Industry 4.0 gets talked about like it is one big thing. In practice, it is a data pipeline. Sensors generate readings. Gateways process them. Cloud platforms store and analyze them. Dashboards surface them. Automation acts on them.
If you are building the software layer for any of this, what matters is understanding how data flows through each stage because that is where the architecture decisions live.
The Six Stages of Factory Data Flow
1. Data Collection
Everything starts at the machine. Sensors capture temperature, vibration, pressure, runtime, energy consumption, cycle time, and production count. PLCs and industrial controllers share machine-level state.
A vibration sensor on a motor picks up early signs of bearing wear weeks before a human notices anything. An energy meter flags that one machine is drawing 30% more power than the identical unit next to it. This is raw operational data with high volume, high frequency, and mostly useless until it moves somewhere it can be processed.
2. Connectivity
Data needs to leave the machine and enter a digital system. This is where protocol selection matters.
Machine-level → Modbus, OPC UA, Profinet
Lightweight IoT → MQTT (pub/sub over TCP)
Long-range → LoRaWAN, NB-IoT
Factory network → Ethernet/IP, Wi-Fi, 5G
MQTT handles most cloud-bound telemetry. OPC UA handles machine-to-machine interoperability. Modbus is still everywhere in legacy equipment. Most factories run at least two protocols simultaneously because the equipment spans decades of technology.
3. Edge Processing
Not everything needs to travel to the cloud. Latency-sensitive decisions happen at the edge.
An edge gateway sitting next to a production line filters noise, aggregates readings, and triggers local actions. If a motor's temperature crosses a safety threshold, the edge system reacts in milliseconds; it does not wait for a round trip to a cloud server.
if sensor_reading["temperature"] > SAFETY_THRESHOLD:
trigger_local_alert("motor_01", "overheating")
send_to_cloud(sensor_reading)
else:
aggregate_and_batch(sensor_reading) # send every 60s
Edge processing also reduces cloud costs. Instead of streaming every raw reading at one-second intervals, the edge batches and compresses, sending summaries rather than firehoses.
4. Cloud Platform
The cloud handles storage, historical analysis, cross-site comparison, and heavy computation.
Time-series databases store machine telemetry. Analytics engines run trend analysis. AI models trained on historical data predict failures before they happen. Multi-plant manufacturers use the cloud layer to compare OEE (Overall Equipment Effectiveness), downtime, and energy usage across locations from a single view.
This is also where factory data connects outward into ERP, MES, maintenance systems, and mobile applications.
5. Dashboards and Alerts
Dashboards turn data into decisions. Operators see live machine status. Maintenance teams see equipment health trends. Plant managers track OEE, downtime, and energy across shifts.
Alerts make it actionable. A vibration spike triggers maintenance notifications. An energy anomaly flags a possible fault. A quality deviation pauses the line for inspection.
The difference between a factory that reacts to breakdowns and one that prevents them is usually this layer at the speed at which the right person sees the right data.
6. Automation and Workflow Actions
The final stage closes the loop. When conditions are met, the system acts without waiting for a human.
Create a maintenance ticket automatically. Notify the supervisor. Adjust process parameters. Stop a machine when safety limits are breached. Update ERP records. Send shift reports to plant managers.
This is where Industry 4.0 stops being a monitoring project and starts being an operational system.
Why the Architecture Matters More Than the Buzzword
Industry 4.0 is a label. What matters is the data pipeline underneath it how reliably data moves from machine to cloud, how fast the edge responds, how well your protocols handle legacy equipment alongside modern sensors, and whether your automation layer can act on what the data reveals.
Get the pipeline right, and the buzzword takes care of itself.
This post focused on the data pipeline, one piece of the industry 4.0 picture. For the full breakdown covering core technologies, real-world use cases, and a practical implementation roadmap, the Industry 4.0 and IoT guide on Promeraki covers the complete picture.
What does your factory data pipeline look like, and which stage gave you the most trouble to get, right?
