Editor's Choice


MES, OT and the IIoT – what’s required for digitalisation?

May 2021 Editor's Choice

My last opinion piece on the MES and OT saga turned out to be a good gauge of the perception of professionals in both realms. In the article, which appeared in the October 2020 issue of SA Instrumentation and Control magazine (https://www.instrumentation.co.za/11648r), I asked whether OT will ever swallow up MES. The response on LinkedIn and email was surprising. Some commentators vehemently defended the separation of the two, while others didn’t completely discount the possibility.

We defined MES as applications that execute plant-related data in the business layer. We also defined OT as technology that is used in the process control layer. These are very simplistic definitions but will suffice for now, as that is another rabbit hole and there are many books written about the definitions and meanings of MES and OT.

The IIoT is what glues it all together

Where does the IIoT fit in? Well, first let’s define it. The Industrial Internet of Things is the ability to connect devices (or things) to the Internet and to each other over various types of networks, using various types of protocols. The idea is that previously disadvantaged devices can now benefit from Internet exposure. Being connected allows these devices to share data with their owners and operators, which was previously impossible, or at least very difficult. Now apply that to an industrial environment and we open up a whole new world of possibilities (or a can of worms?) – namely, digitalisation.

Clear demarcations, for a reason

The world of OT exists for a reason. We cannot simply apply IT standards and processes to an industrial environment where we are focused on manufacturing processes that must run continuously without those pesky IT processes, standards and seemingly endless red tape, getting in the way. This is a popular misconception! For digitalisation to succeed the two domains have to integrate, they have to find that common ground where the goals of the enterprise become the shared objective. Securely allowing network traffic to flow as and when required, initiated by the OT domain data decision makers, is the thinking that has to be adopted before digital transformation can be achieved.

But how?

Hand over the data decisions to the OT guys? Calm down IT professionals, there is a time and a place for everything. Digitalisation in its simplest form makes data available from where it is being created. MES systems, ERP systems, WMS systems and logistics systems are not the truest, rawest source from which data can be gathered. We want data from sensors, machines, PLCs, DCSs and HMIs etc. We want the data to be gathered from all stores, at any level and of any type. This is the value in the IIoT – the idea that we can get a window into the entire enterprise by having data connections to all relevant systems and data stores, not on an historical stack level, but on an holistic data-hub level. Traditionally, data would go from the sensor to the PLC (edge), HMI, scada and then to the MES in the business layer and from there onto the ERP and other business systems. The IIoT structure encompasses an extraction layer from any, and all, systems that aggregate and store data into the Unified Name Space (more on this in a future article).

Visualisation is the window from which the information (worked and refined data) is visible to C-suite executives, buyers, planners, operators and engineers. This data is gathered from all relevant sources and then filtered, defined and refined for relevant eyes to make relevant decisions. The possibility exists for new information from existing assets to bring greater insights into existing processes. The IIoT architecture, protocols, software applications and partnerships (a hot topic right now in the world of 4IR) are how we will achieve digitalisation and the integration of OT and MES.

And why?

Well, because we need to unlock the benefits of 4IR through digitalisation. Having worked in a manufacturing IT environment for 12 years, I’ve been involved in the integration of MES and OT systems down into the plant networks, as well as up into the business layers. Based on those experiences, I believe that the IIoT is the vehicle that will allow us to achieve digitalisation to a level that unlocks the benefits of 4IR – a true transformation.


About Lance Turner


Lance Turner.

Lance Turner is an MES/IIT/OT specialist employed at Sasol’s Secunda plant. He has an honours degree in Information Systems and an Adv. Diploma in Industrial Data Communications, Networks and IT. A certified MESA MES/MOM student, his passion is amalgamating general IT across the manufacturing spectrum. Lance’s vision is for a converged IT and manufacturing discipline that will become the reality of Industry 4.0. His team motto is MES services that are always available, always stable, and always dependable.




Share this article:
Share via emailShare via LinkedInPrint this page

Further reading:

Simple and efficient level measurement in the mining, minerals and metals industries
Endress+Hauser South Africa Editor's Choice Level Measurement & Control
Measuring devices in the mining, minerals and metals industries face the challenge of varying material states and long distances in measurement height. Endress+Hauser’s answer to these challenges is the new Micropilot family.

Read more...
PC-based control for fertiliser
Beckhoff Automation Editor's Choice Fieldbus & Industrial Networking
On a farm in the USA, valuable ammonia is extracted from slurry and processed into ammonium sulphate. NSI Byosis has transformed this complex process into a flexible modular system. This modular approach requires an automation solution with flexible scalability in both hardware and software, which this Dutch company has found in PC-based control from Beckhoff.

Read more...
Loop signature 28: Things to consider when tuning.
Michael Brown Control Engineering Editor's Choice Fieldbus & Industrial Networking
I was giving a course at a remote mine in the middle of the Namibian desert. We were discussing tuning responses, and as I always do on my courses, I mentioned that in my opinion ¼ amplitude damped tuning is not desirable, and is in fact not good.

Read more...
Control without complexity
Editor's Choice Motion Control & Drives
In an era where precision, performance and smart control define industrial success, the right driver can make all the difference. At Axiom Hydraulics, we’ve seen firsthand how the Sun Hydraulics XMD series transforms hydraulic systems, from mining and construction to agriculture and automation.

Read more...
The thermal combustion balancing act
Editor's Choice
From carbon taxes to export tariffs, and cost containment to security of supply and sustainability, companies are under increasing pressure to switch to greener fuel sources. Associated Energy Services warns that this pivotal change has some potentially serious knock-on effects.

Read more...
What’s driving the IE3 motor revolution?
WEG Africa Editor's Choice
The International Efficiency 3 (IE3) motor standard will soon become South Africa’s legal minimum standard, mandating that local suppliers offer more efficient electric motors. What is driving this change, and how does it affect the many industries that rely on these modern electric workhorses?

Read more...
Unlocking the smart factory
ElectroMechanica Editor's Choice Motion Control & Drives
At ElectroMechanica, we recognise that transitioning to smart automation isn’t just about adopting new technology; it’s about solving real challenges. Labour shortages, rising costs and downtime due to outdated machinery make digital transformation essential for long-term competitiveness.

Read more...
Case History 197: Bad reboiler temperature control.
Michael Brown Control Engineering Editor's Choice Flow Measurement & Control
It is very important that reboiler temperature controls operate well in petrochemical refineries, or the product quality can really suffer. I was asked to check such a control in a refinery where they were having problems with one of these controls.

Read more...
The future of industrial automation: fieldbus and industrial networking
LAPP Southern Africa Editor's Choice
As a global leader in integrated solutions in the field of cable and connection technology, LAPP recognises that fieldbus and industrial networking technologies are pivotal in shaping the future of manufacturing and production processes.

Read more...
AI-driven innovations with CCTV and cyber security
RJ Connect Editor's Choice Fieldbus & Industrial Networking
The fast progress of artificial intelligence (AI) and video analytics is redefining the rail surveillance landscape. Advancements have bolstered proactive event detection, predictive maintenance and enhanced situational awareness.

Read more...