THE CHALLENGE
• Disparate PLC, SCADA, and historian data models
• No standardized naming or asset hierarchy
• Limited visibility into network health and data flow
• High effort required to integrate new systems
• No standardized naming or asset hierarchy
• Limited visibility into network health and data flow
• High effort required to integrate new systems
OVERVIEW
A global manufacturing organization struggled with fragmented OT systems across multiple sites. Inconsistent tag structures, lack of standardization, and limited visibility into data reliability created significant barriers to scaling digital initiatives.
THE SOLUTION
DASH Engineering delivered a standardized, scalable OT data architecture designed to unify data across all facilities and enable enterprise-wide visibility. Our approach included:
THE RESULTS
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DATA POINTS COLLECTED
Hypercare & Continuous Improvement
- Real-time monitoring and defect resolution
- Data model and UDT refinements
- Performance tuning across gateways and databases
Data Standardization & Structuring
- Normalized OT data across all sites
- Implemented consistent naming conventions and metadata standards
- Developed reusable equipment models (UDTs)
End-to-End Integration Architecture
- Connected OT assets to Ignition, Litmus, and enterprise databases
- Implemented scalable data pipelines (UNS, Postgres, InfluxDB)
Unified Data Model (ISA-95 Aligned)
- Established a standardized enterprise asset hierarchy
- Created a common data framework across all facilities
Validation, Deployment & Enablement
- Performed full system validation and performance testing
- Delivered training, documentation, and post-go-live support
Real-Time Monitoring & Diagnostics
- Built dashboards using Ignition for PLC network health and system performance
- Enabled real-time validation of data ingestion and UNS pipelines
THE IMPACT
DASH Engineering transformed a fragmented OT landscape into a unified, scalable data ecosystem—enabling real-time visibility, standardized data models, and a strong foundation for enterprise digital transformation.
