Smart Factory Digital Transformation

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Smart Factory Digital Transformation

Connect your shop floor, optimise ERP performance, and secure OT systems

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Modern manufacturing relies on data. From ERP systems managing production schedules to IoT sensors on the production line, your IT infrastructure is the backbone of your operation. This guide covers everything from warehouse WiFi to securing operational technology.

15 min

Read Time

Checklist Items

Dec 2025

Last Updated

What's In This Guide

1. Warehouse & Shop Floor WiFi

2. ERP Performance Optimisation

3. OT Security (Operational Technology)

4. Industry 4.0 & IoT Implementation

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Warehouse & Shop Floor WiFi

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)

Action Checklist

Conduct professional WiFi site survey

High Priority

Document current dead zones and problem areas

High Priority

Test scanner connectivity at all rack locations

Critical

Upgrade to industrial-grade access points

High Priority

Configure seamless roaming for mobile devices

High Priority

ERP Performance Optimisation

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

Action Checklist

Schedule weekly database maintenance jobs

Critical

Review server RAM allocation (32GB+ recommended)

High Priority

Move database to SSD storage

High Priority

Archive data older than 5 years

Recommended

Review and optimise custom reports

Recommended

OT Security (Operational Technology)

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

Action Checklist

Inventory all OT devices and connections

Critical

Implement IT/OT network segmentation

Critical

Block OT network from internet access

Critical

Deploy jump server for maintenance access

High Priority

Establish OT patching schedule where possible

High Priority

Industry 4.0 & IoT Implementation

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Smart Factory Digital Transformation

Smart Factory Digital Transformation

What's In This Guide

Contents

Warehouse & Shop Floor WiFi

Common Problems:

The Solution: Industrial WiFi Design

Scanner-Specific Considerations:

Action Checklist

ERP Performance Optimisation

Common Performance Issues:

Server-Side Optimisation:

Network Optimisation:

Application Review:

Action Checklist

OT Security (Operational Technology)

The Convergence Problem:

Recent Incidents:

Protection Strategy:

Action Checklist

Industry 4.0 & IoT Implementation

Premium Content

Ready to Implement?

Related Resources

Signal for Help

Send a Signal