Making Factories “Smarter” With OT Data Integration

What’s the difference between traditional manufacturing environments and smart manufacturing environments? In each, the manufacturing production line is made up of sequential process steps that perform a specific function. At the beginning of the production line is “raw” material, and at the very end of the line is a finished product.

Traditional manufacturing environments mostly rely on manual execution of these steps. Each workstation in a manufacturing facility has a “recipe” detailing which steps the operator must take to make the workstation as efficient as possible. A not-so-smart factory relies on human effort to manage these processes. Since manufacturers generally have a strong requirement for production uptime, all measurements, analysis or changes to this production process are executed by hand during breaks in production.

Smart factories, on the other hand, are connected using emerging tech data threads. This can be as simple as using cameras to count units on the production line rather than manually counting each one, or as complex as full automation of manufacturing execution systems (MES). The goal is to automate as much of the manufacturing process as possible, not only to improve efficiency but to analyze the quality of the final products and determine how to improve the production process going forward.

Generally, the more automated a production process is, the easier it is for manufacturing organizations to see tangible results, like:

• Improved availability from predictive maintenance. Integration of OT data with predictive analytics enables the early detection of equipment malfunctions, reducing downtime and future maintenance costs.
• Increased operational efficiency. Real-time data access and analytics empower decision-makers to optimize processes, identify bottlenecks and improve overall efficiency.
• Enhanced product quality. Continuous data monitoring and analysis can lead to product quality improvements and fewer defects.
• Improved safety and compliance. Monitoring critical parameters in real time allows for timely responses to potential safety issues, ensuring compliance with regulatory standards.
• Greater business agility. IT and OT convergence fosters an agile environment, allowing organizations to adapt quickly to changing market demands and opportunities.
• Improved security posture. Converging IT and OT security strategies enhances overall cybersecurity as both domains can collaborate to identify and mitigate threats effectively.

Smart factory automation sounds great on paper, but bringing OT data together with IT systems is not always a straightforward task. For starters, OT and IT teams have typically operated separately from one another — in some cases, aggressively so.

Prioritizing uptime, safety and real-time operations, OT refers to the technologies used to monitor, manage and secure an organization’s industrial operations. Examples of operational technology (OT) include production line robots, industrial control systems (ICS), supervisory control and data acquisition (SCADA) systems, programmable logic controllers (PLCs), and computer numerical control (CNC).

OT data comes from the sensors and controllers which are directly connected to physical industrial equipment. This includes machines on the factory floor that provide real-time information about the equipment's status, performance and operational parameters like temperature, pressure, vibration and current. This data allows for monitoring and control of physical processes within a facility or system.

IT, on the other hand, is focused on data security, long-term strategic goals, and enterprise-level systems. Historically, IT teams have been siloed from OT teams, as OT teams would rather not risk machinery uptime due to IT upgrade initiatives and the risks that come with it.

Beyond this difference, there are several challenges in bringing these two historically disparate teams together, including:

• Outdated equipment and security gaps. Many OT environments rely on outdated or proprietary equipment and protocols. When connected to IT systems, these environments may have major vulnerabilities that leave the organization open to cyber threats.
• Overly complex environments. Integrating legacy OT systems with modern IT platforms can be complex and costly, often requiring custom interfaces or retrofitting equipment.
• Scalability Limitations. Expanding OT Networks to accommodate emerging technology growth requires careful investment and planning, especially factoring in real-time data processing needs for high reliability, low latency and an “always on” priority.
• Skills gaps. IT professionals may lack OT domain expertise, and OT professionals may lack familiarity with IT systems.
• Team culture. The overall mindset of most OT teams tends to be, “If it isn’t broken, don’t fix it,” while IT teams prioritize longer-term strategies, innovation and staying ahead of the curve.

Though OT data integration can be a steep climb for some manufacturers looking to start or enhance their journey toward smart factory automation, cross-functional collaboration strategies can help address these challenges and ensure a secure, seamless transition. This is where to start:

1. Bring OT and IT teams together. OT data integration will take collaboration from both teams to make the transition work for each side of the business. Neither IT nor OT teams can manage all of the moving parts themselves. Start by bringing together key members of both teams to determine the steps that each team must take to integrate OT data without impacting productivity and manufacturing operations.
2. Gain visibility into all of your assets. Successful OT data integration is impossible without a view into the assets on your network and what they are doing. Without comprehensive visibility into all OT assets, critical vulnerabilities can go unidentified and unpatched, providing attackers easy access points for exploitation.
3. Prioritize assets by value. Once you have a clear picture of the assets on your network, the next step is to determine which are the highest value to the business. The assets that are severity level one (SEV 1), which would cause critical production issues if impacted, should be prioritized first.
4. Secure your assets. During OT and IT integration, many organizations may try and secure everything all at once, only prioritizing those assets with easily identifiable vulnerabilities. Rather than playing this game of “whack-a-mole” with your assets, start by prioritizing those assets which carry the most impact to your business.
5. Adopt an integration framework. Standardized frameworks like IEC62443 can help improve data sharing and operational efficiency while ensuring that all critical assets are protected. This will help determine where to start when segmenting OT networks, securing remote access, and deploying real-time threat detection and response tools to quickly address potential breaches.
6. Measure overall equipment effectiveness (OEE). OEE is a standard used by manufacturers to measure operational efficiency and productivity in day-to-day operations. The OEE formula is: (availability)*(performance)*(quality). Benchmarks vary across industries, but an OEE score of 65%- 85% is common. This will give your organization a “starting point” from which to track improvements.

Manufacturers may be at several different points in their journey toward smart factory automation. While OT data integration promises substantial benefits like improved efficiency, productivity and decision-making within smart factory environments, getting there requires overcoming a few key hurdles.

Working with a solution integrator who has deep expertise in manufacturing, operational technology and both OT and IT security can help you safely and securely adopt these advanced technologies to take your organization to the next level. A CDW Transformation Workshop, for example, is designed to help your organization gain insight into your critical business functions and determine which high-value areas to start with before implementing a technology transformation initiative.