Turn an automated factory into a smart factory by connecting existing machines and sensors, making their data usable in real time, and adding analytics and other capabilities in stages. Automation controls equipment and repeatable tasks; a smart factory connects systems so they can use data to respond to changing conditions. The network, connectors, and power backup that keep those systems working are part of the upgrade—not afterthoughts.
What changes when automation becomes a smart factory?
Industrial automation uses computer-driven sensors, actuators, and control systems to monitor and control machinery and processes. It can make work safer and more efficient than hands-on operation, especially for repetitive tasks. A smart factory builds on that foundation: connected processes exchange data through distributed control systems and intelligent networks, then use it to adapt operations.
Industry 4.0 is the broader context for this shift toward connected, data-driven manufacturing. The distinction is not simply that a factory has more robots or more automation. It is whether equipment and processes can share useful information and act on it.
“Automation does not a smart factory make.” — Randall Scasny, Senior Community Content Specialist, Newark/Avnet element14 Community, Electronic Design, October 23, 2024.
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That distinction also helps set expectations: connected technologies are complementary layers, not one product that transforms a plant on its own.
How to make the transition in stages
Modernize around the equipment you already have. A practical sequence is to connect assets first, then add intelligence and simulation, and introduce more advanced tools where they address a real operational need.
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Instrument and connect existing assets
Use industrial IoT (IIoT) to connect devices such as machines and sensors so they can collect, analyze, and act on data. The intended uses include improving operational efficiency and productivity, supporting decisions, predicting maintenance needs, monitoring asset health, and increasing supply-chain visibility. Start with the information your plant needs to make a decision or take action; connecting a device without a useful purpose does not, by itself, make the operation smarter.
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Add AI and machine learning to useful data
AI and machine learning can recognize patterns, help optimize processes, and support predictive analytics. They are most relevant after the underlying equipment can provide data that the factory can use. Treat them as an intelligence layer on top of connected operations, not a substitute for instrumentation or reliable data paths.
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Model changes before making them
A digital twin represents equipment or an operating environment and can be used to simulate workflows, actions, or layouts. Use that capability to examine a proposed change in a model before changing the physical process.
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Automate physical work selectively
Robots can work on assembly lines, collaborate with people, or move autonomously to select components. Choose the kind of robotic work that fits the task rather than treating robotics as a required first step in every smart-factory project.
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Use cloud and immersive tools where they help
Cloud computing offers shared, on-demand computing, storage, and applications. Augmented or virtual reality can present schematics, fault codes, and maintenance logs for training and diagnosis. These tools add value when workers or systems need access to that information; they are not prerequisites for connecting a factory.
Do you need industrial Ethernet for PLCs and sensors?
Industrial Ethernet is designed for harsh factory conditions, including temperature, humidity, electromagnetic interference, and physical stress. It is suited to applications that need predictable timing and low latency, such as robotic assembly, chemical processing, and packaging. The Electronic Design article identifies PLCs, sensors, actuators, and HMIs as compatible equipment.
That makes industrial Ethernet a sensible option to evaluate for links where timing, environmental durability, and compatibility with plant equipment matter. Do not choose a cable solely by its name: confirm that the cable and connectors match the devices, route, environment, and application.
When should you consider single-pair Ethernet?
Single-pair Ethernet (SPE) is presented as a more compact and cost-effective option when multi-gigabit throughput is unnecessary. It can be worth evaluating for a lower-throughput link where reducing cable size or cost matters, but the source does not establish that SPE is suitable for every factory application or device combination.
| Decision factor | Industrial Ethernet | Single-pair Ethernet |
|---|---|---|
| Timing and latency | Designed for predictable timing and low latency. | Not stated in Scasny’s October 23, 2024 Electronic Design article. |
| Factory environment | Designed for conditions including temperature, humidity, electromagnetic interference, and physical stress. | Not stated in Scasny’s October 23, 2024 Electronic Design article. |
| Throughput and cable size | Not stated in Scasny’s October 23, 2024 Electronic Design article. | A compact option for cases where multi-gigabit throughput is unnecessary. |
| Equipment compatibility | Identified as compatible with PLCs, sensors, actuators, and HMIs. | Not stated in Scasny’s October 23, 2024 Electronic Design article. |
| Cost | Not stated in Scasny’s October 23, 2024 Electronic Design article. | Presented as a more cost-effective option. |
For either type, check the specific installation before buying or specifying components. Verify cable category, shielding, connector, temperature rating, protocol, and length against the plant’s equipment and conditions. The cited article does not give product-level specifications that would settle those choices.
How to keep connected systems running through a power outage
A connected factory depends on communications, control lines, and data centers being available. More computing makes resilience part of the architecture: a power disruption can affect more than the machine that stops first. Plan backup and recovery for the systems the operation relies on.
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- Provide backup power: Consider uninterruptible power supply (UPS) units and energy storage for critical loads.
- Build in alternate paths: Use dual power feeds, redundant power distribution, and smart switching to redundant sources where appropriate.
- Document recovery: Write a disaster-recovery plan that states how the operation will respond to an outage.
- Test the plan: Periodically test outage scenarios so recovery procedures are exercised rather than merely documented.
The cited article does not prescribe system sizes, runtimes, or a particular UPS configuration. Those requirements depend on the equipment and loads the plant needs to keep available.
Independent reader supportYour contribution helps us test, update, and keep practical guides available for everyone.What to check in the bill of materials
Connected equipment depends on its physical links as well as its software. Cable, connectors, and I/O components are part of the reliability chain between a sensor and the system using its data. Include these items when checking whether an installation is suitable for its environment:
- Industrial Ethernet or single-pair Ethernet cable selected for the link’s requirements.
- Factory-molded connectors and DIN valve connectors where the equipment calls for them.
- I/O modules and sensor cables appropriate to the devices being connected.
- Industrial UPS equipment and, where needed, energy storage for the power-resilience design.
Newark is identified by Scasny as a supplier of connectors, DIN valve connectors, I/O modules, and sensor cables. Confirm the specific part’s electrical, mechanical, environmental, and protocol compatibility for the intended installation; a category name alone is not a specification.
How to judge whether the move is working
The cited article describes potential gains in productivity, quality, versatility, efficiency, and decision-making, but does not provide a quantified return on investment or a measured improvement that applies to every plant. Set a baseline for the process you intend to improve, then evaluate the result against that baseline. Useful questions include whether data is reaching the systems that need it, whether the intended process can respond to it, whether the chosen links meet timing and environmental needs, and whether power and recovery arrangements support the required availability.
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Those checks keep the project focused on operational outcomes rather than the number of connected devices or technologies deployed.
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