How integrated approaches bridge the gap between SCADA, sensors, and network infrastructure

The digitalization of industrial processes is leading to ever closer integration between IT and OT systems. However, this also increases the demand for reliable monitoring that covers all levels of a production environment. Traditional IT monitoring solutions are often insufficient for this purpose, as they have limited understanding of industrial protocols and do not offer complete transparency. Even specialized SCADA systems reach their limits when it comes to monitoring modern IoT sensors or integrating complex networks. To ensure operational reliability and avoid downtime, end-to-end monitoring is required that brings all components together in a central platform.

Limitations of traditional monitoring approaches

Many companies still use isolated solutions that only monitor parts of the infrastructure. SCADA systems, for example, are designed to control and visualize production processes, while classic IT monitoring tools keep an eye on network devices or servers. The challenge is that these systems do not communicate seamlessly with each other, creating blind spots. If problems are not detected in time, they can develop into critical malfunctions and, in the worst case, affect the entire production process.

Complexity of industrial networks

A typical example from practice illustrates the challenges: Production facilities consist of a large number of interconnected systems – control units, network components, sensors, and machines. While a SCADA system reliably monitors the production process, it is not designed to control switches or edge devices. At the same time, environmental sensors for temperature or humidity must also be included in the monitoring. Without a consolidated platform, this means using numerous individual solutions, which are difficult to manage as a whole.

Uniform end-to-end monitoring

The key to a stable OT environment lies in a holistic monitoring approach. Modern solutions support a wide range of industrial communication protocols and can consolidate information from different sources. This provides a comprehensive overview of all levels – from central control systems to field devices. The following standards are particularly relevant:

• OPC UA: Enables manufacturer-independent communication between automation systems and provides access to controllers and HMIs.
• Modbus-TCP: Remains indispensable for connecting older field devices that do not support modern protocols.
• MQTT: Has established itself in the IIoT device environment and enables efficient monitoring of edge devices and distributed sensor networks.

Monitoring as a supplement to SCADA

Holistic monitoring does not replace a SCADA system, but rather expands its functionality. While SCADA controls the processes, monitoring oversees the underlying infrastructure. Integration via OPC UA servers allows monitoring data to be transferred to SCADA or HMI systems in real time. This enables a combined view of production and infrastructure data within a central dashboard. Companies thus benefit from greater transparency without having to fundamentally rebuild existing systems.

Added value beyond pure monitoring

Holistic monitoring not only offers transparency, but also strategic advantages:

• Centralization: A single platform reduces administrative effort and lowers licensing and training costs.
• Compliance: Automated logs facilitate compliance with regulatory requirements in sensitive industries.
• Automation: The collection of sensor data reduces the need for manual checks.
• Predictive maintenance: Trend analyses enable the early identification of devices at risk of failure and proactive maintenance.

Structured introduction to monitoring

Companies that want to set up end-to-end monitoring should proceed systematically. First, it is advisable to make a complete inventory of all OT components, including controllers, HMIs, and additional devices. The next step is to document the communication flows between IT and OT systems and prioritize critical areas. Initial benefits can already be achieved through basic availability checks. Monitoring can then be expanded step by step and refined based on practical experience.
Integrated monitoring that takes both IT and OT systems into account offers companies the opportunity to keep a holistic view of their industrial infrastructure. It closes the gap between process control and infrastructure monitoring, ensures greater resilience, and supports the implementation of modern maintenance strategies. In this way, downtime can be reduced, regulatory requirements better met, and the efficiency of production processes sustainably increased.