Plant digitization layers sensor data (IIoT) under execution systems (MES) under analytics — the wins are visibility, downtime prevention, and
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Sensors and PLCs emit; edge gateways buffer and normalize; MES orchestrates orders, routing, and quality; analytics ride on top — OEE visibility is usually the first paying win.
Legacy protocols (OPC UA and older), network segmentation between plant floor and cloud, and latency-critical loops staying local — the architecture respects the plant's physics and security boundaries.
Downtime-cause capture, then anomaly alerts, then predictive maintenance on the assets whose failure costs most — the maturity ladder climbed on data quality, not vendor promises.
Genealogy from raw lot to finished unit with process parameters attached — recalls shrink from crises to queries, and quality systems plug into the same spine.
Skipping the discipline this article describes until an incident, audit, or stalled project forces it — every practice above is cheaper adopted early than retrofitted under pressure.
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