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ManufacturingSecure AI Deployment

Third-party AI on a legacy production line

+6 ptsEquipment effectiveness
−22%Unplanned downtime
ZeroInbound connections to OT
Abstract artwork for the Third-party AI on a legacy production line case study

Situation

The business case for the vendor model was clear. The risk was clear too: a new cloud connection into a plant that had never had one, carrying data that described exactly how the product is made.

What we did

  • Built a one-way data path from OT to a brokered zone, aligned to IEC 62443.
  • Minimised and tokenised process data field by field before it reached the vendor model.
  • Ran the model in recommend-only mode: it advises, operators decide and act.

Guardrails

  • No write path to any control system.
  • Data minimisation per field, with the mapping kept on site.
  • Bounds on model output, drift monitoring and a kill switch the plant controls.