Are You Ready for Digital Transformation in Your Industry Network?

The Internet of Things (IoT), cloud computing, and artificial intelligence (AI) are among the most widely used technologies for digital transformation in the industry. Thanks to these technological innovations, achieving goals such as preventive maintenance, production optimization, reduced defect rates, energy conservation, carbon footprint reduction, etc. has become more feasible. However, supporting these technologies necessitates a reliable foundation that consistently delivers trustworthy operational (OT) data. Put simply, a dependable industrial network is essential.

Advancing OT Networks

In a previous piece titled Unveiling the Mysteries of OT Data for Industrial Digital Transformation, we highlighted the fact that digital transformation in the industry constantly enhances the value of OT data by qualitatively and quantitatively altering it. Concurrently with these fundamental changes, there has been a progression in industrial networking technology.

Initially, most machinery on factory floors operated independently, and OT data was primarily used to oversee and manage specific equipment operations. Data was primarily confined within the devices that generated it and was transmitted via simple serial-based communication setups. However, with the emergence of automated systems, factories started connecting various machines to enable communication between them. This led to a significant increase in data transmission volume and a shift from basic serial communication to a more complex structure incorporating Ethernet at regional levels.

The Industry 4.0 Era, also known as the era of industrial digital transformation, facilitated customers in optimizing their machinery operations and moving beyond mere monitoring to more advanced functionalities. A notable outcome of this shift is the elevated status of OT data as a cornerstone of industrial digital transformation. To achieve the desired levels of optimization, OT data now needs to be forwarded to IT systems or cloud platforms for further analysis. Therefore, OT data can no longer be confined to the originating devices. These developments have triggered three major transformations in industrial networking:

• From Intranet to the Internet: Expanding Horizons

To enable smooth transmission of OT data between OT networks, IT networks, or the cloud, the old silos that previously provided protection within internal networks must be dismantled. Moreover, with the increasing connection of OT systems to the Internet, emphasis must shift from securing physical locations to safeguarding OT data, focusing on data security and OT network security. Merely managing physical security risks, such as restricting access to OT areas or prohibiting personal USBs and laptops on-site, is no longer sufficient. For example, when linking trackside PLCs to a central control center, it is imperative to ensure that up-to-date antivirus software protects the PLCs. Without such precautions, PLCs can pose a severe security threat to the internal network system. Therefore, cybersecurity must be a primary consideration during implementation.

• From Segregated to Integrated: Integrating Across Generations

As devices shift from reactive to interactive modes, subsystems that previously functioned autonomously must now collaborate. This transformation necessitates the integration of industrial networking technologies developed in different eras into a cohesive network. Subsequently, this integration gives rise to new managerial challenges that can only be resolved through a comprehensive visualization of the network. For instance, a client in the intelligent transportation system sector recently encountered difficulty navigating their system once the entire network was interconnected. Instead of reducing labor requirements as anticipated, an additional 67% of their workforce was needed solely to identify a disconnected link in the vast network. This underscores the importance of effective industrial network management.

• OT vs. IT: Bridging the Historical Divide

For a more in-depth analysis, OT networks now require a broader range of data, including equipment statuses, images, and video feeds, in addition to the traditional control data transmitted. Consider the mining sector, where remote intelligent operation systems must promptly identify potential risks to miners entering hazardous zones. These systems achieve this by gathering real-time data, such as live feeds from deployed automated mining equipment and underground mining conditions, alongside immediate data on air quality, toxic gas levels, etc. However, accommodating both OT and IT data on the same network can lead to bandwidth congestion. Such congestion delays the dissemination of critical control data throughout the system, resulting in production disruptions. Therefore, maintaining an evolving intelligent system while exercising firm control over deployed devices is crucial.

Shouldn’t Your Management Approach Evolve as Your OT Network Does?

Recognizing the significance of evolving OT networks is paramount, as any significant glitch could impact production and jeopardize personnel safety. Consequently, mastering effective industrial network management is a prerequisite for engagement in this domain. Unfortunately, in many cases, only the data visible on monitoring systems (e.g., SCADA) and terminal equipment is managed, while data generated by communication equipment connecting monitoring systems to field devices, or among the devices themselves, often goes unattended. This oversight could have severe repercussions in case of a disconnection. Thus, enhancing one’s capabilities in managing OT networks effectively is not only essential but crucial. To delve into more practical experiences in the OT field, tune in to our OT Data Next Podcast.