Smart Factory IT Guide

WiFi in industrial environments is challenging. Metal racking, moving equipment, and building structures create dead zones that disconnect handheld scanners.

Common Problems:

• Scanners drop connection behind racking
• Slow speeds in far corners of warehouse
• Interference from machinery
• Consumer access points can't handle density

The Solution: Industrial WiFi Design

• Site survey with heatmapping (measure before installing)
• Industrial-grade access points (wider temperature range)
• Higher density placement (more APs, lower power)
• Wired backhaul between APs (don't rely on mesh)
• Band steering (keep devices on 5GHz where possible)

Scanner-Specific Considerations:

• Seamless roaming (devices don't disconnect between APs)
• Legacy 2.4GHz support for older scanners
• QoS for warehouse management system traffic
• Battery impact (poor signal drains batteries faster)

When Sage, SAP, or your ERP system slows down, everything stops. Orders can't be processed, goods can't be dispatched, and trucks sit at the loading bay.

Common Performance Issues:

• Slow report generation
• Lag when opening large customer orders
• Timeout errors during peak times
• "Thinking" when switching between modules

Server-Side Optimisation:

• Database maintenance (index rebuilds, statistics updates)
• Memory allocation (ERP databases love RAM)
• SSD storage (eliminates disk bottlenecks)
• Dedicated SQL Server (don't share with other apps)

Network Optimisation:

• Gigabit connections to all ERP clients
• Quality of Service (prioritise ERP traffic)
• Local caching for remote sites
• VPN split tunnelling for remote workers

Application Review:

• Archive old data (completed orders from 5+ years ago)
• Disable unused modules
• Review custom reports (some are very inefficient)
• Update to latest patches

Operational Technology (OT) - PLCs, HMIs, SCADA systems - was designed for reliability, not security. Connecting it to the internet creates serious risks.

The Convergence Problem:

IT and OT used to be separate. Now, dashboards need real-time production data, ERP needs machine output, and managers want mobile access. This connectivity creates attack surface.

Recent Incidents:

• Colonial Pipeline (2021): Ransomware stopped fuel distribution
• JBS Foods (2021): Meat processing plants shut down globally
• Multiple water treatment plants targeted

Protection Strategy:

1. Network Segmentation: OT on separate, firewalled network
2. No Direct Internet: OT devices should not reach the internet
3. Jump Servers: Controlled access points between IT and OT
4. Monitoring: Detect anomalous traffic patterns
5. Patch Where Possible: Many OT systems can be updated
6. Compensating Controls: Where patching isn't possible

Industry 4.0 promises real-time visibility, predictive maintenance, and data-driven decisions. But implementation requires careful planning.

Starting Small:

Don't try to transform everything at once. Pick high-value, low-risk pilots:

• Machine utilisation monitoring (OEE dashboards)
• Environmental sensors (temperature, humidity)
• Energy monitoring (identify waste)
• Predictive maintenance on critical equipment

Platform Considerations:

• Microsoft Azure IoT Hub for enterprise integration
• Simpler platforms (e.g., Ubidots) for basic monitoring
• Edge computing for latency-sensitive applications
• Consider vendor lock-in before committing

Security from Day One:

• Separate IoT VLAN (don't mix with production OT)
• Device authentication (no default passwords)
• Encrypted communications (TLS everywhere)
• Regular firmware updates
• Monitor for anomalous behaviour