Hans Otto Weinhold

Illuminating Dark Data, Mastering Retrofit: Enhancing Plant Efficiency and Safety

Wolfgang Laufmann, Business Developer Smart Factory at WAGO, and Hans-Otto Weinhold, Principal Solution Architect at AVEVA, discuss the challenges and solutions for digitalizing existing systems. The focus is on how companies can unlock previously unused data sources—so-called “dark data”—using retrofit solutions and modern IoT technologies. A key use case is the optimization of tank loading and monitoring. Technologies such as the WAGO I/O System and the AVEVA PI System are used to capture data from existing systems, securely transmit it, and integrate it into ERP or cloud systems. Security mechanisms, such as cameras for anomaly detection, ensure a high level of operational safety. The combination of modular hardware and flexible interfaces bridges the gap between OT and IT worlds, enhancing efficiency, reducing costs, and significantly decreasing manual labor. Customers also benefit from quickly available KPIs and improved data utilization, enabling informed decision-making. The guests emphasize that such retrofit solutions allow companies to launch pilot projects with a small budget and gradually scale them up upon success. The outlook reveals that WAGO and AVEVA plan to offer pre-configured solution packages in the future to simplify and accelerate IoT implementations. This approach not only optimizes plant availability but also establishes a foundation for long-term digital innovation.