At the core of industrial digitalization lies the so-called IT/OT integration, which connects machines, equipment, and peripheral devices from operational technology (OT) with ERP applications and other software systems from information technology (IT). A prime example is the highly specialized PCB production at KSG GmbH, one of Europe’s leading manufacturers in this sector. Together with Schaeffler Digital Solutions, the company has developed an IoT solution that meets all typical requirements of IT/OT integration and enables a scalable, future-proof data infrastructure.
The challenge: Heterogeneous systems and high complexity
Like many manufacturing companies, KSG GmbH operates a heterogeneous landscape of machines with control systems from various vendors. This diversity makes IT/OT integration particularly difficult. In addition, KSG wanted to transmit extra information to the control systems.
PCB production involves complex chemical processes that require precise parameters. Even minor deviations can quickly lead to scrap or entire defective batches. At the same time, the existing systems offered limited scalability. Custom integrations, non-standardized data labels, and extensive maintenance efforts made centralized evaluation of production data difficult.
KSG sought an integrated, future-oriented solution for data-driven manufacturing with the following characteristics:
- Low manual effort
- Simple IT/OT integration
- Foundation for end-to-end processes
- Centralized data structure
- Automated parameter control
- Basis for comprehensive OEE analysis and predictive maintenance
Challenges at a glance:
- Heterogeneous machines complicate IT/OT integration
- Manual data handling and high workload
- Lack of transparency in process parameters
- Non-scalable system structures hinder analysis
The solution: Central platform for IT/OT integration
In collaboration with Schaeffler Digital Solutions, KSG developed an architecture based on the autinityDAP platform. This application enables the networking of various machines, controllers, and sensors. It provides this data centrally, allowing third-party systems to access the combined information through an open interface.
IT/OT integration with autinityDAP
As an entry point to IT/OT integration, the two partners chose autinityDAP Starter to connect initial machines with manageable effort and to integrate the platform into existing systems. Specialized edge devices capture all machine and production data, transmitting measurements, data points, and units to a central software platform. Within the system, additional apps can be deployed, including third-party solutions or in-house developments.
This is made possible by the system’s open, container-based architecture. Each application is encapsulated within a so-called container, allowing it to operate independently. In simple terms, each containerized application brings along all the resources it needs to function. This makes it possible to run many applications in parallel and easily adapt to increasing performance requirements.
Proven technology with development potential
Another advantage of the platform is its unified data infrastructure, which supports a wide range of well-known industrial protocols, including OPC UA, MQTT, and Profinet. The platform also comprises the following components:
- The Central Tech Library is the central data model for IT/OT integration and defines standardized names and structures for each connected machine, the so called tags.
- The machine data is stored in a PostgreSQL database. This is an open source solution, a vendor independent database system based on the SQL standard.
- Machine and process data are processed with Node-RED. This is a low code development tool for visual programming. It specializes in linking hardware devices, APIs, and online services in the IoT.
- Finally, the data is visualized with Grafana. The open source web application is interactive and can generate flexible charts and graphs.
Using open source software means there are no additional license costs for proprietary tools. All internals and interfaces of the software used are disclosed. This ensures the digital sovereignty that is increasingly required.
IT/OT integration, automated and failsafe
The solution records the condition of the machine during its operating time and presents it visually. Downtimes, fault states, and maintenance phases are visible at a glance and can be analyzed systematically. Two primary use cases of IT/OT integration are at the forefront: the structured collection of machine data and the automated transfer of production parameters from the ERP system to the PLC.
An incorrect parameter can significantly disrupt production. The solution prevents this and increases process reliability. For each printed circuit board, the application retrieves the relevant data from the ERP system and passes it to the controller. This prevents operating errors and ensures consistent quality.
Another advantage of the platform solution is that the uniform data foundation makes it possible to calculate Overall Equipment Effectiveness OEE. This key figure consists of three components, availability, performance, and quality. It identifies weaknesses in the processes and assesses the productivity of the equipment.
The result: Technology from practice for practice
autinityDAP from Schaeffler Digital Solutions goes beyond IT/OT integration. It includes proven, real world solutions that have been tested in Schaeffler plants and are now available to external customers as well. This gives KSG access to a mature system that meets the needs of companies in industrial manufacturing.
Thanks to its open architecture, the solution adapts flexibly and grows along with requirements. New machines or entire production lines can be integrated into existing systems with minimal effort. The infrastructure remains open for individual extensions, since the container based architecture enables the safe operation of additional applications.
This is not an off the shelf solution. Even during the pilot phase, insights gained from testing were directly incorporated into further platform development. As a result, both companies continue to identify new use cases and steadily automate all processes.
The project demonstrates how digitalization can be structurally anchored in manufacturing. A unified, scalable data infrastructure concept, standardized information, and close interconnection between IT and OT provide the foundation for data driven decisions and efficient processes.
Results at a glance:
- Automated control of production parameters
- Unified data foundation for OEE analysis
- Reduction of manual error sources
- Flexible, scalable, and modular infrastructure
