Material Handling Automation: Don’t Forget About Cybersecurity

The efficiency and cost-effectiveness of a material handler’s operations depend on efficient integration of the systems they use to transport, move and store materials.

Seamless coordination and automation between things like conveyor systems and belts, robots and cobots, automated guided vehicles (AGVs), forklifts and pallet jacks not only boosts productivity but also minimizes downtime, operational costs and the potential for human error.

There are many factors to consider when working toward this level of material handling automation and integration, including:

• Investing in state-of-the-art technology
• Ensuring that all systems are compatible and interoperable
• Creating plans for maintenance and updates
• Preparing employees to work with new technologies and adhere to appropriate safety protocols
• Implementing analytics and monitoring tools to track performance and pinpoint issues when they arise

The role of IT-OT convergence in material handling automation

As the material handling market works to make its existing processes more efficient through automation, IT-OT convergence will play a crucial role in making it happen, enabling capabilities like real-time data access, smoother operations and much more. It’s a critical step that helps material handlers increase efficiency and productivity.

By integrating IT systems (data management and analytics) with OT systems (machines and equipment) so data can flow seamlessly between both worlds, material handlers will be able to not only better understand and fulfill what their customers want but also streamline their own operations.

But making this transformation can be difficult without support. There are many hurdles to overcome:

• Optimizing legacy systems that aren’t designed to integrate with modern technologies and protocols
  
  
• Working with systems that lack robust security features, making them vulnerable to threats
  
  
• Unifying teams and datasets that are used to existing in disparate silos with different goals, processes and protocols
  
  
• Understanding which information matters most among the large volumes of data that are generated from IT and OT systems

It often requires an outside party like Belden to help OT and IT collaborate and work through how to best connect systems and networks. For example, OT needs help from IT to manage the intricacies of connected architecture, while IT needs help from OT to navigate equipment and control systems.

IT-OT convergence lays the groundwork for the IIoT solutions required for automated material handling environments. They bring advanced sensors, devices and connectivity to the equation for predictive maintenance, faster and smarter decision-making and enhanced efficiency.

To support material handling automation, the data captured by IIoT devices must be as transparent and standardized as possible from the field via OPC UA, MQTT, TSN or possible combinations thereof. Integration of protocol gateways is often required as well so different systems and devices can communicate effectively. This allows networking of machines and devices so they can collect and analyze data in real-time.

Prioritize cybersecurity to protect the warehouse and office

A significantly important part of automating material handling environments is the holistic implementation of cybersecurity solutions, which should not only be viewed as technological but also as a mindset. You need not only the right tools and technologies but also the right internal culture—employees who are aware and are proactive thinkers. Everyone should be involved in and understand the importance of cybersecurity.

Parameters must be implemented to manage OT’s access and connectivity to IT—and IT’s access and connectivity to OT—as the warehouse floor connects to the outside world for the first time.

In addition to protecting IT and OT from the outside world, material handling networks also need to be protected from one another. For instance, while a firewall protects against unsolicited incoming network traffic, it can’t protect OT from IT—or IT from OT. OT and IT must remain together—but separate.

Here’s an example that illustrates why: If someone working in the office accidentally interacts with a fraudulent email that infiltrates the IT network, then OT is exposed to that risk.

Belden is your material handling expert

Looking ahead, leaders in this market must be prepared to take advantage of material handling automation to improve efficiency and keep up with constantly changing customer needs. Otherwise, ineffective material-flow planning can lead to delays, bottlenecks and downtime.

When automating your material handling environment, it’s crucial to seek out experts who come from your industry, understand your challenges and know how to guide you through the digital transformation process. We aren’t talking about products—we’re talking about a partner who can:

• Act as a consultant and advisor
• Navigate compliance and cybersecurity standards
• Plan and create a roadmap for your digital transformation
• Help you install infrastructure
• Implement plans for maintenance and updates

A fully integrated solution from Belden provides a foundation for root-cause analysis, KPI tracking and digitized workflows. With the right connections, warehouses can better serve customers, optimize labor and reduce operating costs.

We can help you connect the machines, robots, people and processes in your warehouse so you can securely collect, orchestrate and analyze critical performance data that guides action.

Learn how we support material handling.

Related links:

• Material Handling Automation: 5 Reasons Why It's So Important
• Material Handling Networks: Solutions for Poor Performance
• Why Material Handlers Should Get to Know the Cloud Now
• What Drives Automation in Material Handling?