Cristina Flores

Nowadays, few companies question the fact that digitalisation is key to remaining competitive in the industrial sector. However, transitioning from a traditional factory to a “digital factory” is not always straightforward. Many initiatives are driven by the IT (Information Technologies) department, aiming to modernise operations and harness the power of data. But if the reality of the plant environment (OT, Operational Technologies) is not considered, the project can end up being more of a headache than a step forward. Digitalising a factory is not simply about installing sensors or software. It requires an understanding of processes, people and machines that have been operating for years under logics very different from those of an office. Let’s look at some of the most common mistakes made when digitalisation is led solely by IT. 1. Treating the factory as if it were an office In a corporate environment, devices tend to be homogeneous and easy to update. In contrast, an industrial plant may include machines that are 20 or 30 years old alongside modern systems, each with its own language and protocols. Trying to manage everything as if it were 'just another corporate network' often leads to frustration. 2. Not involving those who work on the plant floor A very common mistake is to design projects from an office, without speaking to production, maintenance or process engineering teams. Yet these are precisely the areas that understand the daily challenges firsthand and can provide a practical perspective on what’s actually needed. Without their involvement, technology risks being perceived as something imposed and not particularly useful — and most likely not very effective — because the main stakeholders are left out of the needs definition process. 3. Forgetting that the factory cannot stop One of the biggest misunderstandings when digitalising from IT is underestimating the cost of interruption in a plant. In an office environment, shutting down servers or applying security patches overnight or at weekends is standard practice, since the operational impact is limited. In contrast, the rules are very different in industrial environments: Many factories operate 24/7, with continuous shifts and tight delivery commitments. An unplanned stoppage of just 30 minutes can cost the company thousands or even millions of euros, depending on the production line and product being manufactured. Beyond the economic impact, an unexpected machine restart can pose safety risks for operators or damage in-process products that cannot be recovered, affecting product quality or increasing waste. When new digital solutions are introduced — whether monitoring systems, software updates, industrial networks or data integration — IT often proposes maintenance windows or interventions as if it were a corporate setting. This is where a clash with the plant reality occurs: there’s not always a 'low activity window', and stopping a production line requires careful planning. This is why any digitalisation project must include from the outset a robust operational continuity plan that considers: Redundancy strategies: mirror or backup systems that allow operations to continue during updates or failures. Separating the IT and OT networks (essential). Testing in controlled environments before rolling out to the actual plant — test or quality servers before going live. Close coordination with production and maintenance to define the right time for interventions. Calculating the cost of each minute of downtime, so that IT understands the scale of the impact. In short, forgetting that the factory cannot stop is one of the most serious and frequent mistakes. Cyber Security Cloud Connectivity & IoT AI & Data Smart Data Path, the road to Industry 4.0 December 4, 2024 4. Thinking about technology before thinking about value It’s not uncommon to see data platforms, sensors or AI systems being implemented simply because they’re “trending”, without a clear definition of what business problem they’re solving. Digitalisation should not be a technology showcase, but a tool to deliver tangible value: improved efficiency, reduced costs, better quality, safety or traceability. It’s essential to define or understand the needs of the plant firsthand and, based on that list, find the right technology to meet those needs. Doing it the other way around often creates problems during implementation, as requirements begin to emerge that the chosen technology cannot fulfil — and these needs went unidentified because they were never properly analysed. 5. Creating pilots that don’t scale Another common mistake is developing small pilot projects that work well in isolation but were never designed to scale or integrate with the rest of the systems. This creates a 'technology island' that is hard to maintain and even harder to connect with the wider organisation. A solid digital strategy should be scalable and built with long-term integration in mind. Conclusion Digitalising a factory is not just an IT issue, nor only an OT one. It’s a joint effort that requires cross-functional collaboration, strategic vision and a deep understanding of the specific characteristics of the industrial environment. Success doesn’t lie in deploying the latest technology, but in using it as a means to drive business improvement. Listening to those operating the plant, planning with continuity and safety in mind, and investing in scalable solutions are fundamental steps to make digital transformation both real and sustainable. The factory of the future won’t be built overnight, but it can start being designed today — by avoiding these common mistakes and embracing a shared vision between IT and OT. Telefónica Tech Challenges and solutions for integrating industrial technologies June 25, 2025

What is a SCADA System? A SCADA system is a software and hardware solution designed to monitor, control, and collect real-time data from industrial processes. These systems are composed of a number of components, including sensors, controllers, data acquisition devices and a user interface that allows operators to monitor and manage processes from a centralized location. The architecture of a SCADA system consists of several layers, including the field layer, where the sensors and actuators are located, the control layer, which is responsible for processing the information and acting on the plant itself, and the supervisory layer, which provides a graphical interface for operators to monitor and control the processes. SCADA supervises and manages industrial processes in real time, integrating hardware and software for efficient centralized monitoring. We place it in the middle layer within the classic automation pyramid, as it is a key tool that allows data to be extracted from the lower layers and exploited with software found in the upper layers such as MOM systems and ERP. The following is a detailed breakdown of the three main layers of a Scada system: Supervisory: This part of the system involves the visualization and supervision of process data in a user-friendly interface. Operators can monitor equipment status, process conditions and other important parameters. Control: Scada allows operators to control industrial processes by issuing commands through the user interface. This can include parameter adjustments, equipment activation or deactivation, and other actions necessary to keep the process running optimally. Data Acquisition: This function involves the collection of real-time data from sensors and other devices connected to the system. This data is then processed and presented on the user interface for monitoring and analysis. The implementation of a SCADA (Supervisory Control and Data Acquisition) system plays a key role in the digital transformation of a production plant by providing a comprehensive technology platform to monitor, control and optimize production processes. Here are some key points in which a SCADA contributes to this transformation: Data centralization SCADA centralizes the collection of data from different devices and systems throughout the plant. ✅ This provides a unified view of production data and facilitates access to critical information from a single user interface. Real-time monitoring SCADA enables real-time monitoring of all aspects of plant operation, including production levels, product quality and environmental conditions. ✅ Operators can quickly detect and respond to any anomalies or problems, minimizing downtime and helping to maximize operational efficiency. Remote control The remote control capability of SCADA allows operators to monitor and control production processes from any location, including via mobile devices thanks to the web environment provided by many of the software manufacturers. ✅ This provides greater flexibility and responsiveness, especially in emergency situations or when quick adjustments need to be made to the production line. Process Automation SCADA facilitates process automation by enabling task scheduling and script execution. ✅ This reduces dependence on human intervention at night, for example, and improves accuracy and consistency in the execution of repetitive tasks. Efficiency optimization SCADA provides valuable information on plant performance and individual processes by collecting and analyzing data in real time. Monitoring line availability is necessary to ensure the highest possible efficiency in each process. ✅ This makes it possible to identify areas for improvement and optimize processes to maximize productivity. System integration SCADA facilitates the integration of heterogeneous systems and devices throughout the plant, including PLCs, sensors, energy management systems, and quality management systems. ✅ This creates a connected ecosystem where data can flow freely between different layers, facilitating informed decision making and optimization of plant operations. Regulatory compliance and reporting SCADA provides a detailed record of process data such as variables and environmental parameters involved in production, facilitating compliance with regulations and industry standards. Reports generated by SCADA can be used to document compliance and respond to internal and external audit requests efficiently. Conclusion SCADA systems play a critical role in the digital transformation of a production plant by providing a comprehensive technology platform for monitoring, control, and data acquisition of production processes. This allows us to create a very stable ecosystem for scaling up to the business layer with other indispensable tools such as MES, GMAP, APS, etc. In this way we can improve the operational efficiency, productivity, and competitiveness of the plant in today's market. Cyber Security AI of Things Blockchain The (call it 'x') industrial revolution: Introducing new trends in industrial Cyber Security December 20, 2023 Image by ArtPhoto_studio at Freepik.

In the era of modern industry, efficiency and optimization are essential elements for the success of any industrial plant. The evolution of management systems, from the traditional MES (Manufacturing Execution Systems) to the more advanced MOM (Manufacturing Operations Management) systems, represents a significant milestone in the way production process plants manage their operations. This change involves not only a technological upgrade, but also a fundamental transformation in the way production operations are planned, executed and analyzed. In this article, we will explore in depth the evolution from MES to MOM and the advantages that this transition brings to industrial plants in their production processes. From MES to MOM: A technological evolution The MES (Manufacturing Execution System) has long been the backbone of operations management in industrial plants since the 1990s where the first of them was developed. Its focus has always been primarily to control the execution of operations in real time on the shop floor. This system provides tools to monitor and control daily activities such as production productivity, quality management and control of manufactured units. However, with the advancement of technology and the increasing complexity of industrial operations, the need for a more complete and strategic solution arose. The evolution towards MOM (Manufacturing Operations Management) systems represents an extension of the capabilities of MES, also integrating the planning and analysis of production operations, even managing operational areas that were previously managed independently through other systems. MOM systems not only monitor and control operations in real time, but also offer advanced production planning, supply chain optimization and data analysis capabilities. This evolution enables more complete and proactive management of production operations, addressing both the operational and strategic aspects of industrial management. Advantages of the transition to MOM systems The transition from a MES system to a MOM system offers several significant advantages for industrial process plants. These advantages go beyond a simple technological upgrade, impacting directly on the efficiency, quality, and competitiveness of the plant. These are some of the main advantages of this transition: Full operations integration One of the highlights of the evolution from MES to MOM is the complete integration of all manufacturing operations. Whereas MES systems focused primarily on the execution of tasks on the shop floor, MOM systems encompass the planning and analysis of these operations as well. ✅ This integration enables a holistic, real-time view of the entire production chain, from production planning to delivery of the final product. Continuous process optimization MOM systems provide a platform for continuous optimization of manufacturing processes. MOM systems allow you to proactively identify areas for improvement and take corrective action by collecting real-time data on plant performance, product quality, and other key performance indicators. ✅ This advanced analytics capability helps companies optimize operational efficiency, reduce cycle times, and improve product quality. Improved operational efficiency The integration and optimization facilitated by MOM systems lead to significant improvement in the operational efficiency of manufacturing plants. These systems help identify bottlenecks, minimize downtime, and maximize resource utilization by providing real-time visibility of all operations. ✅ This leads to more efficient and profitable production. Regulatory compliance and traceability Another important benefit of MOM systems is their ability to ensure regulatory compliance and product traceability. These systems facilitate auditing and compliance with industry standards, such as ISO 22005, which ensures traceability in the food chain, by keeping a detailed record of all manufacturing operations from raw material receipt to final product shipment. ✅ Full traceability also helps to quickly identify and resolve any quality or safety issues with customers or suppliers. Informed and reliable decision making MOM systems provide managers and middle managers with the information and tools they need to make proactive and strategic decisions. Managers can identify trends, anticipate problems, and respond quickly to changes in the production environment thanks to the reliability of the data provided by these tools, with access to real-time data and advanced analytics. ✅ It enables them to optimize resource allocation, improve production planning and remain competitive in an ever-changing and demanding marketplace. Flexibility and adaptability MOM systems are highly flexible and adaptable to the specific needs of each company and production process. Their modular architecture allows integration with other enterprise systems such as ERP and customization according to the unique requirements of each plant. ✅ This flexibility enables companies to implement changes and enhancements quickly and efficiently, allowing them to remain agile and adaptable in a dynamic business environment. Conclusions The evolution from MES to MOM represents a significant advance in operations management in industrial production process plants. MOM systems offer more comprehensive and strategic operations management by integrating the planning and analysis of production operations, driving plant efficiency, quality, and competitiveness. The transition to MOM systems is essential for companies looking to improve their operational performance and stay at the forefront of innovation. It is time to embrace this technological evolution and take full advantage of the benefits it offers for modern industrial management. Connectivity & IoT IA & Data The digitalization of the industry: a practical guide October 4, 2023 Image by Aleksandar Littlewolf / Freepik.