Applications such as CPG, food and beverage, and pharmaceutical manufacturing are leveraging data-driven capabilities to unlock new levels of efficiency and flexibility. This is driving the need for data infrastructure that is future-ready, writes Ursulla Barr, Offer Manager for PAC & Software at Schneider Electric.
Manufacturers in consumer packaged goods (CPG), food and beverage, and pharmaceuticals are all under pressure to deliver consistent quality while quickly adapting to changing market demands. Each of these industries have differing regulations and compliance challenges, but what is shared across every factory is the costly risk of downtime.
The true cost of downtime is difficult to quantify with reports varying widely. In fact, only business owners themselves will understand the true cost that even a moment of downtime would cause in their smart factories. Unplanned downtime in CPG, food & beverage, and pharmaceutical smart factories means missed deadlines, wasted product, wasted energy, and sometimes non-compliance.
Always-on data for process continuity
The ‘smart’ in smart factory doesn’t happen in the Cloud alone, it starts at the Edge of the network, where sensors and connected devices feed data to central systems via I/O modules.
While it is rarely seen as the star of the show, I/O is a critical interface between physical processes and digital networks. This is where next-generation, intelligent Edge I/O platforms play an important role.
An I/O module is the bridge between a control system and plant assets. It provides the physical interface between the PLC (programmable logic controller) and the real-world devices it controls or monitors so that data can be received and stored and commands can be sent out.
A failure at the I/O would make a site’s control system blind to what’s happening in the process, which means operators can’t respond to issues and automated systems can’t take action. In the wider context of a smart factory, the I/O module does not just protect the productivity of one machine, it also mitigates the risk of downtime across all systems. The latest generation of I/O solution provides this support through technology that is open, modular, robust and cybersecure.
Smart must be cybersecure
Manufacturers of all shapes and sizes are experiencing cyber attacks with increasing frequency and complexity. The National Cyber Security Centre (NCSC) Annual Review notes that manufacturing is among the top sectors reporting ransomware activity. Looking broader, recent data from research company Statista shows that manufacturing experiences the highest share of cyberattacks when compared to other industries, including financial.
When working with connected OT, a challenge is that cybersecurity didn’t exist in the 80s and 90s when data networks were first developed. The first generation of PLCs was never connected to the outside world, so cybersecurity is an afterthought for most I/O platforms. As a result, legacy I/O equipment does not provide cyber protection.
However, that has changed and today’s operators need cybersecurity as a top priority. The latest generation of I/O technology includes features role-based access and control and encrypted communication. These enable operators to isolate threats and contain breaches. In turn, the I/O level can now actively support the cybersecurity of a smart factory’s data network and ultimately reduce the risk of downtime.
When comparing I/O products, an important feature to look for is in-built compliance with the IEC 62443-4-2 cybersecurity standard. Over time, it’s likely that this standard will become a hygiene factor when choosing I/O but it’s currently only available with the very latest technology.
Long-term resilience
I/O platforms are not just short term enablers of connectivity, they also provide long term resilience. Smart factories in CPG, food and beverage, and pharmaceuticals need data infrastructure can keep pace with accelerating demands.
Modern I/O technology can support this in several ways. One is hot swap capability. With the latest I/O system, it’s possible to switch any number or type of modules while the system is powered up. This compares with previous technology, when operators faced restrictions on the number or type of modules that could be removed at one time. The new development cuts downtime as there’s no need to power down the network to switch restricted modules.
Robustness is another important feature for protecting uptime over a long service life. The latest type of I/O system, such as Schneider Electric’s Modicon Edge I/O NTS, has a wide operating temperature range, and can withstand EMC emissions and vibration. As a result, a smart factory’s systems will remain online, leading the way in digital transformation with its advanced assets and equipment.
No matter what the sector, a smart factory’s I/O level should be optimised to deliver the performance needs of today and solve the challenges of tomorrow. Ultimately an intelligent Edge I/O reduces downtime risks and ensures compatibility so operators can focus on digital transformation.
Author biography:
As Schneider Electric’s Offer Manager for PAC & Software, Ursula Barr leads in the development and delivery of advanced process automation solutions for the UK & Ireland markets. She has been at Schneider Electric for over seven years, and in that time has specialised in product management, customer project delivery, and power management portfolios.
Ursula holds a Master of Electrical and Electronic Engineering. In her current role, Ursula’s expertise spans Industrial Automation Software, the Modicon PLC and PAC families, and advanced IT & OT cybersecurity.
