2. INDUSTRIAL DATAOPS AND UNIFIED NAMESPACE
02
In today’s manufacturing and supply chain landscape,
integrating AI and robust data operations is critical for
maintaining a competitive edge.
HOW ARE AI AND DATA
ANALYTICS RESHAPING
MANUFACTURING?
In the increasingly competitive landscape of global manufacturing
and supply chain management, eliminating waste and unlocking
efficiency gains has become essential to stay profitable. Exposing
the hidden inefficiencies by harnessing machine, process and other
related data has become critical. With the increase in the popularity
of use cases for AI and analytics and reduction in the entry cost
and tech threshold for companies to digitize, enabling AI systems
and digital tools to break complexities and improve the lives of
planners to plant managers is viable and attractive. However, to
deploy and sustain this at scale, organizations require robust
foundational industrial data operations capabilities. This means
fundamentally rethinking existing processes, resource allocations,
and data infrastructures.
Establishing these foundations can be challenging. Businesses face
significant hurdles, such as ensuring high-quality data, enhancing
data accessibility, and overcoming the inertia of existing suboptimal
IT/OT architectures. These challenges are compounded by the
complexity and fragmentation of systems, which often result
from rapid, uncoordinated technological implementations. With a
modernized infrastructure that can support advanced analytics
and scale flexibly, companies can avoid becoming mired in a cycle
of inefficient investment and technological redundancy. Addressing
these foundational challenges is imperative for businesses that
capitalize on AI and data analytics.
A modern IT/OT infrastructure that includes not just compute and
network components but also tools and automation to ensure
efficient delivery is crucial for optimizing resources, maintaining
security standards, and ultimately defining a company’s digital
journey's success. Companies must prioritize strategic overhauls
of their data and technology systems to break free from legacy
constraints, unlock the full potential of digital transformation, and
move toward a future of software-defined manufacturing and
operations [read more about it here].
In modern manufacturing, integrating industrial data operations
fundamentally transforms practices by harnessing the power of
connectivity and real-time data. Enabled by connectivity across
devices and facilities, communication across production lines
and logistics significantly enhances operational synchronization
and adaptability. This real-time data access is critical for decision-
making, enabling managers to respond quickly to changes,
optimize resources, and predict potential issues, creating a
solid foundation to remain efficient. Furthermore, deep data
analysis exposes hidden inefficiencies—often termed the “hidden
factory”—highlighting areas for innovation and continuous
improvement. Overall, the strategic deployment of technologies to
utilize industrial data revolutionizes manufacturing processes and
sustains a competitive edge in a rapidly evolving industry.
3. INDUSTRIAL DATAOPS AND UNIFIED NAMESPACE
03
Many modern manufacturers operate with a technology stack that
is rigid and compartmentalized, leading to data silos and increased
costs. This structure also hinders the seamless integration of data.
This setup results in several significant challenges. Data silos emerge,
confining information to specific layers or systems, complicating
data integration from diverse sources, and increasing costs. Such
fragmentation hinders a unified, real-time operational view and
impairs data-driven decision-making across the enterprise.
Moreover, these traditional architectures struggle with the increasing
volume, variety, and velocity of data from modern industrial
systems. Adapting and scaling existing structures to incorporate
new technologies and data sources typically demands considerable
investments in technology and expertise. Reliance on proprietary
interfaces leads to vendor lock-in and technical debt, reducing
flexibility and making adopting new technologies or switching
solutions difficult. Furthermore, restricted data access limits cross-
functional collaboration and reduces the effectiveness of data across
different applications, stifling innovation.
Traditional industrial data architectures are becoming less
suitable for modern manufacturing due to their rigid, layered
structures, which allow only point-to-point data transfer.
TRADITIONAL INDUSTRIAL
DATA ARCHITECTURES
LEVEL 04
BUSINESS PLANNING (ERP)
LEVEL 03
PROCESS CONTROL EDGE (MES)
LEVEL 02
SUPERVISORY CONTROL (SCADA)
LEVEL 01
OPERATIONS ANALYTICS (PLC)
LEVEL 00
PHYSICAL ASSETS (SENSORS SIGNALS)
4. INDUSTRIAL DATAOPS AND UNIFIED NAMESPACE
04
While traditional models enabled information collection and
connectivity, the evolution of the ISA-95 stack introduced a
hierarchical organization of IT and OT systems with clearly
established levels. This layered approach helps organizations
invest appropriately and prepare systems for real-time data
capture and flow. The ISA-95 stack focuses on Manufacturing
Operations Management and Standardization, improving
interoperability, role definition, data contextualization, and
alignment with business objectives. It enhances scalability and
Industrial Internet of Things (IIoT) integration, even with legacy
devices. However, as new technologies and solutions emerge,
interconnectivity between systems becomes more critical to
optimize operations within these levels. When systems cannot
communicate effectively, data silos and ad hoc solutions arise.
This challenge has led to the adoption of Unified Namespace (UNS)
and industrial DataOps integration, which act as intermediaries to
integrate information regardless of operational protocols. Modern,
unified data architectures support seamless integration, scalability,
and accessibility across an organization. By breaking down data silos
and enabling real-time data exchange, these architectures facilitate
better decision-making, enhance operational excellence, and foster
innovation in a rapidly changing technological environment.
5. INDUSTRIAL DATAOPS AND UNIFIED NAMESPACE
05
UNIFIED NAMESPACE AND
INDUSTRIAL DATAOPS
REFERENCE ARCHITECTURE
In the increasingly competitive landscape of global manufacturing
UNS is an emergent architectural strategy that centralizes diverse
data sources into a unified, contextual framework. It establishes
a single source of truth for real-time data, enabling precise and
accessible information across different business sectors. In UNS,
each component—whether Programmable Logic Controllers
(PLCs), Supervisory Control and Data Acquisition systems (SCADA)
systems, Manufacturing Execution Systems (MES), or Enterprise
Resource Planning (ERP)—is treated as a node within a vast
ecosystem. These nodes publish data to UNS, where it can be
accessed by other nodes via subscription, simplifying data flow and
reducing the need for complex system-to-system connections.
UNS data organization often follows a semantic hierarchy
aligned with ISA-95 standard guidelines, enhancing systematic
categorization and retrieval of information. UNS frequently
utilizes IIoT protocols like MQTT, which is known for its efficiency,
scalability, and secure data exchange capabilities. Its adaptability
is highlighted by its compatibility with various platforms that
meet minimum technical standards, including MQTT and
Sparkplug. This flexibility allows customization to meet specific
organizational needs, making UNS pivotal in enhancing operational
visibility and agility for modern digital enterprises. It also serves
as a foundational component to enable software-defined
manufacturing and operations in the future.
EDGE GATEWAY
Edge gateway applications
and hardware connect to
sensors, PLCs, and machines
to translate proprietary
industrial protocols to open
standards like OPC UA
and MQTT.
DATA HUB
A data hub models and
processes data and brings
various sources into context.
Built for industrial DataOps,
these hubs can connect to OT
and IT methods and parse,
cleanse, and transform data
so it is ready to consume.
MESSAGE BROKER
(SITE)
The site message broker
utilizes a lightweight publish
and subscribe mechanism
like MQTT to serve as a
single source of truth for
industrial edge applications
and higher-level broker
enterprise brokers.
MESSAGE BROKER
(ENTERPRISE)
Like the site broker, the
enterprise message broker
serves as the single source
of truth for the enterprise’s
current state. It is highly
available and scalable, with
transformed consumable
data available for any current
or future application to
subscribe to.
SUBSCRIBERS AND
CONSUMERS
UNS allows any application
or system to subscribe to
the information needed
without complicated data
manipulation. Connectivity
can be via event-based
subscription, streaming data
applications, and prepared
data payloads: Analytics,
business intelligence,
persistent data stores, AI
and ML, and ERP.
5
4
1 3
2
OT
MESSAGE
BROKER
4
5
INDUSTRIAL EDGE ENTERPRISE EDGE
MANUFACTURING SITE 1 .. N DATA CENTER APPLICATION
SITE UNS ENTERPRISE UNS
OT DEVICES
Machine 1
PLC 1
Historian
MES/SCADA
DATA HUB
Proprietary protocols
EDGE
GATEWAY
Protocol Conversion
Data Aggregation
DATA HUB
Data Modeling
Contextualization
Normalization
2
1
ORGANIZATION
SITE
LINE
ASSET
EVENT 1
EVENT 2
ERP
IoT/IIoT
MESSAGE
BROKER
3
LINE
ASSET
EVENT 1
EVENT 2
Proprietary protocols
Persistent data
Persistent data
ANALYTICS
DATALAKE/DWH
BI REPORTING
AI ML
PREDICTIVE MAINT.
DIGITAL TWIN
Subscribe
Subscribe
stream
Bulk query
stream
Publish
Row and persistent data
IT
CLOUD
6. INDUSTRIAL DATAOPS AND UNIFIED NAMESPACE
06
Industrial DataOps is a cutting-edge approach designed to enhance
data integration and security, which is crucial for improving data
quality and streamlining preparation times across enterprises.
This approach has emerged as a vital category of software
solutions tailored to the architectural needs of industrial
companies transitioning into Industry 4.0, digital transformation,
and smart manufacturing.
Industrial DataOps solutions perform data contextualization
and standardization and ensure secure data flow to applications
operating at the edge, within on-premises data centers, or hosted
in the cloud. These solutions significantly boost data utilization
efficiency, enhancing data analytics' velocity, reliability, and quality.
As the volume of data from industrial sensors and controllers
continues to grow, the importance of Industrial DataOps becomes
increasingly paramount. Originally conceived as a set of best
practices, DataOps has evolved into a distinct and mature
methodology in data analytics. For manufacturers, Industrial
DataOps is an essential tool to establish and maintain a robust
data infrastructure, enabling them to achieve and sustain
digitalization effectively.
7. INDUSTRIAL DATAOPS AND UNIFIED NAMESPACE
07
BENEFITS OF UNS OVER
TRADITIONAL ARCHITECTURE
The Unified Namespace architecture not only simplifies data
management and reduces IT/OT complexity but also enhances
operational agility, making it a superior choice for enterprises
looking to thrive in the digital age. UNS enhances the ability to
scale at high speeds, which makes it a catalyst for innovation and
a foundational element for businesses aiming to leverage data for
competitive advantage.
By centralizing data from diverse sources into a single, accessible
repository, UNS establishes a consistent and reliable single source
of truth that enhances data accessibility and integrity across an
organization. This centralized approach significantly simplifies the
IT infrastructure, reducing the complexity and costs of maintaining
multiple systems and custom integrations. As a result, UNS
decreases operational expenses and streamlines scaling
as business needs evolve, accommodating new technologies and
systems with minimal disruption.
Moreover, UNS facilitates real-time data access and universal
availability, which is critical for responsive decision-making and
effective cross-departmental collaboration. The seamless data flow
enabled by UNS supports advanced data analytics, empowering
organizations to leverage comprehensive insights for predictive
analytics and machine learning applications. This capability drives
innovation and maintains a competitive edge in rapidly evolving
markets. The enhanced security features inherent in the UNS
architecture, such as sophisticated access controls and streamlined
audit processes, ensure robust data security and compliance with
regulatory standards.
8. INDUSTRIAL DATAOPS AND UNIFIED NAMESPACE
08
The table below visualizes and compares the core features of traditional IIoT architecture, ISA-95, and UNS.
ASPECT TRADITIONAL IIOT ARCHITECTURE ISA-95 STACK UNIFIED NAMESPACE (UNS)
Structure
4–5 layers: perception, network,
processing, application
(sometimes business)
Five levels: 0 (physical process) to 4
(business planning and logistics)
Flat, topic-based hierarchy
Data flow Primarily bottom-up Hierarchical, mostly bottom-up Bidirectional, any-to-any
Integration Can create data silos Focuses on vertical integration
Seamless horizontal and vertical
integration hub-type connectivity
Flexibility Moderately flexible Standardized approach Highly flexible and adaptable
Real-time capabilities Supports real-time operations
Supports real-time decisions
and operations
Designed for real-time
data-sharing and decision-making
Scalability Scalable, but can become complex
Limited scalability due to
hierarchical structure
Highly scalable and easily extensible
Legacy system
integration
Can be challenging
Well-suited for traditional
manufacturing systems
Provides a pathway for
integrating legacy systems
Central component
Various (cloud platforms,
edge gateways)
Different components across
the levels
Message broker (often MQTT
and/or Apache Kafka
Data storage Distributed across layers Hierarchical databases Centralized “data lake”
Security Layer-specific security measures
Well-defined security
boundaries between levels
Requires comprehensive
security strategy
Standards/Protocols
Various IoT protocols
(MQTT, CoAP, etc.)
Specific standards for each level
Often uses MQTT, supports
multiple protocols
Primary use General IoT applications
Manufacturing and process
industries
Modern, data-driven
manufacturing and IIoT
Data
contextualization
Limited, often siloed Structured within each level
Comprehensive across the
entire business
Interoperability Can be limited between layers
Suitable within levels,
challenges between levels
High interoperability across
all systems
9. INDUSTRIAL DATAOPS AND UNIFIED NAMESPACE
09
Building Industrial DataOps and UNS capabilities is not a one-size-fits-all process; the
journey may vary depending on your organization's specific needs, resources, and
objectives. While your organization may have specific goals, you should consider the
following characteristics while designing and implementing a modern IT/OT architecture.
This can ensure you’re building a flexible solution that enables quality data at scale.
STRUCTURING WITH UNS
UNS is the cornerstone of digital transformation, acting as a single
source of truth and a central hub for organizational communication.
It provides a structured representation of all events relevant to the
business, including ISA-95 Part 2 standards. By structuring with UNS,
you can efficiently organize asset hierarchies, allowing seamless data
browsing and access across the entire plant and enterprise. This
approach helps in breaking down silos and establishing connections,
thus democratizing data availability. UNS also enables the separation
of data consumption from data production, offering users a more
personalized and focused browsing experience. Implementing UNS
ensures your organization has a robust IT/OT architecture capable
of supporting quality data at scale and driving comprehensive digital
transformation initiatives.
PROTOCOL CONVERSION
Protocol conversion is a crucial element that enables seamless
communication between devices, systems, and applications
that use different protocols. This interoperability is essential for
integrating legacy systems with newer technologies, optimizing
industrial processes, and enhancing data acquisition. Applications
are available in the market that convert data from legacy
automation systems to MQTT and OPC UA protocols.
EVENT-BASED DATAFLOW
In an event-based dataflow, messaging protocols (like MQTT)
transmit data from one point to another in response to specific
events. This means that data is not continuously transmitted but
only when a particular event occurs (like a change in temperature or
pressure). This makes event-based dataflow ideal for IoT applications
where devices must communicate efficiently and in real-time with
the central servers, removing point-to-point connections.
DATA HUBS FOR CONNECTING INDUSTRIAL DATA
Data hubs play a pivotal role in integrating and contextualizing
industrial data, aligning seamlessly with an industrial DataOps
strategy. By facilitating codeless integration with any system, data
hubs enhance efficiency in transforming disparate data into a
cohesive, consumable format within UNS or other systems. These
hubs enable a few experts to work at the intersections of data,
accelerating integration and adaptation processes.
In a modern IT/OT architecture, data hubs standardize and
contextualize information models in real-time, ensuring that
data is enriched with additional meaning or relevance based on
its relationships and usage scenarios. This contextualized data
becomes a single source of truth, serving as the authoritative
reference point for accurate and reliable decision-making
processes. Organizations can streamline their data operations by
leveraging data hubs, making it easier to model and consume data
efficiently and effectively.
NEED FOR INTEROPERABLE DESIGN
Designed for interoperability, the architecture is built with flexibility
and compatibility in mind from the ground up. This means that the
architecture is designed to be adaptable, scalable, and interoperable
with other systems, and it is built using widely accepted standards,
open-source software, or publicly available APIs. This approach
facilitates more straightforward integration with other systems,
future-proofs the architecture against technological changes, and
promotes transparency and collaboration. For this purpose, while
different protocols like OPC and MQTT are prevalent, choosing the
right technology to handle multiple protocols simultaneously is
crucial for robust data operations.
SECURITY FRAMEWORKS
In implementing UNS, security is paramount to ensure data
integrity, confidentiality, and availability across interconnected
systems. A robust security framework should be established,
incorporating multilayered defenses such as encryption,
authentication, and access control mechanisms. Encryption
ensures that data transmitted within UNS is protected from
unauthorized access, while strong authentication protocols verify
the identities of users and devices interacting with the system.
Access control mechanisms, including role-based access control
(RBAC) and least privilege principles, restrict access to sensitive
data and functionalities based on user roles and responsibilities.
Additionally, continuous monitoring and auditing of UNS are
essential to detect and respond to potential security threats in
real time. By integrating these security measures, organizations
can safeguard their UNS against cyber threats and ensure their
interconnected systems' secure and reliable operation.
IMPLEMENTATION
STRATEGIES
10. INDUSTRIAL DATAOPS AND UNIFIED NAMESPACE
10
Despite UNS's numerous benefits, which can significantly enhance
organizational value, it’s important to be mindful of the associated challenges.
TOPIC CHALLENGE CONSIDERATION
Data governance
and standardization
Establishing consistent data governance policies and
standardization across diverse data sources can be
complex. Additionally, achieving this at scale with many
sites can be challenging compared to deploying at a
single facility.
Enterprises need robust data governance frameworks
to ensure data integrity, accuracy, and consistency.
This includes defining clear data ownership and usage
policies and complying with regulatory requirements.
System integration
and compatibility
Integrating legacy systems and ensuring compatibility
between different technologies can be difficult
A detailed assessment of existing IT/OT infrastructure
and systems is crucial. Enterprises may need to invest
in middleware or adapters to ensure seamless
integration without disrupting existing operations.
Performance and
system optimization
As data volumes grow, ensuring optimal system
performance and maintaining seamless operations
within UNS can become challenging.
It is essential to plan for performance optimization
from the outset. This involves choosing scalable
technologies and architectures to handle increased
loads and data complexity.
Security and
privacy concerns
Centralizing data increases the risk of breaches
and data leaks
Enterprises must implement robust security
protocols, including end-to-end encryption and secure
communication protocols. Regular security audits and
strong authentication mechanisms are essential.
Technology and
vendor lock-in
Dependence on specific technologies or vendors
can limit flexibility and control.
Supports real-time decisions
and operations
Change management
Resistance to change from within the organization
can hinder the adoption of UNS.
Effective change management strategies, including
training, communication, and stakeholder engagement,
are critical to ensuring a smooth transition and adoption.
Cost implications
Initial setup and ongoing maintenance of UNS
can be costly.
Conduct a thorough cost-benefit analysis to
understand the financial implications. Consider phased
implementations and self-funding transformation
by leveraging speed to scale, unlocking value early,
and using that savings to support funding the
broader transformation.
CHALLENGES AND
CONSIDERATIONS
11. INDUSTRIAL DATAOPS AND UNIFIED NAMESPACE
11
ISSUE
A global transportation client experienced a substantial increase
in shipment volume, compelling it to begin nearly 24/7 operations
that limited maintenance windows for its facility distribution
assets. At the same time, the company faced hiring difficulties and
rising wages in the challenging US labor market. The organization
needed a predictive maintenance strategy for its facilities to reduce
capacity loss, drive efficiencies, and optimize delivery service levels
SOLUTION
We recognized the importance of adopting a modern architecture
strategy to enable the client to scale outcomes, connect disparate
systems at different facilities, and merge that data at the edge
before sending it to the cloud for analytics. We recommended that
the client adopt a Unified Namespace to facilitate its operational
data management needs.
This initiative aimed to establish a standardized and centralized
data hub across the client’s network. The strategy involved
utilizing PLCs and a variety of sensors as data sources, with the
intention of processing and merging this data at the edge before its
transmission to the cloud.
The architectural framework enabled real-time data processing
for multiple facilities at the edge, which was subsequently
consolidated at a central location. Thus, individual facilities were
linked to a centralized hub encompassing all locations, creating
a unified namespace.
IMPACT
This setup allows any system within the network to instantly
subscribe to data from different data sources for approximately
25,000 assets spread across more than 40 facilities, facilitating
clean and centralized data management. It meets the operational,
business, and IT needs for predictive maintenance and has
simplified the integration of future use cases.
CASE STUDY
11
12. INDUSTRIAL DATAOPS AND UNIFIED NAMESPACE
12
In conclusion, Unified Namespace and industrial DataOps mark
a significant turning point in manufacturing data management,
essential for future-proofing businesses in the fast-evolving digital
age. As the landscape of Industry 4.0 expands, the efficiency of
data collection, processing, and utilization enhances operational
capabilities and becomes critical for organizational survival and
growth. UNS offers a unified, standardized platform that simplifies
the integration of diverse data sources. At the same time, industrial
DataOps equips businesses with the tools and methodologies to
convert raw data into actionable, valuable insights.
These systems collectively deliver a robust framework that supports
several key operational benefits crucial for adaptive, future-ready
manufacturing environments. The flexibility of UNS allows for
seamless integration of emerging technologies and data sources,
ensuring businesses remain at the cutting edge of innovation. This
adaptability and the scalable nature of industrial DataOps prepare
enterprises for future expansions and complexities. Additionally, the
real-time data processing and analysis facilitated by these integrated
systems empower rapid decision-making and enhance operational
agility, providing a competitive edge in today’s fast-paced market.
Moreover, UNS and industrial DataOps break down traditional
data silos, fostering a culture of collaboration and enabling a
comprehensive view across operations, which is vital for continuous
improvement and innovation. The foundation laid by these
technologies is also instrumental in advancing the use of AI and
machine learning, driving significant efficiencies, and pioneering
new capabilities in manufacturing. As these technologies evolve,
their role in promoting sustainability, enhancing risk management,
and empowering a data-literate workforce will be indispensable.
By investing in UNS and industrial DataOps, manufacturers are
not merely optimizing their current processes but strategically
positioning themselves for sustainable success and leadership
in the future landscape of smart manufacturing. The path to fully
optimized manufacturing data continues, but with these tools,
organizations are well-equipped to navigate and thrive in the
complexities of the digital future.
CONCLUSION
13. INDUSTRIAL DATAOPS AND UNIFIED NAMESPACE
13
ABOUT DELOITTE
Deloitte brings expertise and a proven track record in implementing
UNS and industrial DataOps solutions. With a deep understanding
of industry-specific challenges and a comprehensive approach to
digital transformation, we help organizations seamlessly integrate
these advanced systems into their existing infrastructure. Our
tailored consulting services, cutting-edge technology solutions, and
robust analytics capabilities ensure that businesses can maximize
the value of their data, improve operational efficiencies, and achieve
sustainable growth. By partnering with Deloitte, companies can
leverage best practices, innovative methodologies, and strategic
insights to stay ahead of the competition and thrive in the ever-
evolving landscape of Industry 4.0.
AUTHORS
Tim Gaus
Principal, Deloitte Consulting LLP
tgaus@deloitte.com
Jennifer Brown
Principal, Deloitte Consulting LLP
jennibrown@deloitte.com
Brian Zakrajsek
Specialist Leader, Deloitte Consulting LLP
bzakrajsek@deloitte.com
Suhas Sathyanarayana
Senior Manager, Deloitte Consulting LLP
suhass@deloitte.com
CONTRIBUTORS
Deloitte Consulting practitioners Chris Culver, Sathya Karuveli,
Ishaan Borawake, Praveen Prahladan, Veena Krishnamurthy
and Nicole Becker were instrumental in the preparation of
this publication.