Brownfield reality
PLCs still run the line. Rip-and-replace is a fantasy.
SCADA, MES, and ageing controllers stay in place. Integration has to respect live production windows — or it never leaves the pilot bay.
Rayns · Industrial IoT
Connect the shop floor to cloud intelligence — without rip-and-replace
OT/IT convergence, edge telemetry, and governed pipelines — delivered by one accountable squad that respects production uptime and plant security.
ot-it · topologylive plant
Shop FloorPLCs · Sensors
MES / SCADALegacy OT
Edge GatewayMQTT · OPC-UA
Cloud PlatformStream · Store
Dashboards / AIAlert · Predict
ingestbuffergovernact
4–6wk
OT/IT assessment to roadmap
99.5%
Telemetry pipeline uptime target
<500ms
Edge alert latency design goal
1
Accountable squad owner
Why most plant digital programmes stall
IT-centric pilots ignore OT constraints. Winners integrate brownfield assets, secure plant networks, and ship uptime outcomes — not slide-deck demos.
OT security pressure
IEC 62443 now reaches the plant network — not just IT.
Segmentation, zero-trust paths, and DMZ patterns have to ship with the gateway. Security bolted on after ingestion is how plants get breached.
Edge vs cloud split
Real-time belongs at the edge. Governance belongs in the cloud.
Get the split wrong and you burn budget on latency you don't need — or analytics that never see clean telemetry.
Convergence Pillars
Four capabilities that connect physical operations to intelligent systems — without proprietary platform lock-in.
01
Device & Edge
OPC-UA, MQTT, and Modbus adapters behind gateways that buffer, normalise, and secure telemetry before it leaves the plant.
02
Industrial Streaming
Event-driven ingestion for high-frequency time-series — backpressure, schema governance, and observability edge to cloud.
03
OT/IT Bridge
Shop-floor systems connected to MES, ERP, and cloud — without trading away uptime or network isolation.
04
Predictive Ops
Condition monitoring and alerting grounded in asset health models — not generic dashboard wallpaper.
Telemetry Command Center
From protocol adapters at the edge to predictive alerting in the cloud. Expand each chapter for deliverables and stack tags.
plant-telemetry · livestreaming
Production Line Aedge · cloud
Asset health
94%
+2.1%
T1
T2
T3
T4
T5
Protocol adapters, edge gateways, and secure OT network integration.
- OPC-UA, MQTT, and Modbus protocol adapters
- Edge gateway deployment and buffer management
- OT network segmentation and DMZ architecture
OPC-UAMQTTModbusEdge gateways
High-throughput telemetry pipelines with governed time-series storage.
- Kafka or event-hub streaming architecture
- Time-series storage (InfluxDB, Timescale, Azure Data Explorer)
- Data quality rules and schema versioning
KafkaTimescaleAzure IoTAWS IoT Core
MES/ERP integration and unified asset models for cross-system visibility.
- MES and ERP connector development
- Unified asset hierarchy and digital thread mapping
- Cross-domain data model and lineage documentation
MES/ERPSAPAsset modelsData lineage
Condition monitoring, alerting, and AI-assisted predictive maintenance workflows.
- Threshold and anomaly-based alerting rules
- Predictive maintenance model integration
- Operations dashboards and mobile alert routing
Condition monitoringML modelsAlertingDashboards
Transformation Pipeline
A four-stage model for brownfield plants — pilot-first rollout, OT-safe change management, and measurable progress at every gate.
01
Assess
OT landscape mapping, protocol inventory, security baseline, and a prioritised integration roadmap — locked to production constraints.
02
Connect
Edge gateway deployment, protocol adapters, and secure telemetry ingestion — validated on a pilot line before plant-wide rollout.
03
Unify
MES/ERP/cloud data model alignment, asset hierarchy mapping, and governed streaming with full observability.
04
Optimise
Condition monitoring, predictive alerting, and improvement loops measured against downtime, yield, and MTTR.
Engagement Models
Matched to your OT maturity, plant complexity, and team capacity — not a one-size delivery menu.
OT/IT Readiness Assessment
2–4 week structured assessment — protocol inventory, security baseline, integration options, and a pragmatic 90-day plan.
Edge-to-Cloud Integration Squad
Embedded engineers in your plant and cloud — adapters, pipelines, and dashboards with clear sprint ownership.
Predictive Operations Advisory
Fractional OT/IT architecture support — rollout governance, vendor evaluation, and scaling without lock-in.
Case Study · Automotive & Manufacturing
From reactive maintenance to predictive operations
A discrete manufacturer with disconnected shop-floor systems and ageing OT needed governed telemetry — without interrupting live production lines.
Challenge
Manual maintenance schedules, siloed PLC data, and no unified view of asset health across lines.
Integration Approach
OPC-UA and MQTT via edge gateways, governed cloud streaming, condition monitoring, and AI-assisted alerting — rolled out line-by-line.
Outcomes
- Reactive maintenance
- →
- Predictive work orders
- Siloed PLC data
- →
- Unified asset health view
- Plant-wide cutover risk
- →
- Line-by-line, zero downtime
Bring us your plant, protocols, and production constraints
Start with an OT/IT readiness assessment — or jump straight to a scoping conversation about your lines and latency budget.