Plug and play in industrial plants

Contradictory to the common belief that technology necessary for Industry 4.0 is expensive, the Combine and Conquer report by Accenture found that combining technologies such as AR/VR, big data and machine learning can save large businesses an average of £60,000 per employee. 

Here, Nick Boughton, sales manager at industrial systems integrator, Boulting Technology, explores the growing trend of plug and play technologies. 

Despite Industry 4.0 being far from a new concept, first being coined in 2011 at the Hanover Fair, the long lifespan of industrial machinery and the high perceived costs associated with purchasing smart technologies means manufacturers may still be reluctant to take advantage of the Industrial Internet of Things (IIoT).

A growing trend for many manufacturers looking to ‘smarten’ up their factory and integrate Industry 4.0 technology’s such as remote monitoring and predictive maintenance, is the introduction of plug and play devices. However, with growing concern about vendor lock-in, choosing hardware that is compatible with the existing products within a plant is essential to saving costs in addition to ensuring compatibility. 

Plug and play
Plug and play devices are one way of maximising compatibility between new products and existing systems.

A plug and play device or computer bus has a specification that allows for the discovery of a hardware component in a system without physical device configuration or user intervention.

A multitude of IoT functions are now available with plug and play IoT kits. One popular example is the use of sensors that allow for digital condition monitoring for any kind of machinery. A direct physical attachment means they are able to take measurements such as vibration and temperature to facilitate maintenance plans, without any compatibility complications. 

Because many manufacturers and developers of industrial automation equipment are producing their own devices to fill this market, it can be difficult for engineers to choose the best solution for their plant and application. As industrial machinery often has a long lifespan, for example, a motor control centre can be expected to last for twenty years with the correct maintenance, many plants will be faced with this dilemma each and every time they choose to purchase new equipment.

Universal systems
True plug and play technologies are able to integrate with equipment from all vendors, eliminating any integration headaches and potential issues. They can also deliver a quality and performance that matches plant requirements exactly.

Although the concept of true, open, plug and play technologies might sound idealistic to many, it is a growing trend for many manufacturers of industrial automation solutions, such as intelligent drives and remote monitoring software.

Experienced and independent systems integrators such as Boulting Technology are experts at recommending the best system for a plant’s unique requirements and capabilities. This includes ensuring the seamless integration of plug and play, out-of-the-box systems while retaining the cybersecurity and tried and tested processes from the existing system.

Integration
As plants are constantly being upgraded and technology is evolving, the choice of products, services, software and hardware is becoming ever more complicated. Retrofitting existing systems with new sensors and communication software is, therefore, becoming more popular each year, as it is often a far cheaper solution. However, even within the retrofitting sector, vendor lock-in can be an issue.

The choice to retrofit plug and play technology, which requires less complex integration and user training, can continue to ensure cybersecurity through consistent protocols and firewalls. This is proving to be the best solution for many plants as a means of lowering costs associated with industry 4.0.

Protecting utilities

Minimising cyber security threats on industrial control systems 

In 2017, the UK Government proposed the implementation of the Security of Networking and Information Systems (NIS) Directive,  with the aim of improving the security of essential services such as water and energy. Should providers fail to protect their systems, a £17 million penalty could be enforced. Here, Nick Boughton, sales manager at leading industrial systems integrator Boulting Technology, discusses why it is important for utility providers to protect themselves from cyberattacks. 

Plant managers within utility companies are now demanding more from their industrial control systems (ICS) to deliver operational improvements through smarter, information-enabled machines. As a result, the domains of IT and OT are converging and becoming increasingly connected as many ICSs are now overlapping with enterprise systems to provide accessible, secure information that is visible across organisations. With these increased benefits, however, comes a rise in additional security risks.

Typically working on closed, proprietary communication protocols, the migration to open protocols can present several issues, including unpatched software and hard-coded passwords. Robust systems, such as PLCs, were built to last before network connectivity was even considered.

When connecting a legacy system to an open protocol, it is essential that it is done safely and securely. Security patches can be vital in reducing potential cyber-attacks, however many manufacturers forgo their roll out as the associated costs can be high. Every missed patch makes it much harder and more expensive to ensure a legacy system is protected.

It is these risks that the Joint Committee on the National Security Strategy discussed in late May 2018. If ICSs are not protected properly within the utility sector, then it is not just breaches of the GDPR we should be worried about, but the supply of water and energy.

There is no one size fits all solution to protecting industrial control systems and it shouldn’t just cover the protection of a single system. IT and OT convergence means a holistic approach to industrial security should be taken, extending from a single enterprise system, to the people, processes and technologies within a plant.

In its 2016/17 report, the cyber threat to UK business, the National Cyber Security Centre (NCSC) suggested cyber security is most effective when integrated with risk management procedures.

To give maximum protection against cyber-attacks, a plant must have a robust security framework that encompasses people, processes and technologies. Our alliance with Netbuilder, a leading provider of software and IT consulting services, allows us develop and implement seamless solutions across IT and OT, which have traditionally been managed separately.

While having the latest firewalls, antivirus and intrusion detection software is important, it is redundant if staff are not trained properly. Working with an experienced supplier, such as Boulting Technology, will aid in developing one such framework.

Without a strong commitment to security, manufacturers will fall victim to the many pitfalls faced by open protocols.