Industrial Data: The Foundation of a Resilient, Smart Factory

Industrial data is the backbone of a resilient, efficient, and future-ready factory. Data is no longer just a byproduct of operations—it is a strategic asset that enables businesses to optimise performance, enhance decision-making and gain a competitive edge. However, simply having data isn’t enough; manufacturers must learn to seamlessly access and apply intelligent analysis effectively while providing visibility to the right personnel to drive real value.

Discovering the Power of Industrial Data

Every machine, sensor and system in a modern manufacturing environment generates vast data sets. However, without a structured approach, much of this data remains untapped, trapped in silos or underutilised. Manufacturers that leverage data effectively can:

One of manufacturers’ most significant challenges is integrating operational technology (OT) with information technology (IT).

Cybersecurity is a crucial concern. OT equipment has become more IT-aligned by necessity through standard protocols and ethernet/IP connectivity. Like a bucket of cold water, this fact woke the IT world to the significant vulnerabilities presented by connected operational systems. Furthermore, the press has continued to fill with stories of backdoors exploited by nefarious actors and the dire consequences of which to reputations, service, and profitability. It is time for OT to be taken seriously and become part of the IT estate with the same high standards and best practice approaches to security.

So, what does this mean for you as a manufacturer?

While OT focuses on real-time control and automation, IT manages enterprise-wide data and business systems. Manufacturers must bridge this gap to create a truly connected, intelligent operation. Here’s how:

Large volumes of data from PLCs, sensors, SCADA, MES, and ERP systems remain siloed and hard to analyse due to a lack of standardisation. Implementing solutions such as data historians with the correct connectivity ensures that information is collected consistently, stored securely and made available for analysis across all levels of the business. This structured approach enables manufacturers to track trends, monitor equipment health and improve efficiency with real-time insights.

A common challenge in manufacturing is that MES, SCADA and ERP systems often operate independently, making it difficult to achieve complete operational visibility. Manufacturers must ensure seamless data exchange between production and enterprise applications to bridge this gap. Open architecture solutions and industry-standard communication protocols like OPC UA and MQTT enable manufacturers to create a unified, real-time view of their operations, enhancing decision-making and efficiency.

Traditional IT cybersecurity measures, such as firewalls, intrusion detection and access controls, must be adapted for OT environments to protect critical production systems from cyberattacks. Implementing network segmentation, role-based access control (RBAC) and regular security patching helps safeguard sensitive industrial data while maintaining the accessibility required for smooth operations.

Companies can leverage cloud storage and edge computing to manage and analyse the vast amounts of data generated in modern manufacturing. Cloud platforms provide scalability and advanced analytics, enabling long-term data storage and AI-driven insights. Meanwhile, edge computing processes data closer to production equipment, reducing latency and ensuring real-time decision-making without overloading network bandwidth. Combining cloud and edge processing allows manufacturers to optimise efficiency and deliver information when and where needed while improving responsiveness to production demands.

The excitement around artificial intelligence in manufacturing continues to grow, but AI is only as powerful as the data it relies on. Without a strong data foundation, automation and AI-driven initiatives struggle to deliver meaningful insights or measurable improvements. A well-structured industrial data strategy ensures that manufacturers can extract value from their digital investments.

Successful digital transformation depends on the ability to collect, store, and manage data in a structured, reliable way. Without this foundation, manufacturers risk working with incomplete or inconsistent information, which limits the effectiveness of advanced analytics, AI and automation. High-quality, structured data enables machine learning models to produce accurate insights, helping businesses make informed decisions. Standardising your data collection methods, validation processes and formatting across all systems ensures that insights are actionable and aligned with operational goals.

Scalability is another critical factor. A well-planned data strategy allows businesses to expand their digital transformation efforts without costly overhauls or compatibility issues. Instead of implementing AI and automation in isolated, fragmented ways, companies can seamlessly integrate new technologies into existing operations. Starting with targeted areas such as predictive maintenance or quality control allows manufacturers to build confidence in their digital initiatives before scaling them across the entire production environment.

Maximising the return on AI and automation investments requires a data-first approach. When data is correctly managed and governed, businesses can fully leverage AI applications to improve efficiency, lower operational costs, and enhance decision-making. Without a structured data strategy, even the most advanced AI tools risk becoming underutilised or ineffective due to poor data quality. By focusing on data accuracy, interoperability, and governance from the outset, manufacturers can ensure that digital investments lead to long-term, measurable success.

Manufacturers looking to fully realise the benefits of digital transformation must take a structured approach to industrial data management. Success depends on collecting data and ensuring it is standardised, accessible, and actionable across the organisation. High-quality, structured data is the foundation for accurate analysis and informed decision-making. Implementing robust data collection tools, such as historians and IIoT-enabled devices, ensures that information from machines, sensors, and systems is captured in real time and stored uniformly. Manufacturers can seamlessly integrate processes and improve efficiency by eliminating inconsistencies between production lines.

Real-time access to production data is essential for moving from reactive to proactive decision-making. SCADA and IIoT platforms provide a live view of key performance metrics, allowing operators and managers to quickly detect inefficiencies, monitor equipment health, and respond to anomalies before they escalate into costly downtime. Instant visibility into production performance enhances resource allocation, increases operational efficiency, and helps businesses maintain a competitive edge.

Beyond monitoring, advanced analytics plays a critical role in optimising operations. By analysing historical and real-time data, manufacturers can anticipate equipment failures before they happen, refine supply chain logistics, and improve product quality. AI-powered analytics reveal patterns that might go unnoticed, enabling continuous process improvements and long-term operational gains.

To maximise the value of industrial data, decision-makers at every level must have access to transparent, actionable insights. Intuitive dashboards and reporting tools transform raw data into visual formats that are easily interpreted. Whether real-time machine performance metrics on the shop floor or high-level production trends for leadership, well-designed visualisations enable faster, more intelligent decision-making, ensuring that digital transformation efforts deliver tangible results.

Navigating the complexities of industrial data requires expertise and experience. At Novotek, we help manufacturers develop a tailored data strategy that aligns with their operational goals. Our deep understanding of industrial data ensures that businesses can break down silos, bridge IT/OT gaps, and turn raw data into measurable improvements.

Are you making the most of your industrial data?

The journey to a data-driven manufacturing future starts now. Contact Novotek to discover how our expertise in industrial data and GE Vernova’s digital solutions can help you build a more complete, resilient operation.