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INDUSTRY 4.0/IIoT ENSURE YOUR DIGITAL TWINS STAY SECURE
Joe Lomako, Business Development Manager (IoT) at TÜV SÜD, outlines the benefits of Industry 4.0 and the IIoT, but also warns of the cybersecurity issues that must be considered when implementing a ‘smart factory’
ost manufacturing lines depend on human supervision to monitor performance and efficiency. However, this is changing, as production, manufacturing and processing are now becoming smarter thanks to Industry 4.0 (I4.0) or the Industrial Internet of Things (IIoT).
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I4.0 and IIoT can be described, in the simplest terms, as “industrial processes and manufacturing connecting directly with the latest IoT technology”. This is just the first step, as many designers and innovators are now also producing a digital copy of their systems at the same time as they build the physical system. This is known as the ‘digital twin’. The digital twin uses technologies such as
artificial intelligence (AI), IoT, virtual reality (VR/AR), and sensor technologies to create digital models (twins) of real devices, systems, or processes. This includes a manufacturing or production line – the ‘smart factory’ – where models can be used to monitor the real system to improve production processes and optimise performance, for example to predict machinery breakdowns.
A typical manufacturing environment is usually made up of several systems that are interconnected, often running the risk of a breakdown, which could cause a ripple effect throughout the entire production line. For example, if a robot, integral to the rest of the production, breaks down it can have serious consequences. Production could be slowed, interrupted or even drastically halted, leading to a loss of revenue or even discontinuity of the business. Digital twins can therefore help manufacturers to optimise performance and more accurately predict business obstacles. In today’s I4.0 domain, digital twins operating in parallel to the physical factory, where thousands of sensors constantly collect, process locally (edge computing) or send back data for processing on a larger scale, are becoming more commonplace. Benefits of the digital twin approach include: • Constant monitoring – to determine if a machine is about to fail, so any potential issue
28 SEPTEMBER 2023 | PROCESS & CONTROL
can be mitigated without
interrupting function, but it can be modelled on the digital twin in real- time to assess the size of any problem.
• Data monitoring and analysis - to make iterative improvements to operations, increase efficiency and reduce costs in real- time. For example, a programmed robot which is operated in a specific sequence could be constantly modelled in parallel to reduce cycle time of that sequence.
• Ability to plan - probably one of the greatest uses of the digital twin, as an entire factory can be simulated before the first brick is laid. Of course, there are challenges to reaping the benefits of deploying a digital twin. These include issues caused by multiple technologies of varying ages vying for a place in the IIoT, which introduces the problem of
interoperability. This means that any digital twin may have to cope with processing data from many different protocols and legacy systems. As this requires decoding and recoding activity, extra latency and a greater margin for error is introduced. There is also the cost associated with replacing existing equipment to interoperate and dock effectively with the digital twin.
As the convergence of enterprise IT and operational technology sees systems and devices exchanging and interpreting shared data, cybersecurity also becomes a threat to the smart factory. Digitisation can bring enormous opportunities, but also unforeseeable risks and vulnerabilities that can be exploited by new forms of cybercrime. As I4.0 uses more complex technology and connectivity, these systems present a greater number of attack surfaces and have the potential to cause a much more severe impact than a mechanical breakdown. This means that robust information and digital
security is a major priority factor. It is essential to deal with cybersecurity measures at the early planning stage of any system, be it a product or a production plant. While there are defined cybersecurity standards available globally, some may not be complete and ratified, or mandatory. However, they do represent a first line of defence, and any ‘connected’ stakeholder must:
• Think “secure by design” and take a proactive approach by recognising that cyber attacks are “when” and not “if”. • Ensure up to date compliance with all standards.
• Constantly review the “cyber resistance” status of all systems.
Many manufacturers, whilst having internal security knowledge, will benefit from working with external advisors who have wider exposure to assessing various types of product or infrastructure, and will be better equipped to help manage threats. Building a network of trusted partners is therefore a strong first step towards planning cost- effective end-to-end security. Tackling the problems of cybersecurity risks can, after all, only be realised by comprehensive planning, periodic evaluation, updates and monitoring - from design through to obsolescence. While it is clear that the digital twin is changing industry, there remain many challenges which must still be resolved. TÜV SÜD
https://www.tuvsud.com/en- gb/services/cyber-security
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