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3 Reasons Why Upgrading to Industry 4.0 Offers a Cybersecurity Opportunity

3 Reasons Why Upgrading to Industry 4.0 Offers a Cybersecurity Opportunity

Cyber security network graphic

Manufacturers should view upgrading their factories as a chance to revisit their cybersecurity and data governance practices.

The smart technology revolution that is currently taking the manufacturing sector by storm brings with it a range of operational advantages the full scope of which have yet to be fully grasped. From advanced robots that are able to perform complex and delicate operations in the blink of an eye, to big data analytics delivering nuanced insights into production processes, many factories are still looking for ways to incorporate these technologies to their greatest potential. And, as these technologies continue to evolve, the efficiencies they provide will only grow along with them.

However, if there is one stumbling block to the adoption of Industry 4.0, it is that many manufacturers have not yet taken the initial step of upgrading their IT systems and cybersecurity protocols. These outmoded systems have left the manufacturing sector unusually vulnerable to attack. The broad footprint of a modern factory, with its hundreds of Internet-enabled machines, is an added complication, because without comprehensive cybersecurity practices in place, one breach could compromise the broader system.

While this may seem like a cause for alarm, it is in fact an incentive to reassess data governance and cybersecurity practices more broadly. Here’s why meeting cybersecurity compliance standards and upgrading your automated factory systems are mutually supportive goals.

#1) Strong cybersecurity practices offer protection against broader business threats

To start, let’s review why industrial cybersecurity should be an operational priority for manufacturers. Even though stories break every day about large scale data breaches, security hacks, and infectious malware, many business owners continue to view security threats as something that could happen to others, but not themselves.

However, an investment in cybersecurity can save a business from more than just embarrassment. It can:

  • Retain customer trust. Consumers are growing increasingly weary of having their own private information compromised due to another entity’s negligence. When large-scale business operations are at stake, a breach of a partner’s identifiable information can mark the end of that relationship.
  • Avoid legal challenges. Businesses can be held accountable for financial damages if it is discovered that a security breach or data hack happened due to their own negligence. Documenting both your security practices and evidence that you followed them can save you from legal trouble.
  • Protect valuable IP and confidential information. Cybersecurity is more than a PR move. Your own information—including technical blueprints and operational details—can also be compromised. Moreover, industrial espionage often targets OEM suppliers on the assumption that they will be a weaker link.
  • Safeguard operations on the factory floor. Computer viruses don’t just target data. They can also hack operational equipment, either causing that equipment to malfunction, or holding it for ransom.

Reading the above, you may be tempted to think that you can avoid these threats by not investing in newer technology. However, many older machines still run on exploitable operating systems, even if they aren’t connected to the Internet. For instance, in 2010, a virus passed through a USB drive was responsible for a cyber-attack on an Iranian nuclear facility—proof that staying offline won’t save you.

Instead, make sure your modern factory can keep up with modern cyber threats. In the current cybersecurity arms race, most attacks search for weak links. Keeping your systems robust will deter would-be hackers who know there are easier targets elsewhere.

#2) Meeting cybersecurity compliance prerequisites allows manufacturers to bid on more projects 

Anyone who has bid on government contracts, particularly for the Department of Defense, is familiar with the compliance standards required to handle this kind of work. The DoD isn’t the only one, however. Many other companies include cybersecurity requirements to protect their intellectual property, guard customer data, and to ensure confidential information about their operations stays safe.

Manufacturers may be used to highlighting features of their own facilities when bidding on contracts, but it’s becoming increasingly clear that robust cybersecurity practices—and the documentation to back them up—are just as strong a selling point. It’s not just about protecting against security threats, either. The business who can demonstrate the attention to detail required to guard against cyber-attacks and data leaks can reasonably argue that this care applies to other aspects of their business as well—from quality control to process management.

#3) Adopting advanced manufacturing processes strengthens factories competitively

By now, it’s well established that factory automation increases a manufacturing plant’s output, improves the quality of the final product, and reduces waste. As a result, modern plants are able to cut down on operating costs, mitigate the risk of broad product recalls, and offer lower prices to consumers. In some cases, factory automation can even enhance a product, by making possible various processes that are otherwise incompatible with a human-operated assembly.

Many of the most exciting Industry 4.0 advances, such as large-scale data collection or the Industrial Internet of Things, must be safeguarded against security threats. However, they are also better equipped to run more sophisticated cybersecurity programs. Just like keeping your operating system software up to date is essential for receiving security patches, keeping your factory technology up to date also helps you take advantage of new security features.

The advantages of advanced factory automation are too great to be undermined by poor cybersecurity.

The reality is that even manufacturers who haven’t fully upgraded their technology are not immune to cyberattacks. In fact, those running older systems are even more exposed to security threats given the known vulnerabilities of these systems, and the absence of the more sophisticated protections built into newer devices. This means that a factory upgrade presents a first-class opportunity to also bring in expert guidance to review your company’s data governance and cybersecurity policies and give them an upgrade as well.

Top Factors to Consider When Choosing a System Integrator 

Top Factors to Consider When Choosing a System Integrator 

Three people shaking hands in warehouse

Selecting the right systems integrator is crucial for any company seeking to enhance operational efficiency and achieve its ambitious goals. This decision, however, can be difficult. Finding a partner that seamlessly aligns with your business needs, understands your unique challenges, and possesses the expertise to deliver successful projects requires careful consideration. 

As an experienced system integration provider, we can provide valuable guidance for companies navigating this critical selection process. It is important to explore key factors to assess when evaluating potential integrators. These will help you make an informed choice in your selection and ultimately drive meaningful results for your company. 

Here are a few tips on what any company should be looking for when they choose a systems integrator. 

#1) Resources 

As you would with even a household project, you should seek out recommendations from a trusted source. In the system integrator game – the Control Systems Integrator Association (CSIA) is a good choice. A CSIA certified integrator ensures that industries everywhere have access to low-risk, safe and successful automation applications. 

There are other organizations that you can consult as well such as the Robotic Industries Association (if you are looking at a robotics application), as well as partner organizations of companies that may have the right hardware and/or software for your solution. 

The media offers another reputable source of unbiased information. The annual list of SI Giants is released at the end of December with CFE Media’s Global System Integrator Report. The report celebrates recent achievements by highlighting integrators who will make a difference in the years to come. 

#2) Business Health 

It’s important to investigate the business health of a Systems Integrator. How long have they been around? Have they been growing? Do they have a list of customers that will provide a recommendation for a similar solution? Are their customers long-term, or do they have a long list of “one and done” clients? Again, just as you wouldn’t hire a company to do a project in your house that hadn’t done a similar project for someone else, you need to look for experience, depth of industry knowledge, and qualifications they can show you before you engage. 

#3) Bench Strength 

Can the integrator you are considering vertically integrate local offerings to achieve business outcomes and deliver on its promise of outstanding service? Do they have enough people on their team to work on your project in “real-time?” You don’t want to contract with a company only to find out that they can’t really work on your project for six months. To avoid this, you need a company that provides you with a project plan that includes a roadmap to success, regular check-ins and check-offs, and regular communication that keeps you informed and involved. 

As a top 10 Systems Integrator, CONVERGIX Automation Solutions knows what companies are looking for. Being a systems integration giant means we have the capacity, bench strength and resources to solve our customer’s production-related problems. Contact Convergix today – we’re here to help! 

What Innovations Are Advancing Electric Vehicle Manufacturing?

What Innovations Are Advancing Electric Vehicle Manufacturing?

A translucent vehicle with all the electric systems visible

Advancements in automation and sophisticated testing systems are driving innovations of electric vehicle technology and manufacturing

Few industries are as committed to constant innovation as the automotive industry. Every few years, automotive manufacturers rethink and redesign every aspect of the automobile from the ground up. In an industry where marginal improvements yield significant results, OEMs have a lot to gain from investing heavily in machinery that can produce high-caliber results. 

For many years now, the area of automotive manufacturing that has led research and public interest has been electric vehicles—and, by association, autonomous driver technology. These technologies often work hand-in-hand, with cutting-edge electronic vehicles incorporating advanced driver-assistance technology systems, and autonomous vehicles operating on hybrid-electric engines for fuel efficiency. 

At Convergix, we are committed to delivering automated platforms that can take your electric vehicle manufacturing and battery testing to the next level. Whether you are an OEM or a supplier, we can provide the equipment you need to remain at the forefront of automotive innovation. Here are three ways our technology is leading the way. 

#1) Advanced testing for autonomous systems 

Autonomous vehicles rely on two powerful technologies: LIDAR, which scans an environment at high speed and with enough detail to create a dynamic, real-time map of surroundings, even as the vehicle is moving, and AI systems that interpret this input and responds by sending directions to the automobile. 

The safety of any autonomous vehicle is only as good as the sensors powering it. Accordingly, autonomous systems require extensive testing to ensure they are accurately mapping surrounding environments and that they are responding quickly enough to avoid accidents. 

Very few vehicles currently rely on fully autonomous driving. However, more and more vehicles are equipped with assisted driving technology that combines autonomous systems with human control. These assisted technologies include: 

  • Adaptive cruise control 
  • Lane departure warning 
  • Blind spot detection 
  • Collision warning 
  • Pedestrian warning
  • Traffic sign detection 
  • Parking assistance

At Convergix, we provide advanced testing systems for autonomous and assisted driving systems. These test technologies can be incorporated into your production equipment so that you can test at any point in the assembly process to be sure your components meet the high standards required of autonomous systems. 

#2) Testing and assembly for fuel cells and batteries 

Electric vehicles draw their energy from one of two sources: batteries or fuel cells. Batteries store energy and need to be recharged after a certain amount of use; fuel cells generate energy from a chemical reaction—most commonly between hydrogen and oxygen, with water as the byproduct—and, as a result, require refueling to continue operating.

Both of these technologies is currently undergoing extensive research and testing in order to improve them for electric vehicle use. Already, the advances made by these technologies have extended the range of electric vehicles while also reducing the refueling and recharging time. However, there are still major opportunities for improvement, and the EV manufacturers who find the most efficient solution stand to gain significantly in the automobile market.

The technologies we employ during the assembly process for batteries and fuel cells include robotic handling and assembly, and the application of thermal adhesives, catalyst coatings, conductive coatings, and other chemical surface treatments.

We also have advanced testing and verification tools that can be used throughout the assembly process to ensure components meet specification standards.

#3) Factory automation for EV components 

While the components for electric generation and storage power an electric vehicle, they aren’t the only parts required to make an electric vehicle run. An electric vehicle’s drivetrain functions differently all down the line, from the motor, which is composed of both a rotor and a stator, to the inverter, which translates direct current into alternating current, to the drive unit, which communicates driver input from the accelerator to the inverter, thereby controlling speed. 

Every one of these components requires its own processes for production, assembly, and testing. Our facilities can do all this, with both in-line and end-of-line testing as needed. Our assembly and test capabilities for EV drive trains include: 

  • EV motors and test stands 
  • Drive units 
  • Inverters 
  • Hybrid engines 

We thrive off developing advanced solutions for our customers 

The battery equipment we build for electric vehicles is also used in home battery packs, marine applications, consumer products such as headphones and hearing aids. Our automated solutions in this space are also used by the Department of Defense. The advanced testing capabilities we use for autonomous vehicle systems can be applied to other autonomous technologies as well. The assembly techniques we use for EV components are part of the toolkit we use in all our automated factory solutions. 

Most importantly, we bring a mindset of efficiency and innovation to every project. We are always looking for ways to improve our assembly design, by reducing the number of steps required for a full assembly, improving the production quality of components, or shrinking the footprint of the production equipment on the factory floor. 

We are prepared to apply the same dedication to your project. If you are looking for an automation partner to design systems for your factory, contact us. We can discuss your project, our capabilities, and come to a solution that will yield the results you need. 

CONVERGIX Automation Will Attend MD&M West 2025

CONVERGIX Automation Will Attend MD&M West 2025

CONVERGIX Automation Solutions is excited to announce our participation in MD&M West 2025, taking place February 4-6, 2025, at the Anaheim Convention Center in Anaheim, California. We will be exhibiting in the ATX sector of the main floor at Booth #5400. 

MD&M West is the premier event for medical device and manufacturing professionals, bringing together 1,700+ exhibiting suppliers showcasing the latest innovations across four key industry sectors: MedTech, Automation, Design & Manufacturing, and Plastics. With over 13,500+ verified attendees from 52 countries, this event offers unparalleled opportunities for networking, learning, and discovering the latest advancements in the industry. 

At booth #5400, we will share our expertise in automating manufacturing and warehouse processes for the Life Sciences industry. This includes material handling, assembly, testing, machine vision inspection, and more for medical devices and pharmaceutical products. We look forward to discussing how our innovative solutions can help you: 

  • Improve efficiency and productivity: Learn how you can streamline your manufacturing processes to reduce downtime and increase your outputs. 
  • Enhance quality and compliance: Reduce errors and improve product quality with automated systems that ensure accuracy and consistency. 
  • Increase flexibility and scalability: Adapt to changing market demands and easily scale your operations to meet growing production needs.
  • Reduce costs: Minimize labor costs, improve resource utilization, and optimize your overall operational efficiency. 

We invite you to visit us at Booth #5400 to discover how Convergix can support your business goals in the Life Sciences industry. Let’s connect at MD&M West and discuss your specific automation needs. 

MD&M West conference information graphic

Why Attend MD&M West? 

There are several reasons to attend this conference, if you have a business in any of the industries mentioned above. The top reasons include:

  • Cutting-Edge Technology: Discover the latest innovations in robotics, sensors, motion control, and automated systems designed to boost efficiency and meet the growing demand for medical devices and pharmaceuticals. 
  • Industry-Leading Suppliers: Connect with leading suppliers and gain valuable insights into the latest technologies and solutions available for your specific needs. 
  • Expert Education: Participate in 100+ educational sessions, including conferences, workshops, and theater presentations, to expand your knowledge and gain valuable insights from industry experts. 
  • Networking Opportunities: Connect with industry peers, build relationships, and explore potential collaborations. 
  • Manufacturing Excellence: Gain valuable insights into best practices for optimizing your manufacturing processes, improving efficiency, and reducing costs. 
How Factory Automation Supports the Medical Device Industry

How Factory Automation Supports the Medical Device Industry

Advanced Medical Printer Producing Artificial Heart Valves with Biopolymers.

Medical devices are subject to strict regulations and high-quality control standards. Automation can help.

The healthcare industry is among the most highly advanced manufacturing fields in the world, with tight controls and restrictions governing the development and production of medical devices at every stage. At the same time, researchers and developers in the healthcare industry benefit from manufacturing solutions that are flexible, reliable, and innovative.

The tension in the healthcare industry between innovation and regulation has historically been difficult to balance. However, factory automation offers a resolution to some of these competing priorities by helping medical device manufacturers produce cutting-edge products that meet even the most stringent industry requirements. Here’s how:

1. Automation offers advanced quality control measures

Quality control is important in every industry, but in healthcare, the consequences of a flawed device can be dire. As such, advanced quality control measures are even more important.

Automation already directly benefits production quality by enhancing standardization and removing opportunities for human error. A human operator on an assembly line will have limits to their consistency. Some inconsistencies may not have significant impacts, but others might be flaws in themselves or lead to flaws further down the production line. Automation is not only more consistent than manual production but can be optimized to a more precise tolerance level than what human workers can achieve.

Given the quality benefits of automation in the manufacturing process, it’s only natural to apply these same processes to testing and inspection. Traditional quality control measures have used mistake-proofing techniques to prevent defects as they occur. Modern methods, such as vision technology and advanced sensors, expand the range of quality testing a company can incorporate directly into the production lines.

2. Advanced robotics help manufacturers keep their operations flexible

Stationary automated assembly lines have long been the standard for many high-volume manufacturers, but the downside of these assemblies is that the specialized equipment cannot easily be switched over to new uses if a production technique changes, or if market demand suddenly shifts. Given the myriad supply chain disruptions, industries around the world have faced since the onset of the Covid-19 pandemic, manufacturing flexibility is a growing priority in some sectors.

Modern robots offer a compelling solution. With a range of effectors that can be rapidly switched during an assembly, a single robot can perform numerous operations repeatedly and consistently. Programming robots has also become more user-friendly, with some interfaces allowing an operator to easily reprogram a robot with the push of a few buttons.

This means that robots are now able to work alongside human operators, assisting in routine tasks both on the factory floor and in other work settings.

3. Manufacturing consistency helps devices meet FDA approval

While flexibility around production can help manufacturers change gears in a pinch, consistency also has its benefits. Medical devices must meet various levels of FDA approval, with entirely novel devices requiring a higher standard and longer approval process than those that are similar to devices already being produced.

If a proven production process is used to produce components of a new device, this similarity works in the manufacturer’s favor. In this way, a consistent production process not only means more reliable quality control but also a faster approval process.

4. High-mix, low-volume (HMLV) production allows for customization

While some medical devices are suited for production by the millions, others are complex enough that a manufacturer may only receive orders in the hundreds or thousands. For these devices, which have a high variety of components, manufacturers benefit from sophisticated automated solutions, such as those that can be provided by the latest high-end robots.

Similarly, some medical devices need to be customized for the patient. These are the kinds of extremely low-volume products that have typically eluded automation.

5. Production tracking helps businesses meet compliance standards

Some medical devices require manufacturers to be able to trace the production process of individual components through each stage of the automated assembly line. This is especially true for a device that might be implanted within a human body, like a pacemaker. If there ends up being a fault with the device, then it is essential that this flaw can be traced back to its point of origin, so that any other faulty devices can be identified.

Factory automation will fuel advances in the medical device technology of the future

Automation has already revolutionized the medical device industry, but Industry 4.0 promises to bring even more change. Advanced simulations will give device manufacturers innovative ways to model their assemblies; IIoT and Big Data will provide new tracking tools and deeper insights into production methods, and augmented reality will transform how operators interact with equipment. 

At CONVERGIX Automation Solutions, our expertise in the healthcare industry means we know how to meet class 10,000 cleanroom standards, GAMP regulations, and FDA regulations. Our team can work with your business to provide expert guidance in the development of automated assemblies for medical devices. Contact us today to learn more.