Know exactly what you have. This is the foundation. Capture hardware specs (CPU, RAM, TPM), OS details, all installed ICS software versions, and network context for every Windows 10 device.
“From the Trenches” Tip: Don’t rely solely on documentation. Physically walk the plant floor to find undocumented panels and workstations.

Test the full migration process on a non-critical or redundant system. Before starting, clearly define success criteria (e.g., “72 hours continuous operation with no errors”). Most importantly, involve operators and gather their feedback; their buy-in is critical for a smooth rollout.

Frame the project as essential business risk mitigation, not an IT upgrade. Quantify the cost of inaction: estimate revenue lost per hour of downtime, research potential compliance fines, and show the escalating costs of the ESU program. Tailor your message to the CFO, Plant Manager, and IT Director.

Microsoft does not support in-place upgrades from any standard Windows 10 edition to LTSC. You must perform a clean installation, which means backing up your data, reformatting the drive, and reinstalling all applications. This is actually preferred in industrial environments because it gives you a clean, validated configuration. Plan for several hours per system and always test your backup/restore procedures first.

Download Microsoft’s PC Health Check tool or use PowerShell command “Get-TPM” to check TPM status. For Windows 11 IoT LTSC, you need at least 2GB RAM, 16GB storage, and a 64-bit processor. The IoT version is much more forgiving than standard Windows 11—it doesn’t require TPM 2.0 or Secure Boot. Most industrial PCs from the last 8-10 years will work, but always test in a lab environment first.

Yes, Microsoft provides 90-day evaluation versions of both Windows 10 and Windows 11 LTSC that you can download from their Evaluation Center. Use these to build your test environment and validate your applications. This is essential—never buy licenses for hundreds of systems without thorough testing first. The evaluation versions are fully functional and perfect for proof-of-concept work.

Windows LTSC works fine with Active Directory, but you’ll need to update your Group Policy Objects (GPOs) to account for LTSC-specific settings. The main difference is that LTSC doesn’t receive feature updates, so disable any GPOs related to Windows Update feature updates. Also, LTSC doesn’t include Microsoft Store apps, so remove any policies trying to manage store apps.

Functionally, they’re nearly identical. The key difference is licensing and hardware requirements. Standard Enterprise LTSC enforces strict hardware requirements (TPM 2.0, Secure Boot, modern CPU). IoT Enterprise LTSC makes these optional, allowing installation on older industrial hardware. If your hardware meets the requirements, either works. If not, IoT Enterprise LTSC is your only Windows 11 option.

Your systems will keep working day-to-day, but you’ll accumulate security vulnerabilities that can never be patched. Your cyber insurance may be cancelled, audits will fail, and you’ll violate compliance frameworks like NIST SP 800-171. Eventually, software vendors will stop supporting applications on Windows 10, and hardware vendors won’t provide drivers for new equipment. You’ll be stuck with aging, increasingly vulnerable systems that can’t be modernized.