Cyber-Physical Convergence: Using Hybrid Networks to Secure the Manufacturing Floor
In today’s manufacturing environment, fueled by advancements in the Internet of Things (IoT), we’re witnessing a rapid shift towards “smart factories.”
Technologies like robotic cells, smart sensors, drones, and autonomous guided vehicles are transforming production lines, boosting efficiency, and reducing manual labor costs.
These advancements necessitate a robust communication network to handle the vast amounts of data flowing from the factory floor to the data center's IT infrastructure. In sprawling manufacturing complexes, establishing such a network presents unique challenges, especially when incorporating wireless technology. Today’s dynamic manufacturing landscape requires networks to be more than just connected—they must be vigilant.
Wi-Fi Evolution: From Bottlenecks to Breakthroughs
Historically, achieving reliable industrial-grade Wi-Fi with high-density coverage and seamless roaming involved choosing between multi-channel and single-channel architectures.
But multi-channel systems, while common, can suffer from interference in dynamic environments, and roaming can be disruptive due to the need to re-establish security credentials. Single-channel systems simplify deployment and eliminate interference, but often have lower overall throughput.
Hybrid networks now offer a solution, combining the throughput of multi-channel with the easy deployment and seamless roaming of single channel. This is achieved by configuring both architectures simultaneously on the same hardware, tailoring the network to specific applications within the manufacturing environment.
True hybrid networks deliver not only enhanced security and operational efficiency but also a strong return on investment by reducing downtime.
True hybrid networks deliver not only enhanced security and operational efficiency but also a strong return on investment by reducing downtime. Given that Siemens estimates the costs of a lost hour in fast moving consumer goods of $36,000 per hour and in automotive of $2.3 million, the reliability and redundancy offered by hybrid networks become critical for minimizing financial losses in manufacturing environments.
There are key security and operational advantages of hybrid networks in manufacturing:
- Efficiency. Hybrid networks enable real-time monitoring and response by combining live video surveillance with Wi-Fi-based device and personnel tracking. This allows for immediate identification of security breaches, safety incidents, or production bottlenecks.
- Intelligent operational environment. Leveraging smart cameras and Wi-Fi-enabled devices facilitates object and person detection, machine anomaly detection, and a reduction in false alarms. This enhances both security and operational efficiency by providing accurate and actionable insights.
- Situational awareness. Integrating various sensors (air quality, noise, temperature, device speed, vibration) into the Wi-Fi network increases worker safety and helps to predict and prevent machine failures, extending equipment lifespan.
- Reduced network infrastructure. Utilizing Wi-Fi and PoE-enabled endpoints (access control systems, sensors, scanners, LCDs, lighting, etc.) minimizes the need for extensive cabling, reducing infrastructure costs and maintenance overhead.
- Single pane of glass management: Combining the network management system (NMS) simplifies network administration, reduces the need for on-site technicians, and provides a centralized view of both the network and security devices.
- Streamlined regulatory compliance. The detailed monitoring and logging capabilities of hybrid networks aid in meeting regulatory compliance requirements related to safety, security, and operational procedures.
- Combining cyber and physical security. Hybrid networks help to bridge the gap between cyber and physical security by identifying machine interference and site intrusions that may be targeting control systems, protecting critical manufacturing assets.
Paramount Bed: Ensuring Reliable Connectivity in Manufacturing
In a real-world example of how a hybrid network brings benefits to the manufacturing outfitter, let’s look to Paramount Bed, a leading medical products company with a presence in more than 110 countries.
It needed to enhance the wireless connectivity at its Indonesian factory, which utilizes advanced technology, including sensor bed mats and eye scan cameras. The company required a high-performing Wi-Fi environment to improve wireless coverage and simplify network operations. The existing Wi-Fi system suffered from frequent disconnections and disruptions, hindering both office operations and product demonstrations.
Security is no longer a bolt-on; it's fundamental to the smart factory.
The solution included enterprise-class wireless access points and Autonomous Wave Control (AWC) to provide a self-tuning network. This hybrid approach ensured reliable connectivity across the factory, supporting both internal operations and the demonstration of Paramount Bed’s products.
The new network also included PoE switches, UTM firewalls, and cloud-based network management, simplifying administration and enhancing security—making disruptions and disconnections a thing of the past.
Security is no longer a bolt-on; it's fundamental to the smart factory. True hybrid networks provide the robust foundation manufacturers need to protect their operations, optimize efficiency, and drive innovation. Investing in this technology is not merely a choice, but a necessity for survival and success in the evolving manufacturing landscape.
Luis Coton is director of strategic channels for Allied Telesis, a global leader in connectivity solutions and intelligent networking tools. Coton leads a team responsible for growing and engaging with integrators, VAR's, distribution, eco-system partners, and end users in the networking solutions space across North America.
© Luis Coton, Allied Telesis
