Industrial Internet of Things (IIoT)

The Industrial Internet of Things (IIoT) refers to the integration of industrial machinery and equipment with networked sensors and software to collect and exchange data. IIoT systems leverage real-time data and advanced analytics to optimize operations, predict maintenance needs, and enhance overall industrial performance.

The Industrial Internet of Things (IIoT) refers to the interconnected network of physical devices, sensors, and software in industrial settings. IIoT devices and applications vary widely, and most are purpose-built for specific applications. IIoT devices support the collection and exchange of data between machines, systems, and people. This makes it possible to automate digital processes, track assets in real time, manage energy consumption, and predict equipment failures on a shop floor. These have translated into business benefits like improved safety conditions, optimized supply chains, and efficient energy management.

IIoT, also known as the industrial internet, emerged as a subset of the Internet of Things (IoT) in the early 2010s. Enterprises like General Electric Company (GE) and Philips Professional Lighting Solutions were conceptualizing and funding development of IoT-like devices specifically for industrial environments. By 2014, awareness was growing across multiple economic sectors, and company leaders were learning how IIoT could improve business efficiency, productivity, and operations. When the concept of the Fourth Industrial Revolution (4IR) was popularized in 2016, it quickly became intertwined with the potential and promise of IIoT. Digital transformation, smart manufacturing, and cyber-physical systems are possible due to IIoT technologies and concepts.

Because the world of IoT includes consumer-grade devices and applications, a new classification was needed to describe the devices that were to be integrated into an industrial workflow.

IIoT and IoT devices are similar in that they connect devices and enable the exchange of data. A closer look reveals significant differences.

IIoT devices and systems may also have other operational requirements like low latency and real-time processing, and they usually handle much larger volumes of data than an IoT device. Industry-specific regulatory compliance standards may also apply.

Operational technology (OT) systems monitor and control physical processes and devices in industrial environments. The concept emerged in the 1960s when the first SCADA and PLC systems were used in production. OT encompasses several technologies that are classified by application:

• Programmable logic controllers (PLCs): Automation and control of industrial processes
• Supervisory control and data acquisition (SCADA): Remote monitoring and control
• Distributed control systems (DCS): Localized control of production processes
• Industrial control systems (ICS): Comprehensive control systems in industrial production
• Building management systems (BMS): Management of building services
• Human-machine interfaces (HMI): Interfaces for human interaction with control systems
• Safety instrumented systems (SIS): Safety-critical process control
• Energy management systems (EMS): Monitoring and optimizing energy systems
• Manufacturing execution systems (MES): Management of factory floor operations (These may also be called manufacturing operations management (MOM) systems.)
• Process control systems: Automatic control of industrial processes 

IIoT extends the capabilities of OT by enabling real-time data collection, analysis, and insights across an entire industrial operation. Operational technology focuses on controlling specific processes, and IIoT enables the interconnected approach to industrial management and optimization.

Cyber-physical systems (CPS) predate IIoT by a decade. These are systems that depend on the tight coupling of computers and networks with machines and physical environments. The embedded digital components of OT monitor and control the physical processes and create feedback loops that are used to adjust the processes as needed. Here are some examples of how this compares to IIoT:

While cyber-physical systems can include IIoT technologies, they operate at a higher level in the industrial systems. CPS systems enable complex interactions and feedback loops between the digital and physical realms.

Because IIoT devices are critical to manufacturing and critical infrastructure, they are often deployed in challenging physical environments. Harsh weather, extreme temperatures, and dust or other particulates can interfere with sensors and other IIoT components. These devices must be resilient and remain in production because they apply to critical infrastructure or other high-priority functions. Earthquake and volcano sensors can help professionals predict natural disasters and potentially save lives, but only if those sensors are operating properly and not diminished by corrosion, particulates, or extreme temperatures.

There are many of these devices in places like Yellowstone National Park, where officials monitor various natural occurrences to help predict volcanic or earthquake activity. Continuous monitoring stations allow teams to collect data on emission levels, even when heavy snowfall limits travel through the park. Many protected locations like Yellowstone National Park also have sensitive areas that park officials and members of the public should avoid. Resilient remote monitoring systems can give the officials what they need and minimize the human interaction with these fragile areas.

Underwater acoustic systems monitor water speed and direction to help identify and predict wave activity. Fiber optic cable deployed across active volcanos helps officials detect volcanic strain signals and locate the origins of explosions. These are examples of lifesaving activities made possible by rugged systems that can withstand a harsh environment without inhibiting the sensitivity of the device.

There are many business and infrastructure uses for deploying IIoT in rough environments. The production and transportation of food and medicines may require continuous monitoring for deviations in temperature, humidity, or air quality. Weather stations, electrical substations, municipal water pipes, and even railroad tracks have IIoT sensors that need constant protection from environmental hazards.

For this reason, IIoT deployment planning should always consider the deployment environment. Weatherproof and rugged enclosures can protect the IIoT device from dust, water, chemical corrosion, and other hazards. Requirements for these devices usually include enhanced ingress protection (IP) levels, shock and vibration resistance, and an extended range of operation temperature and operating humidity. Consider the size of the device as well, especially if is going to be installed in a cabinet or another restricted space.

IIoT devices may be deployed to many remote locations, but they can still be included in central enterprise connectivity and security systems. SASE offers many capabilities that support and facilitate the deployment and management of IIoT devices.

To secure your industrial internet from cyberattacks, you need to include several best practices and strategies in your company’s cybersecurity planning. The following are some common considerations when defending IIoT and other devices from advanced threats:

• Zero Trust security: No device, user, or application is trusted by default. Continuous verification is required.
• Network segmentation: Divide the network into smaller segments to limit the spread of attacks.
• Regular updates and patches: Keep all devices, software, and applications up-to-date with the latest security patches.
• Encryption: Encrypt data at rest and in transit to protect sensitive information from unauthorized access.
• Endpoint security: Ensure all endpoints (devices) have security measures like antivirus, anti-malware, and intrusion detection systems installed.
• Access controls / least privilege: Limit access to IIoT devices and systems to only those who need it.
• Monitoring and logging: Continuously monitor network traffic and maintain logs to detect and respond to suspicious activities promptly.
• Employee training: Educate employees about the risks associated with IIoT devices.

Companies with legacy devices that are beyond end-of-life may wish to augment the above list with the following:

• Virtual patching: Deploy intrusion prevention systems (IPS) or web application firewalls (WAF) that can detect and block exploit attempts without requiring changes.
• Network access control (NAC): In the absence of Zero Trust security, configure NAC to authenticate devices and users before granting network access, and continuously monitor for unauthorized devices.
• Perimeter defense: Deploy network security solutions with advanced threat protection, intrusion detection/prevention, and other advanced features.
• Audits and assessments: Schedule periodic audits of IIoT systems and network infrastructure to identify and address security gaps or compliance issues.

A unified SASE platform provides consistent security policies and controls across all devices, users, and locations, regardless of where IIoT devices are deployed. SASE enforces security at the edge of the network, putting policy enforcement closer to the IIoT device. SASE’s cloud-based nature allows for more scalable and flexible security management, easier updates, and real-time threat intelligence integration.