Industrial Networking Systems Secure Integration | Cisco & Polestar Case Study
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The document details a case study of a pharmaceutical manufacturing company in Nottingham, U.K., that integrated secure industrial networking systems to enhance production efficiency and comply with healthcare regulations. The solution involved partnership with vendors like Cisco and Polestar to implement technologies that ensure secure access, real-time visibility, and operational improvement through digitization. The project aimed to modernize the infrastructure while maintaining robust security standards across the manufacturing process.
Industrial Networking Systems Secure Integration | Cisco & Polestar Case Study
- 1. Designing Smarter Factories Industrial Networking Systems Secure Integration A Polestar | Cisco Case Study Customer: Pharmaceuticals & FMCG Industry: Healthcare | Pharmaceutical Manufacturing Line. Solution: Secure Industrial Network Implementation and UCS deployment Location: Nottingham, U.K. © COPYRIGHT 2020. POLESTAR | CISCO ALL RIGHTS RESERVED The customer required the integration of hardware and software with existing factory lines and process systems to avoid downtime. Additionally, a new network was needed to comply with government standards for healthcare & pharmaceutical production. It was a priority to ensure that the new network is secure and connect to SD-WAN, allowing multiple services to run in tandem and being segregated for security. Integrated Legacy Networks In digital service resiliency through compute infrastructure modernization. With regulations for healthcare & pharmaceutical production. Reducing risks, complexity, and improving overall security and operating uptime. IN PARTNERSHIP WITH ROUTECO & ANTARES Government Compliance 70% Improvement
- 2. The Customer is a +40,000 employees corporation, famous for manufacturing hygiene, health, and home products across more than 45 facilities. It operates through the Health & Home segments, focusing on nutrition, health relief & hygiene. To be a leader in its market, the group set the goal of becoming a global health manufacturing organization. This requires enhanced resources and quality, greater investment behind technology and compliance, and direct communications between operations and the C-Suite level executives, especially its EVP of Supply. Additionally, Health & Hygiene product manufacturing is under strict government regulations in order to guarantee good/ethical practices and to comply with strict quality standards. Digital transformation plays a major role in meeting these requirements. Production is enhanced through the integration of hardware and software with existing factory lines and process systems, allowing greater compliance. Solution Brief. Continuous and stable connections are crucial for assuring operating performance and achieving quality standards. To enhance communication, protect plant assets and guarantee production integrity, the client sought to work with Polestar’s suite of industrial security products, technologies, and services, along with the following partners: 1. Polestar: Project Management & Consultancy. Industrial Networking Systems secure implementation between factory floor and ERP. Selection of compatible hardware with the software app. 2. Cisco: Hardware vendor contributing to initial design work and consultancy. 3. Routeco: Provision of hardware and logistics. 4. Antares: Software App applied to infrastructure, which was installed by Polestar. Cisco’s.UCS (Unified Computing System) help manufacturing businesses to achieve the consistency, availability and performance they need through a modern, end-to-end tech infrastructure that is self-monitoring, self-analyzing, and self-optimizing. Implementing secure by design architectures and infrastructure is critical to improve resiliency and ensure high- availability. Connecting Manufacturing Lines to Cisco’s UCS through Secure Industrial Networking Systems 2. POLESTAR | CISCO © 2020. ALL RIGHTS RESERVED
- 3. Business Challenge The client was seeking to drive operational improvements into their production systems and assets through digitization and Industry 4.0 systems. However, IIoT initiatives require securely connected production environments allowing business partners access to real-time visibility, rich data streams, and remote control of systems and assets. In addition, the U.K. government applies strict controls to ensure that healthcare and hygiene products meet applicable standards of safety, quality, and efficacy, not only during production but also across the whole supply chain. Secure and stable data access and visibility are important to IIoT and Industry 4.0 initiatives, especially when seeking to continuously improve efficiency, quality, decrease costs, and increase overall equipment effectiveness. These are only accessible through secure industrial connections, which are necessary to enabling predictive maintenance, real-time quality monitoring, asset tracking, and safety enhancements. This way it is enabled to achieve efficiency goals and meet government regulations and standards. 3. Case Study BROWNFIELD IMPLEMENTATION | Secure Industrial Networking Systems Integration. Finally, the brownfield facility accounted for several legacy systems, which represented a security risk for the discovery of assets in OT environments. These old systems are also inflexible and complex, which constitutes an obstacle for operational efficiency. Such challenges require complete computing systems and security solutions that can be built for the needs of the management, operations, quality, IT, and OT teams. The company understood the need for an IIoT service to help bridge the gaps between different areas while achieving the following goals: 1. Delivery of production visibility on the network and allowing a centralized view of network activity, ensuring quality standards and efficiency. 2. Enabling security policies and traceability. POLESTAR | CISCO © 2020. ALL RIGHTS RESERVED
- 4. Our Solution 4. Project Architecture • Cisco TrustSec & IND: Software- defined (SD) network segmentation to protect business assets. The IND software helps teams gain visibility into the automation network for better availability and effectiveness. • VMware: Host for Virtual Machines. • Veeam: Business Continuity (Back- up & Replication). • Microsoft Enterprise Software: MS. POLESTAR | CISCO © 2020. ALL RIGHTS RESERVED As shown in the diagram below, the technologies (OT’s) that we implemented included: • Cisco UCS Servers & Switches: An integrated infrastructure to automate the deployment of virtualization, cloud, and edge computing and in- memory analytics supporting remote local facilities and substantial quantities of data from IIoT. Case Study BROWNFIELD IMPLEMENTATION | Secure Industrial Networking Systems Integration. Factory Cabinet X DUAL MEDIA CONSOLE COM IN2 REF IN1 EXPRESS SETUP - DC-A + ! + 12-54V 3.4-3.0A - DC-B + OUT IN2 IN1 SYS EXP USB ALARM SD CARD SPEED DUPLEX PoE SYNCE HSR/PRP DIS PLAY MODE 1 2 3 4 2 3 1 4 13 14 15 16 17 18 19 20 X 5 6 7 8 9 10 11 12 X PoE DUAL MEDIA CONSOLE COM IN2 REF IN1 EXPRESS SETUP - DC-A + ! + 12-54V 3.4-3.0A - DC-B + OUT IN2 IN1 SYS EXP USB ALARM SD CARD SPEED DUPLEX PoE SYNCE HSR/PRP DIS PLAY MODE 1 2 3 4 2 3 1 4 13 14 15 16 17 18 19 20 X 5 6 7 8 9 10 11 12 X PoE EXPRESS SETUP ALARM TIMECD REDUN DUPLX 2 OUT 2 SPEED GPS SD USB SYS PSU ALARMS L + N - ~ Hi PSU1 100-250V , 2A 100-240V~, 50-60Hz, 2A + - Lo 24-60V , 10A ! L + N - ~ Hi 100-250V , 2A 100-240V~, 50-60Hz, 2A + - Lo 24-60V , 10A PSU2 CONSOLE TOD ! 13 16 1 4 17 20 5 8 21 24 9 12 25 28 10/100/1000 PoE+ 100/1000 SFP 1000/10G SFP+ IN OUT IN OUT GPS ANT. DIG. TIMECODE ANA. TIMECODE 1 4 1 3 SYNCE PoE MODE EXPRESS SETUP ALARM TIMECD REDUN DUPLX 2 OUT 2 SPEED GPS SD USB SYS PSU ALARMS L + N - ~ Hi PSU1 100-250V , 2A 100-240V~, 50-60Hz, 2A + - Lo 24-60V , 10A ! L + N - ~ Hi 100-250V , 2A 100-240V~, 50-60Hz, 2A + - Lo 24-60V , 10A PSU2 CONSOLE TOD ! 13 16 1 4 17 20 5 8 21 24 9 12 25 28 10/100/1000 PoE+ 100/1000 SFP 1000/10G SFP+ IN OUT IN OUT GPS ANT. DIG. TIMECODE ANA. TIMECODE 1 4 1 3 SYNCE PoE MODE EXPRESS SETUP ALARM TIMECD REDUN DUPLX 2 OUT 2 SPEED GPS SD USB SYS PSU ALARMS L + N - ~ Hi PSU1 100-250V , 2A 100-240V~, 50-60Hz, 2A + - Lo 24-60V , 10A ! L + N - ~ Hi 100-250V , 2A 100-240V~, 50-60Hz, 2A + - Lo 24-60V , 10A PSU2 CONSOLE TOD ! 13 16 1 4 17 20 5 8 21 24 9 12 25 28 10/100/1000 PoE+ 100/1000 SFP 1000/10G SFP+ IN OUT IN OUT GPS ANT. DIG. TIMECODE ANA. TIMECODE 1 4 1 3 SYNCE PoE MODE EXPRESS SETUP ALARM TIMECD REDUN DUPLX 2 OUT 2 SPEED GPS SD USB SYS PSU ALARMS L + N - ~ Hi PSU1 100-250V , 2A 100-240V~, 50-60Hz, 2A + - Lo 24-60V , 10A ! L + N - ~ Hi 100-250V , 2A 100-240V~, 50-60Hz, 2A + - Lo 24-60V , 10A PSU2 CONSOLE TOD ! 13 16 1 4 17 20 5 8 21 24 9 12 25 28 10/100/1000 PoE+ 100/1000 SFP 1000/10G SFP+ IN OUT IN OUT GPS ANT. DIG. TIMECODE ANA. TIMECODE 1 4 1 3 SYNCE PoE MODE SS Catalsyt 9500 Series C9500-48Y4C RFID ... 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 SS Catalsyt 9500 Series C9500-48Y4C RFID ... 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 CONSOLE MODE STAT D UPLX SPE ED STAC K SYS T A CTV XPS S-PWR UID Catalyst 3850 XS 10G SFP+ 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 CONSOLE MODE STAT D UPLX SPE ED STAC K SYS T A CTV XPS S-PWR UID Catalyst 3850 XS 10G SFP+ 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25X 36X 37X 48X Catalyst 9300 48 PoE+ NETWORK MODULE C9300- NM-8X 4 3 6 5 8 7 TE/G 2 1 01X 12X 13X 24X 25X 36X 37X 48X Catalyst 9300 48 PoE+ NETWORK MODULE C9300- NM-8X 4 3 6 5 8 7 TE/G 2 1 01X 12X 13X 24X EXPRESS SETUP ALARM CONSOLE L + N - ~ Hi PSU1 100-250V , 2A 100-240V~, 50-60Hz, 2A + - Lo 24-60V , 10A ! L + N - ~ Hi 100-250V , 2A 100-240V~, 50-60Hz, 2A + - Lo 24-60V , 10A PSU2 REDUN DUPLX 2 OUT 2 SPEED SD USB SYS PSU ALARMS 1 4 1 3 SYNCE PoE DISPLAY MODE ! 25 28 100/1000 SFP 13 16 1 4 17 20 5 8 21 24 9 12 10/100/1000 PoE+ 100/1000 SFP EXPRESS SETUP ALARM CONSOLE L + N - ~ Hi PSU1 100-250V , 2A 100-240V~, 50-60Hz, 2A + - Lo 24-60V , 10A ! L + N - ~ Hi 100-250V , 2A 100-240V~, 50-60Hz, 2A + - Lo 24-60V , 10A PSU2 REDUN DUPLX 2 OUT 2 SPEED SD USB SYS PSU ALARMS 1 4 1 3 SYNCE PoE DISPLAY MODE ! 25 28 100/1000 SFP 13 16 1 4 17 20 5 8 21 24 9 12 10/100/1000 PoE+ 100/1000 SFP CONSOLE MODE STAT D UPLX SPE ED STAC K SYS T A CTV XPS S-PWR UID Catalyst 3850 XS 10G SFP+ 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 CONSOLE MODE STAT D UPLX SPE ED STAC K SYS T A CTV XPS S-PWR UID Catalyst 3850 XS 10G SFP+ 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Catalyst 3850 48 25X 36X37X 48X 01X 12X13X 24X CONSOLE MODE SYST ACTV XPS S-PWR STAT DUPLX SPEED STACK Catalyst 3850 48 25X 36X37X 48X 01X 12X13X 24X CONSOLE MODE SYST ACTV XPS S-PWR STAT DUPLX SPEED STACK L0/1/2: Industrial Hardware Line 1 Line 21 Distribution Cabinets 1/2 Factory Cabinets 1/2 VM Infrastructure VM Infrastructure MS Cloud Services L4 and Above Stratus Services VM Infrastructure Machinery Machinery Machinery Machinery Machinery SDWAN MS Cloud Services L4: DMZ L3: Data Room N L3: Data Room F L2: Packing Lines L2: Production Area Legacy Network
- 5. Our Solution 5. Through a partnership with Cisco and the other vendors, Polestar planned a multilayered design that incorporates several security mechanisms at different levels. From levels 0 to 2 (Industrial Hardware) we installed several switches intended to run containers for data collection. At level 2 and below (Packing and Production Areas) communication from industrial hardware is 100/1000Mbit, with all production switches being dual and uplinked to core switches. Resilient switch interconnect links were proposed as optional within the same cabinet, as they may reduce the load on core systems. Distribution and access layers are consolidated in the factory floor design. At level 3 (Data Rooms) top of rack switches are stacked and are all dual, uplinked into the core switch. The installation of Cisco's Unified Computing System (UCS) servers was thought for delivering performance, flexibility, and density in devices, allowing workloads for: • Big data & database management systems, • Cloud computing environments, delivering virtual machines and bare- metal servers, • High-frequency trading, • Internet infrastructure applications, • Mission-critical enterprise apps, • Virtualized environments. The Cisco UCS servers are powered by the latest Intel® Xeon® scalable processors, forming the core of a versatile and efficient data center that meets diverse business needs with cost- effectiveness. At level 4 (Legacy Network and DMZ) an SD-WAN firewall provides routing to all services outside of the factory network and is configured/controlled by the vendor with management access via Polestar. From level 4 and above the system connects to the cloud, varying by type. The solution consisted not only in the implementation of the technologies shown in the diagram but also consulting & design validation, project and multiple vendor management, documentation, and in life support. POLESTAR | CISCO © 2020. ALL RIGHTS RESERVED Case Study BROWNFIELD IMPLEMENTATION | Secure Industrial Networking Systems Integration.
- 6. Over the project we provided an industrial network that is secure by design and redundant for serialisation compliance, meeting the latest security requirements, complying with industry standards, and granting continuous access to production at all levels. Polestar delivered to the customer three main outcomes from this installation: 1. An effective deployment of the OT system, making the network IIoT ready and securely connected. The choice of Cisco IIoT products allowed the system to benefit from the full capabilities of digitalization (operational efficiency, competitiveness, and the creation of new revenue streams). Outcomes 6. 2. A fully automated oversight and management view of production at all levels of their pharmaceutical and healthcare lines, and at all stages of the process. 3. The assurance of quality and efficiency, observing the U.K. government standards for healthcare and pharmaceutical production. Full documentation was also provided for compliance. Thanks to the sector experience and domain expertise that we have at Polestar, we continually improve the processes of any industrial business through the latest IIoT systems. Our goal is to help businesses to have their people, products, and machines securely connected to the Internet, efficiently and automatically. ________________________________ For more information To find out about Polestar’s Secure Implementations and other Industrial Internet of Things (IIoT) solutions, go to: “Our UCS is an API-driven business computing platform with, streamlined virtualization and seamless automation. From core, to edge, to cloud: If you can imagine it, we can build you a bridge to a modern data center infrastructure.” - Cisco +44 (0)115 911 6699 www.polestarinteractive.com info@polestarinteractive.com The Sir Colin Campbell Building, Innovation Park, Triumph Road, Nottingham, NG7 2TU, U.K. POLESTAR | CISCO © 2020. ALL RIGHTS RESERVED Case Study BROWNFIELD IMPLEMENTATION | Secure Industrial Networking Systems Integration.