IoT has impacted the way we interact with our objects, homes and cities, but it is also revolutionising industrial automation and healthcare. At the heart of this transformative technology are the IoT Gateways, a set of networking and computing devices which play the main role in connecting and managing the things we connect to the internet (IoT devices). In this article, we'll delve into the different types of IoT devices and IoT gateway devices and the latter's functionalities. Examples of IoT Devices The Internet of Things (IoT) encompasses a wide range of devices across various industries and applications. Here is a list of examples of IoT devices: Industrial or Business-grade IoT Devices Industrial Sensors: Sensors used in manufacturing and industrial settings to monitor equipment health, production processes, and safety. For instance: Tooling Performance Sensors: Specialised sensors used in manufacturing and machining processes to monitor and optimise the performance of tools, such as servos, e-chains, LM rails and guides, cutting tools, drills, and milling tools. These can help to monitor tool wear, temperature, force and torque, tool breakage, tool life, process compliance, quality and OEE, often in real-time. Data can be shared to MES / SCADA applications for maintenance and OEE monitoring. Predictive Maintenance Sensors: In industrial settings, sensors are utilised for predictive maintenance. For instance, vibration sensors such as those from NSK, SKF or Rockwell Automation can monitor the vibrations of rotating machinery. By analysing these vibrations, the system can forecast when equipment might fail, allowing for timely maintenance to prevent costly breakdowns. Temperature and Humidity Sensors in Food Storage: In the food industry, temperature and humidity sensors are critical for maintaining product quality. IoT sensors can be placed in refrigerators, freezers, and storage areas. These sensors monitor conditions in real-time and send alerts if temperatures or humidity levels deviate from safe ranges. Smart Thermostats: These devices can be controlled remotely and adapt to your heating and cooling preferences. Energy Efficiency IoT Devices: Energy Management IoT Devices play a critical role in the manufacturing industry by helping companies monitor, control, and optimise their energy consumption, contributing also to environmental sustainability. Some of these include IoT-enabled Smart Electricity Meters, Power Quality Monitors, Energy Flow Sensors, IoT-Enabled HVAC Controls, Smart Lighting Solutions, IoT-Enabled Demand Response Controllers and Battery Energy Storage Systems (BESS). Advanced Plant Monitoring: APM (Advanced Plant Monitoring) IoT Devices enable monitoring of the manufacturing plant, extracting data from manufacturing systems such as robots, CNC machines, autonomous mobile robots, PLCs and energy meters, presenting the data on various front ends such WEB application and mobile App, which can be used interchangeably. The user can have alerts, production level in a certain time frame, OEE and other information displayed on the holographic interface. Learn more about IoT Edge for Industrial purposes. Connected Cameras: Industrial cameras aid computer vision in industrial processes, facilitating predictive maintenance, product quality and process efficiency. Security cameras that stream video to your smartphone and offer features like motion detection. Asset Tracking Tags: Small, battery-powered devices used in logistics and supply chain management to track the location and condition of assets. Environmental Sensors: Devices that measure air quality, temperature, humidity, and other environmental factors for home or industrial use. For instance: Air Quality Monitor: Devices such as the "AirVisual Node" that measure air quality by detecting pollutants like particulate matter (PM2.5), volatile organic compounds (VOCs), and carbon dioxide (CO2). These sensors provide real-time data and can connect to your smartphone to provide air quality alerts and historical trends, aiding you in making informed decisions regarding indoor air quality. Smart Thermostat with Environmental Sensors: Some smart thermostats, like the Ecobee SmartThermostat, incorporate environmental sensors to monitor temperature, humidity, and occupancy. These sensors help optimise heating and cooling settings based on room conditions, making your HVAC system more energy-efficient. Smart Smoke Detectors: Smoke detectors that send alerts to your phone and provide real-time information about potential fires. Smart Agriculture Devices: IoT devices used in agriculture for soil monitoring, crop health, and automated irrigation. Smart Streetlights: Streetlights equipped with sensors to adjust lighting based on traffic and weather conditions, saving energy. Smart Grid Devices: Devices used in the electrical grid to monitor and manage energy distribution efficiently. Water Quality Sensors: Sensors placed in bodies of water to monitor water quality and detect pollution. Smart Vending Machines: Vending machines equipped with sensors and connectivity for inventory management and sales tracking. Retail IoT Devices: Devices like smart shelves and beacons used in retail stores for inventory management and customer engagement. Smart Mirrors: Mirrors with built-in displays that provide information like weather, news, and fitness data. Healthcare IoT Devices: Devices like connected glucose monitors, pill dispensers, and remote patient monitoring systems. For instance: Remote Patient Monitoring Devices: IoT devices in healthcare encompass remote patient monitoring solutions. These systems enable patients to measure and transmit vital signs, such as blood pressure, heart rate, and glucose levels, to healthcare providers remotely. This facilitates continuous monitoring of patients with chronic conditions and reduces the need for frequent hospital visits. IoT-enabled Medical Devices: Medical devices such as insulin pumps, pacemakers, and continuous glucose monitors with remote monitoring capabilities IoT-Enabled Imaging: Advanced X-ray, CT or Ultrasound machines in healthcare facilities are now equipped with IoT capabilities. These devices capture high-resolution medical images and transmit them digitally to a secure network for immediate analysis by radiologists and other specialists. This technology improves the speed and accuracy of diagnoses. Smart Hospital Beds: These beds come with occupancy sensors that monitor patient movement and occupancy status. Healthcare staff can check the availability of beds and receive alerts when a patient needs assistance. IoT-Based Patient Room Monitoring: Smart sensors in patient rooms can detect occupancy and adjust lighting, temperature, and other environmental factors to enhance patient comfort and conserve energy when rooms are unoccupied. Medical Equipment Tracking: Hospitals use IoT-enabled tags and sensors to track the location and status of medical equipment such as defibrillators, infusion pumps, and wheelchairs. This ensures equipment availability and reduces the time spent searching for essential items. Pharmaceutical Inventory Management: IoT devices are employed to monitor pharmaceutical inventory levels in hospitals and clinics. When stocks are low, automatic alerts are generated, helping to prevent medication shortages. Temperature and Humidity Control: Healthcare facilities require precise control of temperature and humidity for patient comfort and the safe storage of medications and laboratory samples. IoT sensors and systems regulate these conditions, with remote monitoring and alerts for maintenance. Airborne Pathogen Monitoring: IoT devices can monitor the air for potential pathogens and contaminants, providing early detection of airborne diseases or pollution, which is crucial for infection control in healthcare settings. Smart Pill Dispensers: These devices dispense medication according to a prescribed schedule and send reminders to patients' smartphones. They also track medication adherence and can alert healthcare providers or family members if doses are missed. Personal-use IoT Devices Smart Home Lighting: Bulbs and fixtures that can be controlled and scheduled through a smartphone app or voice commands. Smart Locks: Locks that can be controlled and monitored remotely, allowing you to grant access to your home or business securely. Smart Appliances: Appliances like refrigerators, ovens, and washing machines that can be controlled and Wearable Fitness Trackers: Some devices can monitor your health and activity levels. Smartwatches: Watches with IoT capabilities, including notifications, health tracking, and even making calls. Connected Cars: Vehicles equipped with sensors and connectivity features for navigation, diagnostics, and entertainment. Pet Trackers: GPS-enabled devices that help you keep tabs on your pets' location and activity. Connected Coffee Makers: Coffee machines that can be controlled and programmed through a smartphone app. Smart Garden Devices: IoT devices for gardening and landscaping, including automated irrigation and soil monitoring. Connected Gaming Consoles: Gaming consoles that offer online multiplayer gaming and content streaming. What is an IoT Gateway Device? An IoT gateway is a hardware device which includes software to act as a data protocol intermediary and data transferrer between IoT devices and the Cloud, a Central Data Centre, or an Edge Computing device. These gateways are responsible for collecting data from IoT device sensors, processing real-life data locally, and then transmitting it to the cloud or an edge computing platform for further analysis and use. They play a vital role in ensuring the security, reliability, and efficiency of IoT ecosystems (Examples of IoT Gateway Devices). Examples of IoT Gateway Devices Edge Gateways: Edge gateways are deployed at the edge of the network, close to IoT devices, and sensors. They are designed to perform data preprocessing and filtering tasks. Edge gateways are particularly useful in scenarios where low-latency processing is crucial, such as industrial automation and autonomous vehicles. Their key functionalities include data aggregation, protocol translation, and local analytics. Cloud Gateways: Cloud gateways, also known as cloud connectors, facilitate the communication between IoT devices and cloud platforms. These gateways are responsible for securely transmitting data to the cloud, where it can be stored, analysed, and visualised. They often employ standard IoT protocols like MQTT or HTTP to send data to cloud-based applications. Mobile IoT Gateways: Mobile IoT gateways are designed to support IoT deployments in remote or mobile environments. They can operate in areas without a fixed internet connection by utilising cellular networks and Data Sims. These gateways are commonly used in applications such as asset/fleet management, agriculture, and personnel/asset tracking. Industrial IoT (IIoT) Gateways: IIoT gateways are tailored for industrial environments and are built to withstand harsh conditions. They often feature ruggedised designs and support industry-specific communication protocols like Modbus or OPC UA. IIoT gateways help in connecting and managing sensors, controllers, and machinery on the factory floor. Multi-Protocol Gateways: Multi-protocol gateways are versatile devices that support multiple communication protocols simultaneously. This flexibility makes them ideal for IoT ecosystems with diverse devices using various communication standards. They can bridge the gap between devices that communicate using different protocols, ensuring seamless data exchange. Security Gateways: Security gateways prioritise data security and privacy. They often incorporate advanced encryption and authentication mechanisms to protect data in transit and at rest. Security gateways are vital in applications where sensitive information is collected, such as healthcare and financial services. Know more about our portfolio of IoT Gateway Devices. Functionality of IoT Gateway Devices: Data Aggregation: IoT gateways collect data from multiple devices and sensors, aggregating it into a coherent dataset for further processing. Protocol Translation: They can translate data between different communication protocols, ensuring that devices with varying protocols can communicate effectively. Local Processing: Edge gateways perform local data processing and analytics, reducing the need to transmit large volumes of data to the cloud. This helps in reducing latency and conserving bandwidth. Data Filtering: IoT gateways filter out irrelevant or redundant data, ensuring that only meaningful information is transmitted, which improves network efficiency. Security: Many IoT gateways include security features such as firewalls, encryption, and intrusion detection to protect data and devices from cyber threats. Device Management: Gateways often provide device management capabilities, allowing administrators to configure, monitor, and update connected IoT devices remotely. Scalability: IoT gateways are designed to scale as the IoT ecosystem grows. They can handle an increasing number of devices and adapt to changing requirements. Conclusion on IoT Gateways & IoT Devices IoT gateways are indispensable components of IoT ecosystems, serving as bridges between IoT devices and the cloud. They come in various types, each tailored to specific applications and environments. Understanding the different types of IoT gateway devices and their functionalities is essential for designing efficient and secure IoT solutions that meet the unique needs of various industries and use cases. As IoT continues to evolve, these gateways will play an increasingly critical role in ensuring the success and sustainability of IoT deployments. 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A mix of automation with advanced analytics in the form of IoT Edge Apps can drive smarter, faster business decisions for industrial companies, regardless of their size. Through scalable IIoT platforms, these Edge to Cloud Apps can help increase manufacturing efficiency through the data-based optimisation of production quality, performance, uptime and OEE. The Industrial IoT Edge for Machine Tools employs Edge & Cloud Computing for the Manufacturing industry to run applications on a computing platform that is located near the shop floor and can also communicate via IoT. The proximity enables the expansion of automation capabilities, the implementation of resource-intensive stream processing and learning algorithms, and the hosting of integration code for site automation. The Cloud enables AI, Remote Access and Scalability capabilities. The following Smart Factory IoT Edge Apps will help boost your production efficiency. IoT Edge Apps for Performance Improvement: Turn data collected from production equipment into clear process overviews that help improve your manufacturing performance. The following IIoT solutions can also support you in reducing production costs and improving profitability. Robot Performance Check App This solution helps you to monitor robotic machines, PLCs, sensors, peripheral devices, and other equipment in the factory. Data can be collected and visualised to provide more information about manufacturing processes and their history. The App allows you to review the operational results on the machine level. You can review the production results and compare them against the production plan. Key benefits include: Improve productivity due to detailed machine data and improve uptime by periodic maintenance info. Check machine utilisation and find machines that are underutilised. Visibility on tool life information for increased uptime, alarm history, program history, signal history and macro value history. Save time by getting automatic custom regular reports and having a backup for CNC systems and programs. Communication with an upper host system such as a manufacturing execution system (MES). Production Progress Monitor A lightweight dashboard providing a clear overview of production progress and actual equipment statuses for all connected devices. Individual monitoring allows seeing the running status of devices, productivity and alarm history. Some of the benefits of this IoT Edge App are: Real-time production status visibility. The production progress of any connected machine can be tracked. Malfunctioning machines are immediately visible and repair can be arranged proactively. Productivity can be analysed based on historical data. AI Computervision for Manufacturing This is the next-generation pick-and-place system for industrial robots. The App uses artificial intelligence and optical sensing to enable robots to perform high-precision grasping of new objects, even in high-mix low volume production environments. This system is particularly well-suited for industries that rely on plastic or metal components and where traditional pneumatic grippers are not suitable. Features include: Automated object recognition: Industrial robots recognise and handle new objects without reprogramming with a 24h gap between 3D design and first sample to running production. Tag scanning for tracking components. Mixed product line differentiation and sorting. Inventory management through integration with your logistics system. Custom solution development is available. Interested in these Apps? Contact us for more info. Uptime Enhancement IoT Edge Apps: A breakdown on the factory floor can cause significant production downtime and costs. However, it is possible to detect anomalies and receive notifications in advance to eliminate unplanned production stoppages. Machinery Daily Check Daily Check is an application that allows an easy and reliable execution and recording of daily checks on machinery, performed through mobile devices. Checked items will be uploaded to the Edge to Cloud system by reading QR codes placed on field equipment. Records can be input by selecting checks in the App, filling in a form, and/or photo-taking, and the check results can be confirmed via remote PCs. This allows manufacturers to: Improve their machine and process reliability by enabling frequent high-quality checks. Improve control of the machine's condition through remote supervision. Remote I/O Management App A Wireless Remote IO System with OPC UA enables IO information to be sent not only to the Fieldbus machine control system but also directly to an IoT Edge system. It provides the OPC UA data required for ERP, MRS and dashboard software integration directly from the remote IO station, with no need for protocol conversion. With a Wireless IO OPC UA app, manufacturers can: Set alarm outputs for cycle counts to enable a preventative maintenance edge to their business. Integrate data easily into dashboard web clients for display purposes, as well as industrial connectivity for PLC control. Reduce downtime to Zero from comms cable failure. Get local or remote access to I/O diagnostics. Integrate other apps for condition monitoring purposes or quality monitoring by learning standard production patterns. Zero Downtime Viewer An application that helps check the status of all downtime servers registered in this application on a single screen. This app helps reduce unexpected downtime of robots and machinery by monitoring their condition. Features include: Monitoring of abnormalities from normal equipment conditions. Improved analysis through easy access to robot data. Visualisation of all the production assets on a single screen. Servo & Spindle Monitor An app that visualises anomalies of drive systems for servos and spindles through machine learning. It can analyse daily processing data and display the results in intuitive graphs. Manufacturing managers can easily monitor abnormalities on the machines and analyse the recorded production data of each drive system. Features include: Monitoring of mechanical elements of an axis. Data collection from the machine servo motor. Easy creation of failure prediction systems. Monitoring of anomaly scores in intuitive graphs. Automatic creation of an ML baseline model. Guide Lubrication & Damage Status App A vibration sensor fitted into any machine LM rails will detect oscillations during specific movements triggered by CNC or Robot controllers. The oscillations are analysed into signals for lubrication and damage by a unique algorithm in the amplifier. These lubrication and damage signals are plotted on the App dashboard. This App allows manufacturers to easily: Visualise sensor oscillation data and analyse signals for lubrication and damage status through the App's unique algorithm. Apply Condition-based Maintenance to connected devices. Connect Line Operations at scale (up to 90 sensors per connector). Bearing Condition Monitoring / Diagnostic Software This app monitors the operating status of machine elements by diagnosing the early signs of damage or deterioration in bearings, ball screws, and linear guides. It helps keep equipment running at peak performance, and visualise the state of these critical machine elements as a key part of predictive maintenance. Some features of this solution include: Unique vibration diagnosis technology built on years of R&D on the mechanisms behind damage and deterioration in bearings, ball screws, and linear guides. Diagnostics of multiple mounted bearings and ball screws all at once. Detection and diagnosis of flaking (spalling) in bearings due to rolling fatigue, the intrusion of foreign matter, and scratches caused by excessive load. Detection and diagnostics of ball screw wear and deterioration due to poor lubrication and the entry of foreign matter. Detection and diagnosis of flaking, scratches, and poor lubrication in linear guides. e-chain & Polymer Bearings Condition Monitoring App This solution provides predictive maintenance information for e-chain systems and polymer bearings, shared through IoT Edge Systems. The dashboard app informs customers about the condition of e-chain systems by advising the number of days remaining until the next suggested maintenance. In addition, the app has a feature for sending alert messages in case of unexpected conditions or upcoming maintenance needs. Benefits of this solution include: The system detects changes early and prolongs the life of an e-chain system by providing predictive info. Indication of the number of days until the next recommended maintenance. Info regarding the next suggested maintenance and alerts displayed in a web browser, also sent by email/SMS notifications. Sharing sensor data from the converter to other IoT Edge applications, including MES / SCADA systems. Interested in these Apps? Contact us for more info. IoT Edge Apps for Quality Management: Product quality issues can negatively impact your profitability, so real-time data collection becomes key where quality improvement is a primary goal. In a smart factory, the gathering, monitoring and analysis of production data supports greater repeatability. The following apps can add better stability and quality traceability to your manufacturing process. AI Computervision for Manufacturing The App uses artificial intelligence and optical sensing to Minimise waste with accurate defects detection, improve product quality and customer satisfaction, and reduce tag scanning time. Using this Computervision app allow you to process components or products in a production or assembly line for automated visual inspection (up to 30 detections per second). QA/QC Features include: Automated QA visual inspection. The app allows you for automated recognition of defects and incorrectly assembled products. Custom solution development is available. OEE Management IoT Edge Apps: OEE management involves monitoring and analysing three key factors: Availability, Performance, and Quality. With the following IoT Edge Apps you can measure actual production times compared to planned production times, assess how efficiently the equipment is operating during production, and the number of defective or non-conforming products produced. Smart OEE Dashboard An industrial web-based app for IoT Edge device monitoring that gathers in real-time all device variables related to OEE. This solution allows for seamless integration with MES Platforms. Some of the benefits of this solution include a detailed and intuitive overview of the reasons for OEE losses, real-time visibility at the shop floor, and an understanding of the reasons for different OEE Values. Features include: Bidirectional communication with IoT Edge systems. Real-time visualisation of part programs and tasks running on the machines. Calculation & Visualisation of Machinery OEE data. Predictive OEE App This industrial-grade app automatically gathers in real-time critical parameters (vibration, temperature, pressure, etc.) that could generate machine failure and/or produce scrap or defective products. The app continuously monitors equipment critical variables and, using cloud neural networks, helps to identify and predict anomalous deviations that could result in machine failure (indicating the need for maintenance) or a defective product (predictive quality). The app also calculates and predicts machinery reliability. Some of its features include: Diagnostics of deviations and anomalous behaviour using AI-driven techniques. Prediction of deviations in specific process parameters that affect product quality and process stability/efficiency. Notifications for operators, maintenance or quality managers when the system predicts that a variable will go out of its limits. Seamless integration with Open MES Platforms. Interested in implementing these Apps at your manufacturing facilities? Just contact us and request more information.

Despite an economic downturn in Europe, manufacturers worldwide are increasingly acquiring factories in the region. Similarly, the UK manufacturing industry is continuing to re-shore suppliers as supply chain volatility becomes permanent. IoT Edge connectivity is particularly important for reshoring manufacturing due to its ability to facilitate real-time monitoring, control, and optimisation of manufacturing processes. It also enables efficient and streamlined operations, enhances productivity, and supports real-time decision-making. Read: What is IoT Edge? Specifically, here is why IoT Edge Connectivity is crucial in this context: IoT Egde for real-time data collection and analysis IoT devices at the Edge of the manufacturing environment can capture and transmit real-time data on various parameters such as production output, equipment performance, energy consumption, and quality metrics. This data provides valuable insights into the manufacturing process, allowing manufacturers to make informed decisions, optimise operations, and address issues promptly. Real-time data collection and analysis are especially beneficial in reshored manufacturing, as it enables quick response times and improved agility in dispersed production setups. IoT Egde for improved data privacy and security IoT Edge computing allows sensitive data to be processed and stored locally, reducing the need to transmit critical information over long distances or through external networks. This localised approach enhances data privacy and security, reducing the risk of data breaches or unauthorised access. As reshoring often involves the relocation of sensitive manufacturing processes and intellectual property, the ability to maintain data privacy and security becomes crucial for protecting trade secrets and maintaining competitive advantages. Manufacturers can decide what data will be available in the Cloud. IoT Egde for lowered operational costs IoT Edge computing can help reduce operational costs associated with data transmission and storage. By processing and analysing data at the edge, manufacturers can minimise the amount of data sent to the cloud, thus reducing bandwidth requirements and associated costs. Edge computing also reduces dependence on expensive cloud infrastructure, leading to potential cost savings in terms of storage and computing resources. Lower operational costs contribute to the overall viability and cost-effectiveness of reshoring manufacturing operations. IoT Egde for increased scalability and agility IoT Edge enables localised computing resources that can be easily scaled up or down to accommodate changing manufacturing demands. This flexibility allows manufacturers to quickly adapt to shifts in production volume, optimise resource allocation, and respond to market fluctuations. The scalability and agility offered by edge computing are especially beneficial in reshoring scenarios where manufacturers need to rapidly adjust their operations to meet changing local market demands. Process optimisation and automation IoT edge connectivity enables the integration of smart sensors, actuators, and control systems at different points in the manufacturing process. These devices can help monitor and control equipment, monitor conditions, detect anomalies, gather data on performance, identify maintenance needs or quality issues, and automatically adjust settings or trigger actions to optimise production. By leveraging IoT edge connectivity, manufacturers can automate tasks, streamline workflows, and reduce human error, leading to improved efficiency and productivity. This optimisation is crucial in reshoring manufacturing, as it helps companies achieve competitive production capabilities in global markets. Remote monitoring and maintenance Reshoring often involves locating manufacturing facilities closer to the company's headquarters or engineering teams. IoT edge connectivity allows for remote monitoring and maintenance of equipment and production lines, even across different locations. Through remote access, manufacturers can monitor equipment health, diagnose issues, and perform preventive or corrective maintenance activities. This capability reduces the need for on-site visits, minimises downtime, and supports efficient operations in reshored manufacturing. Remote Access allows also for enhanced collaboration and communication. IoT Edge connectivity enables seamless communication and collaboration across different stakeholders involved in the reshoring process. Manufacturers can connect with suppliers, customers, and other partners in real-time, fostering closer collaboration, sharing of information, and joint problem-solving. Supply chain visibility and collaboration Reshoring/Nearshoring often involves shorter and more localised supply chains. IoT edge devices can be employed to track and monitor raw material availability, inventory levels, logistics operations, transportation status, and supply chain performance. By having real-time visibility into these aspects, manufacturers can better coordinate their reshored manufacturing activities with suppliers, customers, and other stakeholders. IoT edge connectivity facilitates seamless communication and data sharing, enabling improved collaboration, faster response times, and better risk management in the supply chain. This enhanced visibility and collaboration contribute to efficient reshoring operations. Quality control and traceability IoT devices at the edge enable continuous monitoring of product quality parameters, ensuring consistency and adherence to desired standards. These devices can collect data on quality metrics, perform real-time analysis, and trigger alerts or corrective actions in case of deviations. Moreover, IoT-based solutions can provide detailed traceability information, recording the origin, production steps, and handling conditions of each product. Such traceability is crucial for compliance, quality assurance, and customer satisfaction in reshored manufacturing. Learn about our IoT Edge Solutions IoT Edge connectivity plays a vital role in reshoring manufacturing by enabling real-time data collection and analysis, process optimisation, remote monitoring, supply chain visibility, quality control, and traceability. Leveraging Edge computing technologies with IoT capabilities empowers manufacturers to achieve efficient and competitive reshoring operations in both local and global markets.

The Internet of Things (IoT) has transformed the way we interact with technology, and one of its remarkable advancements is IoT Edge. In the realm of manufacturing, IoT Edge devices are revolutionising the industry by bringing intelligence, connectivity, and efficiency to the factory floor. The IoT Edge is where sensors and devices exchange real-time data through a network to either an IoT or an Edge platform for processing. By processing data closer to its source, IoT Edge computing resolves the problem of delays often encountered in cloud-based systems. In addition to minimising latency, the architecture of IoT Edge ensures improved safety measures and a seamless experience for end-users. Data is processed right where it’s generated, meaning in your production machines, machine tools, processes, and plants. Now you can finally make practical use of this data to optimise workflows, save resources, and improve quality. Industrial Edge also lets you use cloud computing as needed – for example, in order to benefit from higher computing power, more storage, and Remote Access. Understanding IoT Edge IoT Edge refers to a decentralised approach to IoT architecture, where data processing and analysis occur at or near the source of data generation, rather than relying solely on cloud-based platforms. This proximity enables faster data processing, reduces latency, enhances real-time decision-making capabilities, and minimises bandwidth requirements. Essentially, IoT Edge brings intelligence and computing power closer to the devices and sensors at the edge of the network. IoT Edge Devices IoT Edge devices act as endpoints that collect, process, and transmit data in real-time. These devices are equipped with sensors, actuators, and embedded computing power, allowing them to interact with the physical world and communicate with other devices or centralised systems. Examples of IoT Edge devices in manufacturing include intelligent sensors, industrial gateways, programmable logic controllers (PLCs), and robotic systems. An IoT gateway facilitates communication between devices and between devices and the cloud, performing essential tasks such as data filtering and analysis. It can also be programmed to authenticate data intended for cloud services, enhancing real-time data security and bolstering IoT security measures. When an Edge agent needs to communicate with another device or the cloud, the IoT gateway handles the request by processing, verifying, and transmitting the information to the intended destination. The transmitted data can be analysed, and the insights gained utilised to identify opportunities for improving system efficiency. Get to know our portfolio of IoT Edge Solutions: The Role of IoT Edge in Manufacturing The Industrial Edge is a comprehensive Edge computing platform designed to be accessible and immediately deployable. It encompasses Edge devices, Edge apps, Edge connectivity, and infrastructure for managing applications and devices. These type of platforms simplify the process of gathering and analysing data from industrial resources, facilitates rapid and dependable implementation of applications within factory settings, and offers centralised management for devices and apps with exceptional scalability. With an IoT Edge manufacturers can determine what data stays local and what can be used with an IoT/Cloud solution. Some of the use cases in the industry are: Real-time Monitoring and Analytics IoT Edge devices enable real-time monitoring and analytics of manufacturing processes. By collecting and analysing data at the edge, manufacturers can gain immediate insights into equipment performance, production line efficiency, and product quality. This allows for proactive maintenance, reduced downtime, and improved overall operational efficiency. IoT devices and sensors placed at various points in the manufacturing process that collect data on product quality, production parameters, and environmental conditions help managers to identify defects, deviations, or inefficiencies in real-time. By making data-driven decisions, manufacturers can optimise processes, reduce defects, improve yield rates, and enhance overall product quality. IoT also allows manufacturers to remotely monitor and control operations across multiple facilities or even globally. Through connected devices and centralised management platforms, manufacturers can access real-time data, oversee production processes, and adjust parameters remotely. This capability enables better coordination, faster response times, and efficient resource allocation, regardless of geographic location. Worker Safety and Monitoring IoT devices, wearables, and environmental sensors enhance worker safety in manufacturing environments. They can monitor factors such as temperature, humidity, air quality, and hazardous conditions, alerting workers and supervisors in case of potential dangers. IoT-powered safety systems enable prompt responses, reduce accidents, and create a safer work environment. Enhanced Predictive Maintenance IoT Edge devices facilitate predictive maintenance in manufacturing. By continuously monitoring equipment conditions, detecting anomalies, and analysing data locally, these devices can identify potential failures before they occur. This enables manufacturers to schedule maintenance activities, replace components proactively, and prevent costly unplanned downtime. IoT sensors embedded in machinery and equipment can monitor performance metrics such as temperature, vibration, and energy consumption. By collecting real-time data, manufacturers can analyse patterns and detect anomalies that indicate potential failures or maintenance needs. This proactive approach to maintenance helps minimise unplanned downtime, optimise equipment lifespan, and reduce repair costs. Optimised Resource Utilisation IoT Edge devices help optimise resource utilisation on the factory floor. By analysing data in real-time, manufacturers can identify energy consumption patterns, track material usage, and optimise workflow efficiency. IoT also enables real-time tracking and monitoring of inventory, materials, and products throughout the supply chain. Connected sensors provide visibility into the location, condition, and status of goods, helping manufacturers streamline logistics, improve inventory management, and ensure timely deliveries. This leads to reduced waste, improved efficiency and sustainability, cost savings, and enhanced customer satisfaction. Energy Management IoT plays a vital role in energy management by providing visibility into energy consumption patterns and identifying areas of inefficiency. Connected sensors can monitor energy usage in real-time and provide insights for optimising energy consumption, scheduling operations during off-peak hours, and implementing energy-saving measures. This not only reduces costs but also contributes to sustainability efforts. Seamless Integration with Legacy Systems IoT Edge technology provides a bridge between legacy systems and modern IoT solutions. By integrating with existing infrastructure and equipment, manufacturers can leverage the benefits of IoT without completely replacing their current systems. This flexibility allows for a smooth transition and gradual adoption of IoT technologies. How Polestar can Help? Seamless Connectivity Polestar assists Manufacturers and Industrial companies with connecting machinery, programmable logic controllers (PLCs), and enterprise resource planning (ERP) systems through Edge computing solutions. This typically involves several of our services, which include: Understanding the requirements We start by identifying the specific goals and requirements for connecting your machinery, PLCs, and ERP system. Determine the data that needs to be exchanged, the frequency of data transfer, and any specific functionalities required. IT Architecture Design Based on the requirements, we design an architecture that allows for seamless communication between the machinery, PLCs, and the ERP system. An edge computing solution typically involves deploying edge devices or gateways near the machinery to collect, process, and transmit data. Deployment of edge devices or gateways We install edge devices or gateways near the machinery or at strategic locations on the factory floor. These devices act as intermediaries between the machinery/PLCs and the ERP system. They collect data from the machinery and send it to the ERP system while also receiving commands and instructions from the ERP system to control the machinery. Data acquisition implementation We configure the edge devices or gateways to acquire data from the machinery and PLCs. This can involve connecting to the PLCs using appropriate industrial communication protocols such as Modbus, OPC-UA, or Ethernet/IP. Retrieve relevant data points such as sensor readings, machine status, production counts, etc. Data processing and filtering We guide you to process and filter the acquired data at the edge devices or gateways to ensure only relevant information is sent to the ERP system. This can involve data aggregation, data transformation, normalisation, and any necessary data analytics or calculations. Enabling secure data transmission We establish a secure connection between the edge devices or gateways and the ERP system to ensure the confidentiality and integrity of the data being transmitted. This can be done using encryption protocols such as TLS/SSL and implementing appropriate authentication and access controls. Data integration with ERP We develop or configure the necessary software components to integrate edge devices or gateways with the ERP system. This can involve using APIs or middleware that enable seamless data exchange between the two systems. Ensure that the data is mapped correctly to the corresponding fields in the ERP system. Implementing control and monitoring Enable the ERP system to send commands and instructions to the edge devices or gateways for controlling the machinery. This can include starting or stopping specific machines, adjusting settings, or initiating maintenance actions. Provide real-time monitoring capabilities in the ERP system to track the status and performance of the machinery. Testing and Optimisation Thoroughly test the entire system to ensure proper functionality and data accuracy. Fine-tune the system as needed to optimise performance and address any issues or limitations that may arise during testing. Continuous monitoring and maintenance Implement monitoring and maintenance procedures to ensure the ongoing stability and reliability of the connection between the machinery, PLCs, and ERP system. Regularly monitor the system for any anomalies, update software components as necessary, and perform periodic maintenance tasks. It's worth noting that the specific implementation details may vary depending on the machinery, PLCs, and ERP system being used. We work along with experts in industrial automation and software integration to ensure a successful implementation of edge computing solutions. Enhanced Safety and Security Every network-connected device possesses the potential to be exploited by attackers, making both IoT edge devices and the devices they connect vulnerable endpoints. Some edge devices are equipped with default passwords like "admin," which users may neglect to change to a more secure option. Additionally, personal devices such as smartphones or smart cars can be left unlocked, granting unauthorised access to the network, particularly if they are stolen while the user remains logged in Manufacturers can enhance workplace safety and security with Polestar's IoT Edge devices. Real-time monitoring of environmental conditions, equipment status, and employee activities enables the detection of potential hazards or breaches. Immediate notifications and automated responses can be triggered to mitigate risks and ensure a safer work environment. Polestar's Network Access Control (NAC) solutions offer enhanced security by implementing a zero-trust framework to prevent unauthorised network access. Through NAC, IoT edge devices connecting to the network undergo identification and evaluation processes. The system carefully examines and verifies the credentials of each device before granting it permission to interact with the network.

Azure is a comprehensive cloud platform consisting of over 200 products and services. It aims to assist manufacturers and industrial companies in creating innovative solutions to tackle current issues and shape the future. With Azure, you can develop, operate, and oversee applications across various clouds, on-premises environments, and edge devices. It provides a range of tools and frameworks, allowing you the freedom to choose the ones that best suit your needs. Microsoft Azure is useful for manufacturers due to its comprehensive suite of cloud-based services and capabilities that can help optimize and streamline various aspects of manufacturing operations. Here are several reasons why Azure is beneficial for manufacturers: Scalability and Flexibility Azure allows manufacturers to scale their operations up or down based on demand. Manufacturers can leverage Azure's cloud infrastructure to quickly provision additional computing resources, storage, and networking capabilities as needed. This scalability enables manufacturers to adapt to changing market conditions, handle peak loads, and optimize resource allocation. For instance, a manufacturer experiences seasonal fluctuations in demand for their products. During peak seasons, they need additional computing resources to handle increased production. By leveraging Azure, they can easily scale up their infrastructure by provisioning additional virtual machines, storage, and networking resources. This ensures they can meet customer demands without investing in and managing on-premises hardware that may remain underutilized during off-peak periods. IoT Integration Azure provides robust Internet of Things (IoT) capabilities, allowing manufacturers to connect and monitor their production equipment, machinery, and devices in real-time. By collecting and analyzing data from connected sensors and devices, manufacturers can gain valuable insights into their operations, optimize processes, improve efficiency, and proactively address maintenance issues. Consider a manufacturing company that has implemented IoT sensors on its production equipment to monitor performance and gather data. Azure IoT Hub enables them to securely connect these sensors and collect real-time data on machine performance, production output, and energy consumption. By analyzing this data with Azure's machine learning capabilities, manufacturers can identify patterns, detect anomalies, and predict equipment failures. This allows them to schedule proactive maintenance, reducing downtime and optimizing the lifespan of their machinery. Predictive Maintenance Azure's machine learning and advanced analytics capabilities enable manufacturers to implement predictive maintenance strategies. By analyzing data collected from IoT devices and applying machine learning algorithms, manufacturers can detect patterns and anomalies that indicate equipment failures or maintenance needs. This proactive approach helps minimize downtime, optimize maintenance schedules, and reduce costs associated with unexpected breakdowns. Using Azure Machine Learning and Azure IoT Hub, any manufacturer can analyze historical sensor data and create predictive maintenance models. For example, they may identify specific vibrations or temperature patterns that indicate a potential machine failure. By leveraging these models, they can monitor live sensor data, detect deviations from normal behavior, and trigger maintenance alerts. This approach helps them avoid unexpected breakdowns, reduce repair costs, and maintain smooth operations. Data Analytics and Insights Azure offers a rich set of analytics tools and services that enable manufacturers to gain actionable insights from their data. By leveraging Azure's data analytics capabilities, manufacturers can analyze historical production data, identify trends, optimize supply chain processes, improve quality control, and make data-driven decisions to enhance overall operational efficiency. Manufacturing companies collect vast amounts of data across their production processes, including quality control checks, machine performance metrics, and production line efficiency. With Azure's data analytics services like Azure Synapse Analytics or Azure Machine Learning, they can process and analyze this data to identify bottlenecks, optimize production workflows, and improve overall efficiency. Insights derived from these analytics can guide decision-making, such as identifying areas for process improvement or adjusting production schedules based on demand forecasts. Supply Chain Optimisation Azure provides tools and services that help manufacturers optimize their supply chain operations. With Azure, manufacturers can collaborate with suppliers, distributors, and partners by securely sharing data and information across the supply chain. This promotes real-time visibility, improves coordination, reduces lead times, minimizes inventory levels, and enhances overall supply chain performance. For example, consider a manufacturing company that collaborates with multiple suppliers and distributors to ensure timely delivery of raw materials and finished products. By utilizing Azure's supply chain management services, they can share data and collaborate seamlessly with their partners. This includes sharing demand forecasts, monitoring inventory levels, and coordinating production schedules. With real-time visibility into the supply chain, they can optimize inventory management, reduce lead times, and improve overall supply chain efficiency. Enhanced Security and Compliance Azure offers robust security features and adheres to industry-leading security standards. For manufacturers dealing with sensitive intellectual property, customer data, or regulatory requirements, Azure provides a secure cloud environment with built-in compliance features to meet various industry-specific standards. As manufacturers deal with sensitive customer data and intellectual property, ensuring data security and compliance is crucial. Azure provides robust security features, including encryption, access controls, and threat detection mechanisms. By utilizing Azure's security capabilities, they can protect their data from unauthorized access and ensure compliance with industry regulations such as GDPR or HIPAA. Integration with Existing Systems Azure supports seamless integration with existing on-premises systems and applications. This allows manufacturers to extend their current infrastructure into the cloud without significant disruptions. Manufacturers can leverage Azure's hybrid capabilities to build hybrid environments that integrate their on-premises systems with Azure services, enabling a gradual transition to the cloud. Most manufacturers count on existing on-premises ERP systems to manage their manufacturing processes and inventory. With Azure's hybrid capabilities, they can integrate their on-premises system with Azure services seamlessly. For example, they can connect their ERP system to Azure Data Lake Storage to leverage Azure's advanced analytics capabilities while maintaining their existing on-premises infrastructure. This integration allows them to leverage the benefits of the cloud while preserving their investments in legacy systems. These are just a few examples of how Microsoft Azure can benefit manufacturers. By leveraging Azure's cloud-based services and capabilities, manufacturers can improve operational efficiency, optimize processes, gain actionable insights, and drive innovation in their industry.

In the rapidly evolving landscape of industrial automation, the integration of Manufacturing Execution Systems (MES) and Supervisory Control and Data Acquisition (SCADA) has emerged as a powerful combination. A seamless convergence of MES and SCADA technologies holds immense potential for optimising operational efficiency, improving decision-making processes, and driving overall productivity in diverse industries. In this article, we will explore the benefits of MES and SCADA integration and how it revolutionises industrial operations. What is a Supervisory Control and Data Acquisition (SCADA) system? A SCADA system enables real-time monitoring and control of industrial processes. Manufacturing Companies can gather data from various sensors, devices, and equipment on the production floor and visualise it in a centralised control room. This real-time visibility allows Manufacturing Companies to monitor critical parameters, detect anomalies or deviations, and take immediate action to optimise operations, ensure product quality, and minimise downtime. With a comprehensive SCADA platform for IIoT, manufacturers can improve efficiency and productivity, reduce costs and waste and give you greater control over disparate systems. SCADA combines software and hardware to create a control system that is frequently referred to as automation technology. The system receives data about processes and related equipment, which supervisors then use to control and optimise operations. By implementing a SCADA system, Manufacturing Companies can automate and streamline their operations. Manual data collection and monitoring processes are replaced by automated data acquisition and remote control capabilities. This reduces the need for manual intervention, minimises errors, and improves overall operational efficiency. With a SCADA system, Manufacturing Companies can optimise resource utilisation, reduce waste, and increase productivity. By monitoring and controlling processes in real-time, Manufacturing Companies can detect hazardous situations promptly and trigger alarms or automated responses to prevent accidents. Additionally, SCADA systems provide security features such as user authentication, data encryption, and access control, ensuring that only authorised personnel can access and control the system, protecting sensitive data and preventing unauthorised actions. One of the significant advantages of a SCADA system is the ability to remotely monitor and manage operations. Manufacturing Companies can access real-time data, control processes, and receive alerts or notifications from any location with an internet connection. Implementing a SCADA system can lead to cost savings for Manufacturing Companies. By improving operational efficiency, reducing downtime, optimising resource utilisation, and preventing costly errors or accidents, Manufacturing Companies can realise significant cost savings over time. Additionally, remote monitoring capabilities reduce the need for on-site personnel, resulting in potential cost reductions in labor and travel expenses. What is a Manufacturing Execution System (MES)? MES platforms provide real-time visibility into production processes, allowing Manufacturing Companies to optimise their operations. With a comprehensive MES solution, manufacturers can digitise, standardise, optimise and govern operational processes and work activities across industrial manufacturing plants. By capturing and analysing data from various sources, such as machines, sensors, and workers, an MES system enables Manufacturing Companies to identify bottlenecks, streamline workflows, and improve overall efficiency. This leads to reduced cycle times, minimised downtime, and improved resource utilisation. A MES system also enables Manufacturing Companies to implement robust quality control measures by monitoring and controlling critical process parameters in real-time. It provides Manufacturing Companies with advanced planning and scheduling capabilities as well. By integrating real-time data from various production stages, an MES system helps Manufacturing Companies optimise production plans, allocate resources effectively, and meet customer demands more efficiently. MES systems are designed to be scalable, accommodating the growth and evolving needs of Manufacturing Companies. As Manufacturing Companies expand their operations, an MES system can easily adapt to the increasing complexity and volume of production. Furthermore, an MES system allows for integration with other enterprise systems, such as Enterprise Resource Planning (ERP) and Customer Relationship Management (CRM), enabling Manufacturing Companies to streamline their overall business processes. The Difference between SCADA and MES Systems SCADA (Supervisory Control and Data Acquisition) and MES (Manufacturing Execution Systems) are two distinct but interconnected systems used in the manufacturing industry. While they serve different purposes, they can complement each other to enhance overall operational efficiency. Here are the key differences between SCADA and MES systems: Scope and Focus SCADA System: SCADA systems primarily focus on monitoring and control of industrial processes, utilising with PLCs in real-time. They are designed to gather and visualise data from sensors, devices, and equipment on the production floor. SCADA systems provide operators with real-time insights into the status of equipment and processes, enabling them to monitor and control operations effectively. MES System: MES systems, on the other hand, have a broader scope and focus on managing and optimising manufacturing operations as a whole. They provide functionalities to plan, schedule, track, and manage production activities, including work orders, inventory, resource allocation, quality control, and data analysis. MES systems facilitate efficient production planning, execution, and tracking, ensuring seamless coordination across different departments and stages of the manufacturing process. Timeframe SCADA System: SCADA systems operate in real-time, monitoring and controlling processes as they happen. They provide immediate visibility into the current state of the production environment and enable operators to respond quickly to deviations or anomalies. MES System: MES systems can operate in real-time but also provide capabilities for historical data analysis and long-term performance monitoring. MES systems capture and store data over an extended period, allowing for trend analysis, performance evaluation, and continuous improvement initiatives. Data Focus SCADA System: SCADA systems primarily focus on collecting and visualising real-time data related to process variables, such as temperature, pressure, flow rates, and equipment status. The data collected by SCADA systems is essential for immediate process control and monitoring. MES System: MES systems capture and analyse a broader range of data, including production metrics, quality data, inventory levels, equipment downtime, and labor utilisation. MES systems provide a comprehensive view of the manufacturing process, enabling data-driven decision-making and performance optimisation. Role in Operations SCADA System: SCADA systems primarily serve operational needs by providing real-time monitoring, control, and visualisation of processes. They are essential for maintaining process stability, safety, and efficiency. MES System: MES systems play a more significant role in managing and optimising manufacturing operations. They provide functionalities for planning, scheduling, tracking, and analysing production activities, as well as managing resources, materials, and quality control. MES systems bridge the gap between production and business functions, facilitating coordination and decision-making across the organisation. Integration SCADA System: SCADA systems are typically integrated with equipment and devices on the production floor, such as sensors, PLCs (Programmable Logic Controllers), and HMIs (Human Machine Interfaces). They establish a direct connection to these devices for data acquisition and control. MES System: MES systems integrate with various enterprise systems, including ERP (Enterprise Resource Planning), PLM (Product Lifecycle Management), and other systems involved in production planning, inventory management, and business processes. MES systems act as a bridge between shop floor operations and higher-level business systems, facilitating data exchange and coordination across the organisation. Integrating a MES to the ERP allows real-time production adjustments, more efficient scheduling, change order efficiency and accurate demand forecasts. However, ERP system does receive (via MES) data from the production process, but the amount of this information is very limited. Mainly it is summarised data important for the business process (sales, accounting, supply chain) which refers to the total amount of raw materials used in production, a total number of final products produced product quality information, etc. Benefits of integrating SCADA with MES When the initial versions of MES programs were introduced, they primarily focused on incorporating manual operations by utilising data entry interfaces. To streamline the process of gathering information and ensuring traceability, MES software started managing devices like barcode readers and tag printers directly or through automated systems, but not typically through supervision software. Presenting SCADA as an intermediary stage between the "ground" (manual operations) and the MES is not an accurate depiction of reality. In practice, supervision and MES systems follow distinct paths, existing as separate entities. Additionally, these tools often embody different cultures: supervision developments reflect a perspective centered around automation and low-level input/output systems, while MES developments embody an operational perspective, being more structured and computationally-oriented. Consequently, there haven't been well-defined structured exchanges between SCADA and MES. Instead, MES programs find it easier to collect data directly from the source. SCADA systems focus on real-time process monitoring and control, while MES systems have a broader scope, encompassing production planning, execution, and analysis. While SCADA systems primarily operate in real-time, MES systems can handle both real-time and historical data for long-term performance evaluation and improvement. Both systems play crucial roles in optimising manufacturing operations, and integration between SCADA and MES systems can create a comprehensive solution for efficient production management. Combing an MES with a SCADA system will reduce your investments in licensing fees and hardware. Likewise, process complexity is minimised when operators are required to interact with fewer screens. The following is a list of some of the benefitis of this technology convergence: Streamlined Data Acquisition and Analysis MES & SCADA integration facilitates the collection and analysis of real-time data from various sources across the production floor. SCADA systems provide real-time monitoring and control of industrial processes, capturing data from sensors, devices, and equipment. MES complements this by collecting data from multiple production stages, such as inventory, quality control, and scheduling. By integrating these systems, organisations can leverage a comprehensive dataset to gain deeper insights into their operations, identify bottlenecks, and make data-driven decisions promptly. Enhanced Operational Visibility and Control The integration of MES and SCADA empowers organisations with a holistic view of their operations. Real-time data from SCADA systems combined with MES data allows for a comprehensive overview of the production floor, including real-time machine status, process parameters, inventory levels, and resource utilisation. This heightened visibility enables organisations to identify and address operational issues promptly, optimise production processes, and improve overall efficiency. Improved Efficiency and Productivity MES & SCADA integration streamlines workflows by automating data exchange between systems, reducing manual data entry errors, and eliminating redundant tasks. This automation saves time and effort while improving accuracy. By aligning production plans with real-time data from SCADA, MES ensures optimal utilisation of resources, minimises downtime, and enhances productivity. Additionally, the integration enables the implementation of advanced analytics and predictive maintenance, allowing organisations to detect equipment failures in advance and schedule maintenance proactively, preventing costly unplanned downtime. Enhanced Quality Control and Compliance The combination of MES and SCADA facilitates real-time monitoring and control of critical process parameters. This capability enables organisations to maintain stringent quality standards by continuously monitoring and adjusting production processes. MES & SCADA integration also simplifies compliance with regulatory requirements and industry standards, as data capture and reporting become more accurate, reliable, and transparent. This integration helps organisations demonstrate compliance during audits and inspections, reducing the risk of non-compliance penalties and reputation damage. Improved Decision-Making Integrating MES and SCADA systems provides decision-makers with access to accurate, real-time data, enabling them to make informed decisions quickly. The availability of comprehensive data across the production floor allows for better forecasting, planning, and scheduling. Real-time insights derived from integrated systems empower decision-makers to identify opportunities for process optimisation, cost reduction, and resource allocation. This proactive decision-making approach drives agility and competitiveness in the market. Streamlined Data Analysis The integration of MES and SCADA technologies offers significant advantages for modern industrial operations. From streamlined data acquisition and analysis to enhanced operational visibility, improved efficiency, and informed decision-making, organisations can unlock a multitude of benefits by leveraging the synergies of these systems. As industries continue to embrace digital transformation, investing in MES & SCADA integration becomes imperative for organisations looking to maximise their operational potential, improve productivity, and remain competitive in an ever-evolving market. Polestar Data Services allow you to automatically integrate all production information from industrial plants, improving process efficiency by collecting historical and real-time data. Our integration services enable agile access to MES & SCADA information and the integration of MES applications for the calculation and analysis of OEE, incorporating the results of OEE analysis to other native applications such as SCADA, reports, and others.

Industry 4.0 (fourth industrial revolution) is driving the convergence of physical and digital systems, revolutionising the manufacturing and industrial sectors. At the heart of this transformation is the Internet of Things (IoT), which connects countless devices, sensors, and machines to gather and exchange data. A key enabler of IoT connectivity are IoT Data SIMs, which are specialised SIM cards designed for the unique requirements of IoT devices. In this article, we explore the crucial role played by IoT Data SIMs in Industry 4.0 and how they are transforming various industries. M2M SIM cards, also called Universal Integrated Circuit Cards or UICC, store the credentials and security keys that uniquely identify a cellular subscription. The SIM uses a so-called IMSI number, or International Mobile Subscriber Identity, which is unique for every connected device on or off the network, anywhere in the world. An IoT/M2M SIM card is a variation of the traditional SIM card used in smartphones, with additional features designed for IoT devices. SIM cards designed for the Industrial Internet of Things include greater durability, security, and flexibility. Machine to Machine SIM cards work by establishing a connection to your host network and transferring data between your device and the rest of your IoT platform. A significant proportion of IoT devices are remote or mobile and require roaming across multiple networks. However, the way in which your SIM card connects to networks outside of your primary network can vary. Unlike SIM cards for consumers, IoT SIM cards offer the option of either steered or non-steered multi-network roaming to align with your requirements. Steered IoT SIM cards prioritise the network of your chosen provider, even if there are stronger networks available. They remain connected to your preferred mobile network operator until they are completely out of range, which may result in IoT devices losing connectivity or operating with a very weak signal if no alternative network is selected as a fallback. On the other hand, non-steered IoT SIM cards do not give preference to specific networks and instead connect to the strongest available network, even if it is not the original provider's network. This can be achieved through agreements between operators that allow non-steered SIM cards to use the strongest available signal. Non-steered connections are particularly crucial for many IoT devices, such as medical or tracking devices, where uninterrupted connectivity is essential. IoT connected devices are generally any piece of hardware that is connected to the Internet and sends data on either itself or the environment the device is in. IIoT devices are used in a variety of industries, such as Utilities and Energy, Healthcare, Retail, Manufacturing, Transportation & Logistics, Agriculture/Smart Farming, or Automotive. Examples of connected devices include: Agriculture / Smart Farming: Tractors, irrigation units, livestock, AGVs, farming equipment. Healthcare: Human body parts, drug dispensers, medical equipment, tablets for staff. Manufacturing: Materials, containers, finished goods, vehicles, factory machines, robot arms, worker wearables, warehouse equipment. Retail/Warehouses: POS devices/terminals, store shelves, vending machines. Transportation / Logistics: Trucks (drivetrain, brakes, etc.), cars, EV charge points, railways, roads, bridges, airport facilities, buses, trains, trams, subways, (temporary) road signs- Utilities: Solar panels, wind turbines, pipes, valves, batteries, tanks, electricity poles, electricity meters, tablets for staff. Reliable and Secure Connectivity IoT Data SIMs provide reliable and secure connectivity to IoT devices, facilitating seamless data transmission and communication across vast networks. Unlike traditional SIM cards, IoT Data SIMs are optimised for machine-to-machine (M2M) communication, offering extended coverage, improved signal strength, and increased data transmission speeds. These SIMs support various wireless technologies such as 2G, 3G, 4G, and emerging 5G networks, ensuring IoT devices can connect and operate effectively in diverse environments. Furthermore, IoT Data SIMs incorporate robust security features to protect sensitive data transmitted by IoT devices. Advanced encryption protocols and authentication mechanisms safeguard data integrity and confidentiality, mitigating the risks of cyber threats and unauthorised access. By providing reliable and secure connectivity, IoT Data SIMs enable real-time monitoring, control, and analysis of industrial processes, thereby enhancing operational efficiency and productivity. What about eUICC? Another clear advantage of electronic IoT SIMs comes in the form of embedded Universal Integrated Circuit Card (eUICC) technology. By making eSIMs and traditional SIM-connected devices completely reprogrammable, this technology provides numerous possibilities to future proof and adapt connected devices remotely. The added flexibility and durability eUICC offers is particularly useful for devices deployed for a long period of time or in hard-to-reach locations. eUICC can be applied to traditional SIM cards of different sizes from mini SIM (2FF) to the smallest nano-SIM (4FF) as well as vacuum-sealed, soldered-down eSIM chips (MFF2). Global Reach and Scalability IoT Data SIMs offer global reach and scalability, allowing organisations to deploy and manage IoT devices across geographically dispersed locations. With multi-network roaming capabilities, these SIMs can seamlessly switch between different cellular networks, ensuring uninterrupted connectivity even when devices move between regions or countries. This global coverage empowers industries to expand their operations internationally, opening up new markets and business opportunities. Moreover, IoT Data SIMs provide scalability by enabling organisations to easily add or remove devices from their IoT networks. Through centralised management platforms, businesses can efficiently provision, monitor, and control thousands or even millions of IoT devices, optimising resource allocation and reducing maintenance costs. The scalability of IoT Data SIMs facilitates the rapid growth of Industry 4.0 applications and enables enterprises to embrace digital transformation with flexibility and ease. Cost Optimisation and Efficiency IoT Data SIMs contribute to cost optimisation and efficiency in Industry 4.0 deployments. These SIMs offer data plans tailored specifically for IoT devices, allowing organisations to choose the most suitable pricing models based on their data usage patterns. Data plans can be customised to match the specific requirements of diverse IoT applications, such as predictive maintenance, asset tracking, supply chain optimisation, and energy management. This flexibility in data plans ensures that organisations pay only for the data they require, eliminating unnecessary expenses and optimising cost-efficiency. Additionally, IoT Data SIMs facilitate remote device management and over-the-air (OTA) firmware updates. This remote management capability minimises the need for manual intervention, reducing maintenance costs and improving operational efficiency. Organisations can remotely monitor device performance, diagnose issues, and implement updates or patches, ensuring the seamless operation of IoT devices and minimising downtime. Enhanced Analytics and Decision-Making The vast amount of data generated by IoT devices in Industry 4.0 can unlock valuable insights when analysed effectively. IoT Data SIMs play a crucial role in collecting and transmitting this data to cloud-based platforms for analysis. By leveraging IoT Data SIMs, industries can harness the power of advanced analytics, machine learning, and artificial intelligence algorithms to gain real-time insights into operational processes, identify patterns, predict failures, and optimise decision-making. By combining IoT Data SIMs with cloud-based platforms and edge computing technologies, businesses can process data closer to the source, reducing latency and enabling real-time analytics. This capability facilitates proactive maintenance, enabling predictive and preventive actions to avoid costly downtime and enhance overall equipment effectiveness. Moreover, by analysing IoT data, organisations can identify trends, optimise resource allocation, and uncover new revenue streams, driving innovation and competitive advantage. Interested in Acquiring IoT Data SIMs? IoT SIM Cards for the Food & Beverage Industry The food and beverage industry is undergoing a significant transformation with the adoption of IoT technologies. IoT SIM cards play a crucial role in this industry by providing numerous benefits that enhance efficiency, safety, and quality control. Here are some exemplified benefits of IoT SIM cards in the food and beverage industry. Supply Chain Optimisation IoT SIM cards contribute to supply chain optimisation by providing real-time visibility and tracking capabilities. Manufacturers can monitor the movement of raw materials, ingredients, and finished products throughout the supply chain, ensuring timely delivery and preventing delays. IoT SIM cards integrated with GPS and location tracking enable manufacturers to track shipments, monitor temperature conditions, and ensure that products are transported within the required temperature range. This visibility enhances inventory management, reduces waste, and improves overall supply chain efficiency. Cold Chain Management Maintaining the integrity of temperature-sensitive products is critical in the food and beverage industry. IoT SIM cards enable real-time monitoring of temperature and humidity levels throughout the supply chain. By integrating IoT sensors with these SIM cards, companies can track and analyse data, ensuring that perishable goods are stored and transported under optimal conditions. Any deviations from the desired temperature range can trigger alerts, allowing prompt action to prevent spoilage and maintain product quality. Inventory Management Efficient inventory management is essential for avoiding stockouts, reducing waste, and optimising costs. IoT SIM cards enable real-time tracking and monitoring of inventory levels. By integrating IoT sensors with SIM cards, businesses can accurately monitor stock levels, automatically trigger reordering processes when inventory reaches predefined thresholds, and improve overall supply chain visibility. This data-driven approach minimises stockouts, avoids overstocking, and streamlines the inventory management process. Quality Control, Traceability & Compliance IoT SIM cards facilitate quality control and traceability, which are crucial in ensuring food safety and compliance with regulations. By equipping products, packaging, or containers with IoT sensors and SIM cards, companies can monitor and track product conditions throughout the entire production and distribution process. This allows for real-time data collection, including temperature, humidity, pH levels, location, and other relevant parameters. In the event of an issue or contamination, businesses can quickly identify the affected products, trace their origins, and initiate targeted recalls, minimising potential health risks and protecting brand reputation. In case of deviations, manufacturers receive immediate alerts, enabling prompt corrective actions and preventing the production of substandard or unsafe products. Moreover, the data collected by IoT SIM cards provides manufacturers with comprehensive traceability records, facilitating compliance with regulatory requirements and supporting recall management if needed. Remote Equipment Monitoring for Maintenance and Predictive Analytics Unplanned equipment downtime can disrupt operations and result in significant financial losses. IoT SIM cards integrated with sensors can continuously monitor equipment performance, capturing data on factors like temperature, pressure, vibration, and power consumption. This data enables predictive maintenance, where algorithms analyse patterns and identify potential issues before they lead to breakdowns. By addressing maintenance needs proactively, businesses can reduce downtime, extend equipment lifespan, and optimise maintenance schedules, resulting in increased productivity and cost savings. IoT SIM Cards for the Automotive Industry For automotive manufacturers, IoT SIM cards bring numerous benefits that enhance production efficiency, vehicle performance, and customer experience. Here are some benefits of IoT SIM cards for an automotive manufacturer. Manufacturing Process Optimisation IoT SIM cards facilitate real-time monitoring and optimisation of manufacturing processes in automotive plants. By integrating IoT sensors with these SIM cards, manufacturers can collect data on production line efficiency, equipment performance, and energy usage. This data enables manufacturers to identify bottlenecks, optimise workflows, reduce downtime, and improve overall production efficiency. IoT SIM cards also enable remote monitoring of critical systems, allowing for prompt maintenance and minimising production disruptions. Supply Chain Visibility IoT SIM cards enhance supply chain visibility for automotive manufacturers. By integrating IoT sensors with these SIM cards, manufacturers can track and monitor the movement of components, parts, and finished vehicles across the supply chain. Real-time data on location, temperature, and other parameters helps optimise logistics, minimise delays, and ensure timely delivery. Improved supply chain visibility leads to better inventory management, reduced costs, and enhanced customer satisfaction. IoT SIM Cards for Warehouses & the Logistics Industry For the warehouse & logistics industry, IoT SIM cards offer several benefits that enhance operational efficiency, inventory management, and security. Here the benefits of IoT SIM cards for warehouse owners: Inventory Tracking IoT SIM cards enable real-time tracking of inventory within the warehouse. By integrating IoT sensors with these SIM cards, warehouse owners can monitor the location, movement, and status of products in real-time. This visibility helps optimise inventory management, streamline order fulfillment, and reduce stockouts or overstocking. Warehouse owners can also set up automated alerts and notifications for low stock levels or irregularities, enabling timely replenishment and preventing inventory discrepancies. Asset Monitoring IoT SIM cards facilitate the monitoring of warehouse assets, such as AGVs, forklifts, pallet jacks, and equipment. By equipping these assets with IoT sensors and SIM cards, owners can track their location, usage, and performance. This data allows for better asset utilisation, preventive maintenance planning, and reducing the risk of theft or unauthorised usage. Real-time insights provided by IoT SIM cards enable warehouse owners to optimise asset allocation, identify underused equipment, and improve operational efficiency. Temperature and Environment Monitoring Maintaining optimal temperature and environmental conditions is crucial for certain products in a warehouse, such as perishable goods or sensitive materials. IoT SIM cards enable continuous monitoring of temperature, humidity, and other environmental factors within the warehouse. Integrated IoT sensors provide real-time data on these parameters, triggering alerts and notifications if conditions deviate from the desired range. This helps ensure the quality and integrity of stored goods, preventing spoilage, and reducing waste. Security and Access Control IoT SIM cards contribute to enhanced security and access control in warehouses. By integrating IoT-enabled security systems with these SIM cards, warehouse owners can monitor entry points, video surveillance, and alarm systems in real-time. In the event of unauthorised access or security breaches, immediate alerts can be sent to designated personnel or security providers. IoT SIM cards enable remote management and control of security systems, enabling efficient response and mitigating potential risks. Energy Management Energy costs represent a significant expense for warehouse operations. IoT SIM cards enable remote monitoring and control of energy-consuming systems, such as lighting, HVAC, and machinery. By integrating IoT sensors with these SIM cards, warehouse owners can track and analyse energy consumption patterns, identify inefficiencies, and implement energy-saving measures. Real-time data provided by IoT SIM cards helps optimise energy usage, reduce costs, and support sustainability efforts. Conclusion on the Benefits of IoT SIMs for Manufacturers IoT Data SIMs are revolutionising Industry 4.0 by providing reliable and secure connectivity, global reach, scalability, cost optimisation, and enhanced analytics capabilities. These specialised SIM cards enable seamless communication among IoT devices, unlocking the potential of the Internet of Things in transforming industries. As organisations continue to embrace the digital revolution, IoT Data SIMs will remain a critical component in realising the full potential of Industry 4.0, driving innovation, efficiency, and productivity across various sectors. IoT SIMs not only need to keep devices connected, but they need to be remotely manageable as well. This is because they are typically activated in bulk, whereas regular SIMs are activated one at a time by an individual consumer. IoT SIMs are also created to support data plan aggregation, where every SIM added to an IoT project increases the data cap. This type of data plans make IIoT projects more affordable and cost-effective For global IoT deployments, IoT Sim Cards require multi-network access without the need for different SIMs. For this reason, Polestar’s universal SIM cards connect to 2G, 3G, 4G, 5G, LTE-M & NB-IoT networks across more than 260 roaming partners, in more than 160 countries and with multiple roaming partners in most countries. This means that as an IoT deployment grows there’s no need to integrate with new providers, given that our Multi-Sim technology switch profiles automatically and under request.

For a business to be resilient, it's assets, including IT Hardware, OT Systems, Networks, Machinery and Data need to be secure both physically and digitally. But Cybersecurity is much more than just malware prevention. Processes performed traditionally on-premise (industrial control and monitoring, machinery commissioning, asset tracking, and others) are now being digitally transformed to be performed remotely. With more manufacturers adopting IoT Technologies, security breaches are on the rise. In this workshop you can learn more about securing your industrial assets with system resilience and cybersecurity. Industrial Cybersecurity & Resilience Topics Discussed: Business Continuity 07:40 Threats to Industrial Systems & OT Networks 17:40 Trends on Cybersecurity & System Resilience 19:23 Preventive Solutions 22:47 Corrective Solutions 39:13 Cybersecurity & Resilience Risk Analysis 48:41 The Resilience Roadmap (Wrap Up) 49:59 In short, we discussed: The importance of keeping your day-to-day operations up and running The threats that menace the operational continuity of your Industrial Networks and OT Systems Some of the latest trends on resilience and cybersecurity that you need to consider to minimise and prevent those risks The basics on how to perform a risk analysis to prioritise areas of work and determine the cybersecurity and resilience projects that you should be implementing A step-by-step roadmap that you can follow to embrace a resilience strategy in your industrial organisation. Listen to Julian Smith, CEO of Polestar, Andy Llewellyn, Cybersecurity and Networks Engineer at Polestar, and Matthew Carver, Product Specialist. Our Industrial Cybersecurity and Resilience Services enable manufacturers to use digital technologies and internet services without worrying (too much) about security incidents.

In manufacturing, the process of designing, testing, and validating equipment and systems is critical to ensuring quality, reliability, and compliance with regulations. One widely accepted method for achieving this is through the validation of IQ OQ PQ. IQ, OQ, PQ stands for Installation Qualification (IQ), Operational Qualification (OQ), and Performance Qualification (PQ). These are three distinct stages of validation that are carried out sequentially, and each stage involves specific tests and documentation to ensure that the equipment or system being validated meets the requirements and specifications for its intended use. The IQ stage verifies that the equipment has been installed correctly and that all components are present and properly installed. This includes checking that the equipment is connected to the appropriate power supply, that it is grounded correctly, that all necessary connections have been made, and that the equipment has been calibrated and verified according to its technical specifications. The OQ stage is where the equipment or system is tested to ensure that it operates according to its specifications under normal conditions. This stage involves testing the system's functionality, verifying that it meets the manufacturer's specifications and that it can perform the tasks for which it was designed. This includes testing things like control systems, alarms, and interlocks, as well as verifying that the system can operate within specific temperature, humidity, and pressure ranges. The PQ stage is the final stage of the validation process and focuses on demonstrating that the equipment or system consistently produces the desired results under normal operating conditions. This stage involves running the equipment or system for an extended period while monitoring its performance and ensuring that it meets the requirements for its intended use. Need to document your IQ OQ PQ compliance? Let us help you... The Relevance of IQ OQ PQ in Manufacturing IQ OQ PQ compliance provides a structured equipment and system validation approach that ensures quality, reliability, and compliance. By following the IQ OQ PQ approach, manufacturers can ensure that their equipment and systems operate and are installed correctly, that they meet the intended specifications, and that they are consistent and reliable over time. In addition to ensuring quality and reliability, the use of IQ OQ PQ can also help manufacturers comply with regulatory requirements. Many regulatory agencies require manufacturers to provide evidence that their equipment and systems have been validated before they can be used in production. By using the IQ OQ PQ approach, manufacturers can demonstrate that they have taken the necessary steps to validate their equipment and systems and ensure that they meet regulatory requirements. Therefore, the IQ OQ PQ process is implemented to: Create a documented record that demonstrates the correct installation of mechanical, piping, or IT systems and ensures they meet the design specifications. This process also confirms that the system or process yields consistent and reproducible results under varying loads. Prevent installation, operational, and performance errors from occurring. Ensure dependable system performance. “Commissioning” vs the “IQ OQ PQ” Process The primary purpose of commissioning is to test the engineering aspects of a new plant and ensure it is functioning correctly. This process involves all equipment in the manufacturing facility. On the other hand, the IQ OQ PQ process is distinct in several ways: It only applies to equipment that has a direct or indirect impact on product quality and user safety, as well as the components within those systems that are product contact critical or operationally critical. This determination is made using system and component impact assessments, as well as risk management tools. Regulatory authorities place particular emphasis on the IQ OQ PQ process when evaluating the medicines produced in the facility. The IQ OQ PQ process is much more rigorous, requiring a focus on documentation. IQ OQ PQ in the Pharmaceutical Industry During the commissioning and qualification of a new plant or process, even minor installation errors or equipment performance issues can quickly escalate into significant product quality problems that could potentially harm patients. This is particularly concerning with novel or new systems, where there is no prior performance or failure history, and even the smallest problems could result in patients becoming ill or dying. The IQ OQ PQ process is of utmost importance in the pharmaceutical industry because it ensures that drugs and medical devices are manufactured in a safe, reliable, and consistent manner. The IQ OQ PQ process is also essential to achieving compliance with regulatory bodies such as the FDA, EMA, and MHRA. These regulatory bodies require that pharmaceutical companies follow a comprehensive validation process to demonstrate that their products meet quality and safety standards. For example, a pharmaceutical company might use the IQ OQ PQ process when introducing a new piece of manufacturing equipment to their facility. During the IQ phase, the company would verify that the equipment was installed correctly, all parts were present and functioning, and that the equipment was designed to meet their specific requirements. Next, during the OQ phase, the company would perform various tests on the equipment to ensure that it was operating as intended. This would include testing the equipment's performance under different loads and operating conditions, and verifying that the equipment was able to consistently produce the desired output. Finally, during the PQ phase, the company would produce a large batch of products using the new equipment to ensure that the manufacturing process was capable of consistently producing high-quality products. This would involve monitoring various parameters such as temperature, pressure, and flow rate, to ensure that the process was stable and capable of producing consistent results. By performing the IQ OQ PQ process, the pharmaceutical company would be able to demonstrate to regulatory bodies that their manufacturing process was robust and capable of consistently producing high-quality products. This would help ensure patient safety and protect the company's reputation in the industry. IQ OQ PQ in the Food & Beverage Industry The IQ OQ PQ process is critical in the Food & Beverage Industry to ensure the safety and quality of the products being manufactured. The process involves assessing and validating equipment, systems, and processes that have a direct or indirect impact on food and beverage quality and safety. Implementing the IQ OQ PQ process helps to identify and prevent potential hazards and risks that could arise during the manufacturing process. It also ensures that the equipment and processes are installed correctly, meet the design specifications, and operate consistently and reliably under varying loads. In addition, regulatory bodies such as the FDA and USDA require food and beverage manufacturers to comply with strict regulations and guidelines. Implementing the IQ OQ PQ process can help manufacturers demonstrate compliance with these regulations and guidelines and streamline the approval process. Let's take an example of a company that produces bottled beverages. The company needs to implement the IQ OQ PQ process to ensure that the equipment used for producing and bottling the beverages is safe, reliable, and meets the required standards. During the IQ phase, the company will assess and document the installation of the equipment, including the bottling line and packaging equipment. The company will ensure that the equipment is installed correctly and meets the design specifications. During the OQ phase, the company will conduct testing on the equipment to ensure that it operates consistently and reliably under varying loads. This testing will include checks for temperature control, filling levels, and packaging materials to ensure that they meet quality standards. During the PQ phase, the company will conduct testing under real-world conditions to ensure that the equipment and processes operate as intended and produce consistent and safe products. This testing will involve producing a large number of bottles of beverages under different conditions and checking that they meet quality standards. By implementing the IQ OQ PQ process, the company can identify and prevent potential hazards and risks that could arise during the production process, ensure compliance with regulatory requirements, and produce high-quality products that meet consumers' expectations. IQ OQ PQ in the Automotive Industry The IQ OQ PQ process is critical in the automotive industry to ensure that the manufacturing processes and equipment used for producing automotive products are safe, reliable, and meet the required standards. Implementing the IQ OQ PQ process in the automotive industry helps to identify and prevent potential hazards and risks that could arise during the manufacturing process. It also ensures that the equipment and processes are installed correctly, meet the design specifications, and operate consistently and reliably under varying loads. In addition, regulatory bodies such as the National Highway Traffic Safety Administration (NHTSA) and other relevant authorities require automotive manufacturers to comply with strict regulations and guidelines. Implementing the IQ OQ PQ process can help manufacturers demonstrate compliance with these regulations and guidelines and streamline the approval process. Moreover, in the automotive industry, customers expect high-quality and safe vehicles. Implementing the IQ OQ PQ process can help to ensure that the products are consistent, reliable, and meet customers' expectations, which can lead to increased customer satisfaction and loyalty. For instance, for an automotive manufacturer that produces car engines the IQ OQ PQ process is essential for ensuring that the engine production process and equipment used are safe, reliable, and meet the required standards. During the IQ phase, the manufacturer will assess and document the installation of the equipment used to produce the engines. This could include machinery for machining engine blocks, equipment for assembling engine components, and test equipment for engine validation. The manufacturer will ensure that the equipment is installed correctly and meets the design specifications. During the OQ phase, the manufacturer will conduct testing on the equipment to ensure that it operates consistently and reliably under varying loads. This testing will include checks for torque values, assembly tolerances, and dimensional measurements to ensure that they meet the quality standards. During the PQ phase, the manufacturer will conduct testing under real-world conditions to ensure that the engines produced meet the required quality standards. This testing will involve producing a large number of engines under different conditions and checking that they meet quality standards. By implementing the IQ OQ PQ process, the manufacturer can identify and prevent potential hazards and risks that could arise during the engine production process. It also ensures compliance with regulatory requirements, such as emissions standards and safety regulations, and produces high-quality products that meet customer expectations. Furthermore, the automotive industry is highly competitive, and any defects in the production process can result in costly recalls, damage to reputation, and loss of market share. Implementing the IQ OQ PQ process can help to minimise the risk of defects and ensure that the production process is efficient and cost-effective. Do SMEs need to implement IQ OQ PQ processes? Yes, SMEs (Small and Medium-sized Enterprises) can benefit from the IQ OQ PQ process, especially if they are involved in industries where product quality and safety are critical, such as pharmaceuticals, food and beverage, and medical device manufacturing. While the IQ OQ PQ process may seem daunting, it can help SMEs to improve their production processes, ensure compliance with regulatory requirements, and maintain high product quality. Implementing the IQ OQ PQ process can also help SMEs to identify potential issues early on and prevent costly errors that could negatively impact their reputation or bottom line. Additionally, by establishing a documented evidence trail of their equipment and processes, SMEs can increase their credibility with customers and regulatory bodies. It's important to note that the level of IQ OQ PQ implementation will vary depending on the size and complexity of the SME's operations. While larger companies may have dedicated personnel and resources to manage the IQ OQ PQ process, SMEs may need to outsource some of the work or seek assistance from a third-party service provider. By following the IQ OQ PQ approach, manufacturers can ensure that their equipment and systems meet the intended specifications and perform consistently and reliably over time. This, in turn, leads to improved product quality and increased customer satisfaction, making IQ OQ PQ an essential tool for manufacturers looking to improve their operations and meet the demands of their customers. At Polestar, our engineers are regularly responsible for performing IQ/OQ/PQ tasks for your IT & OT equipment. All validation activities will be documented and approved by key stakeholders throughout the company. Alternatively, we can provide documentation that allows on-site engineers to conduct the necessary validation. Our team is experienced in IQ/OQ/PQ tasks and is available to answer any questions you may have regarding equipment qualification.

To enable the implementation of a smart factory, there is a need for new technologies and ideas, covering various aspects from production to marketing, transportation and logistics. Emerging applications such as mobile robots in production, autonomous vehicles in transportation and logistics, and augmented and virtual reality applications for service and maintenance would require high-performance networks, which current networks may struggle to provide. The advanced capabilities of Industrial 5G, including unparalleled reliability, minimal latencies, and extensive IIoT connectivity, can facilitate the integration of innovative applications in industrial settings. To address this need for sustainable communication solutions, we are working closely with Siemens on developing an Industrial 5G ecosystem. This ecosystem includes a private 5G infrastructure and a range of end devices. Do you need help implementing Industrial 5G in your Industrial Settings? In recent years, the term "5G" has been buzzing around the tech world, and for good reason. 5G is the fifth-generation mobile network that promises to change the way we connect to the internet, and it's not just limited to our smartphones. Industrial 5G networks are being developed and implemented to create smart factories, power grids, transportation systems, and more. In this page we'll explore the relevance and characteristics of industrial 5G networks. What are Industrial 5G Networks? Industrial 5G networks are private cellular networks built for industrial use cases. Unlike traditional cellular networks, which are built for public use, industrial 5G networks are built for specific industrial purposes, such as manufacturing, transportation, and energy. These networks use the same technology as public 5G networks but are customised to meet the unique needs of industrial applications. The IIoT has seen a significant boost in potential thanks to the emergence of reliable wireless connectivity. This new form of machine-to-machine communication has revolutionised production by making it faster, easier, and more dependable than ever before. Industrial 5G has emerged as a game-changer in M2M communication, thanks to its ability to provide ultra-low latency. This enables mobile units, such as AGVs, to transmit information within milliseconds. To make the most of Industrial 5G's benefits, industrial users should prioritise private 5G networks. This guarantees privacy and allows for optimal configuration to support all industrial applications. These private 5G networks use a 3.7 to 3.8 GHz 5G frequency band. Relevance of Industrial 5G Networks Industrial 5G networks are becoming increasingly relevant as more industries adopt smart technologies. These networks offer several benefits, including: Faster and more reliable connectivity: Industrial 5G networks offer faster and more reliable connectivity than traditional wired networks. This makes it possible to transmit large amounts of data quickly and efficiently, enabling real-time monitoring and control of industrial processes. Lower latency: Latency refers to the time it takes for data to travel from one point to another. Industrial 5G networks have lower latency than traditional wired networks, making it possible to perform real-time control of industrial processes. This is particularly important for applications such as autonomous vehicles, which require real-time response to changing road conditions. Improved efficiency: Industrial 5G networks enable the use of smart sensors and devices, which can collect and transmit data in real-time. This data can be used to optimise industrial processes, leading to improved efficiency and reduced downtime. Enhanced safety: Industrial 5G networks can be used to monitor and control industrial processes in real-time, reducing the risk of accidents and improving overall safety. Secure remote access: A public 5G network is indeed the right answer for applications requiring remote access to distant machinery or equipment. Public mobile networks enable access to distant participants, even in other countries. Also, service technicians can connect to the machinery to be serviced via mobile communications while en route. 4 Characteristics of Industrial 5G Networks Industrial 5G networks have several characteristics that make them unique: Private: Industrial 5G networks are private networks built specifically for industrial use cases. This means that they are not accessible to the general public, and access is restricted to authorised personnel. Customisable: Industrial 5G networks are customisable to meet the specific needs of different industrial applications. This means that they can be tailored to provide the required bandwidth, latency, and reliability for different use cases. Secure: Industrial 5G networks are designed to be secure, with features such as encryption, authentication, and access control. This ensures that sensitive data transmitted over the network is protected from unauthorised access. Scalable: Industrial 5G networks are designed to be scalable, meaning that they can be easily expanded as the needs of the industrial application grow. Conclusion on Industrial 5G Industrial 5G networks are becoming increasingly relevant as more industries adopt smart technologies. These networks offer several benefits, including faster and more reliable connectivity, lower latency, improved efficiency, and enhanced safety. Industrial 5G networks are customisable, secure, and scalable, making them ideal for a wide range of industrial applications. As the world becomes more connected, industrial 5G networks will play an increasingly important role in enabling the next generation of industrial processes. The key enablers for Industrial 5G networks are here. Contact us to know more about the mobile Industrial 5G routers available to offer you powerful performance for the next generation of wireless connectivity. Discover all the features and benefits of our innovative 5G routers – and get started on your way to the world of Industrial 5G.

IT/OT Convergence: A Game-changing Trend in Industrial Automation In recent years, the convergence of information technology (IT) and operational technology (OT) has emerged as a game-changing trend in industrial automation. This trend has been driven by the growing demand for greater efficiency, reliability, and safety in industrial processes, as well as the need to integrate data from various sources to enable better decision-making. What is IT/OT Convergence? IT/OT convergence refers to the integration of information technology (IT) systems and operational technology (OT) systems within industrial processes. IT systems are typically used for data management, analytics, and communication, while OT systems are used for the control and automation of physical processes, such as manufacturing, energy production, and transportation. Traditionally, these two types of systems have worked separately, with IT systems focusing on business functions and OT systems focusing on production processes. However, as the digitalisation of industrial processes has accelerated the need for integration between IT and OT has become more pressing. Why is IT/OT Convergence Important? IT/OT convergence offers a range of benefits for industrial organisations, including improved efficiency, productivity, and safety. By integrating IT and OT systems, organisations can gain greater visibility into their operations, identify inefficiencies, and make data-driven decisions to optimise their processes. For example, by integrating data from sensors, machines, and other sources, organisations can gain real-time insights into the performance of their equipment and identify potential issues before they become critical. This can help to reduce downtime, increase productivity, and improve safety by enabling proactive maintenance and repair. In addition, IT/OT convergence can help organisations to improve collaboration between departments and functions, by breaking down silos and enabling greater sharing of information. This can help to improve decision-making and facilitate more effective problem-solving, as well as enabling organisations to respond more quickly to changing market conditions. IT/OT convergence can help organisations improve their cybersecurity posture by enabling them to implement more effective security controls and monitoring across their entire infrastructure. This is becoming increasingly important as industrial organisations become more digitised and connected, and face growing threats from cyberattacks. Challenges of IT/OT Convergence Despite the benefits of IT/OT convergence, there are also a number of challenges that organisations need to address in order to successfully implement this trend. These challenges include: Cultural barriers: IT and OT teams often have different cultures, priorities, and ways of working, which can make it difficult to achieve collaboration and integration. Legacy systems: Many industrial organisations have invested heavily in legacy OT systems, which can be difficult to integrate with modern IT systems. Security risks: The integration of IT and OT systems can create new security risks, such as the potential for cyberattacks and data breaches. Lack of standardisation: There is a lack of standardisation in the IT/OT space, which can make it difficult to achieve interoperability between different systems and vendors. Skills shortage: There is a shortage of skilled professionals who have the knowledge and experience to integrate IT and OT systems effectively. Overcoming these challenges requires a holistic approach that involves collaboration between IT and OT teams, as well as a clear understanding of the organisation's goals and priorities. Need guidance on how to integrate your IT & OT systems? 10 Best Practices for IT/OT Convergence To successfully implement IT/OT convergence, organisations can adopt the next 10 best practices, including: Develop a clear strategy with defined goals, metrics, and timelines. Build a cross-functional team with input from IT, OT, cybersecurity, and data analytics. Use standards-based approaches to achieve interoperability between systems and vendors. Conduct a comprehensive risk assessment to identify potential security risks and develop a plan to mitigate them. Prioritise communication and collaboration between IT and OT teams, and foster a culture of openness and knowledge sharing. Internal Marketing Activities can aid with team communication. Invest in training and development for IT and OT professionals to build the necessary skills and knowledge. Work with an IT services company specialised in Industrial Settings and Enterprise Integration to deploy a converged network and to connect your OT to your IT systems. Use pilot projects to test and refine the convergence strategy before scaling up. Develop a roadmap for implementation that takes into account existing systems, legacy infrastructure, and budget constraints. Continuously monitor and evaluate the effectiveness of the convergence strategy, and adjust as needed to ensure it remains aligned with business goals and priorities. Learn more about IT & OT Convergence by watching this webinar with real-life manufacturing case studies: Know more at https://www.polestarinteractive.com/it-ot-convergence

Security by design refers to the integration of security and risk management into the structure of a network, achieved through the implementation of segmentation and Agile infrastructure design. Essentially, security measures are incorporated from the outset to ensure the network is secure from the ground up. Creating a secure environment for sensitive information is essential, as such data often needs to be moved, stored and accessed, making it vulnerable to cyber-attacks. If these systems are breached, the consequences can be significant and costly. The following is a collection of guidelines that can assist in developing a secure-by-design network and systems that are resistant to cyber-attacks while simultaneously being simple to manage and upgrade. Secure Design Principles The aim of these principles is to guarantee that the networks and technologies which support modern enterprise and industrial systems are designed and built with a clear emphasis on security. The principles have been conceived to be applied to both digital and cyber-physical systems. They are divided into five categories that correspond to different stages at which a security breach can be mitigated: Determine the Context: Define all the elements which compose your system, so your defensive measures will have no blind spots. Make Compromise Difficult: An attacker can only target the parts of a system they can reach. Make your system as difficult to access as possible. This is called the attack surface. Make Disruption Difficult: Design a system that is resilient to denial of service, attacks and usage spikes. Make Threat Detection Easy: Design your system so you can spot suspicious activity as it happens and take necessary action. Reduce the Impact: If eventually an attacker succeeds in gaining a foothold, they will then move to exploit your system. Make sure what they find is not easy to compromise, but if they do, you get your assets and data safeguarded and with proper backups. Secure Network Design Process The design of a secure data network is based on the following assumptions about the business and its teams: There is a limited IT workforce and no dedicated security personnel. The OT team is not much involved in IT and security systems/decisions. The IT team primarily serves non-technical personnel. The budget for security, and IT in general, is restricted or non-existent. There is insufficient time to train numerous users on new procedures. However, there is a strong need for making the users, operations and business data secure. The most significant challenge faced by small and medium-sized companies in terms of security is that their networks and systems cannot be secured by a single standard solution. Due to limited personnel and budget, these businesses cannot afford to hire a security team, and they may not be aware of all the potential threats they face. This awareness gap, coupled with the fear of malicious hackers and the understanding that there is no external assistance available, makes the attractive-sounding, "black box" solutions from vendors more appealing than many would care to admit. Nevertheless, a simple security-by-design approach would help to prevent most threats. What is crucial is to establish grounded achievable security and availability goals, in order to prevent and make risk manageable. Key goals must include: Protect high-value assets Reduce the internal attack surface Limit access to the unpatched/vulnerable devices Few/no visible changes to end-users The initial step for a secure-by-design network is to gain an understanding of the assets in your communications infrastructure. You can't secure what you don't see, so it is impossible to safeguard assets that have not been properly identified and characterised. As the objective is to secure the network, crucial information required will be: Current Network Architecture and Integrations. Servers: Applications or Server roles, OS Versions, Open Ports. Clients: OS Versions, Number of Clients, Connection Locations. Networking Equipment: Management IP Addresses, Software/Hardware/Firmware versions, licensing/warranty information. OT Systems: PLCs, SCADA, MES and other Industrial Control Systems. Connected (or to-be-Connected) Devices: Field Assets such as CNC Machinery, Robots, EAVs, Cranes, Conveyor Belts, Environmental Sensors, IP Cameras, CCTVs, Automated Access Systems, and Mobile Devices. It is not surprising that numerous small and medium-sized companies adopt flat network architectures, as it facilitates plug-and-play operations. This means that any device connected to the network can communicate with other devices without any restrictions. While this approach benefits functionality, it poses security challenges. To address this risk, it is key to restrict open communication without disrupting network operations. With the right configuration of the network hardware and software is possible to: Create Virtual Local Area Networks (VLANs) to segment the network. Create Access Control Lists (ACLs) that will control what parts of the network can talk to what other parts of the network. Reduce the attack surfaces of the network. Virtual Local Area Networks (VLANs) If a port is not designated as a trunk port, it can only transmit data for the VLAN it is assigned to. A trunk port encapsulates and tags VLAN traffic with the originating VLAN number so the plugged device knows what VLAN the packet is for. VLANs are treated as distinct networks that function on distinct hardware. Traffic from one VLAN will only ever reach another VLAN through a router. Access Control Lists (ACLs) An ACL is simply a rules-based firewall that checks outgoing or incoming packets. When a packet is being processed, the check begins with the first rule in the ACL and proceeds down the list, stopping at the first rule that matches the packet. Network Segmentation Effective network segmentation is likely the most cost-effective security measure in any setting. Aggressive traffic control within your network restricts an attacker's ability to move around covertly and without interaction. If attackers are unaware of traffic restrictions, they may raise red flags while attempting to understand them. The following phased deployment will have no impact on the function of the network: Segmentation of the network (no/minimal filtering). Segmenting the network enhances security for devices that are typically less secure, such as older or unpatched machines in the environment. Additionally, network segmentation can help prevent attackers from tampering with the network infrastructure. Managing wireless networks can be a challenging task, requiring careful planning and consideration of various factors. However, you can separate the Wi-Fi from the rest of the network as soon as possible. Both guests and employees will use the same wireless network, secured with standard measures such as WPA2-PSK, AES, and a 12-character password displayed prominently in the reception area. Monitoring and analysing traffic to high-value or vulnerable assets. By segmenting the network into VLANs, you have effectively created distinct networks. This setup creates a convenient traffic bottleneck at the router, which we can use to monitor network activity. If the switch supports port mirroring, which copies traffic from one interface to another for analysis, then you have optimal data flows. Alternatively, you can opt for a switch that can mirror traffic specific to a VLAN. However, if these do not have any mirroring capabilities, it will be needed to place a monitoring device between our switch and router to capture and analyze traffic. Implementing ACLs/firewalls to restrict unnecessary traffic. Designing and Deploying the ACLs or aliases substitutes in for a set of rules or addresses/protocols. You can use them as short-hand, so it isn't needed to write out a bunch of the same addresses in different places. Additionally, ML-powered, cloud-based network security leverages inline deep learning to stop unknown zero-day attacks. NGFWs make network security intelligent and proactive, so it's always a good idea to find a vendor to implement them. Harden the network. There is a long list of things that can be done in the interest of generally hardening the network infrastructure. We are going to focus on the things that align with what we have already done. Most of our hardening is a matter of reducing the attack surface of the network components. Luckily, we've built a huge component of that into our CLIENTS ACL in the previous section. This protects the network infrastructure from some software vulnerabilities that they may have that would allow an attacker to change the configuration of your infrastructure. Business Resilience Creation Security is much more than just malware prevention. Designing a comprehensive resilient network with industrial-grade systems (long-range connectivity, routers, repeaters, and network configurations and typologies built for industrial purposes) and proper backup and recovery solutions will grant the security of your data and assets in any case, anytime. Learn more about business resilience in the next video: Guidelines for Manufacturers The manufacturing industry is the second most targeted industry when you look at the number of reported cyber attacks. Cybercriminals target small and medium-sized manufacturers because many of these companies do not have adequate preventative measures in place. These simple, low-cost steps (5 Functions of the Cybersecurity Framework) are based on the official NIST guidance from the Cybersecurity Framework and have been tailored to meet the needs of any industrial company so they can identify, assess and manage cybersecurity risks. NIST Manufacturing Profile – NISTIR 8183 The “Manufacturing Profile” of the CSF is a guide that can help manufacturers reduce cybersecurity risk while adhering to sector goals and industry best practices. It presents a voluntary, risk-based framework for managing cybersecurity activities and mitigating cyber threats to manufacturing systems. While it is intended to supplement existing cybersecurity standards and industry guidelines, it does not serve as a replacement for them. Manufacturers Guide to Cybersecurity for Small and Medium-Sized Manufacturers This guide outlines common cybersecurity practices for small and medium-sized manufacturers. The activities are grouped according to the 5 Functions of the Cybersecurity Framework. The majority of manufacturers are obligated to comply with various standards, regulations, laws, or requirements pertaining to cybersecurity and privacy. These mandates may originate from federal, state, local, or tribal governments, industry mandates, or be voluntary. The following is a non-exhaustive list of some of the most prevalent cybersecurity and privacy laws and requirements: Defense Federal Acquisition Regulation Supplement (DFARS): manufacturers in the defense supply chain may see one or more DFARS cybersecurity requirements in their contracts. The International Traffic in Arms Regulations ("ITAR," 22 CFR 120-130): Governs the export and temporary import of defense articles and services. Payment Card Industry Data Security Standard (PCI DSS): A security standard used to ensure the safe and secure transfer of credit card data. Sarbanes-Oxley (Pub L. 107-204): Requires any publicly traded company to have formal data security policies and to communicate and enforce those policies. State privacy laws: Many states have enacted privacy laws covering how businesses can collect and use information about consumers. The Children's Online Privacy Protection Act (15 USC §6501 et seq.): Governs the collection of information about minors. The Federal Trade Commission Act (15 USC § 41 et seq.): Gives the FTC broad authority to protect consumers against organizations that fail to follow basic cybersecurity and privacy best practices. The General Data Protection Regulation (GDPR): Governs the collection, use, transmission, and security of data collected from residents of the European Union. ISA/IEC 62443 This series of standards define requirements and processes for implementing and maintaining electronically secure industrial automation and control systems (IACS). These standards provide a comprehensive approach to cybersecurity, encompassing both operations and information technology as well as process safety and cybersecurity, and establish the best practices for security and performance assessment. The ISA/IEC standards are designed to establish cybersecurity benchmarks for all industries that employ IACS, such as building automation, medical devices, electric power generation and distribution, transportation, and process industries including oil and gas and chemicals. Furthermore, these standards establish requirements for key stakeholder groups involved in control system cybersecurity, such as asset owners, automation product suppliers, integrators, and service suppliers who support the operation of control systems and their components. People, processes, and technology all play critical roles in securing automation and control systems. The ISA/IEC 62443 series addresses the security of industrial automation and control systems (IACS) throughout their lifecycle (which applies to all automation and control systems, not only industrial). The ISA/IEC 62443 standards provide guidance that includes: Defining common terms, concepts, and models that can be used by all stakeholders responsible for control systems cybersecurity Helping asset owners determine the level of security required to meet their unique business and risk needs Establishing a common set of requirements and a cybersecurity lifecycle methodology for product developers, including a mechanism to certify products and vendor development processes Defining the risk assessment processes that are critical to protecting control systems Polestar's background in computer networking is second to none in helping small, medium and corporate sized manufacturers and industrial companies to implement segmentation and security-by-design as a cost-effective method for better security controls and asset protection.