iShield Solutions Series, Enterprise Operations (ERP) · Manufacturing
Manufacturing & Asset Performance
Design, Make and Maintain from One Model, with the Plant's Technology Protected
Manufacturing & Asset Performance runs design, planning, execution, maintenance and quality on iShield One from one revision-controlled model, while iShield Nexus keeps the plant's technology assets recorded, protected and ready for a major disruption.
MES, EAM, quality and PLM with OT bridge — one model from design to plant-floor execution.
Who leads, who contributes
- LeadiShield One
- ContributoriShield Nexus
- ContributoriShield Link
Product lifecycle, material planning, manufacturing execution, enterprise asset and plant maintenance, and quality.
The enterprise challenge
The production loop and the technology loop meet at the machine.
Manufacturers run two loops that rarely talk. The production loop — design, plan, make, maintain, improve — lives in manufacturing and maintenance systems. The technology loop — the servers, networks and gateways the plant depends on — lives with IT and security teams.
When a controller fails, a gateway is compromised or a line stops, both loops are needed at once. Connecting them through the plant asset they share lets maintenance, security and command act on the same facts.
Where iShield Nexus contributes
iShield Nexus contributes technology asset records, security operations and crisis command for plant technology (Asset Management, Security Operations, Crisis Management). iShield One leads manufacturing; iShield Link bridges the plant floor.
The Nexus angle
Plant technology assets need security and crisis readiness.
- Technology services and controls are managed apart from the business process
- Evidence and ownership are fragmented
Solution overview. Run discrete and process manufacturing on iShield One — MRP, MES, Plant Maintenance, EAM, Quality and PLM — with the iShield Link OT Bridge speaking OPC-UA, MQTT and Modbus. Nexus SecOps applies Purdue-zone guardrails.
Buyer challenges
Revisions that drift
A design change reaches the plant floor late, so material is planned and work is executed against an old revision.
Maintenance by calendar
Assets are serviced on fixed intervals rather than on their condition, because plant telemetry is not connected to maintenance.
Plant technology off the record
Servers, network switches and gateways on the plant floor are missing from the technology asset record, so vulnerabilities go unseen.
Disruption without command
When a line stops for a technology reason, production, maintenance and IT each run their own response.
Decision owners
- Plant manager
- Production priorities and when a line stops or restarts.
- Maintenance lead
- Maintenance strategy per asset — preventive, predictive or condition-based.
- Quality manager
- Disposition of quality deviations and corrective action.
- OT and IT security lead
- How plant technology is protected and when a security event becomes a crisis.
Who leads, who contributes, and where each stops
This is a cross-product solution. Each platform keeps its own responsibility and boundary; none is presented as a module of another.
- iShield OneLead
Owns
Product lifecycle, material planning, manufacturing execution, enterprise asset and plant maintenance, and quality.
Boundary
Does not hold the IT record of plant servers and networks or run security operations.
- iShield NexusContributor
Owns
Technology asset records for plant IT, security incident and vulnerability handling, and crisis command for major disruptions.
Boundary
Does not plan production or maintain machines.
- iShield LinkContributor
Owns
Plant-floor connectivity through the OT Bridge, and OEE and quality pattern agents, as listed in the composition.
Boundary
Moves and normalizes signals; it does not decide maintenance or quality actions.
Module responsibilities
| Module | Platform | Responsibility in this solution | Hands on |
|---|---|---|---|
| Asset Management | iShield Nexus | Records plant technology assets and their relationships to services. | Technology asset records |
| Security Operations | iShield Nexus | Handles security incidents and vulnerabilities on plant technology. | Security incidents and remediation tasks |
| Crisis Management | iShield Nexus | Commands major disruptions across production, maintenance and IT. | Crisis decisions and communications |
Published composition, by owning platform
The modules in the solution's published composition, grouped by the platform that owns them.
iShield One
Why this composition
OEE, predictive maintenance and quality investigations all need the same asset and PLM context. Run MES, EAM, Quality and PLM together and the same revision-controlled BOM drives execution, maintenance triggers and CAPA — closed-loop across IT and OT.
Cross-platform journey
Two loops, one plant asset between them
Follow a production asset through both loops. The production loop on the left is led by iShield One; the technology loop on the right is supported by iShield Nexus. They meet at the asset.
- Design to plan · Product Lifecycle Management · MRP iShield One
- Make · Manufacturing Execution iShield One
- Sense · OT Bridge · OEE Anomaly Agent iShield Link
- Maintain · EAM & Plant Maintenance iShield One
- Improve quality · Quality (SPC, NCR, CAPA) iShield One
- Record the technology · Asset Management iShield Nexus
- Protect · Security Operations iShield Nexus
- Command · Crisis Management iShield Nexus
Stage 1 of 8 · iShield One Design to plan
Product Lifecycle Management · MRP
A released revision drives material planning and the work orders that follow.
- Decision
- Engineering releases the revision.
- Exception path
- A change to a released revision triggers a change order.
- Recorded as
- Released revision and planned orders
Next: Make in Manufacturing Execution (iShield One)
This journey shows how responsibilities are intended to divide between the platforms. It describes an operating model, not a pre-built integration between them.
Decisions, exceptions and who owns them
Incident and crisis decisions are logged.
| Decision | Accountable owner | Evidence recorded | Exception path |
|---|---|---|---|
| Release a revision | Engineering | Change order and released revision | Open work on the old revision is reviewed before release. |
| Choose a maintenance strategy | Maintenance lead | Asset criticality and condition history | Emergency work is recorded against the asset. |
| Accept a plant security risk | Risk owner | Exception with compensating measures and expiry | Expired exceptions return for decision. |
| Declare a crisis | Crisis lead | Situation and impact on the decision log | Stand-down is logged with its reason. |
How plant security obligations are handled
Plant security requirements and zoning are defined by the organization's OT and IT security owners. Nexus records the technology assets, incidents, vulnerabilities and exceptions against those requirements; no industrial security mapping is pre-built.
- Security exceptions name the requirement they depart from, their owner and expiry.
- Crisis decisions and communications are kept on the decision log.
- Applicability of industrial security standards is decided by the security owner.
Regulatory context
Regulations and frameworks organizations in this domain commonly work with. Listed as context for planning, not as a certification, attestation or pre-built mapping.
Recognized practice behind the operating model
Mappings describe how the operating model aligns with recognized practice. They are not attestations or certifications.
On the Nexus side, technology asset records follow ISO/IEC 19770-1 and crisis command follows ISO 22320, both mapped on accepted module pages.
| Framework | Practice | How the solution operates | Relationship |
|---|---|---|---|
| ISO/IEC 19770-1:2017 | IT asset management system | Plant technology assets are recorded with ownership and lifecycle.Mapped on the accepted Asset Management page. | Aligned practice |
| ISO 22320:2018 | Emergency management — command and control | Major disruptions are commanded with roles, a decision log and communications.Mapped on the accepted Crisis Management page. | Aligned practice |
Intelligence in explicit modes, by platform
Nexus AI capabilities assist the people involved; decisions remain with accountable owners.
- Assistance drafts, answers or summarizes
- Recommendation proposes for a person to accept
- Predictive anticipates or flags
- Workflow-triggered runs only as configured and approved
Exposure prioritization
RecommendationRanks vulnerabilities on plant technology with business context.
Security Operations — Exposure prioritizationSituation summaries
AssistanceCondenses updates for incoming crisis leaders.
Crisis Management — Situation summaries
What changes for the organization
Outcomes are described qualitatively. Figures are published only once evidenced.
One revision on the floor
Plans and work orders follow the released design.
Maintenance by condition
Plant signals inform when an asset is serviced.
Plant technology on the record
The devices the line depends on are known, owned and patched.
One command when the line stops
Production, maintenance and IT act under one command and decision log.
What sets this solution apart
Security with production in mind
Remediation that cannot fit a production window becomes an owned, time-bound exception.
Command across teams
A single crisis structure brings production, maintenance and IT together.
Delivery and industry context
Planning information carried over from the solution record.
30 / 60 / 90-day value plan
Days 0–30 — Foundation
Stand up the iShield workspace, integrate sources of truth, ingest baseline data.
- Tenant provisioned in chosen region (KSA / UAE / EU / US)
- SSO + RBAC mapped to enterprise identity (Entra ID / Okta)
- Top 5 integrations connected and reconciled
- Baseline KPIs measured before any change
Days 31–60 — Activation
Turn on automation, AI agents and guardrails for the priority value stream.
- Workflows live for the top 3 use cases
- Link AI agents enabled with explicit guardrails and approvals
- Power-user enablement and admin training complete
- First measurable KPI improvement vs baseline
Days 61–90 — Scale
Industrialize, roll out to additional teams, prove ROI to the steering committee.
- Solution rolled out to additional business units / geos
- Executive dashboard with target vs actual outcomes
- Continuous improvement backlog established
- Signed ROI memo and renewal / expansion plan
Personas served
Illustrative industry scenarios
Representative situations by industry. Regulations named here are context, not certifications or commitments.
Oil & Gas (Upstream)
API 1164 OT segmentation, predictive maintenance on rotating equipment, OPC-UA to ERP work-order automation.
Discrete Manufacturing
MES + PLM revision-controlled BOMs driving MRP; OEE anomalies routed to engineering with CAPA closure.
Utilities (Power, Water)
EAM lifecycle for substation / treatment-plant assets with NCA OTCC-1:2022 segmentation and crisis bridge to SOC.
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