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Production security through data management

Annina Schopen,

Revolution of OT backup and versioning

Production reliability through innovative data management: Octoplant software automatically backs up configurations and project statuses for a wide range of automation devices from different types and manufacturers. Constant access to the current set-up and the transparency of all changes prevent production downtimes and increase production efficiency.

OT data management software increases production reliability through automatic back-ups, version management and the documentation of changes to automation devices. © Auvesy-MDT/ IM Imagery/stock.adobe.com

"On our private cell phones, it is common practice to back up our apps and photos. In the production of huge companies, it is all the more essential - and yet it is still not done everywhere," explains Stefan Jesse, CEO at Auvesy-MDT. Regular backups are ubiquitous in everyday private life - and can easily be done for individual devices with a USB stick. When scaled to industrial production, the whole thing looks more complicated, as modern production systems are made up of a large number of different components from different manufacturers. So how can backups be generated with increasing levels of automation, multiple production sites and growing complexity? Maintaining an overview here is challenging and almost impossible without compatible technology. Auvesy-MDT offers tailor-made versioning and OT back-ups for precisely these problems. Among other things, the global market leader has developed the Octoplant software platform, which keeps automated production processes running reliably by making changes to production systems transparent on a data basis, even on heterogeneous store floors. This prevents production downtimes and significantly increases the efficiency and safety of production.

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Overview of complex processes

Octoplant enables the manufacturer-independent integration of different automation technologies. Reliable end-point management consistently records changes to configurations and project statuses of the operational technology (OT). In this way, the gap between OT in production and IT can be sustainably closed, and automated production is secured in a robust and controllable manner in accordance with high IT standards - regardless of whether PLC, HMI, CNC, SCADA systems or robots are involved.

The biggest advantage in day-to-day work: Octoplant offers the highest level of compatibility with automation devices from various manufacturers and industries - and that in a global market comparison. The platform can be used and combined with the systems of the world's most renowned manufacturers - whether Siemens, Rockwell Automation, Schneider Electric, ABB or Omron. The latest version Octoplant 101.2.0 is also compatible with Rockwell Studio 5000 v35 and SE EcoStruxure Control Expert v15. Almost every element of a production system can be protected, backed up and versioned in a single system - and everyone involved knows what has been changed, when and by whom.

Back-ups for smooth processes worldwide

With Octoplant as a data management platform, not only are changes and compliance with specific rules and standards monitored, but security gaps are also made transparent. Here, too, the gap between IT and OT requirements is closed. This is made possible by a reliable back-up solution - after all, with a large number of automation devices, there are just as many back-up jobs. One car manufacturer, for example, uses Octoplant for 20,000 back-ups per night.

Octoplant can be used to reset project statuses based on a previous backup. © Auvesy-MD

A volume of data like this is impossible to collect manually, but Octoplant makes it possible. The software localizes changes in automation processes, highlights unforeseen deviations and compiles all information in individually configurable emails. This means that the right people receive relevant information quickly and clearly and are able to react to the current status and changes at any time.

The data management of the Auvesy-MDT software is server-based on site. The metadata of individual assets can be called up from anywhere and, if required, they make the entire back-up status of production transparent worldwide. Octoplant thus also helps with data management on a global level.

In an emergency: disaster recovery

But what if something really goes wrong? A US producer of cleaning and hygiene products experienced the extent of such a mistake in February 2023. Due to a change in the automation program that had gone unnoticed for weeks, a large-scale product recall had to be carried out: A batch of almost five million bottles of a cleaner that had been produced during this period was defective - damage that could have been avoided. It is no coincidence that the company now uses Octoplant to safeguard its automation processes.

Maintenance teams can use the backups to restore the programs to a previous system configuration in the event of a system failure. Octoplant can not only restore the last status, but also compare change details with each other. After a malfunction, the last time the system worked without errors can be determined. This version can then be restored and integrated into the production process so that the plant is running smoothly again in the shortest possible time.

It should come as no surprise that around 60 percent of the best-known production companies currently rely on Octoplant. In numbers, that's 2,800 customers around the globe who count on Auvesy-MDT and its strong network of over 100 partners on all continents.

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