INDUSTRIAL DYNAMICS Manufacturing IoT Hardening

Manufacturing facility operating outdated PLC systems with no real-time monitoring and declining production efficiency.

As the organization scaled, these challenges became increasingly critical to address. The need for a comprehensive solution that could unify operations, reduce technical debt, and deliver measurable results became paramount for continued growth and competitiveness.

The ecosystem had become critical to how the business operated, but it wasn't built to run as one connected system.

20-year-old PLC systems with no modern security features. Each system played a role in delivering value, but they were managed independently, creating significant operational friction.

Running this environment required constant coordination:

• 20-year-old PLC systems with no modern security features
• No real-time monitoring of production processes
• Declining production efficiency affecting competitiveness
• High maintenance costs and frequent system failures

Even routine issues became time-consuming, requiring coordination across teams before resolution could begin. A slowdown in one platform could trigger issues in others, but there was no single view to trace root cause and impact quickly.

With NexGen, the organization was able to redesign the operating model to make day-to-day operations easier to manage and less dependent on manual coordination.

This approach combined structural changes with technology-driven capabilities:

• Phase 1: Legacy System Security Assessment
• Phase 2: IoT Network Architecture Design
• Phase 3: Sensor Deployment & Integration
• Phase 4: Analytics Platform Implementation

Together, these changes reduced delays caused by disconnected systems and made it easier to identify and fix issues before they affected operations.

The transformation delivered measurable improvements across cost, speed and operational efficiency:

• Increased production efficiency by 85%
• enabled real-time monitoring of 500+ sensors
• and reduced maintenance costs by 40%