Is the Brilliance of OT Data Visible Beyond its Protective Cover?

Don’t miss the OT Data Revolution Series for more insights:

• Unraveling the Mysteries of OT Data in Industrial Digital Transformation
• Avoiding Pitfalls: Safeguarding Your Industrial Digital Transformation with OT Data
• A Transformation Tale: Elevating OT Data to Excellence with Four Key Capabilities
• Fostering a Robust OT Cybersecurity Foundation: The Importance of Asking the Right Questions
• Access our comprehensive white paper on unlocking the potential of OT data.
• To delve deeper, explore our dedicated microsite.

OT Data Embracing the IT Realm

What is propelling operational data (OT data) to venture into the domain of IT? What factors are motivating OT data to break free from its familiar boundaries and explore new territories? And why is this transition critical for the future of industrial automation? In the latest episode of OT Data Next, our expert at Moxa, Johnny Wang, delves deep into the significance of OT data delving into the IT realm and uncovers the potential risks that lie ahead.

According to Wang, the migration of OT data is intrinsically linked to our operational requirements. Wang highlighted the significance of utilizing OT data effectively. Let’s trace the evolution of OT data, commencing from the era of Industry 2.0. This period heralded the introduction of electricity and assembly-line manufacturing, leading to the development of control systems to better manage the devices on the factory floor amidst the surge in mass production. The implementation of rudimentary on-off switches by these control systems facilitated the completion of basic routine tasks. Initially, data was limited in volume and remained confined to the devices that generated it. During its early stages, OT data in the Industry 2.0 era was restricted to operations within the respective devices.

The third Industrial Revolution introduced automation systems as the new norm. Advancements in computing and communication technologies enabled the integration of automated production processes, allowing devices to connect and communicate seamlessly. This was achieved by incorporating sensors into the initial control systems, establishing a closed loop wherein sensors collected data for preliminary calculations by the controller. Subsequent feedback based on these calculations aided in executing commands. This transition marked the first instance of OT data traversing from an enclosed device-centric environment to circulating among a limited number of devices within a closed-loop system.

Driven by continuous technological progress, the metamorphosis of OT data was inevitable. With the advent of Industry 4.0, or Industrial Digital Transformation, the demand for sophisticated, self-adaptive systems surpassed the conventional preprogrammed automation modes. This elevation in expectations propelled the evolution of OT data to the next phase. Consequently, the focus now shifts towards maximizing the inherent value of OT data. To accomplish this feat, OT data must expand its horizons beyond traditional boundaries and enter data centers or the cloud for advanced analytics to enhance production efficiency, elevate product quality, minimize expenses, and potentially introduce novel business services. This evolutionary leap kickstarted a paradigm shift that transformed protected and localized OT data into actionable insights when transmitted to remote IT systems and subsequently fed back to the OT environment for real-time optimization. This paradigm shift, dubbed the Infinite Data Stream by Moxa, illustrates the perpetual circulation of data between OT and IT segments, creating a continuous feedback loop.

Wang highlighted a case involving an automotive parts manufacturer to exemplify this transformative process. The factory featured a critical piece of equipment known as a “bottleneck device,” necessitating the passage of all items through this equipment during the manufacturing process. Consequently, any halt in this equipment’s operation led to a standstill in the production line, underscoring the significance of maintaining this equipment. To address this challenge effectively, the manufacturer opted for predictive maintenance on the equipment to anticipate impending component failures and preemptively stock up on replacements to avert production disruptions. Additional sensors were installed on the bottleneck equipment to capture relevant OT data, which was then analyzed in cloud-based computing platforms. Subsequent evaluations of parts status facilitated predictive insights for managerial action. (For more detailed insights, please refer to Dual Strategies for Maximizing IIoT Benefits in Manufacturing.)

Is OT Data Primed for Integration into the IT Ecosystem?

While the maneuver of transferring data from the OT domain to the IT domain seems promising, several factors must be considered before plunging into this comprehensive transition. Wang outlined three essential considerations before embarking on this journey:

1. Data Compatibility:The foremost and prevalent challenge encountered during the migration of OT data beyond its traditional boundaries pertains to the harmonization of OT/IT datasets. Since the communication protocols employed in the OT domain often differ significantly from those in the IT domain, systems frequently encounter communication discrepancies when attempting to exchange data between the two realms. For instance, when an OT data output displays a singular value like “5” without context, the IT system remains oblivious to its significance, resulting in communication breakdowns. To facilitate the seamless exchange of data between OT and IT realms, preprocessing of OT data is essential.

2. Data Consistency:The secondary challenge involves ensuring the comprehensive transmission of OT data through connectivity technologies without fragmentation. This task is particularly arduous due to the myriad disturbances prevalent in OT environments, including electromagnetic interference generated upon device activation, extreme temperature fluctuations, adverse environmental conditions, and the potential interference between the control network and the OT data network. These disturbances may lead to communication interruptions or instabilities, resulting in partial or interrupted data transmissions that can compromise data analysis accuracy and subsequent decision-making processes. In such scenarios, reinforcing the “robustness of data transmission” is imperative to guarantee the complete and timely transmission of data.

3. Data Protection: Finally, as the value of OT data escalates, ensuring the secure transmission of this data becomes paramount. Historically, cybersecurity concerns were relatively rare because the physical barriers of a traditional factory provided ample protection for the data contained within. However, with the integration of OT data into IT networks or cloud-based platforms, the conventional protective measures within factory premises are inadequate. Consequently, enhancing the “security of OT network” emerges as a critical focal point for enterprises seeking to safeguard their data assets.

Selecting the Right Ally for Your OT Data

As your OT data embarks on this transformative journey, selecting the apt ally is integral to navigating through these multifaceted challenges securely. Amidst a landscape rife with potential threats, how can you identify the ideal custodian to guide your OT data? Click on the link below to explore more about the ideal companion for your OT data on this episode of OT Data Next.