Breaking Down OT Networking: How Small Plants Can Start Smart
How small and midsize plants can use OT networking to improve visibility, reduce downtime, and build supportable systems without starting from scratch.
You don’t need a better system. You need a better plan.
In today’s manufacturing environment, small and midsize plants are under increasing pressure to improve uptime, reduce maintenance costs, and extend the life of aging equipment—all while managing limited staff and budget. One of the most practical ways to address these challenges is by improving operational technology (OT) networking.
Yet for many facilities, OT upgrades seem out of reach. Not because they’re unnecessary, but because they are often presented as all-or-nothing initiatives. In reality, a thoughtful, phased approach can deliver meaningful improvements without disrupting production or requiring major capital spending.
Understanding OT Networking in Practical Terms
OT networking refers to the practice of connecting key control components—PLCs, VFDs, HMIs, sensors—so they can share useful data and enable better plant-floor decisions. Effective implementation allows for:
- Clear, actionable alarm messages
- Real-time access to performance data
- Streamlined troubleshooting
- On-screen access to documentation and schematics
- Early identification of small issues before they escalate
The objective is not complexity. It is clarity and maintainability.
A Practical, Incremental Approach
Many small and midsize plants are constrained by limited internal resources, tight budgets, and a strong need to minimize downtime. A practical OT networking strategy respects these realities. Instead of launching plant-wide initiatives, success often begins with targeted upgrades to the most problematic equipment or process areas.
A phased approach might include:
- Addressing systems that cause frequent downtime or operator confusion
- Adding Ethernet communication to connect PLCs with drives
- Upgrading outdated HMIs to provide improved diagnostics
- Making wiring diagrams and manuals accessible through interface screens
Each improvement builds on the last, creating a stronger, more supportable foundation.
Case Studies in Practical OT Networking
151 Foods, a commercial bakery, offers a compelling example of this approach. Initially, cost concerns led them to defer a plant-wide OT network. However, as production scaled and challenges mounted, they reconsidered. Through phased implementation, their facility now supports over 100 machines across nine lines, with improved fault messaging, remote support capabilities, and machine-to-machine communication. The transition was not immediate. It began with core needs and expanded gradually. The result is a more resilient operation and a plant infrastructure better suited for long-term growth.
Gold Crust, another bakery facility, faced major issues with an outdated and disorganized network. Cornerstone helped clean up the network architecture, added VLANs, upgraded the fiber backbone, and introduced remote access to improve visibility and reduce support delays. The team also designed an OT layout that allows recipe sharing and machine-to-machine interlocking across the line.
At Ellio’s, a frozen pizza manufacturer, Cornerstone supported the OT evolution over several years. What began as a basic fiber loop network grew into a structured system with managed switches, segmented traffic, and built-in firewall support for remote diagnostics. These changes were made incrementally, with a clear plan that kept operations moving while adding long-term value.
Common Operational Gaps Addressed by OT Networking
Many manufacturing plants share similar obstacles:
- Drive faults with no clear cause
- HMIs that display only basic status lights
- Maintenance processes that rely on outdated documentation
- Repeated support calls for issues that could be addressed with better visibility
These are not signs of failure. They’re symptoms of systems designed without today’s demands in mind. OT networking introduces the tools and transparency needed to close these gaps.
High-Impact, Low-Disruption Improvements
Not every upgrade requires a full controls retrofit. In fact, some of the most effective changes include:
- Installing managed switches to segment and stabilize network traffic
- Replacing one or two critical HMIs with models that offer alarm diagnostics
- Introducing segmented VLANs to improve troubleshooting and limit system-wide impact
- Enabling remote support through structured network access
These types of investments often pay for themselves by reducing downtime, avoiding emergency service calls, and enabling in-house teams to handle issues more confidently.
Applicable for Any Size Plant
A common misconception is that OT modernization is only worth pursuing in large, heavily automated facilities. On the contrary, small and midsize plants may benefit even more. With leaner teams and tighter margins, these plants stand to gain efficiency, flexibility, and better internal knowledge transfer from even modest OT upgrades.
Smaller plants also tend to be more agile. A few well-placed improvements can quickly demonstrate value and build momentum for future investment.
Key Considerations for Moving Forward
For operations teams looking to begin this journey, a few guiding questions can help clarify next steps:
- Where is the plant experiencing recurring downtime or confusion?
- Are there systems that lack diagnostics or fault messaging?
- Does the maintenance team rely on tribal knowledge or hardcopy documentation?
- Is the facility vulnerable to equipment obsolescence or knowledge loss?
Answering “yes” to any of these may indicate that OT networking could provide both immediate and long-term benefits.,
Long-Term Reliability Through Simplicity and Support
OT networking improves system visibility, streamlines troubleshooting, and makes controls infrastructure easier to support over time. It also enables more consistent operations, better training for new staff, and a reduced reliance on any one individual’s memory or experience.
These upgrades are not about chasing the newest technologies. They are about building resilient, maintainable systems that empower teams to respond faster, solve problems more effectively, and reduce unplanned downtime.
Even one networked panel, upgraded HMI, or connected drive can be a step in the right direction. The key is to begin with a plan grounded in current realities and long-term needs.