. Annual sales range from 100 to 200 units per year, usually based on government budgets and contracts. Their highly custom machines represent years of research and development and come at a hefty price tag. BPI remains a leader in the market because their products consistently outperform the competition in terms of accuracy and reliability.

Hardware + XP SituationAs a rule, BPI prefers to do things in-house. This includes everything from metal tooling and welding up to developing proprietary cards and software. Their latest model instruments all use 4U rackmount computers as embedded control devices, where a custom card and other I/O devices are installed on an SBC backplane. Beyond Precision’s software was built specifically for use with its cards and a Windows® XP operating system. Knowing that they will soon face issues obtaining XP licenses, BPI must decide whether or not to redesign its cards and software.

Security

Because of its customer base, BPI must pay attention to cyber security. Although they know that many clients still use XP for other systems and have no immediate plans to upgrade, continuing to sell equipment that relies on an unsupported operating system would send the wrong message. They would like to make an OS change before April 8, 2014 to prove their commitment to security.



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Cost

While product management would love to take this opportunity to make updates and improvements to its cards and software, the engineering team is currently occupied with some large (and well-funded) projects. And with government spending cuts in place, upper management is reluctant to invest the time and money necessary for a complete redesign right now. They are pushing for a creative, cost-effective solution.

Performance

Overall, BPI’s products work very well in the field and customer support rarely receives performance complaints. Were they able to design new cards and software based on a Windows 7 operating system, they would certainly take advantage of higher processing capabilities. However, product functionality is not a major concern at this point.

Sustainability

One of the reasons Beyond Precision likes to do things in-house is because it provides more control over the supply chain. They set the development cycle of their card technology and code, but are still dependent on a commercial operating system. Based on previous OS lifecycles, BPI predicts that Microsoft® will stop selling Windows 7 OEM licenses in October 2014, two years after the release of Windows 8. Since 7 is the last licensing downgrade path to XP, they will face sourcing issues shortly after extended support ends.

One of BPI’s software developers suggests looking into an embedded OS. Although he hasn’t worked with them firsthand, he knows that Microsoft usually creates embedded versions that mirror the commercial ones and that they sell and support them for much longer. Perhaps it would extend the life of the current cards long enough to allow for a design refresh when the team finishes its current projects.



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The Tipping Point

With all the projects BPI currently has on its plate, a hunch that they would like to move to an embedded OS, and the clock ticking, they decide to contact a Microsoft Gold Partner with embedded OS experience to evaluate their situation and the developer’s theory.

XP to Embedded – A Truly Custom Solution The partner, who is also a computer system builder, tells Beyond Precision that it is a perfect candidate for Windows Embedded Standard 2009 (WES). WES is based on Windows XP, but is broken into functional components which can be built into highly-customized configurations, ideal for single- or limited-purpose PCs. It will allow the partner to design an OS specific to BPI’s hardware, software, and application. Best of all, it will be supported by Microsoft five years longer than XP, and available for purchase into 2024. BPI is intrigued by this option, but doesn’t have the expertise or manpower to take on the project. They decide to co-develop the solution with the system builder taking the lead.

The partner starts with the custom card and software since these cannot change. It then specifies compatible, long lifecycle hardware components that will support heavy processing and builds in redundant drives for extra reliability.

With a hardware platform established, the partner begins creating Beyond Precision’s WES image. In addition to selecting the components necessary to support the hardware and software, they incorporate additional components to support certain Windows dependencies and build custom drivers. The partner then adds BPI branding for a sleek, purpose-built interface. BPI’s testing crew helps tweak the pilot system until it is exactly what they want. Finally, the system builder partner then moves into production mode where each rackmount is assembled and imaged identically, and units are shipped to BPI for final integration.

After years of managing and configuring its own computers, Beyond Precision loves its new arrangement. By working with a partner and moving to an embedded OS, BPI has cut costs and freed up its engineers for more R&D. The initial cost of developing the system was recovered within eight months due to reduced internal labor and the lower licensing fees for Windows Embedded Standard 2009. BPI plans on sticking with an embedded OS even when it decides to upgrade its cards and software. They were pleased to hear that that transition should be even smoother.



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Windows Embedded Standard 2009 Quick Facts• Embedded/Componentized version of Windows XP Professional, Service Pack 3

• For single-purpose devices, not workstations

• Not available to the general public, only through select distributors

• Must have a Customer License Agreement (CLA) with Microsoft to deploy and resell

• Approximately 1000 OS components to choose from (using all would essentially create an XP Pro, SP3 installation)

• Approximately 9000 drivers

• Can build custom components for applications or drivers

• Minimum image size approximately 40MB (vs. 2.4GB for XP Pro, SP3)



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Chapter Six

ConclusionWere you able to find your organization in one of these scenarios? You are not alone.

In December 2012, XP users accounted for 21.1% of all web users. - Source: http://www.w3schools.com/browsers/browsers_os.asp

“According to data from Web metrics firm Net Applications and Computerworld’s projections, XP will power more than 25% of the world’s Windows PCs in April 2014. That’s an enormous number.” - Source: http://www.computerworld.com/s/article/9234316/Experts_question_Microsoft_s_decision_to_retire_XP

Over 11 years after its release, Windows XP is still a very prevalent operating system. The end of extended support and subsequent end of a commercially available downgrade path present serious issues with continuing to use it, though.

If you have not mapped out your transition, start today.

If you don’t know where to begin or are unsure how to implement your plan, consider working with an experienced partner.

Don’t have a partner? CCS-Inc. offers free consultations to qualifying industrial organizations.

Sign up today at www.endofxp.com/consultation.

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About CCS-Inc.Founded in 1981, CCS-Inc. is an ISO 9001:2008 registered business that provides computing solutions for harsh environments and mission-critical applications in industries such as manufacturing, energy, food and beverage, marine, telecommunications, and defense.

Our solutions fall into three basic categories – modified commercial, industrial white box, and custom – determined by factors like processing and I/O requirements, environmental hazards, lifecycle needs, and budget parameters. On top of our hardware solutions, CCS offers many value-added services (e.g. lifecycle management, export and regulatory compliance, custom shipping and packaging options).

As a Microsoft Gold OEM Partner, our imaging services are top notch. We work with customers to develop images and write custom scripted installations to ensure each computer we ship is configured identically. We have successfully helped companies upgrade to new operating systems, recommended cost-saving licensing structures, and created embedded OS images.

Learn more at www.ccs-inc.com.

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Documents

The Industrial Guide to The End of XP · 2013. 8. 20. · which a typical 32-bit Windows XP operating system is unable to address. A 64-bit install of Windows 7 allows full exploitation