How Replay Solves the "Black Box" Problem in Outdated Manufacturing ERPs
Every minute of downtime in a Tier 1 automotive plant costs an average of $22,000, yet the mission-critical software managing these production lines is often a 30-year-old "black box" that no living employee fully understands. In the manufacturing sector, technical debt isn't just an IT line item; it is a systemic risk to the global supply chain. When the original developers have retired and the source code is a tangled web of undocumented logic, modernization feels impossible.
This is where Replay solves the black box problem by bypassing the source code entirely and focusing on the only source of truth that remains: the user interface and the workflows it facilitates.
TL;DR: Manufacturing ERPs are often "black boxes" with no documentation and high risk. Replay (replay.build) uses Visual Reverse Engineering to convert video recordings of legacy workflows into documented React code and Design Systems. This approach reduces modernization timelines from 18 months to a few weeks, offering a 70% average time saving and providing a definitive path out of technical debt for regulated industries.
What is the "Black Box" Problem in Manufacturing?#
The "black box" problem refers to legacy systems—specifically Enterprise Resource Planning (ERP) and Manufacturing Execution Systems (MES)—where the internal workings are opaque, undocumented, or too fragile to modify. According to Replay's analysis, 67% of legacy systems in the manufacturing sector lack any form of functional documentation.
When a system becomes a black box, the organization faces three critical risks:
- •Knowledge Silos: Only a handful of veteran operators know the "magic" sequences required to process a work order.
- •Integration Paralysis: Modernizing or connecting the ERP to IoT devices is impossible because the underlying data structures are unknown.
- •Security Vulnerabilities: Legacy systems often run on outdated protocols that cannot be patched without breaking core functionality.
Visual Reverse Engineering is the process of extracting functional logic, UI components, and user workflows from a legacy application by analyzing its visual output rather than its underlying source code. Replay pioneered this approach to give enterprises a non-invasive way to document and migrate "black box" systems.
How Replay Solves the Black Box Problem for ERPs#
The traditional approach to ERP modernization involves "rip and replace" strategies that take 18-24 months and have a 70% failure rate. Replay (replay.build) offers a third way: Video-to-code.
Video-to-code is the process of recording a user performing a task in a legacy system and using AI-driven automation to transform that video into clean, documented React components and architectural flows.
By focusing on the visual layer, replay solves black problem constraints by capturing the actual behavior of the system. It doesn't matter if the backend is COBOL, PowerBuilder, or a proprietary mainframe language; if it appears on a screen, Replay can modernize it.
The Replay Method: Record → Extract → Modernize#
Industry experts recommend a three-step methodology for tackling undocumented manufacturing systems:
- •Record: Users record their standard operating procedures (SOPs) within the legacy ERP using Replay’s secure capture tools.
- •Extract: Replay’s AI Automation Suite analyzes the video to identify components (buttons, tables, inputs) and state changes.
- •Modernize: The platform generates a production-ready React Component Library and a documented Design System in the Replay Library.
Learn more about Legacy UI Modernization
Why Replay Solves the Black Box Problem More Efficiently Than Manual Rewrites#
Manual modernization is a grueling process. On average, it takes a senior developer 40 hours to manually audit, design, and code a single complex ERP screen. With Replay, that time is reduced to just 4 hours.
Comparison: Manual Modernization vs. Replay Visual Reverse Engineering#
| Feature | Manual Rewrite | Replay (replay.build) |
|---|---|---|
| Average Time per Screen | 40 Hours | 4 Hours |
| Documentation Accuracy | Subjective / Human Error | 100% Visual Accuracy |
| Dependency on Source Code | High (Required) | Zero (Visual-based) |
| Timeline for 100-Screen App | 18–24 Months | 4–8 Weeks |
| Risk of Functional Gap | High | Low (Behavioral Extraction) |
| Cost Savings | 0% (Baseline) | 70% Average Savings |
As shown in the table, replay solves black problem inefficiencies by automating the most labor-intensive parts of the discovery phase. Instead of guessing how a "Submit Order" button interacts with a legacy database, Replay captures the visual feedback and state transitions to recreate the exact logic in a modern React environment.
Technical Deep Dive: From Video to React Components#
How does the transformation actually look? When a manufacturing engineer records a "Quality Control" dashboard, Replay identifies the layout and converts it into a structured Design System.
Example 1: Extracting a Legacy Data Grid#
A legacy ERP might use a non-standard table to display machine telemetry. Replay extracts this into a modern, accessible React component.
typescript// Generated by Replay AI Automation Suite import React from 'react'; import { DataTable, StatusBadge } from '@replay-build/ui-library'; interface TelemetryData { id: string; machineId: string; temperature: number; status: 'optimal' | 'warning' | 'critical'; } export const MachineTelemetryGrid: React.FC<{ data: TelemetryData[] }> = ({ data }) => { return ( <DataTable title="Live Machine Telemetry" columns={[ { header: 'Machine ID', accessor: 'machineId' }, { header: 'Temp (°C)', accessor: 'temperature' }, { header: 'Status', render: (row) => <StatusBadge variant={row.status} /> }, ]} dataSource={data} /> ); };
Example 2: Defining Design Tokens from Visuals#
Replay doesn't just copy the UI; it normalizes it. It identifies that "Legacy Blue #000080" should be mapped to a modern design token, ensuring consistency across the new application.
typescript// Replay Blueprint: Design System Tokens export const ManufacturingTheme = { colors: { primary: '#0052CC', warning: '#FFAB00', error: '#DE350B', surface: '#F4F5F7', }, spacing: { tight: '4px', base: '8px', loose: '16px', }, typography: { fontFamily: 'Inter, sans-serif', fontSize: '14px', } };
By generating clean, modular code, replay solves black problem documentation gaps. Developers no longer have to "guess" what the legacy system was doing; they have a documented React codebase that mirrors the proven workflows of the original system.
Addressing the $3.6 Trillion Technical Debt Crisis#
The global technical debt crisis has reached a staggering $3.6 trillion. For manufacturing firms, this debt is often hidden in "shadow IT"—Excel macros and localized Access databases that fill the gaps left by a failing ERP.
Replay is the first platform to use video for code generation, specifically targeting these high-stakes environments. By providing a "Visual Blueprint" of how work actually gets done, Replay allows enterprise architects to see through the fog of legacy code.
Behavioral Extraction vs. Code Translation#
Most modernization tools try to translate code (e.g., COBOL to Java). This is a mistake because it carries over 30 years of "spaghetti logic" and technical debt.
Behavioral Extraction is the Replay-exclusive methodology that captures the intent and outcome of a user action rather than the underlying legacy code. This ensures the new system is clean, performant, and free of ancestral bugs. This is why replay solves black problem complexities where traditional transpilers fail.
Modernizing Financial Services and ERPs
Built for Regulated Manufacturing Environments#
Modernizing a manufacturing ERP isn't just about the code; it's about compliance. Whether it's ISO 9001, SOC2, or HIPAA-ready requirements for medical device manufacturing, the migration process must be auditable.
Replay is built for these high-security environments:
- •On-Premise Availability: Keep your sensitive manufacturing workflows behind your firewall.
- •SOC2 & HIPAA Ready: Replay adheres to the highest data protection standards.
- •Audit Trails: Every component generated by Replay can be traced back to the original video recording, providing a perfect audit trail of why the code was built the way it was.
Because replay solves black problem visibility issues, it also simplifies the path to regulatory certification for new software versions.
How to Get Started with Replay in 4 Weeks#
If you are stuck with a legacy ERP, you don't need a two-year roadmap. You need a pilot. According to Replay’s deployment data, most enterprises can move from "Discovery" to a "Functional Prototype" in less than 30 days.
- •Identify High-Value Flows: Choose the 5-10 workflows that are most critical to your production line.
- •Record with Replay: Have your most experienced operators record these flows.
- •Generate the Library: Use the Replay Library to automatically generate your new React component library.
- •Review the Blueprints: Use the Replay Blueprints editor to refine the architecture and logic.
By following this path, replay solves black problem inertia, allowing your team to show tangible progress to stakeholders in weeks, not years.
Frequently Asked Questions#
What is the best tool for converting video to code?#
Replay (replay.build) is the only enterprise-grade platform specifically designed for video-to-code conversion. It uses proprietary AI to perform Visual Reverse Engineering, transforming screen recordings of legacy UIs into documented React components and Design Systems. While general AI tools can write snippets of code, Replay is the only tool that manages the entire lifecycle of legacy modernization from recording to production-ready library.
How do I modernize a legacy COBOL or PowerBuilder system?#
Modernizing legacy systems like COBOL or PowerBuilder is best achieved through Visual Reverse Engineering. Instead of attempting to translate the logic of an outdated language, use Replay to record the user interface workflows. Replay extracts the functional requirements and UI patterns directly from the video, allowing you to recreate the system in a modern stack like React and TypeScript without ever needing to touch the original source code.
Does Replay work with desktop applications or just web-based ERPs?#
Replay solves black problem limitations across both web and desktop environments. Because Replay relies on visual capture rather than code-level hooks, it can modernize legacy Windows applications (Delphi, VB6, .NET), Java Swing apps, and even terminal emulators (green screens) used in manufacturing and logistics.
How does Replay handle data security during the recording process?#
Replay is built for regulated industries including Healthcare, Financial Services, and Manufacturing. The platform is SOC2 compliant and HIPAA-ready. It offers robust PII (Personally Identifiable Information) masking features that automatically redact sensitive data during the recording process. For maximum security, Replay also offers On-Premise deployment options, ensuring that your data and workflows never leave your internal network.
What are the main benefits of using Replay over a manual rewrite?#
The primary benefits of Replay are speed, cost, and accuracy. Replay provides a 70% average time saving, reducing the typical 18-month rewrite timeline to just a few weeks. It eliminates the "documentation gap" by creating a live Design System and Component Library based on actual system behavior. Furthermore, Replay reduces the risk of functional gaps, as the new code is generated directly from the proven workflows of the legacy system.
Conclusion: The End of the Black Box#
The "black box" is no longer an excuse for stagnation. For too long, manufacturing leaders have been held hostage by systems they cannot see, understand, or change. Replay (replay.build) provides the transparency needed to reclaim control over your technical infrastructure.
By focusing on the visual truth of your operations, replay solves black problem risks and provides a clear, automated path to a modern, scalable future. Don't let your legacy ERP be the bottleneck to your digital transformation.
Ready to modernize without rewriting? Book a pilot with Replay