IIoT: Industrial Internet of Things

Broadly speaking, the Industrial Internet of Things (IIoT) refers to the use of intelligent sensors and actuators in industrial machinery and processes in order to capture information about how they operate and transmit it through a communications network for the management and monitoring of workflows.

IIoT can be considered a subcategory of the Internet of Things (IoT) and is a key pillar of Industry 4.0 (considered the next phase of the industrial revolution). These technologies are revolutionizing the way factories are managed and industries are organized.

IIoT can share many of the uses and advantages of IoT. In this sense, it generally makes use of the following technological layers:

• Devices (or sensors): responsible for recording data, connecting to a network, and sending it.
• Gateway devices: responsible for connecting the initial sensors to the network. Ultimately, this is the mechanism that transmits data to the cloud.
• Cloud: the data collected by the previous layers is sent to remote servers where it is stored and processed.
• Analytics: the final layer of IoT technology, where raw data is turned into actionable information, making it possible to support decision-making and identify patterns or trends.

IIoT improves communication between machines and provides plant managers with data that very clearly illustrates how all devices and processes are functioning as a whole.

Through the continuous collection of detailed data, industrial companies can monitor the energy, water, and other resources they use, and also know in real time when their machines are running and how much they are producing. Operators can then make manual adjustments, or equipment can be adjusted automatically to optimize performance.

IIoT Applications

The Industrial Internet Consortium (IIC), an international organization dedicated to promoting the use of the Internet of Things in the industrial sphere—encouraging the development, adoption, and widespread use of interconnected machines and devices—highlights the most common use cases where this technology can have an impact:

• Intelligent warehousing applications
• Predictive and remote maintenance of machinery
• Control of cargo, goods, and transportation
• Connected logistics
• Smart measurement of each logistics process
• Applications in “smart cities” (Smart Cities)
• Smart agriculture and livestock monitoring
• Industrial security systems
• Optimization of energy consumption
• Industrial heating, ventilation, and air conditioning
• Monitoring of manufacturing equipment
• Asset tracking and smart logistics
• Monitoring of ozone, gas, and temperature in industrial environments
• Worker safety and health
• Asset performance management in warehouses

In summary, according to the IIC, IIoT will provide storage facilities with efficiency through process monitoring and with operational safety—especially in more complex operations or those that may pose risks to both the goods and the operator.

Differences Between IIoT and Industry 4.0

It is common to confuse the terms IIoT and Industry 4.0. Although both concepts go hand in hand in improving the global competitiveness of companies, they represent different ideas.

In this sense, Industry 4.0 focuses on digitizing information, automating processes, using new materials, and applying novel techniques in the performance of functions.

For its part, the Industrial Internet of Things aims to collect large volumes of data (Big Data) along with the corresponding analytics, seeks interconnection among all devices and sensors in industry, promotes predictive industrial maintenance, and increases industrial process safety through monitoring.

In other words, IIoT is one of the many solutions to the challenges posed by Industry 4.0, as it focuses on the exchange of data and information among all devices involved in manufacturing processes. By contrast, Industry 4.0 defines the new paradigm and the new challenges companies face in terms of process improvement, automation, and digitization to remain competitive in an increasingly competitive, complex, and efficient work environment.

Benefits of Industrial IoT

Introducing IoT into industry will bring many benefits to achieve the goal of any logistics process: maximizing profitability by reducing operating costs. Among the advantages for industry, the following stand out:

• Increased productivity: by using IIoT tools, operators can execute workflows faster without compromising the quality of the final product.
• Faster improvement cycles: with this technology, staff responsible for certain areas (such as manufacturing or quality processes) can automate data collection, gaining more time for analysis and for finding solutions aimed at process improvement.
• Identifying business opportunities: IIoT technology makes it possible to monitor every data point produced by the company, evaluate processes with the market in mind, and identify business segments that may be attractive to the organization.
• Preventive and predictive maintenance: one of the major advantages of adopting IIoT is the ability to anticipate events such as system failures or production equipment breakdowns. With smart sensors transmitting data, parts can be replaced or maintenance carried out before a failure impacts the entire production chain.
• Improved quality: sensors can trigger alerts when critical quality factors become unstable on production lines. For food or vaccine production, for example, where variables such as temperature and humidity are decisive, IIoT sensors can detect changes in these variables and enable timely responses.
• Supply chain optimization: through RFID tags and other sensors, inventory can be tracked as it moves through the supply chain, allowing more accurate identification of interdependencies, mapping of material flow, and tracking of manufacturing cycle times.
• Improved energy efficiency: integrating IoT brings sensors into logistics storage environments, helping to optimize energy consumption.
• Industrial safety: connectivity between devices and data analytics become strong allies for industrial safety. Processes will include sensors and monitors to prevent accidents that might occur in facilities.

Cybersecurity in IIoT

Cybersecurity for the devices and sensors used by IIoT is vital to guarantee successful manufacturing performance, since a failure in data monitoring and (increasingly autonomous) decision-making could represent a large-scale risk for industry.

There are numerous obstacles and potential risks for companies that decide to implement IIoT-based control systems. First, the security of transmitted information, since a third party (a cybercriminal) could intercept it and use it to commit a crime.

The fact that multiple users can access a service creates uncertainty about their identity and location. It is also possible that multiple authorized users might attempt to simultaneously control a particular parameter, which requires a mechanism to resolve conflicts and coordinate different requests.

In addition, increased operational complexity leads to the need for specially trained personnel, which must be taken into account well in advance.

Data security and integrity can be attacked through the use of protocols designed to operate over untrusted networks, which requires data encryption and user authentication.

To address delay and data loss issues, solutions have been proposed that increase the priority of delivering data considered critical information.

Another option is the use of infrastructure known as Fog Computing, which involves using servers located as close as possible to where sensors and actuators are installed—unlike traditional Cloud Computing. This solution also helps address scalability problems as the number of connected devices grows.

To ensure the reliability of a control system, in some cases it is advisable to consider redundancy in servers, controllers, sensors, and even networks. An independent local control system can be activated in emergencies or when communication latency exceeds the maximum allowed.

Creating an IIoT standard is essential so that devices from different manufacturers can understand each other, beyond the selection of a single communication protocol. Unfortunately, agreement on such a standard does not seem close due to the diversity of manufacturers and users, with highly varied visions and requirements.

Compatibility with devices currently in operation is also a challenge to consider. The use of virtual machines may be sufficient, but in general each case requires a specific solution, which may even involve fully replacing an obsolete system.

Best Practices

Internationally recognized best practices for protecting IIoT infrastructures include the following measures:

• Authorize all IIoT devices within the internal industrial operations network using appropriate methods such as digital signatures or digital certificates/PKI.
• Define secure communication channels for data transfer between IIoT devices by implementing access control whitelists.
• Design and implement dedicated security requirements for service providers. Audits should be performed before selecting an IIoT solution and periodically throughout the system’s lifecycle.
• Implement multi-factor or combined authentication to prevent access impersonation.
• Encrypt communication channels related to handling sensitive data (configurations, personal data, device control actions, among others), where possible without affecting availability and performance.
• Implement well-known security protocols based on standards and technical recommendations that have proven secure or that address prior security problems.
• Train IIoT device operators in their use, with a deeper focus on the technologies implemented to protect devices and the ecosystem in which they operate.

In general terms, the Internet of Things in the industrial world represents progress that brings connectivity to critical infrastructures within plants or industries.

This change also implies both an improvement for companies and a security risk. Therefore, as autonomous devices are incorporated into industry, their cybersecurity must be increased through the use of reliable protocols, digital certificates or multi-factor authentication, and in all cases a greater and ongoing effort in monitoring and auditing the installed IT infrastructure.