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Why Manufacturing Needs Securing Smart IIoT Devices Driving Sustainable
Digital Transformation? in OT Environments Manufacturing through IIoT

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#1 cause of



Industrial




Ethernet



downtime.



















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INDUSTRY
FOCUS






Why Manufacturing





Needs DIGITAL






TRANSFORMATION?







By Rajabahadur V. Arcot

anufacturing involves production storage and after-sales services. Some limitations can be overcome by the use of
of goods, items that satisfy of the important support activities are enabling technologies, such as Industrial
Mhuman wants, by the use of labor associated with the management of the Internet of Things, artificial intelligence,
or human efforts, energy, machines, & company’s financial & human resources, data analytics, and others. By leveraging
tools and by processing / formulation of infrastructure, and design & engineering. these technologies a manufacturing
raw materials /components. Processing or company can perform all its activities
formulation is the production method that Value Chain Activities and digital more efficiently & effectively and thereby
leads to creation of finished goods from transformation maximize the benefits not only to its
raw materials / components. Such goods Each activity consumes time, resources, shareholders but also to its customers.
may be sold to end users / consumers or & efforts and hence it is possible to find This is what the Digital Transformation is
as processed materials or components to a better way of performing them; there all about.
other manufacturers for the production is always scope to perform each of the Digital transformation means the
of other value added goods. Thus in activities more efficiently while being process of intentionally bringing
manufacturing the value accretion takes productive. To achieve such objectives, about comprehensive changes, by
place starting from sourcing / receiving manufacturing companies, since the start leveraging enabling technologies so as
of raw materials and culminating with of 3rd era on industrialization, began to to achieve objectives, which includes,
supply of finished or value added goods use operational technology (OT) systems, in the manufacturing business context,
to end user / consumers. Manufacturing such as distributed control systems improving a company’s business and
companies perform a range of value- (DCS), programmable logic controllers production processes, enhancing customer
creating activities in order to make the (PLC), & others; information technology and shareholder value, becoming more
intended goods, deliver them to their (IT) solutions, such as enterprise efficient and productive, discovering new
customers, and provide necessary post resource planning (ERP) and supply business models, and such others.
sale services. Those activities constitute chain management (SCM); and business
manufacturing value chain. process management (BPM) methods, Enabling Technologies and Their
Some of the primary activities such as total quality management (TQM) Value Propositions
associated with the manufacturing value and lean & six-sigma (LSS), so as improve Let us understand the value proposition
chain are sourcing or procurement of their business processes and operations. of some of the enabling technologies.
raw materials or components, inbound The limitations of these systems, Industrial Internet of Things, also called the
logistics & incoming material storage, solutions, and methods are related to Industrial Internet / cyber physical systems,
production process, marketing & sales, generating, accessing, and analyzing empowers manufacturing companies to
outbound logistics & finished goods large amounts of data. Some of these let their ‘things,’ equipment, machines,



OCTOBER 2021 | 3

INDUSTRY
FOCUS


products, and people, to become internet examples that show why there is need temperature in cement kilns resulting in
connected so as to make them gather & for manufacturing companies to turn to the producing of cement clinkers.
exchange data / information, decentralize Digital Transformation to help them push The clinkers are ground to a fine
decision-making, and become intelligent. the boundaries of their performance. powder in mills. A good understanding
Artificial intelligence is the brain power the production process, gaining of
or cognitive capabilities demonstrated Sourcing which will help in identifying the areas
by computer systems or machines in Let us consider a company’s sourcing that offer some major opportunities for
meaningfully interpreting external data, activity of raw materials. We all know improvements, requires extensive data
learning, and gaining insights from them. that raw materials procured just-in-time collection and analysis. Use of Industrial
Applied properly, artificial intelligence can results in keeping the stock holding Internet of Things, digital twins, machine
be used to predict potential outcomes to the bare minimum and lowering of learning, and such others, makes such
under a set of plausible conditions, solve the costs associated with inventory & analysis feasible. Based on such analysis
problems, and help in decision-making. warehouse operations. If raw material cement companies can achieve enhanced
Use of edge, fog, and cloud computing is procured from multiple sources, then production, reduced energy consumption,
allows companies to distribute the the collection of data relating to sourcing optimized kiln operation & such others and
computing resources at optimal cost and activities, such as raw material costs, adopt predictive maintenance practices
performance. Manufacturing companies delivery times, transportation costs & for equipment, such as grinders, kilns, and
generate massive amounts of data, times, and other such variables of the mills.
often unstructured but of great value for various suppliers and their analysis with Cement production process is energy
the efficient and productive business the help of enabling technologies will intensive. There is significant scope to
management of the company. Data help the sourcing company to arrive at reduce energy consumption thorough the
analytics help companies to uncover the optimal decision(s). For the analysis to efficient operation of grinders, kilns, and
patterns and thereby extract valuable yield useful outcome, the data may have mills. By stabilizing and optimizing the
insights from raw data. Digital twin to be gathered from different sources with operations of grinders, kilns, and mills, the
technology can be used to create a some of them being real-time and others cement plant can achieve among others
digital representation of a physical object, historical. The data required to arrive at enhanced production, fuel saving, and
such as equipment in a manufacturing the right decision will be humongous quality variability reduction. The control
plant or the entire plant itself; with its and thus will require the help of enabling of the clinkering process, which presents
help, one can imitate the working of technologies, such as data analytics. difficulties because of the nonlinear &
the physical object, so as to study and time varying behavior of raw material
improve its performance. With the help Energy Conservation, Production fed into the kiln, has a bearing on the
of augmented reality technology the Enhancement, & Predictive quality of the cement produced and the
computer generated imagery of the real Maintenance overall profitability of the plant. The
physical image is superimposed on the Typically, production processes in conventional automatic control systems,
real physical image. By this process the a manufacturing plants need to be such as distributed control systems /
user’s experience is enhanced. Robots operated under controlled conditions. The programmable logic controllers, only
are not new to manufacturing companies. operating parameters are mostly based measure and control parameters, such as
They have been using them for many on first principles but at times operating speed, temperature, flow, and such others,
years to perform complex and hazardous parameters need to be manipulated so of the kiln that are the secondary variables
jobs for the past several years. Robots are as to maximize yield and this requires and not the primary variable, which is the
becoming more autonomous, flexible, and simulation / analyses of large amounts composition and property of the slurry
collaborative. Additive manufacturing, also of data. This necessitates the use of in the kiln. With the help of enabling
known as 3D printing, creates an item digital twins / artificial intelligence. In technologies, it is possible to perform
through a computer controlled process this context, let us consider the case of predictive and prescriptive analysis of
that creates three dimensional objects by cement production. The important cement data coming from automatic control
depositing materials layer upon layer. production process activities are grinding, systems, laboratory, and historical records
cement clinker production, and milling. The to understand what needs to be done to
Digital Transformation Helps Push raw materials for making cement, such produce the best quality clinkers.
Boundaries of Performance as limestone, clay, sand, and iron ore, are In a way, the quantity of cement
Let us look at few of the following ground and then heated to the sintering produced is related the equipment


4 | OCTOBER 2021

INDUSTRY
FOCUS


uptime. Switching over from breakdown manufacturing firm, it is common to see in a coordinated and proper manner,
maintenance to predictive maintenance conveyors carrying products, which are performing them additionally in an
is one among the desired objectives subject to final visual inspection before efficient and productive manner helps a
of many cement companies. Artificial being sent to the finished goods bay or company to enhance revenues, profits, &
intelligence can analyze data from the next production stage. The use of stakeholders’ values, and gain competitive
control systems including conditioning artificial intelligence will help detect the advantages. How well a manufacturing
monitoring systems, historical archives, defective products by using machine company is able to respond successfully
and other sources and pave the way for vision technology. Analytical capabilities to market dynamics, customers’ changing
the adoption of predictive maintenance of data analytics and artificial intelligence needs and preferences, disruptions
practices. can help the company to identify the root along the value chain, ever-increasing
cause of the defects and thereby improve competition, and such other challenges

Mass Customization product quality. These technologies also determine its ultimate success. Ability
In the present market scenario, will also help a company track the to perform all value chain related activities
customers prefer to buy products that performance of its products in the hands efficiently, productively, and responsively
are customized to meet their personal of the customers and provide improved is therefore crucial for a manufacturing
needs and preferences. Mass producing after sales services. company. It needs to adopt digital
and selling the same for everyone does transformation strategies so as to achieve
not work anymore in the marketplace. Embrace New Business Model those objectives.
The way forward is to adopt mass Manufacturing companies can also switch
customization that combines the over from the common product-business
flexibility and personalization of custom- model (capital expenditure model) to pay-
made products with the low unit costs per-use model (operational expenditure
associated with mass production. model) in which the customer pays for
The concept of mass customization using the product rather than having to
is attributed to Stan Davis and was buy it. The advantage for the customer
defined by Tseng & Jiao as “producing is that he / she need not pay big upfront
goods and services to meet individual amount or in case of a company it need
customer’s needs with near mass incur the related capital expenditure.
production efficiency.” Computer-aided Pay-per-use model includes services in
manufacturing systems, aided by some the pricing and as such extra revenue will
of the enabling technologies can help accrue to supplier companies. Rajabahadur V. Arcot
companies to effectively postpone the The supplier company will also benefit
task of differentiating a product for a from receiving constant feedback about ISA Bangalore Section
specific customer until the last possible the product’s performance and this in the Independent Industry Analyst/
point in the production. In order to be long term can help the supplier to improve Columnist and Digital
more effective, mass customization the product quality. This model lowers the
technique has to be supported by threshold for the potential customers and Transformation Consultant
personalized marketing, as a marketing as such it will let them decide sooner to Life Member of ISA and Member
strategy. By leveraging data analytics and go for a product on a pay-per-use basis. of ISA Smart Manufacturing
other enabling technologies, a company A supplier company can employ pay-per- & IIoT Division. He is an ISA
can deliver individualized messages and use model as a way to lock-in customers accredited mentor and trainer.
product offerings to current or prospective and maximize revenues over the product He authors industry and
customers. life cycle and generate steady cash flows.
The disadvantage for a supplier company technology trend articles, market
Quality Assurance is it means that it will need extra capital to research reports, case studies,
Another example is the need for a fund all these products sold on pay-per- white papers, and automation &
manufacturing company to reduce use model. operational technology insights.
product defects. In a discrete industry, While manufacturing constitutes [email protected]
for example in an auto component performing the value chain activities





OCTOBER 2021 | 5

INDUSTRY
FOCUS


Securing SMART






IIOT DEVICES in




OT Environments







IoT (Industrial Internet of Things) is all
about connecting people, processes,
Iand assets. Traditionally, devices in
OT environments – machines, sensors,
actuators, PLCs, etc. - have been isolated
or connected directly to an ICS system.
IIoT gives these devices a link to the
internet. By bringing these devices “to
life”, users can interact with them in real-
time, draw data from them, and analyze
that data via statistical or predictive
analysis.
Benefits include improved operational
efficiency because IIoT devices can
reduce troubleshooting time from days to
minutes; reduced maintenance costs via
preventative maintenance using sensors
that can detect when equipment will
break down.
So what are the different ways that
critical industries are using smart devices?

Oil and Gas
IIoT devices can be found across the
oil and gas industry value chain – from
upstream exploration and production to
refining and downstream distribution.
RAJESH MAURYA, In the exploration and production phase
Regional Vice President, India & SAARC, (E&P), sensors and robots are used to find
Fortinet oil and gas reservoirs, new hydrocarbon
deposits, determine new drilling spots,
or find new ways to optimize well and
field work. Furthermore, in difficult
environments like offshore platforms, small
IIoT networks can be used for rig or cargo




6 | OCTOBER 2021

INDUSTRY
FOCUS




ship monitoring, reducing the millions potential new entry point for attackers. attempts to scan for vulnerabilities or
lost each year to non-productive time. What about the connectivity and security holes, and prevent any attempt
security repercussions that 5G is likely to exploit those vulnerabilities. For the
Manufacturing to bring? New services will bring faster IIoT infrastructure and ecosystem, since
Using the IIoT approach of Digital Twins, speeds, greater bandwidth, and support most communication is via REST APIs,
manufacturers can virtually replicate a for a large number of endpoints. detecting and stopping any attempts to
product or process, enabling them to Finally, with the introduction of Mobile gain access or exploit these APIs must
analyze the efficiency of a system, make Private Networks and Multi-Access be a high priority.
predictions and forecasts, and help them Edge – also known as edge computing The third factor is recognizing when
create a better version of their products. - the mobile network and the compute a smart device has been compromised.
In production lines, sensors, cameras, infrastructure can be placed very close Following a successful intrusion, there
and data analytics can determine to the devices. This concentration of is a reconnaissance period where the
through predictive maintenance when a network and compute infrastructure attacker will try to gather as much
piece of machinery will fail and can help becomes a critical part of the production information as possible about the
managers plan maintenance and service environment, and protecting it is environment, identify high-value assets,
schedules before a problem occurs. paramount. and determine how best to monetize
the breach. This means that there is a
Power and Utilities Making smart stuff secure – Best short window of opportunity to detect
The power and utilities sector has Practices the breach, identify the compromised
tapped into and embraced the potential When securing any system that devices, and remove them from the
of smart stuff with concepts such as includes smart stuff, there are three network, to contain and block the
smart water and gas management. important factors to consider: attack. Solutions such as anti-botnet,
With smart grid, smart meters can The first is visibility – having a compromise detection, and user &
monitor electricity consumption and global view of the system and its entity behavior analysis, are designed
transmission in real-time, which allows components, understanding which to detect a cyber-attack as soon as it
for more efficient, demand-based devices are connected to the network, happens. Adding Security Orchestration,
electricity generation and distribution. and whether they are operating Automation, and Response technology
They can also alert electricity companies normally. Knowing “what” is connected can take this information and perform
of power outages allowing them to react to the network is a basic cyber hygiene automated investigation and response
at speed and restore services quickly. principle, as you can’t protect what to identify and isolate or remove
Finally, smart meters are a critical you can’t see. For IoT and IIoT, there compromised devices before any
element of the decentralized power are additional challenges due to the damage is done.
model by facilitating the growth of sheer number of devices involved, Finally, all of the above security
energy sources such as solar panels and not to mention the complication that components should be part of a
wind turbines, furthering efficiencies in running endpoint agents on devices is security fabric architecture that delivers
production and distribution. often not possible. What is required is a actionable AI-driven threat intelligence
With critical industries increasingly complete solution that involves network and provides true integration and
relying on “smart stuff” to monitor, access control, device management, automation across the entire security
track, and manage various assets and event management, and inventory infrastructure. With a consistent,
predict, prevent, and control a number management, plus detailed analysis. real-time, and end-to-end security
of incidents, a vital question arises - are The second factor is preventing the posture, visibility of the entire digital
smart devices implicitly safe to use and attack. IIoT devices often have limited attack is ensured and recovery from
trust? connectivity needs, and segmentation attacks is swift. This ensures that your
should be used to restrict access. smart stuff is protected, and if it does
Smart Doesn’t Imply Secure Application-aware firewalls can ensure become compromised, a security fabric
In fact, with each new smart device that only authorized protocols and architecture minimizes the impact and
introduced into the network, the risk applications are allowed. Intrusion reduces the time required to bring your
increases because each device is a prevention can detect and block critical systems back into service.





OCTOBER 2021 | 7

INDUSTRY
FOCUS












Driving




Sustainable




Manufacturing





through IIoT










SUDHEESH NARAYANAN,
Founder & CEO, Knowledge Lens


e all know that automation in COVID-19 world. manufacturers, electronic makers, food
manufacturing is not new, yet One of the most powerful drivers processing companies etc. and plan
Wmanufacturing sector in India that has contributed to the emergence to offer more such incentives in days
is still in the nascent stages of adopting of technological advancements in to come, which will definitely push the
automation. Many manufacturing the Manufacturing sector in India is ‘Make in India’ campaign.
players in India are stuck between Government’s increasing focus on the Moreover, other factors such
Industry 2.0 – 3.0 due to various concept of ‘Atmanirbhar Bharat’ or ‘Self- as mounting pressure to cut cost,
factors such as high cost of automation, reliant India’ or ‘Vocal for Local’ specially increase efficiency in processes;
dependency on manual processes, lack after the world was hit by the COVID-19 reduce dependence on humans by
of awareness of latest technologies, low pandemonium. It is evident there is an manufacturers led them to explore
production etc. unlike other countries increased push from the government automation options. Though we know
like Germany, USA, Japan, Singapore to create a healthy environment to the benefits of smart manufacturing, it
that are reaping benefits of industry 4.0 promote manufacturing sector in is imperative to address key gaps that
adoption. India. For instance, Government of will move India from Industry 2.0/3.0 to
Manufacturing sector contribution to India has increased the contribution of Industry 4.0. Reflecting on the current
India’s GDP is not very significant (16%) manufacturing output to 25% of GDP scenario, I believe the use of emerging
as compared to services (54.77%), by 2025 from 16% currently. They have technologies in manufacturing industry
agriculture and allied sector (17.76%) also announced some production linked is still in its infancy in India, but trends
and it offers greater potential to make incentives to attract companies to set indicate that the field could soon
India self-reliant especially in post up manufacturing plants: smartphone accelerate and play a key role in making




8 | OCTOBER 2021

INDUSTRY
FOCUS


India self-reliant. Traditionally, the focus real time analytics on each industry Encouraging vocational education
has been on the services sector but for attribution to monitor climate change and training programs in partnership
India to fulfill its economic ambitions, and overall pollution in the environment. with educational institutes will
it is vital to invest focus towards Clear dashboards are now available to ensure a continuous supply of
manufacturing. It is important for the every decision maker to make informed highly qualified talent. This will also
manufacturing industry to re-think and choices on how to reduce the carbon enable the students who could be
re-align their strategies and operations footprint and contribute to overall prospect employees to prepare for
with the latest technology innovation improvement of the environment. A a career in the manufacturing sector
towards the goal of Atmanirbhar Bharat. clear and improved governance model by gaining a deeper understanding
According to a new study by the on such tracking systems enables of the technologies used in smart
Institute of Electrical and Electronics clear accountability across various manufacturing. With digital disruption,
Engineers (IEEE), Artificial intelligence stakeholders and prevents any illegal it is vital for all industries including
(AI), machine learning, 5G and Internet disposal of sensitive hazardous waste. manufacturing to reinvent existing
of Things (IoT) would be the most These solutions bring a direct impact to processes to survive and stay ahead in
important technologies in 2021. overall wellbeing of the nation. the innovation game. Hence, the right
Manufacturing (19%), healthcare There is a growing trend in kind of partnership will help.
(18%), financial services (15%) and sustainability-driven innovation in the Government is taking a lot of
education (13%) are the industries manufacturing sector and I believe initiatives to boost manufacturing
that most believe would be impacted that technology will play a major role in India, however, there needs to be
by technology. Thus, the foremost in accelerating this trend. Covid-19 proper and timely implementation
thing that we need to consider is to has put forth an opportunity for of the same otherwise we will lag
automate factories through the right set industries and companies to reinvent behind. Additionally, Government must
of technologies. The technology space their products and services to meet provide enough favorable schemes
has witnessed major transformations new demands and achieve market and incentives so that more and more
in the last few years & the one I would advantages through sustainability companies adopt automation.
like to talk about is Industrial Internet of initiatives. If utilized accurately, IIoT Industry 4.0 technologies have
Things (IIoT) which is the sub category can play a major role in bolstering the the potential to address various
of Internet of Things (IoT). manufacturing sector. In fact, IIoT can environmental challenges such as
The demand for IoT in India is have a tangible benefit to sustainability. climate change, resource exhaustion,
emerging across industries such as Organizations must invest time to and environmental protection. For
utilities, manufacturing, automotive, understand how efficiently IIoT can instance, IIoT can play a vital role
transportation and logistics. IIoT be deployed to lower the use of their in driving sustainability in industrial
uses a data-driven approach to drive resources. One major barrier with manufacturing. This can be achieved via
efficiency into the industries. It involves organizations is the lack of knowledge leveraging the technology to develop/
use of sensors, interconnected devices on how to deploy IIoT/what to do with build better and sustainable products
and cloud data to drive industrial the technology. Therefore understanding which in turn benefits the environment
performance through wide range of the technology first will enable to design and society at large. On the other note,
tools. IoT is expected to add value to sustainable strategies for the long run. while we are all talking about India
business processes and take value Another important aspect to make moving towards being considered a
creation for industrial applications to manufacturing socially inclusive is via global manufacturing hub, the question
the next level, specifically in the case of industry academia partnership. This will that pops up is the country actually
Manufacturing. generate a demand for innovation. Most ready for this recognition in terms
For instance, Environment manufacturing players have a good of Industry 4.0? India’s race against
Sustainability and Climate Change understanding of various systems and vaccine production during COVID-19 is
Accounting has taken a big leap processes that needs to be followed a classic example that demonstrate its
by leveraging IIoT solutions. These in their sectors, however, collaboration capability, ingenuity and yes a success
solutions help in connecting various between industry and academia will of Make in India campaign, similarly
environment sensors, energy meters, bring the best of both worlds to an open more such examples can be achieved
and production systems to provide platform. and this is an opportune time.





OCTOBER 2021 | 9

TECH
INNOVATION


LinkIQ™ Industrial Ethernet




Cable + Network Tester





he LinkIQ™ Industrial Ethernet
Cable + Network Tester solves
Tthe #1 cause of Industrial
Ethernet Failures. The Link IQ can be
used to validate cable performance to
support Ethernet/IP, PROFINET and
EtherCAT, using frequency-based
measurements. Identifies mis-wired and
split pairs on RJ45, M12X, M12D and
M8D terminated cables.
The LinkIQ also performs nearest
switch diagnostics to identify key
network issues and validate switch
configuration, eliminating the need of
using another device.


Cable Testing You Trust
The LinkIQ™ is capable of measuring
lengths up to 1000 feet (305 m) and
provides distance to faults such as
opens, shorts, and unterminated cable.
Using the specially designed Industrial identification, the switch name, port delivered by the switch across the
Ethernet cabling remote ID allows for number, and VLAN info. cabling infrastructure.
a complete wire map of the cable pairs
which helps identify mis-wired and In-Depth PoE Testing Additional Features
split pairs. While Power over Ethernet makes Generates Analog or Digital tones
The primary cable testing feature of installation of devices such as security compatible with the IntelliTone™ Probe
LinkIQ™ is the cable performance test cameras and access points simpler, a or Pro3000™ to assist in locating cables
which qualifies the cabling bandwidth survey by the Ethernet Alliance of over in a wall or telecommunications room
from 10BASE-T to 10GBASE-T (10 Mb/s 800 installers, integrators and end users • Blink Port light on switch to help
up to 10 Gb/s). It performs these tests via found that four of five respondents identify the connected switch port
frequency-based measurements. experienced difficulties in integrating • Compatible with MicroScanner™ PoE
PoE systems. Remote Identifiers for Ethernet outlet
Network Testing You Need To simplify PoE installation and identification
Along with the robust cable testing troubleshooting, the LinkIQ displays the • Touch Sensitive gesture-based
features, the LinkIQ™ also provides pairs where power is provided, including display
detailed information on the nearest the different power levels and pairs • Rechargeable Li-Ion battery
connected switch. The LinkIQ™ for dual-signature implementations. • Easy Feature and Network Testing
negotiates with the switch to Further, the LinkIQ will place a load Upgrades via USB-C via LinkWare™
identify the advertised data rate on the connection to ensure that the PC
(up to 10GBASE-T), half/full duplex advertised power is actually being • Charging via standard USB-C port.

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