Every tag mapped to equipment and process
OPC UA / Modbus / MQTT integration, unified asset model and metric definitions
We connect OPC UA, Modbus, MQTT and business databases, build a unified asset model and metric definitions to ISA-95, and map tags to equipment and equipment to process. Every value has a defined place and meaning in the model; the model becomes a twin once data flows in.
Our approach
One team scopes, executes and retests; conclusions are delivered as evidence, not checklists.
Asset model before data integration
Equipment hierarchy, attributes and relationships are defined to ISA-95 before tags are attached, so all incoming data has a defined owner. New equipment or lines extend the same model without remapping.
Metrics consistent with data governance
Energy, throughput and OEE in the twin reference the enterprise data standard and share its definitions with BI reports, so each metric has the same value in both and needs no manual reconciliation.
Collection zoned to IEC 62443
Collection gateways sit in a DMZ between the production and business networks, with communication boundaries defined by the IEC 62443 zone and conduit model. Collection is read-only, through a unidirectional gateway where required, and the twin has no write path into the control network, adding neither load nor exposure to the production network.
Deliverables
Unified asset model
Equipment hierarchy, attributes, relationships and coding, with tag mapping table. Mappings are sampled at acceptance; every tag traces to its equipment and process position.
Data integration layer
Protocol adapters, edge collection, time-series storage and quality monitoring, with a security boundary description of the collection network (zones, conduits, ports and accounts). Data completeness and end-to-end latency are measured at acceptance against targets agreed at requirements stage.
Metric definitions and calculation
Definitions, calculation logic, refresh frequency and owners. Key metrics are checked item by item against existing reports, with differences documented.
How we deliver
Four stages, each with defined inputs, outputs and a client sign-off.
Source inventory
Protocols, tags, business systems and network conditions.
Model and mapping design
Asset model, tag mapping, metric definitions.
Integration
Collector deployment, mapping configuration, data validation.
Stability check
Completeness and latency tests, handover.
Frequently asked questions
Notes on scope, execution and delivery standards. Contact us for anything not covered here.
OPC UA, OPC DA, Modbus TCP / RTU, MQTT, BACnet and the proprietary protocols of mainstream PLCs via edge gateways. Business data arrives through databases, APIs or message queues.
Start from where you stand
Security, data and AI each start with a review of where you stand. The report and its findings are yours, whether or not the engagement continues.