MANUFACTURING


digitalisation is the fragmentation of data. Production data must move easily between machines, control systems and enterprise platforms (ERP, MES and QMS) to provide useful insights. In many facilities, that is still  own status, but no one has a complete view until the data is pulled together manually. That cannot happen in a new plant. The data model needs to be designed with the same discipline as the line layout. Before commissioning, the project team should agree which information is needed and how it will move through the plant. Otherwise, every later connection becomes a separate integration project that eats resources.


Paving the way for IT/OT convergence


Ongoing implementation of IT/OT convergence has become one of the key topics in the automation discourse. While full convergence is not a given, parts of it are essential for enabling advanced analytics and business integration.


Segmented network architectures provide a practical solution. By maintaining logical separation between IT and OT domains


while working towards controlled data exchange, manufacturers can protect critical operations from external threats and internal disruptions. A proper choice of network architecture plays an important role here – Federation Architecture or NAMUR Open Architecture are two examples of how security could be thought of in the planning stage.


 Discrete manufacturing environments are inherently dynamic. To keep pace, network infrastructure must support rapid  Modular network designs and standardised connectivity make adding SKUs, changing  without rebuilding infrastructure every time. This matters most when the product mix changes quickly. The plant can respond without tying up specialists on avoidable network changes.


The increasing adoption of robotics also places additional demands on network performance. What’s behind failures is usually timing or infrastructure that was sized for average load rather than peak conditions.


By the time this becomes visible, the plant is often already in production. Performance requirements need to be treated as part of the process design, not as a property of the network alone.


 implementation


To address these challenges, a structured and validated approach to network design and deployment is the best way to go. This typically involves three key steps: • Design that’s validated upfront and uses labs and testbeds to prototype  


• Installation that aligns with proven standards and documented practices across every contractor and line


• Commission and hand over a fully documented, production-ready network with the support you need as systems come online and production takes on momentum


This methodology reduces uncertainty during the build phase and accelerates the transition to full production.


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MAY 2026 | ELECTRONICS FOR ENGINEERS 33


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