Pioneering Digital Transformation in Stainless Steel Manufacturing

Discover how our client, a global leader in stainless-steel manufacturing, faced the challenge of staying competitive in an increasingly digital world. Their existing network infrastructure was isolated and lacked centralized management, leading to operational inefficiencies and potential security vulnerabilities. Velocis, provided expertise in IT-OT convergence and cybersecurity to help them overcome these challenges.

Industry 4.0


  • Advanced Networking Infrastructure: Implemented a state-of-the-art converged IT-OT network infrastructure, leveraging Cisco's industrial-grade switches and routers for reliable and secure connectivity.
  • Seamless IT-OT Integration: Achieved harmonized network environment by converging Information Technology (IT) and Operational Technology (OT), facilitating real-time data exchange and analytics for improved decision-making and operational efficiency.
  • Enhanced Security Posture: Fortified the manufacturing plant's defenses by segmenting networks using the Purdue Model and establishing an Industrial Demilitarized Zone (IDMZ), ensuring compliance with industry standards and safeguarding against cyber threats.


As a global leader in the stainless-steel industry, our client is committed to driving innovation and maintaining a competitive edge in the market.  

Their latest initiative involves the integration of Industry 4.0 principles within their state-of-the-art stainless-steel plant, aimed at enhancing operational efficiency, elevating productivity, and strengthening their market position.

Challenges and Requirements

Their primary objective was to develop a cohesive network infrastructure that seamlessly integrates Information Technology (IT) and Operational Technology (OT). Key requirements included:

  • Industrial Automation and Control Systems (IACS): A robust OT network to support IACS, enabling seamless connectivity and control of manufacturing processes.
  • Performance and Reliability: Ensuring high performance and reliability across the network infrastructure to support demanding industrial workloads without interruptions.
  • Secure Connectivity to Business Systems: Maintaining secure and reliable connectivity between OT systems and business applications, facilitating real-time data exchange while safeguarding against cyber threats.
  • Monitoring and Incident Response: Implementing proactive monitoring capabilities and establishing swift incident response mechanisms to minimize downtime and operational disruptions.

By addressing these needs, the client aimed to create a unified network environment that drives operational excellence while enforcing stringent security measures against cyber threats.

Existing Challenges

  • Isolation and Flat Network Topology: Existing networks, created by multiple machine builders, were isolated and flat, leading to vulnerabilities and complexity due to duplicated IP addresses and lack of network segmentation.
  • Lack of Centralized Network Management: Absence of centralized management for the converged IT-OT network, resulting in disjointed control and visibility over the network infrastructure, hindering efficient operations and proactive issue resolution.
  • Reactive Issue Resolution: The current approach to issue resolution was reactive, addressing problems only after they occurred, leading to unplanned downtime and operational delays, negatively impacting productivity and efficiency.


Velocis crafted a comprehensive solution that addressed our client's requirements while future-proofing their operations for continued growth and innovation. The key components of our solution included:

  • Converged IT-OT Network Infrastructure: Implemented a robust network backbone using Cisco's industrial-grade switches, ensuring reliable and high-performance connectivity for IACS applications.
  • Network Segmentation with IDMZ: Adopted the Purdue Model for network segmentation, establishing an Industrial Demilitarized Zone (IDMZ) as a secure buffer between IT and OT networks, enabling controlled data exchange while safeguarding critical systems.
  • Resilient Network Design: Deployed a Resilient Ethernet Protocol (REP) ring topology, providing rapid recovery from network outages and ensuring high availability for continuous manufacturing operations.
  • Static Network Address Translation (NAT): Implemented 1:1 static NAT to resolve IP address conflicts, preserving existing IACS IP schemas and simplifying network architecture without extensive device reconfiguration.
  • Centralized Network Management: Implemented a centralized management system for comprehensive visibility and control over the converged network infrastructure, enabling proactive monitoring and streamlined operations.

By leveraging Cisco's industry-leading networking solutions, Velocis delivered a future-ready infrastructure that not only addressed our client's immediate needs but also positioned them for long-term success in the digital manufacturing landscape.

Business Outcomes

The successful implementation of our solution unlocked numerous benefits within our client's stainless-steel manufacturing operations:

  • Enhanced Operational Efficiency: By mitigating IP conflicts, implementing a resilient REP ring topology, and centralizing network management, the solution has significantly reduced system downtime and optimized resource utilization, leading to improved overall operational efficiency.
  • Increased Productivity: The industrial-grade network infrastructure, coupled with ultra-low latency communication for IACS applications, ensures uninterrupted operations and real-time process control, translating into higher productivity levels across the plant.
  • Robust Security Posture: The implementation of the Purdue Model for network segmentation, along with the secure IDMZ, has fortified the plant's cybersecurity defenses, reducing the risk of cyber threats and ensuring compliance with industry regulations.
  • Scalability for Future Growth: The modular and scalable network design accommodates future expansions, new machinery, and evolving operational requirements, providing a foundation for sustainable growth and innovation.
  • Competitive Advantage: By embracing Industry 4.0 principles and leveraging advanced networking solutions, our client has positioned themselves as a technological leader in the stainless-steel industry, outpacing competitors and solidifying their market position.
  • Data-Driven Decision-Making: The converged IT-OT network infrastructure provides comprehensive visibility into operations, enabling data-driven decision-making and continuous process optimization, further driving efficiency and productivity gains.

These outcomes collectively contribute to the client's long-term sustainability and success, aligning with their strategic goals of integrating Industry 4.0 principles to achieve high efficiency, productivity, and competitiveness.

Industry 4.0

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