OPC UA: The Communication Standard for the Internet of Things?


As we prepare ourselves for the expansion of the IoT (Internet of Things), many businesses today are looking ways to take advantage of the opportunities that are beginning to present themselves. Of course, as with anything new there are many questions and concerns.

Many organizations are struggling with interconnectivity. How do we get existing information systems to communicate with new information systems? If leveraging the IoT requires a wholly rebuilt information infrastructure and a complete reformatting of business processes – well, that’s just not going to work for most people.

There are also organizations who will have questions about how to make use of the unstructured data coming in real time from any number of different sources. How can they create the context to translate this endless stream of raw data into useful information?

And what about the scalability and flexibiilty needed to deal with growth and change. After all, if the changes implemented today need to be undone in order to keep up with the future needs of your organization, then is it really worth it?

Another common concern is that of security. Are we going to push sensitive information up to the cloud, where it may be exposed to any number of potential threats ranging from cyber-terrorism to corporate espionage? And even if our sensitive data is not being broadcast over the internet, how do we protect these interconnected systems from internal threats? How can we ensure that our employees and contractors have access to all of the information they need to do their jobs and nothing more?

These and many other questions are preventing some organizations from realizing the many benefits of the IoT. Some think it will be too difficult or expensive to implement; others may question the value of it. Fortunately for us all, these questions have been asked for several years, and there are answers.

The communication protocol often cited as the best fit for IoT applications has already been developed, tested and deployed in live environments around the world since it was fully released in 2009.

OPC Unified Architecture (UA) is platform-independent, service-oriented architecture developed and maintained by the OPC Foundation. As the interoperability standard for industrial automation, OPC has become an integral part of most SCADA (Supervisory Control and Data Acquisition) systems. As data systems expand beyond their traditional roles to include more sensor data and consolidate data from multiple systems, it makes sense that the OPC Foundation has remained at the forefront of the standardization process and and have developed a communication standard that has been embraced by proponents of Industry 4.0 and the Internet of Things – companies like Microsoft, Oracle, SAP, GE, and many others,

OPC UA is universally embraced because it directly addresses the obstacles faced by organizations involved in IoT implementation projects. The problem of interconnectivity, for example, is exactly the problem that the communication standard was developed to address. Today, OPC drivers exist for thousands of different devices, and many devices today are manufactured with embedded OPC servers to allow for exactly this type of interoperability with other devices and systems.

The concerns about the usefulness of multi-system data is addressed by information modeling. The OPC UA information modeling framework turns data into actionable information. With complete object-oriented capabilities, even the most complex multi-level structures can be modeled and extended. Information modeling also makes an OPC UA-based system significantly more customizable and extensible. As virtual representations of actual systems, information models can be modified or expanded to meet the changing needs of a modern company.

Of course, one of the most important considerations when choosing a communication technology is security, which is one of the great benefits of OPC UA. Security is provided in a number of ways, including: Session Encryption, Message Signing, Authentication, User Control, and Auditing of User Activity.

While it is difficult to say that there is anything “standard” about the Internet of Things, OPC UA is the closest thing we have to a communication standard, and every day it is becoming more widely accepted and adopted. To learn more about the synergy between OPC UA and Industrial IoT applications, read the following whitepaper: https://opcfoundation.org/wp-content/uploads/2015/04/OPC-UA-Interoperability-For-Industrie4-and-IoT-EN.pdf

** B-Scada’s IoT software is built on OPC UA and leverages the full power of these capabilities to provide fully customizable and extensible applications that consolidate and organize data from disparate sources for secure real-time visualization on any device. Learn more at http://scada.com


The Industrial Internet of Things (IIoT): Are We There Yet?

The cat is no longer in the bag. In fact, she’s already rummaging through businesses and homes in your hometown – maybe in your neighborhood. Before our eyes, the Internet of Things (IoT) has evolved from a nice idea to a measured experiment with tangible results. As expected, early adopters are primarily large enterprises with significant resources to dedicate to new technology, but the IoT does not always require a substantial investment. Sometimes, it is as simple as finding a better way to use your current technology and associated data. Some industrial enterprises have already seen the benefits of machine intelligence and the marriage of people and processes. Other organizations are using the IoT to provide better customer service and more targeted marketing. Is it safe to say the experiment is over? Have we burst through the hype bubble to arrive at a practical understanding of what’s at stake?

The Industrial IoT promises more efficient production processes, reduced resource consumption and waste, safer workplaces, and more empowered employees. There are many success stories already, and more are sure to come.

Honda Manufacturing of Alabama

Honda’s largest light truck production facility in the world – a 3.7 million square foot plant – was faced with a problem all too common to large manufacturing facilities. Over the years, a number of different automation systems were introduced to help streamline production. With operations including blanking, stamping, welding, painting, injection molding, and many other processes involved in producing up to 360,000 vehicles and engines per year, it is not surprising that they found themselves struggling to integrate PLCs from multiple manufacturers, multiple MES systems, analytic systems, and database software from different vendors.

Of course, on top of these legacy systems, Honda continued to layer an array of smart devices on the plant floor and embed IT devices in plant equipment. The complexity introduced by this array of automation systems turned out to be slowing down the operations they were intended to streamline.

After reorganizing their business structure to merge IT and plant floor operations into a single department, Honda proceeded to deploy a new automation software platform that enabled them to bring together PLC data with the data coming from MES and ERP systems into a common interface that allowed the entire enterprise to be managed through a single system. This also allowed Honda to manage and analyze much larger data sets that revealed new opportunities for further optimization. While this reorganization required a significant investment of resources, they were able realize benefits immediately, and ultimately positioned themselves to maintain a competitive edge through the next decade or more.


As one the world’s foremost suppliers of industrial robots and modular manufacturing systems, ABB has had their finger on the pulse of industrial technology for years. As the IIoT emerged, ABB was quick to find ways to take advantage of the opportunities presented. The company has installed more than 250,000 robots in numerous industries worldwide: plastics, electronics, pharmaceuticals, food and beverage, and many more.

Before the IIoT, in order to provide service ABB needed to dispatch technicians to remote sites to perform diagnosis. Today, a small operations team in a centralized Control Center are able to monitor in real-time precise and reliable information about each robot’s current status and activity. This has not only enabled ABB to substantially reduce the cost of their maintenance and operations, but the data collected has allowed them to develop a set of predictive KPIs to anticipate problems before they occur, helping their customers benefit from less downtime and increased productivity.


Kennametal was able to increase the productivity of their discrete manufacturing operations by using machine tool data and complex event processing. Whereas the traditional approach to increasing productivity was to reduce downtime, Kennametal focused on improving productivity by reducing cycle time. The solution employs complex event processing software that gathers and analyzes production data in real-time. Kennametal was able to understand which operators out-perform the production plan and guide less-experienced operators toward improvement. As an example: in one machining operation it was determined that taking a fast, shallow cut reduced cycle time by 16% over the slower, deeper cut the production plan called for. Best practices of this sort have been shown to reduce Kennametal’s cycle time by 20-40%.

The examples provided by Honda, ABB, and Kennametal are just a few of the hundreds of different IIoT success stories that can be found on the internet. Companies like GE, Ford, Intel, and dozens more are pouring literally billions of dollars into IIoT technologies this year alone. This is not an investment in possibility and hope. The IIoT is very real and it is happening right now. Of course, as with anything new there will be plenty of hurdles and blind alleyways, but many of the initial obstacles have been discovered and overcome. The foundation is in place and the arrow is pointing up. Companies are no longer asking: Should we? They are asking: How can we and how quickly?
**B-Scada has provided best-of-breed data visualization solutions since 2003, providing industrial and commercial customers the tools they need to transform their processes and empower their personnel to maximize efficiency, productivity, and safety. Learn more at http://scada.com.