Industry 4.0 and smart manufacturing are driving the manufacturing industry to modernize their software infrastructure. The current infrastructure is costly to maintain, creates barriers to sharing data, difficult to integrate with other systems and is limiting corporations to new opportunities promised by Industry 4.0. A key challenge to modernizing a manufacturing infrastructure is how do you integrate old existing systems with new modern systems. Apache Kafka and MQTT are unique positioned to provide the core technology to enable modernization of the manufacturing industry. This presentation will look at the unique business drivers for modernizing the manufacturing industry and how MQTT and Kafka can help make it a reality.

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MODERNIZING THE
MANUFACTURING
INDUSTRY WITH
& MQTT
Dominik Obermaier
CTO and Co-Founder
HiveMQ

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WELCOME
Insert
Picture
• HiveMQ CTO & co-founder
• Strong background in distributed and large scale
systems architecture
• OASIS MQTT TC Member
• Author of „The Technical Foundations of IoT“
• Conference Speaker and Author
• Program committee member for German and
international (I)IoT conferences
• University Lecturer
Dominik
Obermaier
@dobermai
linkedin.com/in/dobermai/

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Smart Sensors
Cloud Computing
Automation
INDUSTRY
Cybersecurity
Future of Manufacturing
Advanced
Analytics AI / ML

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Business Drivers
• Improve factory efficiency
• Optimize intra plant logistics
• More flexible manufacturing
• Measure and Increase OEE ¹:
• Increase availability of our equipment by avoiding
non-planned standstill
• Analyze and increase quality
• Tune the performance of our machines and processes
¹overall equipment effectiveness

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Current Situation

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Brownfield vs. Greenfield

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Lots of Data Silos

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IT / OT Clash

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Manual Interaction with OT Software

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Difficult to Scale / Hours of Downtime

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Goals for Modernization
• More agile software delivery into factories
• Faster mean time to recover
• Enable centralized command and control
• Enable visualization of overall
manufacturing process
• Consistent and Flexible software
architecture

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Integrated Automation
Consistent and
reliable
bidirectional
movement of
data
Level 4 - Corp
Business Planning
& Logistics
Level 3 - Op. Mgmt Level
Manufacturing Operations
Management
Level 2 - Process Mgmt Level
Monitoring & Supervising
Level 1 - Control Level
Sensing & Manipulating
Level 0 - Field Level
Production Process
Months
Days
Hours
Minutes
Seconds
us/ms
ERP
MES
SCADA/HMI
PLC
Sensors /
Signals
Consistent and reliable bidirectional
movement of data

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MES Systems
Manufacturing
Area
Level 2-3
SCADA Systems
Connecting the Factory: Intra-factory
Cloud
Level 4
Automation
Area
Smart Sensors
Machines
Level 0-1
Gateway
Factory
Area
Level 3-4
SAP
PLM
OEE

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Connecting: Inter-Factory
Factory 1
Enterprise Data Center
Data Analytics
Service
Machine Learning
Service
Data Lake
Factory 2
Factory 3 Factory 4
Factory 5
Factory 6

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Consuming Applications:
Data Warehouse,
Analytics Tools,
Reporting, Monitoring
Application Area
Cloud Connector
Smart Sensors
Power, Consumption,
Vibrations, Temperature,
Humidity…
IIoT Area
Automation
Area
Automation
Sensors
PLS/STS
IIoT MQTT Broker
Factory IoT Bus

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Technical Challenges
● Reliable bi-directional connectivity across
all levels of automation
● Consistent data messaging across all
areas
● Security becomes very important when
things are connected
● Lots of different hardware suppliers with
non-standard protocols and platforms

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Ubiquitous connectivity
Globally scalable
platform for all event
producers and
consumers
Immediate data access
Data accessible to all
consumers in real time
Single system of record
Persistent storage to
enable reprocessing of
past events
Continuous queries
Stream processing
capabilities for in-line
data transformation
Microservices
DBs
SaaS apps
Mobile
Customer 360
Real-time
fraud
detection
Data
warehouse
Producers
Consumers
Database
change
Microservices
events
SaaS
data
Customer
experiences
Streams of real time events
Stream processing
apps
Introducing Kafka
Source: Best Practices for Streaming IoT Data with MQTT and Apache Kafka; © Confluent

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Confluent Platform
Operations and Security
Development & Stream Processing
Support,Services,Training&
Partners
Apache Kafka
Security plugins | Role-Based Access Control
Control Center | Replicator | Auto Data Balancer | Operator
Connectors
Clients | REST Proxy
MQTT Proxy | Schema Registry
KSQL
Connect Continuous Commit Log Streams
Complete Event
Streaming Platform
Mission-critical
Reliability
Freedom of Choice
Datacenter Public Cloud Confluent Cloud
Self-Managed Software Fully-Managed Service
Source: Best Practices for Streaming IoT Data with MQTT and Apache Kafka; © Confluent
Introducing Confluent Platform

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A Piece of the Puzzle is Still Needed

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What is MQTT?
● IoT messaging protocol
● Publish/subscribe
● Minimal overhead for client and bandwidth
● Designed for reliable communications over
unreliable channels
● 3 Quality of Service (QoS) levels
● MQTT 5 is required for IIoT
Introducing MQTT

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Publish / Subscribe Pattern

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Connecting the Factory

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MES Systems
Manufacturing
Area
Level 2-3
SCADA Systems
Connecting the Factory: Intra-factory
Cloud
Level 4
Automation
Area
Smart Sensors
Machines
Level 0-1
Gateway
Factory
Area
Level 3-4
SAP
PLM
OEE

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Connecting the Factory: Intra-factory
MQTT
● Bi-directional messaging
● Lightweight protocol suited for
constrained machinery
● PLC providers support MQTT (e.g.
Siemens S7)
● Most MES support MQTT
MES Systems
Manufacturing
Area
Level 2-3
SCADA Systems
MQTT
MQTT
Automation
Area
Smart Sensors
Machines
Level 0-1
Gateway
MQTT

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Connecting the Factory: Intra-factory
MES Systems
Manufacturing
Area
Level 2-3
SCADA Systems
MQTT
MQTT
Kafka and MQTT
Automation
Area
Smart Sensors
Machines
Level 0-1
Gateway
MQTT
MQTT
&
MQTT
&
MQTT
&
Factory
Area
Level 3-4
SAP
PLM
OEE

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Connecting the Factory: Intra-factory
Factory
Area
Level 3-4
SAP
PLM
OEE
MQTT
MQTT
Cloud
Level 4
Automation
Area
Smart Sensors
Machines
Level 0-1
Gateway
MQTT
MQTT
&
MQTT
&
MES Systems
Manufacturing
Area
Level 2-3
SCADA Systems
MQTT
&
MQTT
&
MQTT
&

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Connecting the Factory: Intra-factory
MQTT
MQTT
MQTT
&
MQTT
&
Cloud
Level 4
IIoT Telemetry MQTT Broker
MQTT
MQTT
Automation
Area
Smart Sensors
Machines
Level 0-1
Gateway
MQTT MES Systems
Manufacturing
Area
Level 2-3
SCADA Systems
MQTT
&
Factory
Area
Level 3-4
SAP
PLM
OEE
MQTT
&
MQTT
&

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Connecting: Inter-Factory
Factory 1
Enterprise Data Center
Data Analytics
Service
Machine Learning
Service
Data Lake
Factory 2
Factory 3 Factory 4
Factory 5
Factory 6

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Connecting: Inter-Factory
Factory 1
Gateway MES System
MQTT
● Secure
communication over
public Internet
● High Availability
● Security
● Scalability
MQTT
MQTT
MQTT MQTT
MQTT
MQTT
Factory 1
Factory 2
Factory 3 Factory 4
Factory 5
Factory 6
Enterprise Data Center
Data Analytics
Service
Machine Learning
Service
Data Lake
MQTT
Broker

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Connecting: Inter-Factory
Kafka + MQTT
● Need first class native
integration between
MQTT + Kafka
Enterprise Data Center
Data Analytics Service Machine Learning Service Data Lake
MQTT Broker
MQTT Broker
MQTT Broker
MQTT Broker
Cluster

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Implementation Options

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Implementation Options
Command Line
Interface

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HiveMQ Broker
● Clustering for High Availability
● Scalability to support high
throughput and connections
● Security integration with existing
authentication and authorization
systems
● Observability through HiveMQ
Control Center
● Support for MQTT 5

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Our Customers Are…
…and more
• Building new digital products
• Improving customer experience
• Creating more efficient operations and
insights
• Connecting factories
...and more

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HiveMQ Kafka Advantage
• Bidirectional messaging between IoT devices and
Kafka
• Scales to millions of IoT devices
• Full support for MQTT 5 standard
• Reliable connection and messaging for IoT device
• Seamless integration with Confluent
Platform/Confluent Cloud
• Schema Registry
• RBAC

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HiveMQ Kafka Solution

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HiveMQ Enterprise Extension for Kafka
Seamless and scalable
integration of MQTT data streams
between millions of IoT devices
and multiple Kafka clusters
Connectivity and
Messaging Platform
Event and Data
Streaming Platform

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THANK
YOU
Dominik Obermaier
@dobermai
linkedin.com/in/dobermai/
dominik.obermaier@hivemq.com
Contact

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Additional Resources?
● Blog: Bidirectional IoT Messaging between MQTT and Apache Kafka
● Blog: HiveMQ & Apache Kafka: Streaming IoT Data and MQTT Messages
● Whitepaper: Reference Architecture for VDA 5050
● Webinar: Best Practices for Streaming IoT Data with MQTT and Apache Kafka
● Presentation: MQTT as a Key Technology for Industry 4.0 & IIoT