Transforming Machine Building through Digital Enablement: Using Industrial Data and Connectivity for Next-Level Performance
Published on 15 May, 2025 in Operational Excellence
Reducing Production Bottlenecks, Predicting Failures Proactively, and Embracing IT/OT Convergence
Introduction
Building high-performance machinery for packaging, product handling, and assembly is no small feat. Machine builders are continually adapting to rising customer demands, tighter regulatory requirements, and the constant push for operational efficiency. In an environment where speed, quality, and resilience are paramount, the challenge becomes clear: how do you design machines that not only meet immediate production needs but also lays the groundwork for true digital enablement?
Recent advancements in data capture, edge connectivity, and cloud services have set the stage for a new era of intelligent, future-proof machinery. By tapping into three core industrial communication protocols—IO-Link, EtherCAT, and Socket Services—machine builders can achieve a smoother flow of information across all levels of production. This, in turn, allows simpler IT/OT (Information Technology/Operational Technology) convergence, enabling data-driven decision-making and proactive maintenance strategies. Whether your focus is on packaging machines that require precise sealing and handling or conveyor systems designed to move WIP (Work in Progress) through complex assembly processes, these technologies offer the ability to transform your equipment from reactive to predictive, from traditional to digitally enabled.
In this blog, we’ll explore some key aspects of digital enablement for machine builders:
- Three-Layer Data and IT/OT Convergence
How IO-Link, EtherCAT, and Socket Services each play a role in transporting data from sensors to enterprise systems—and how these layers make the merging of IT and OT systems easier. - Process Data Analysis to Resolve Bottlenecks
How live monitoring of production metrics can identify the exact point of delay or inefficiency, so you can correct issues before they escalate. - Direct-to-Cloud Connectivity and Its AdvantagesHow cloud-based platforms enable remote diagnostics, performance monitoring, and service improvements that benefit both manufacturers and machine builders.
- Equipment Abnormality Data AnalysisHow advanced analytics can spot early signs of mechanical or electrical failure, allowing you to schedule maintenance proactively rather than dealing with expensive unplanned downtime.
This article is designed to guide machine builders on the journey towards more innovative, more efficient machine designs that create increased value for end-users.
Why Digital Enablement Matters for Machine Builders
Industrial machines must increasingly deliver more than simple mechanical reliability—they need to be connected, data-rich platforms that help manufacturers maximise output, reduce waste, and maintain flexible operations. The traditional model of building a machine, installing it onsite, and performing routine checks can’t keep up with market demands for continuous improvement and uptime anymore. Customers now expect data-driven insights, predictive maintenance, and seamless connectivity, viewing these as non-negotiable elements of modern manufacturing.
By embedding digital enablement features into your equipment, you can offer:
- More agile customer support: Remote monitoring, diagnostics, and automatic alerts reduce the reliance on site visits to resolve problems.
- More refined performance metrics: Data from sensors and actuators allows customers to address production bottlenecks, shift strategies mid-run, or scale production volumes quickly and with lower risk.
- Future-proof upgrades: Machines that can integrate with corporate IT systems or cloud-based analytics platforms ensure longevity and reduced total cost of ownership.
- Strong brand positioning: Machine builders who deliver advanced digital solutions position themselves as forward-thinking, innovative partners that stand out in a competitive market.
The relationship between IO-Link, EtherCAT, and Socket Services is central to achieving these benefits, with each protocol serving different tiers of industrial communication. This layered approach simplifies IT/OT convergence by ensuring data flows seamlessly from sensors at the field level to controllers on the factory floor and onward to higher-level systems or cloud platforms.
The Three-Layer Data Model and IT/OT Convergence
1. IO-Link for Sensor-Level Intelligence
IO-Link is designed for point-to-point communication with sensors and actuators, bridging the gap between analog signals and digital intelligence. Sensors traditionally output raw signals that require some form of interpretation in the machine controller. IO-Link sensors, however, can communicate status, diagnostic information, and parameter settings digitally, enabling machine builders to:
- Simplify wiring by using standard unshielded cables and universal connectors.
- Reduce hardware variants since a single IO-Link sensor can be dynamically configured for multiple roles or threshold values.
- Improve reliability by detecting sensor problems or misalignments early, rather than waiting for a complete failure.
These features cut down on installation complexity and set the foundation for advanced analytics at the higher levels of your machine control architecture.
2. EtherCAT for Real-Time Control
While IO-Link manages device-level data, EtherCAT stands out for delivering high-speed, deterministic performance at the controller level. Packaging machines often demand microsecond-level precision—think of a form, fill and seal machine wrapping product at high speed, or a robotic arm picking and placing items in perfect sync with multiple product lines. EtherCAT’s unique architecture allows data packets to be processed on the fly, enabling near-instant feedback loops. This real-time control is essential for:
- Precision motion coordination in multi-axis systems.
- Synchronised tasks like printing, labeling, cutting, or sealing where exact timing is critical.
- Scalability: Adding new nodes with minimal configuration overhead.
By using EtherCAT’s capability to handle data quickly, you ensure your machine’s complex operations don’t get bogged down by network latency.
3. Socket Services for Plant-Level Communication
At the plant level, establishing fast, flexible, and secure communication between machines and enterprise systems is vital for full digital enablement. Socket services—low-level, bidirectional communication channels based on TCP/IP—play an important role in enabling real-time data exchange across distributed systems. Unlike traditional industrial protocols that focus primarily on machine control or fieldbus communication, socket services allow direct, application-level connectivity between operational technology (OT) and IT platforms.
By leveraging socket-based communication, machine builders can:
- Transmit production metrics, error logs, or custom data packets directly to MES, ERP, or cloud platforms.
- Enable remote monitoring and diagnostics without relying solely on middleware or protocol converters.
- Build lightweight, flexible interfaces tailored to specific customer or application requirements.
Socket services are especially valuable when paired with publish/subscribe protocols like MQTT with TLS encryption, which add scalability and security through encrypted, event-driven messaging. Together, they form a critical bridge between plant-floor operations and enterprise systems—facilitating IT/OT convergence with low latency and high adaptability. This is becoming more and more important with the upcoming EU Cyber Resilience Act (CRA), where secure-by-design data exchange and system interoperability are foundational principles. APIs that use socket services help to comply with these standards by supporting encrypted, modular communication that enhances system transparency and resilience.
When used alongside IO-Link and EtherCAT, socket services complete the three-layer data model: device-level intelligence, real-time machine control, and flexible, enterprise-grade communication. This structure empowers machine builders to deliver connected systems that are not only more responsive and insightful, but also compliant with modern cybersecurity expectations.
Using Process Data to Identify and Remove Production Bottlenecks
One of the most impactful benefits of a well-executed data model is the ability to uncover bottlenecks in real time. Packaging and assembly lines rely on numerous modules—conveyors, pick-and-place robots, labellers, weighers—all needing to coordinate perfectly. However, a dirty sensor, a misaligned bracket, or an underperforming motor can cascade into operational slowdowns.
With data streaming continuously from IO-Link sensors to EtherCAT controllers, you can capture cycle times, detection signals, and error codes at each station. By combining these insights, you can identify micro-delays, pinpoint repeated stops, and watch for abnormal performance trends. For example, if a specific process always lags behind scheduled throughput, analysing real-time data might reveal that the bottleneck occurs during product transfer or at a weigh station that occasionally stalls. Corrective action could be as simple as adjusting motion profiles or rewriting a control routine to avoid synchronisation clashes.
Manufacturers can then build these findings into continuous improvement projects. Whether your client wants to ramp up output for a seasonal rush or ensure minimal downtime for just-in-time supply chains, the intelligence gathered from process data helps them tweak operational strategies rather than just guessing.
Direct-to-Cloud Connectivity and Its Benefits
The days of single-machine isolation are rapidly disappearing. Machinery that can send data directly into a cloud platform stands at a major advantage, both for the manufacturer and the machine builder who services it. Some potential benefits include:
- Remote Monitoring and Diagnostics: Service teams no longer need physical visits to see machine logs, check sensor readings, or adjust control parameters. They can resolve many issues remotely, improving uptime and customer satisfaction.
- Performance Benchmarks and Global Comparisons: When multiple machines feed their data into a central portal, owners can benchmark performance across different lines or sites. This big-picture view can help standardise best practices and push for further improvements.
- Pay-per-Use or Servitisation Models: Machine builders can offer advanced support or usage-based contracts, where monthly fees might tie to throughput or run hours. This creates deeper customer relationships and recurring revenue streams.
For packaging and assembly equipment, the ability to stream production metrics or error logs to the cloud helps machine builders refine designs by spotting real-world usage patterns. This intelligence not only improves the next generation of machines but also enables faster response times to customer inquiries and issues.
Embracing Digital Enablement: Overcoming Challenges and Unlocking Value
Machine builders experimenting with digital enablement often contend with:
- Scalability Concerns: Will adding more sensors or advanced analytics clog the network or overload the controller? A well-planned architecture with IO-Link, EtherCAT, and Socket Services ensures each layer handles data at the appropriate speed and volume.
- Security and Data Ownership: When connecting machines to the cloud, establishing secure communication channels, robust authentication, and clear data rights is paramount. Clear guidelines from the outset help avoid confusion later.
- Organisational Shifts: Selling a digitally-enabled machine may require a different conversation with customers. They might need to adapt maintenance policies or IT infrastructure. However, the payoff can be huge—less downtime, deeper insights, and more agile operations.
By carefully crafting your approach—choosing the right protocols for each layer, adopting flexible control architectures, providing robust connectivity options, and employing advanced analytics—machine builders can deliver a truly future-proof solution. It’s an opportunity to partner with customers, not just to sell equipment, and deliver long-term performance improvements.
Conclusion
Digital enablement for packaging and assembly machinery isn’t just about adding a few extra sensors or slapping a network card onto a controller. It’s about unlocking deeper insights, bringing operational and enterprise systems closer together, and shifting from reactive fixes to proactive strategies. By embracing a three-layer data model with IO-Link, EtherCAT, and Socket Services, employing direct-to-cloud connectivity, and analysing abnormal data patterns, machine builders can reinvent how they design, commission, and maintain their equipment.
From spotting hidden bottlenecks to preventing failures before they happen, the potential gains in uptime, product quality, and customer satisfaction are massive. If you’re ready to push beyond traditional machine-building strategies and offer next-generation solutions that truly resonate with modern manufacturing needs, now is the time to explore AI-driven analysis, advanced data capture, and proactive service strategies.
