Extreme OT Data Makeover: From Good to Great with Four Capabilities

Unlocking the Power of Industrial Digital Transformation Through OT Data

Industrial digital transformation is no longer a luxury—it's a necessity for business vitality. Originating from Industry 4.0, this movement has rapidly evolved into a cornerstone of operational success. However, according to the 2020 Industrie 4.0 Maturity Index, more than 90% of businesses are still in the early stages of this journey. Many are struggling to capture, aggregate, and analyze data generated by their operational technology (OT) environments. Without the ability to harness this data, businesses cannot realize the full benefits of big data analytics, AI, and other innovative solutions. So, how can companies make meaningful progress in their digital transformation?

The key lies in unlocking the value of OT data—data that is often difficult to capture and prepare for analysis due to the harsh environments and complexity of industrial systems. At Moxa, we have identified four crucial pillars that can help businesses transform their approach to OT data and, in doing so, accelerate their digital transformation.

1. Breaking Down Data Silos: A Crucial Step for Data Acquisition

One of the biggest challenges companies face is the lack of sufficient data due to data silos. Traditional automation systems were designed to support operations, not data analysis. As a result, valuable data often remains trapped within individual systems, limiting its use for broader business insights.

Take the example of a factory with a critical bottleneck machine. If the machine fails, the entire production line halts. To avoid this, the plant needs predictive maintenance that relies on key data from the machine’s components. However, many machines don’t provide this data, making it necessary to install sensors and convert analog signals to digital ones via remote I/Os. Once digitized, this OT data can be transmitted to servers or the cloud, enabling predictive maintenance and avoiding costly downtime.

To tackle data silos across multiple systems, factories are turning to consistent, open standards such as OPC-UA or using industrial protocol gateways to translate proprietary machine languages into usable data. This step is essential for OT Data Acquisition, laying the foundation for a successful digital transformation.

2. Turning Raw Data Into Actionable Insights: The Importance of Data Preparation

Once data is captured, it must be transformed into meaningful information that can drive decision-making. Raw OT data is often unusable for IT analysts, as it lacks the necessary context to generate insights. For instance, a motor's current readings taken every second over the past seven days are just numbers without additional details like timestamps or operational events.

In this scenario, OT Data Preparationplays a pivotal role. By processing data at the edge, filtering out unnecessary noise, and ensuring only relevant data is sent to IT systems, businesses can prevent data overload. This not only streamlines the flow of information but also reduces costs associated with data transmission and storage. Smart IoT devices can help regulate the frequency of data uploads, ensuring IT systems receive the right data at the right time.

3. Ensuring Complete Data Transmission Across the Network

For industrial digital transformation to succeed, OT data must be transmitted efficiently and in real time. However, traditional OT networks are designed for control, not mass data transmission. As more data is generated for analysis and decision-making, the challenge is to avoid overwhelming OT networks with IT data.

The solution lies in next-generation technologies like Time-Sensitive Networking (TSN), which prioritize critical data transmission without compromising control systems. By integrating TSN, businesses can ensure that real-time control data and IT data coexist on the same network without interference. Robust OT Data Transmission is crucial to achieving zero failures in production environments.

To further safeguard data transmission, contingency plans should be in place to address environmental disturbances like extreme temperatures or electromagnetic interference. Backup mechanisms and local data storage can help prevent data loss during network disruptions, ensuring complete and accurate data transmission.

4. Safeguarding Data Integrity: Enhancing OT Data Security

In today’s connected world, cybersecurity is a top priority. As OT systems become increasingly internet-connected, they are vulnerable to attacks that can compromise both data integrity and operational safety. Many businesses mistakenly believe that traditional IT security solutions can be directly applied to OT environments, but the reality is far more complex.

Unlike IT systems, OT environments prioritize availability and stability, making them less compatible with common security tools like antivirus software. To protect OT systems, businesses must implement industrial-grade cybersecurity solutions. This includes deploying Intrusion Protection Systems (IPS) to monitor critical devices, leveraging network segmentation to contain ransomware attacks, and using network management software to visualize and address risks across different OT communication protocols.

With strong OT Data Securitymeasures in place, companies can safeguard their operations against cyber threats while maintaining the integrity and reliability of their OT data.

Conclusion: Empower Your Digital Transformation with Quality OT Data

As businesses navigate the industrial digital transformation landscape, the quality of their OT data will determine the success of their initiatives. By focusing on data acquisition, data preparation, data transmission, and data security, companies can lay a solid foundation for digital transformation and unlock the full potential of big data and AI. Don’t let poor-quality data hinder your progress—let Moxa’s solutions empower your transformation journey.

Contact us today to learn how we can help you harness the power of OT data and drive your industrial digital transformation forward.

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