For IIoT implementations, one of the first hurdles is at the point where it all starts – the collection of data from the machines, instruments and sensors. (Also, it can be said to end here – with control of actuators and machines!) Most of the machines, especially in small and medium manufacturing enterprises, are not IoT capable yet. Thanks to the previous industrial automation revolution those are equipped with sensors and even programmable devices in the form of Programmable Logic Controllers (PLCs). However, these are still mostly stand-alone setups with zero to local-only connectivity. The Distributed Control Systems (DCS) and Supervisory Control and Data Acquisition (SCADA) systems could be interconnected to form a larger network. But such systems cover only a single plant or factory with no capability to exchange data with the external world. Their integration with the IoT world requires external hardware and software, like a gateway.

Completely replacing such legacy systems with the new age network-enabled systems could be the fastest way to adopt industrial IoT. But the cost and efforts associated with this would be a strong deterrent for widespread adoption. A cheaper and more acceptable approach would be to either upgrade such machines for IoT connectivity or device intermediate mechanisms (like gateways) that could facilitate indirect integration with the IoT world.