Industrial IoT Solutions — Your Factory, Digitised
Your factory data is trapped in PLCs and SCADA historians that nobody can access in real time. Opsio's industrial IoT solutions bridge the OT/IT gap — connecting existing equipment via OPC-UA and Modbus to cloud analytics for real-time OEE, energy monitoring, quality SPC, and MES integration.
Trusted by 100+ organisations across 6 countries
Real-Time
OEE Tracking
OPC-UA
& Modbus
ISA-95
Compliant
0%
Equipment Replaced
What's Included
PLC/SCADA Connectivity
Connect Siemens S7-1500, Allen-Bradley ControlLogix, Mitsubishi MELSEC, Schneider M340, and other PLCs via OPC-UA and Modbus TCP/RTU. We configure SCADA historian integration, handle protocol conversion at industrial edge gateways, and ensure absolutely reliable data collection without impacting production control systems or introducing latency.
Real-Time OEE Tracking
Automatic calculation of Overall Equipment Effectiveness from machine signals — availability (downtime tracking with reason codes), performance (actual vs ideal cycle time), and quality (reject counting from inspection signals). Replace manual OEE spreadsheets with live dashboards that update every production cycle and provide shift, daily, and weekly trending.
Energy Monitoring & Optimisation
Per-machine and per-product energy consumption tracking using CT sensors and smart power meters. Identify energy waste patterns across shifts and operating modes, benchmark consumption across production lines, correlate energy use with production output for accurate per-unit costing, and generate sustainability reports for ESG compliance and carbon accounting.
Quality SPC & Analytics
Statistical process control with real-time control charts (X-bar, R-charts, p-charts, CUSUM), automated out-of-control alerts with Nelson rules, and Cpk/Ppk capability analysis. Connect inspection data to production parameters for automated root cause analysis — identifying which machine settings, materials, or environmental conditions correlate with quality deviations.
Industrial Edge Gateways
Deploy industrial-grade edge computing in DMZ network zones for protocol conversion, local data buffering during network outages with guaranteed delivery, and real-time edge analytics for latency-critical alerting. Hardware selection from Siemens IPC, MOXA, and Advantech with OPC-UA server/client capabilities and ISA-95 compliant network architecture.
MES & ERP Integration
Connect IIoT data to Manufacturing Execution Systems (SAP MII, Siemens Opcenter, AVEVA MES, Rockwell Plex) and ERP platforms (SAP S/4HANA, Oracle, Dynamics). Bi-directional data flow enables production order tracking, material consumption recording, automated work order generation, and real-time production status visibility from shop floor to boardroom.
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Our AWS migration has been a journey that started many years ago, resulting in the consolidation of all our products and services in the cloud. Opsio, our AWS Migration Partner, has been instrumental in helping us assess, mobilize, and migrate to the platform, and we're incredibly grateful for their support at every step.
Roxana Diaconescu
CTO · SilverRail Technologies
Smart Factory Without Replacing Equipment
Most factories operate with a frustrating paradox: their PLCs and SCADA systems contain rich operational data — cycle times, reject counts, energy consumption, downtime reasons — but this data is locked inside proprietary historians and control networks that operators can only access through HMI panels on the factory floor. Production managers rely on manual data collection, spreadsheets, and end-of-shift reports that arrive hours or days too late for actionable decisions. Meanwhile, competitors with real-time OEE dashboards are optimising production cycles in minutes, not shifts. Industrial IoT bridges this OT/IT gap without replacing any existing equipment. Opsio's industrial IoT solutions connect your existing PLCs and SCADA systems to cloud analytics platforms via standard industrial protocols. OPC-UA for modern controllers (Siemens S7-1500, Allen-Bradley ControlLogix, Mitsubishi MELSEC), Modbus TCP/RTU for legacy devices, and MQTT for additional sensor networks. We maintain strict ISA-95 (Purdue model) architecture principles with clear security boundaries between OT and IT networks — ensuring IIoT connectivity never compromises operational technology network integrity or production control system reliability.
The smart factory transformation delivers measurable outcomes from the first production line: real-time OEE tracking replacing manual data collection with automated availability, performance, and quality metrics updated every cycle. Per-machine energy consumption monitoring enabling ESG reporting and waste reduction. Statistical process control (SPC) with automated out-of-control alerts catching quality deviations before they produce scrap. Predictive maintenance signals from equipment sensor data preventing unplanned downtime. And MES/ERP integration providing complete production visibility from customer order to shipment.
Industrial edge gateways are the critical architectural component that makes IIoT reliable in factory environments. We deploy industrial-grade hardware from Siemens IPC, MOXA, and Advantech in DMZ network zones — handling protocol conversion between OT protocols (OPC-UA, Modbus) and IT protocols (MQTT, HTTPS), buffering data locally during network outages with guaranteed delivery when connectivity returns, and performing real-time edge analytics for latency-critical alerting that can't wait for cloud round-trips. Edge gateways ensure your IIoT system works reliably even in factories with challenging network infrastructure.
Common IIoT challenges we solve: legacy PLCs with no modern connectivity options that require Modbus RTU serial extraction, SCADA historians that can't export data in real time, OT security teams that (rightly) refuse to allow any cloud connectivity from the production network without proper segmentation, MES systems that need bi-directional data flow for production order tracking, energy monitoring that must attribute consumption to specific products for accurate costing, and quality systems that need real-time SPC data from production equipment for automated control charting. If your smart factory initiative has stalled on any of these obstacles, Opsio has the manufacturing-specific expertise to solve them.
Opsio's Industry 4.0 approach starts with a factory survey — mapping every piece of equipment, its communication protocol, existing network infrastructure, and the production data it generates. From this survey, we design a phased IIoT deployment starting with one production line as a pilot, demonstrating value with real-time OEE dashboards and energy monitoring before scaling to the full factory. This pilot-first approach lets your operations team build confidence with the technology, validates data quality and accuracy against existing manual records, and generates the ROI evidence needed to justify full-scale investment. Wondering about IIoT costs, whether your legacy equipment can be connected, or how to convince your OT security team that cloud connectivity is safe? Our factory survey answers all three questions with a concrete architecture proposal. Featured reading from our knowledge base: EDI Cloud Solutions: Your Questions Answered, IT Consulting Services: Tailored Solutions for Your Needs, and We Are Your DevOps as a Service Company | Expert Solutions. Related Opsio services: Managed Cloud Security — Protect Your Cloud Estate, and Load Testing Services — Find Your Breaking Point Before Users Do.
How Opsio Compares
| Capability | DIY / Manual Data Collection | Hardware Vendor Platform | Opsio Industrial IoT |
|---|---|---|---|
| PLC/SCADA connectivity | Manual data entry | Vendor PLCs only | Siemens, AB, Mitsubishi, legacy Modbus |
| OEE tracking | End-of-shift spreadsheets | Basic uptime only | Real-time OEE with root cause analysis |
| OT network security | N/A (no connectivity) | Vendor-managed | ISA-95 architecture, unidirectional flow |
| MES/ERP integration | Manual transcription | Limited API | Bi-directional SAP, Oracle, Dynamics |
| Energy monitoring | Monthly utility bills | Vendor meters only | Per-machine, per-product attribution |
| Legacy equipment support | Not connected | Not supported | Modbus RTU, serial, retrofit sensors |
| Typical annual cost | $50K+ (manual labour) | $80-150K (vendor lock-in) | $156-566K (fully managed) |
Ready to get started?
What You Get
Pricing & Investment Tiers
Transparent pricing. No hidden fees. Scope-based quotes.
Factory Survey & Architecture
$20,000–$40,000
1-3 week engagement
Pilot Line Deployment
$60,000–$150,000
Most popular — single line
Managed IIoT Operations
$8,000–$18,000/mo
Ongoing operations
Transparent pricing. No hidden fees. Scope-based quotes.
Questions about pricing? Let's discuss your specific requirements.
Why Choose Opsio for Cloud Services
Manufacturing OT expertise
Deep understanding of production operations, OT environments, and the cultural dynamics of factory digitisation.
ISA-95 security compliance
OT/IT convergence architecture maintaining Purdue model boundaries with unidirectional data flow from production networks.
Zero equipment replacement
Connect existing PLCs and SCADA via OPC-UA and Modbus — no capital expenditure on new production equipment.
Real-time OEE from day one
Replace manual data collection with automated OEE tracking delivering actionable insights every production cycle.
Pilot-first methodology
Prove value on one production line before committing to full factory deployment — de-risked by design.
Production-proven deployments
IIoT solutions running in production factories today across discrete and process manufacturing industries.
Not sure yet? Start with a pilot.
Begin with a focused 2-week assessment. See real results before committing to a full engagement. If you proceed, the pilot cost is credited toward your project.
Our 4-Phase Delivery Process
Factory Survey
Map every piece of equipment, communication protocol, network infrastructure, and production data source. Deliverable: IIoT architecture proposal with security boundaries and pilot line recommendation. Timeline: 1-2 weeks.
Architecture & Security
Design IIoT architecture with ISA-95 compliant security boundaries, edge gateway specification, cloud platform selection, and MES/ERP integration points. Review with OT security and operations teams for buy-in. Timeline: 2-3 weeks.
Pilot Line Deployment
Deploy edge gateways, connect PLCs, build real-time OEE and energy dashboards for one production line. Validate data accuracy against existing manual records and demonstrate value to operations team. Timeline: 3-5 weeks.
Factory Scale-Out
Expand to full factory with additional production lines, MES/ERP integration, SPC analytics, and enterprise dashboards. Ongoing managed IIoT operations including monitoring, maintenance, and quarterly optimisation reviews. Timeline: 4-8 weeks + ongoing.
Key Takeaways
- PLC/SCADA Connectivity
- Real-Time OEE Tracking
- Energy Monitoring & Optimisation
- Quality SPC & Analytics
- Industrial Edge Gateways
Industries Served by Opsio
Discrete Manufacturing
Automotive, aerospace, electronics, and machinery production with cycle-based OEE and quality tracking.
Process Manufacturing
Chemical, pharmaceutical, food, and beverage with batch tracking, SPC, and regulatory compliance.
Heavy Industry
Steel, mining, cement, and paper production with energy-intensive process optimisation and monitoring.
Utilities
Power generation, water treatment, and distribution network monitoring with real-time SCADA analytics.
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Industrial IoT Solutions — Your Factory, Digitised — FAQ
What is Industrial IoT (IIoT) and how does it differ from consumer IoT?
Industrial IoT connects manufacturing equipment, SCADA systems, and operational technology to cloud analytics platforms for real-time operational intelligence. Unlike consumer IoT (smart home devices, wearables), IIoT operates in harsh industrial environments with strict reliability, security, and real-time performance requirements. IIoT must integrate with legacy industrial protocols (OPC-UA, Modbus), maintain ISA-95 security boundaries between OT and IT networks, handle mission-critical data where lost readings have production consequences, and meet industrial safety and compliance standards. The technology stack, security model, and operational requirements are fundamentally different from consumer IoT.
Do we need to replace existing equipment for IIoT?
No — and this is the most important message about industrial IoT. We connect to your existing PLCs and SCADA systems via standard industrial protocols. OPC-UA for modern controllers (Siemens S7-1500, Allen-Bradley ControlLogix, Mitsubishi MELSEC) and Modbus TCP/RTU for legacy equipment. Industrial edge gateways handle protocol conversion and data buffering without modifying your control systems, reprogramming PLCs, or impacting production operations in any way. Even 20-year-old equipment with Modbus RTU serial interfaces can be connected. The only new hardware required is industrial edge gateways (typically $2,000-$5,000 each) and optional additional sensors if your existing equipment doesn't expose the data points you need.
What is OPC-UA and why does it matter for IIoT?
OPC-UA (Open Platform Communications Unified Architecture) is the leading industrial interoperability standard for secure, reliable data exchange between manufacturing equipment and IT systems. It provides platform-independent, encrypted, authenticated communication with built-in information modelling — making it the foundation protocol for Industry 4.0 and smart factory connectivity. OPC-UA matters because it replaces dozens of proprietary vendor protocols with a single standard that works across Siemens, Allen-Bradley, Mitsubishi, Schneider, and other PLC manufacturers. Opsio configures OPC-UA servers on edge gateways to collect data from multiple PLC brands into a unified data model for cloud analytics.
How much do industrial IoT solutions cost?
IIoT investment follows a phased approach. A factory survey and architecture design runs $20,000-$40,000 (1-3 weeks) and delivers a complete IIoT architecture proposal with security boundaries and ROI projections. Pilot deployment on one production line costs $60,000-$100,000 including edge gateways, PLC connectivity, OEE dashboards, and energy monitoring. Full factory deployment with MES/ERP integration ranges from $150,000-$350,000 depending on equipment count and integration complexity. Ongoing managed IIoT operations cost $8,000-$18,000/month covering platform monitoring, edge gateway management, dashboard maintenance, and quarterly optimisation reviews.
How do you ensure IIoT doesn't compromise OT network security?
We follow ISA-95 (Purdue model) architecture with clear security boundaries between OT and IT networks. Edge gateways operate in DMZ zones with strictly unidirectional data flow — data moves from the production network to the cloud, but no cloud-initiated communication can reach PLCs or SCADA systems. Network segmentation, industrial firewalls, and protocol-specific rules ensure the IIoT layer cannot be used as an attack vector against production control systems. We design the security architecture collaboratively with your OT security team and document every network flow for review and approval before deployment.
How long does a factory IIoT deployment take?
A pilot deployment on one production line typically takes 6-10 weeks from survey through live dashboards. Full factory deployment adds 4-8 weeks depending on the number of production lines, protocol diversity, and MES/ERP integration complexity. The total timeline for survey through full factory operation is typically 14-22 weeks. We deploy in phases — the pilot line generates value and ROI evidence within the first 6-10 weeks while the full deployment continues. This approach ensures production teams see benefits quickly and can provide feedback that shapes the broader rollout.
What is OEE and why does real-time tracking matter?
OEE (Overall Equipment Effectiveness) measures manufacturing productivity through three factors: Availability (actual production time vs planned time), Performance (actual speed vs ideal speed), and Quality (good parts vs total parts produced). World-class OEE is 85%. Most factories manually calculate OEE from spreadsheets at the end of each shift — by which time the data is hours old and the root causes of losses are forgotten. Real-time OEE tracking updates every production cycle, enabling immediate response to availability losses (unexpected stops), performance losses (slow cycles), and quality losses (rejects). Our clients typically improve OEE by 5-15 percentage points within the first six months of real-time tracking.
Can IIoT integrate with our MES and ERP systems?
Yes — MES and ERP integration is a standard part of Opsio's IIoT deployments. We integrate with SAP MII, Siemens Opcenter, AVEVA MES, Rockwell Plex, and other MES platforms, plus ERP systems including SAP S/4HANA, Oracle Cloud, and Microsoft Dynamics. Integration is bi-directional: production data (cycle counts, reject rates, energy consumption) flows from IIoT into MES/ERP, and production orders, recipes, and schedules flow from MES/ERP into IIoT dashboards. This creates a complete digital thread from customer order through production execution to shipment — eliminating manual data entry and providing real-time production status visibility across the organisation.
How do you handle legacy equipment with old protocols?
Legacy equipment is the norm in manufacturing — most factories have a mix of modern and decades-old machines. For legacy PLCs with Modbus RTU serial interfaces, we deploy serial-to-Ethernet converters at the edge gateway to extract register data over RS-485 connections. For machines with no digital interface at all, we add retrofit sensors (vibration, current, temperature) that provide condition data independently of the PLC. For SCADA historians running older databases (SQL Server, Access), we connect via database queries rather than real-time protocols. Our factory survey identifies every piece of equipment, assesses its connectivity options, and designs the optimal extraction approach for each.
What ROI can we expect from industrial IoT?
IIoT ROI comes from multiple sources. Real-time OEE visibility typically drives 5-15% OEE improvement within 6 months through faster response to availability, performance, and quality losses. Energy monitoring identifies 10-20% energy waste that can be eliminated through operational changes. Predictive maintenance signals reduce unplanned downtime by 30-50%. Quality SPC catches deviations earlier, reducing scrap by 15-25%. MES integration eliminates hours of daily manual data entry. Combined, most factories see 200-400% ROI on their IIoT investment within 18-24 months. We track and report these metrics from pilot deployment forward so you can document value and justify expansion.
Still have questions? Our team is ready to help.
Ready for Smart Manufacturing?
Your factory data is trapped in PLCs and SCADA systems. Get a free factory survey to see how IIoT unlocks real-time OEE and operational intelligence.
Industrial IoT Solutions — Your Factory, Digitised
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