Some call this change “Advanced Manufacturing”, others “Smart Manufacturing”. Sometimes the term IIoT (Industrial Internet of Things) and sometimes Industry 4.0. We think the visual of Industry 4.0 is a good analogy.
Industrial Revolution is not new. Currently we are categorizing the revolutions in four parts. The most recent part is the growth in automation and technology we are currently experiencing, and it is called Industry 4.0. Previous revolutions are:
- 1.0 – Mechanization. Water and Steam Power
- 2.0 – Mass Production. Assembly Line and Electric Power
- 3.0 – Computer and Automation
- 4.0 – Advanced Analytics (AI, Machine Learning)
A traditional Manufacturing Facility Network looks like the diagram in Figure 1. The Machine Floor Network (Operations Network, or OT) is separate from that of the Business Enterprise networks (IT). Industry 3.0 Facilities can have aspects of Industry 4.0 in that it can move data in OT Network to the IT Network of a facility to provide paths to the Cloud. This system has industry standard that defines each layer of the network. Using the Purdue Model (ISA-95/IEC 62264) as a reference, OT networks reside on Layers 0 to 3.
Some facilities have this features that allow flow of data from the OT to the IT networks today. For example, an email is sent that tells the Manufacturing or Production Manager a Machine is down. Or in more advance way where a Dashboard of information is available remotely and decisions can be made by the Process Engineer and applied locally by the Operator. Sometimes this is managed very well, and sometimes it is just allowed with no insight into the flow of data. The methods and constraints on the OT network and IT network are different. IT is concerned with security and OT is concerned with production.
The differential between Industry 4.0 and Industry 3.0 systems is leveraging of the Cloud where the advanced computing of other servers can be leveraged to add Intelligence to the Data.
OT Production Networks
The Manufacturing Networks are open and vulnerable to outside attacks when compared to the IT networks. This is by design, not by fault. Manufacturing processes us recognizable networks like Ethernet because it is easy to build small communication networks between Programmable Logic Controllers (PLCs), Touch Screens, and Motor Drives as an example. These communications paths need to be fast and open so that Safety of Personnel can be maintained, and production is not delayed. The connection of the Machine Networks to a larger Enterprise network can create unintended delay of program execution. A Printer indicating low ink over the network should not delay an Emergency Stop command to a Motor Drive.
All of this must be considered when connecting the OT and IT networks. The Open Nature of the OT network needs to be defended by the IT space yet allowed to continue because of the needs of Production.