This case study describes the integration of hardware and software with existing factory lines and process systems to avoid downtime. Additionally, a new network was needed to comply with government standards for healthcare pharmaceutical production It was a priority to ensure that the new network is secure and connect to #SD-WAN, allowing multiple services to run in tandem and being segregated for security. Learn more at www.polestarinteractive.com Over the project, we provided an industrial network that is secure by design and redundant for serialisation compliance, meeting the latest security requirements, complying with industry standards, and granting continuous access to production at all levels.

1. Designing Smarter
Factories
Industrial Networking Systems
Secure Integration
A Polestar | Cisco Case Study
Customer:
Pharmaceuticals & FMCG
Industry:
Healthcare | Pharmaceutical
Manufacturing Line.
Solution:
Secure Industrial Network
Implementation and UCS
deployment
Location: Nottingham, U.K.
© COPYRIGHT 2020. POLESTAR | CISCO
ALL RIGHTS RESERVED
The customer required the integration of hardware and
software with existing factory lines and process systems
to avoid downtime. Additionally, a new network was
needed to comply with government standards for
healthcare & pharmaceutical production. It was a priority
to ensure that the new network is secure and connect to
SD-WAN, allowing multiple services to run in tandem and
being segregated for security.
Integrated Legacy
Networks
In digital service resiliency
through compute infrastructure
modernization.
With regulations for healthcare
& pharmaceutical production.
Reducing risks, complexity, and
improving overall security and
operating uptime.
IN PARTNERSHIP WITH
ROUTECO & ANTARES
Government
Compliance
70% Improvement

2. The Customer is a +40,000 employees
corporation, famous for manufacturing
hygiene, health, and home products
across more than 45 facilities.
It operates through the Health & Home
segments, focusing on nutrition, health
relief & hygiene. To be a leader in its
market, the group set the goal of
becoming a global health manufacturing
organization. This requires enhanced
resources and quality, greater
investment behind technology and
compliance, and direct communications
between operations and the C-Suite
level executives, especially its EVP of
Supply.
Additionally, Health & Hygiene product
manufacturing is under strict
government regulations in order to
guarantee good/ethical practices and to
comply with strict quality standards.
Digital transformation plays a major role
in meeting these requirements.
Production is enhanced through the
integration of hardware and software
with existing factory lines and process
systems, allowing greater compliance.
Solution Brief. Continuous and stable
connections are crucial for assuring
operating performance and achieving
quality standards.
To enhance communication, protect
plant assets and guarantee production
integrity, the client sought to work with
Polestar’s suite of industrial security
products, technologies, and services,
along with the following partners:
1. Polestar: Project Management &
Consultancy. Industrial
Networking Systems secure
implementation between factory
floor and ERP. Selection of
compatible hardware with the
software app.
2. Cisco: Hardware vendor
contributing to initial design work
and consultancy.
3. Routeco: Provision of hardware
and logistics.
4. Antares: Software App applied to
infrastructure, which was installed
by Polestar.
Cisco’s.UCS (Unified Computing System) help manufacturing businesses to achieve the
consistency, availability and performance they need through a modern, end-to-end tech
infrastructure that is self-monitoring, self-analyzing, and self-optimizing. Implementing secure by
design architectures and infrastructure is critical to improve resiliency and ensure high-
availability.
Connecting Manufacturing Lines to Cisco’s UCS
through Secure Industrial Networking Systems
2.
POLESTAR | CISCO © 2020. ALL RIGHTS RESERVED

3. Business Challenge
The client was seeking to drive
operational improvements into their
production systems and assets through
digitization and Industry 4.0 systems.
However, IIoT initiatives require
securely connected production
environments allowing business
partners access to real-time visibility,
rich data streams, and remote control of
systems and assets.
In addition, the U.K. government applies
strict controls to ensure that healthcare
and hygiene products meet applicable
standards of safety, quality, and
efficacy, not only during production but
also across the whole supply chain.
Secure and stable data access and
visibility are important to IIoT and
Industry 4.0 initiatives, especially when
seeking to continuously improve
efficiency, quality, decrease costs, and
increase overall equipment
effectiveness.
These are only accessible through
secure industrial connections, which are
necessary to enabling predictive
maintenance, real-time quality
monitoring, asset tracking, and safety
enhancements. This way it is enabled to
achieve efficiency goals and meet
government regulations and standards.
3.
Case Study
BROWNFIELD IMPLEMENTATION | Secure Industrial Networking Systems Integration.
Finally, the brownfield facility accounted
for several legacy systems, which
represented a security risk for the
discovery of assets in OT environments.
These old systems are also inflexible
and complex, which constitutes an
obstacle for operational efficiency.
Such challenges require complete
computing systems and security
solutions that can be built for the needs
of the management, operations, quality,
IT, and OT teams.
The company understood the need for
an IIoT service to help bridge the gaps
between different areas while achieving
the following goals:
1. Delivery of production visibility on
the network and allowing a
centralized view of network activity,
ensuring quality standards and
efficiency.
2. Enabling security policies and
traceability.
POLESTAR | CISCO © 2020. ALL RIGHTS RESERVED

4. Our Solution
4.
Project Architecture
• Cisco TrustSec & IND: Software-
defined (SD) network segmentation to
protect business assets. The IND
software helps teams gain visibility
into the automation network for better
availability and effectiveness.
• VMware: Host for Virtual Machines.
• Veeam: Business Continuity (Back-
up & Replication).
• Microsoft Enterprise Software: MS.
POLESTAR | CISCO © 2020. ALL RIGHTS RESERVED
As shown in the diagram below, the
technologies (OT’s) that we
implemented included:
• Cisco UCS Servers & Switches: An
integrated infrastructure to automate
the deployment of virtualization,
cloud, and edge computing and in-
memory analytics supporting remote
local facilities and substantial
quantities of data from IIoT.
Case Study
BROWNFIELD IMPLEMENTATION | Secure Industrial Networking Systems Integration.
Factory
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L0/1/2: Industrial
Hardware
Line 1
Line 21
Distribution
Cabinets 1/2
Factory
Cabinets 1/2
VM Infrastructure
VM Infrastructure
MS Cloud
Services
L4 and Above
Stratus
Services
VM
Infrastructure
Machinery
Machinery
Machinery
Machinery
Machinery
SDWAN
MS Cloud
Services
L4: DMZ
L3: Data Room N
L3: Data Room F
L2: Packing Lines
L2: Production Area
Legacy Network

5. Our Solution
5.
Through a partnership with Cisco and the
other vendors, Polestar planned a
multilayered design that incorporates several
security mechanisms at different levels.
From levels 0 to 2 (Industrial Hardware) we
installed several switches intended to run
containers for data collection.
At level 2 and below (Packing and
Production Areas) communication from
industrial hardware is 100/1000Mbit, with all
production switches being dual and uplinked
to core switches.
Resilient switch interconnect links were
proposed as optional within the same
cabinet, as they may reduce the load on
core systems. Distribution and access layers
are consolidated in the factory floor design.
At level 3 (Data Rooms) top of rack switches
are stacked and are all dual, uplinked into
the core switch.
The installation of Cisco's Unified Computing
System (UCS) servers was thought for
delivering performance, flexibility, and
density in devices, allowing workloads for:
• Big data & database management
systems,
• Cloud computing environments,
delivering virtual machines and bare-
metal servers,
• High-frequency trading,
• Internet infrastructure applications,
• Mission-critical enterprise apps,
• Virtualized environments.
The Cisco UCS servers are powered by
the latest Intel® Xeon® scalable
processors, forming the core of a
versatile and efficient data center that
meets diverse business needs with cost-
effectiveness.
At level 4 (Legacy Network and DMZ) an
SD-WAN firewall provides routing to all
services outside of the factory network
and is configured/controlled by the
vendor with management access via
Polestar.
From level 4 and above the system
connects to the cloud, varying by type.
The solution consisted not only in the
implementation of the technologies
shown in the diagram but also
consulting & design validation, project
and multiple vendor management,
documentation, and in life support.
POLESTAR | CISCO © 2020. ALL RIGHTS RESERVED
Case Study
BROWNFIELD IMPLEMENTATION | Secure Industrial Networking Systems Integration.

6. Over the project we provided an
industrial network that is secure by
design and redundant for serialisation
compliance, meeting the latest security
requirements, complying with industry
standards, and granting continuous
access to production at all levels.
Polestar delivered to the customer three
main outcomes from this installation:
1. An effective deployment of the OT
system, making the network IIoT
ready and securely connected. The
choice of Cisco IIoT products allowed
the system to benefit from the full
capabilities of digitalization
(operational efficiency,
competitiveness, and the creation of
new revenue streams).
Outcomes
6.
2. A fully automated oversight and
management view of production at all
levels of their pharmaceutical and
healthcare lines, and at all stages of
the process.
3. The assurance of quality and
efficiency, observing the U.K.
government standards for healthcare
and pharmaceutical production. Full
documentation was also provided for
compliance.
Thanks to the sector experience and
domain expertise that we have at
Polestar, we continually improve the
processes of any industrial business
through the latest IIoT systems.
Our goal is to help businesses to have
their people, products, and machines
securely connected to the Internet,
efficiently and automatically.
________________________________
For more information
To find out about Polestar’s
Secure Implementations and other Industrial
Internet of Things (IIoT) solutions, go to:
“Our UCS is an API-driven
business computing
platform with, streamlined
virtualization and
seamless automation.
From core, to edge, to
cloud: If you can imagine
it, we can build you a
bridge to a modern data
center infrastructure.”
- Cisco
+44 (0)115 911 6699
www.polestarinteractive.com
info@polestarinteractive.com
The Sir Colin Campbell Building,
Innovation Park, Triumph Road,
Nottingham, NG7 2TU, U.K.
POLESTAR | CISCO © 2020. ALL RIGHTS RESERVED
Case Study
BROWNFIELD IMPLEMENTATION | Secure Industrial Networking Systems Integration.