Glossary

Active Directory (AD) is a directory service by Microsoft used in Windows networks for the central management of users, computers, groups, and access rights. It is based on the LDAP protocol and enables Single Sign-On (SSO) – employees authenticate once and gain access to all approved resources.

In industrial automation, Active Directory is becoming increasingly important as OT networks (Operational Technology) converge with IT infrastructures. Control systems, SCADA applications, and MES systems can be integrated into unified security and access concepts via AD integration. 

At cts Group, Active Directory is used in industrial informatics to centrally manage user access to process control systems, historian databases, and engineering tools – a key building block for cybersecurity and compliance in Industry 4.0.

See also:  Backend Architecture, Asset Management, Audit Trail

Actuator technology refers to the entirety of all actuators (final control elements) in an automation system – i.e., all components that convert electrical control signals into physical actions. Typical actuators include: electric motors, variable frequency drives, pneumatic and electric valves, solenoid valves, actuating drives, and heaters. 

Actuators form the interface between the control level and the physical process and are the counterpart to sensor technology. In process automation, actuators are controlled via digital or analog outputs of the PLC and are frequently integrated into the control system via fieldbuses (Profibus, Profinet, HART). 

At cts Group, actuators are selected as part of EMSR engineering, documented in EPLAN, wired, and parameterized and tested during commissioning – from simple on/off valves to complex control valves with positioners.

See also:  Analog Signal Processing, Binary Control (Sequential Control), Commissioning, RIO (Remote I/O)

Advanced Analytics refers to the use of modern analysis and evaluation methods – including machine learning, statistical modeling, predictive analytics, and AI algorithms – to extract deeper insights from industrial process and machine data. 

While classical analysis describes historical data (What happened?), Advanced Analytics enables predictive statements (What will happen?) and prescriptive recommendations (What should be done?). Typical industrial applications include: predictive maintenance, quality forecasting, energy optimization, and process optimization. 

cts Group integrates Advanced Analytics solutions into its industrial informatics platforms – based on data sources such as Aveva PI, Aspentech Inmation, or proprietary Big Data architectures – providing the foundation for data-driven decisions in production.

See also: Big Data, Asset Management, Aveva PI, Aspentech Inmation, APC (Advanced Process Control)

Agile project management refers to the application of agile methodologies – such as Scrum, Kanban, or SAFe – to engineering and automation projects. In contrast to classical waterfall planning, the team works in short iteration cycles (sprints), delivers regularly functional interim results, and continuously adapts the project plan to new insights and customer requirements. 

In automation technology, agile project management is increasingly gaining traction – particularly in software development projects (PLC code, SCADA, MES) where requirements may change throughout the project. Agile approaches shorten time-to-market, increase customer satisfaction, and improve quality through continuous review cycles. 

cts Group combines proven methods from classical plant engineering (e.g., FAT, SAT, standards compliance) with agile principles in software development – for efficient, flexible, and transparent project execution.

See also: Factory Acceptance Test (FAT), SAT Checklist (Site Acceptance Test), Batch Systems

AI-assisted process optimization refers to the use of artificial intelligence methods – machine learning, deep learning, reinforcement learning – to continuously analyze, model, and optimize industrial production processes. In contrast to classical rule-based optimization, AI-based systems learn from historical process data and identify patterns and correlations that are invisible to human experts. 

Typical applications include: optimization of energy consumption in production plants, reduction of scrap rates through early defect detection, optimization of process parameters in real time, and prediction of plant failures (predictive maintenance). AI systems are trained on data from historian systems (Aveva PI, Aspentech Inmation), quality databases, and sensor networks. 

cts Group integrates AI-assisted optimization solutions into process and manufacturing automation projects – as a data-driven enhancement to classical automation and control.

See also: Advanced Analytics, APC (Advanced Process Control), Predictive Maintenance, Aveva PI, Industry 4.0

Alarm management encompasses the systematic planning, configuration, monitoring, and continuous improvement of the alarm system in process control systems (PCS/DCS). The goal is to supply operators only with relevant, actionable alarms and to prevent alarm flooding – the uncontrolled flood of alarm messages in fault situations. 

The industry standard EEMUA 191 and the ISA-18.2 standard define best practices for alarm management: from the alarm philosophy through prioritization and rationalization to performance monitoring (alarms/hour, bad actors). A well-structured alarm system increases plant safety and relieves the burden on operating personnel. 

cts Group implements alarm management solutions based on leading process control systems and supports operators in the revision and optimization of existing alarm systems – as part of Service & After Sales.

See also: Asset Management, Audit Trail, Fault Tolerance (Redundancy), Batch Process

Analog signal processing refers to the acquisition, transmission, scaling, and further processing of continuous measurement signals in automation systems. Typical analog signals are current (4-20 mA) or voltage signals (0-10 V) generated by sensors such as pressure transmitters, temperature transmitters, or flow meters. 

Analog signal processing encompasses: signal acquisition via analog input cards of the PLC or Remote I/O, scaling to physical units (e.g., 4-20 mA to 0-400 bar), filtering, limit value monitoring, and forwarding to control loops or control systems. Precise analog signal processing is the foundation for stable control and reliable process monitoring. 

At cts Group, analog signal processing is engineered as part of EMSR engineering, documented in EPLAN, and carefully calibrated and verified during commissioning. 

See also: Actuator Technology, RIO (Remote I/O), Commissioning, EPLAN

Advanced Process Control (APC) refers to advanced control strategies that go beyond classical PID control and regulate multiple process variables simultaneously and predictively. Typical APC methods include Model Predictive Control (MPC), Fuzzy Logic Control, and multivariate statistical process control (MSPC). 

APC systems use mathematical process models to calculate manipulated variables such that target values (product quality, energy consumption, throughput) are optimally met – even under changing boundary conditions and disturbances. In the oil, gas, chemical, and refinery industries, APC typically achieves energy savings of 3-8% and quality improvements in the double-digit percentage range. 

cts Group integrates APC solutions into existing process control systems and links them with data platforms such as Aveva PI or Aspentech Inmation to realize a continuous optimization chain from sensor to enterprise level. 

See also: Advanced Analytics, Aveva PI, Aspentech Inmation, Batch Process, Degree of Automation

Aspentech Inmation is an industrial data aggregation and contextualization platform that consolidates process data from heterogeneous sources – historians, DCS, ERP, LIMS, laboratory systems – into a unified data model and makes it available for analytics applications. 

A key feature of Inmation is the information-at-scale approach: the platform can process, historize, and enrich millions of data points in real time with context (equipment hierarchy, process boundaries, batch assignments). This creates the data foundation for Advanced Analytics, KPI reporting, and APC applications. 

cts Group deploys Aspentech Inmation as part of its industrial informatics solutions – particularly where heterogeneous plant landscapes (brownfield) are to be transferred into a unified data architecture without replacing existing control systems. 

See also: Aveva PI, Advanced Analytics, Big Data, Asset Management, Brownfield Transformation

Asset management in the industrial context refers to the systematic management, monitoring, and optimization of physical assets over their entire lifecycle – from procurement through operation to decommissioning. The goal is to maximize availability, minimize maintenance costs, and extend the service life of assets. 

Digital asset management relies on real-time process data (e.g., from Aveva PI), condition monitoring systems, IIoT sensors, and CMMS (Computerized Maintenance Management Systems). On this basis, predictive maintenance strategies can be implemented that reduce unplanned downtime. 

cts Group supports operators in building digital asset management systems – from data acquisition and integration into historian systems through to visualization on dashboards – as part of its Service & After Sales portfolio. 

See also: Aveva PI, Aspentech Inmation, Advanced Analytics, Manufacturing Data Acquisition (MDA), Fault Tolerance (Redundancy)

ATEX stands for Appareils destines a etre utilises en ATmospheres EXplosibles and refers to the European regulatory framework for equipment and protective systems in potentially explosive atmospheres. It encompasses two EU directives: the Equipment Directive 2014/34/EU (for manufacturers of Ex equipment) and the Workplace Directive 1999/92/EC (for operators of plants with Ex zones). 

ATEX specifies how equipment in potentially explosive atmospheres must be designed, labeled, and used. The types of ignition protection (e.g., Ex-d: flameproof enclosure, Ex-e: increased safety, Ex-i: intrinsic safety) define how a device prevents ignition of an explosive atmosphere. The international standard series IEC 60079 applies additionally.

cts Group plans, procures, and installs ATEX-certified automation components – from control cabinets in Ex-e design through remote I/O systems to Ex-protected instruments – for customers in the chemical, pharmaceutical, and energy sectors. 

See also: EX Zones (Explosion Protection), Control Cabinet, MCC (Motor Control Center), RIO (Remote I/O), Work Permit (Permit-to-Work)

An audit is a systematic, documented, and independent review of processes, products, or systems against defined requirements or standards. In the context of electrical engineering and automation, audits serve quality assurance and the provision of evidence to customers, authorities, or certification bodies. 

Typical types of audits in plant engineering include: supplier audits (vendor qualification), design audits (design review), safety audits (functional safety per IEC 61511), and standards compliance checks per DIN EN 61439 or DIN EN 60204-1. 

At cts Group, audits are an integral part of the quality management system. They accompany the entire project cycle – from planning through control cabinet construction to commissioning. 

See also: Factory Acceptance Test (FAT), SAT Checklist (Site Acceptance Test), Commissioning, DIN EN 61439 / EN 61439 / IEC 61439 (Low-Voltage Switchgear)

An audit trail (also: revision log or change log) is a complete, tamper-proof record of all relevant events, changes, and accesses in an IT or automation system. It documents: who changed what, when – and (where applicable) why. 

Audit trails are required in regulated industries (pharma, food, chemical) by directives such as FDA 21 CFR Part 11, EU GMP Annex 11, and GAMP 5. They serve as proof of data completeness and integrity before authorities and auditors. In safety-relevant systems (SIS, PCS) as well, audit trails are an integral part of the system architecture. 

At cts Group, audit trail functionality is engineered and validated during the implementation of process control systems, MES applications, and historian platforms – as part of plant qualification and compliance management. 

See also: Plant Qualification, Audit, Active Directory, Asset Management

The automation pyramid (also: ISA-95 hierarchy or automation hierarchy) is a classical reference model that structures the various levels of an industrial automation system – from the field level (sensors, actuators) through the control level (PLC, DCS) and process control level (SCADA, HMI) to the operations level (MES) and the enterprise level (ERP, SAP). 

The model illustrates the data flow principles and tasks of each level: at the bottom, raw data is generated; at the top, business decisions are derived from it. With the advent of IIoT and cloud architectures, the strict pyramid structure is increasingly being supplemented by flatter, service-oriented architectures – however, the underlying principles remain relevant. 

cts Group realizes projects at all levels of the automation pyramid – from field device integration through PLC programming and SCADA engineering to MES implementation and ERP connectivity. 

See also: Degree of Automation, Manufacturing Data Acquisition (MDA), Backend Architecture, Batch Systems

Aveva PI (formerly: OSIsoft PI System) is a market-leading industrial data platform for the acquisition, storage, management, and visualization of process time series data. The system consists of several components: PI Data Archive (historization), PI Asset Framework (AF) for modeling plant structures, and PI Vision / PI DataLink for visualization and analysis. 

Aveva PI is widely used in the process, oil, gas, energy, and water industries and is considered the de-facto standard for industrial historian systems. It collects data from thousands of measurement points (PI Points), compresses them efficiently, and makes them available for Advanced Analytics, reporting, and APC applications. 

cts Group installs, configures, and integrates Aveva PI in customer projects – from connecting existing control systems and modeling the plant hierarchy in the Asset Framework to creating dashboards and reports for production operations. 

See also: Aspentech Inmation, Advanced Analytics, Asset Management, APC (Advanced Process Control), Big Data

Backend architecture refers to the server-side layer of a software or automation system – i.e., all components that process, store, and provide data in the background without direct user interaction. In industrial informatics, the backend typically encompasses: database servers, historian systems (Aveva PI, Aspentech Inmation), application servers, API interfaces, and message brokers (e.g., MQTT, Kafka). 

A well-designed backend architecture is scalable, highly available, and secure. It consistently separates data storage, business logic, and presentation from each other (layered architecture) and enables the integration of heterogeneous data sources via standardized interfaces (REST API, OPC UA, GraphQL). 

cts Group develops backend architectures for industrial applications – from simple database connections to complex, cloud-capable IIoT platforms – as part of the industrial informatics portfolio. 

See also: Active Directory, Aveva PI, Aspentech Inmation, Big Data, Automation Pyramid

A batch refers in production technology to a defined quantity of a product that is manufactured in a delimited production cycle under identical conditions – as opposed to continuous processes. The batch is the smallest traceable production unit and forms the basis for quality control, traceability, and batch documentation. In the pharmaceutical and food processing industries, complete batch documentation is legally required. 

Each batch is assigned a unique batch number linking raw materials, production parameters, test results, and filling/packaging data – as the basis for recall actions and regulatory inspections. 

cts Group implements batch control systems according to ISA-88 that ensure automated, GMP-compliant batch documentation (Electronic Batch Record) – linked with audit trail, MES, and ERP. 

See also: Batch Process, Batch Systems, GMP (Good Manufacturing Practice), Audit Trail, Tracking & Tracing

A batch process is a discontinuous form of production in which raw materials are fed in defined quantities (batches), processed, and discharged as finished product – as opposed to continuous processes. 

Typical industries are pharmaceutical, chemical, food, and biotechnology. Batch processes are subject to the ISA-88 standard (IEC 61512), which defines a hierarchical structure for recipes, equipment modules, and procedural stages. The automation of batch processes requires flexible control logic that ensures recipe execution, parameter management, and complete batch documentation (batch records). 

cts Group realizes batch automation projects based on leading DCS and PCS systems – compliant with ISA-88, with complete batch traceability and audit trail functionality for regulated industries. 

See also: Batch Systems, Audit Trail, Plant Qualification, APC (Advanced Process Control)

Batch systems are specialized software platforms and automation solutions that enable the control, monitoring, and documentation of batch processes in accordance with the ISA-88 standard (IEC 61512). They manage formulations, coordinate the execution of equipment phases, and generate complete batch records. 

Leading batch systems on the market include Siemens SIMATIC Batch, Emerson DeltaV Batch, Rockwell FactoryTalk Batch, and ABB IndustrialIT. They are typically integrated into the superordinate process control system (DCS) and communicate bidirectionally with MES systems for production planning and quality management. 

At cts Group, batch systems are engineered, implemented, and validated – including the creation of complete qualification documentation (IQ, OQ, PQ) for pharmaceutical and food technology customers. 

See also: Batch Process, Plant Qualification, Audit Trail, Agile Project Management

Big Data refers to the acquisition, storage, and analysis of data volumes that can no longer be efficiently processed with conventional database tools. In industry, Big Data is generated by IIoT sensors, machine data, process historian systems, and quality data – characterized by the three Vs: Volume (data quantity), Velocity (data speed), and Variety (data diversity). 

Industrial Big Data architectures rely on data lakes, time-series databases (such as InfluxDB or Aveva PI), streaming platforms (Apache Kafka), and analysis frameworks (Spark, Python-based ML pipelines). They create the data foundation for Advanced Analytics, Predictive Maintenance, and AI applications. 

cts Group advises and supports industrial customers in building Big Data infrastructures – from the data acquisition layer through storage architecture to analysis and visualization layers – as part of digital transformation. 

See also: Advanced Analytics, Aveva PI, Aspentech Inmation, Backend Architecture, Asset Management

A binary control – also called sequential control or switching control – is an automation system based on binary (digital) input and output signals that controls process sequences in defined steps and transitions. In contrast to control loops, there is no continuous feedback loop, but a state-based sequential logic. 

In PLC programming according to IEC 61131-3, sequential controls are typically implemented in Sequential Function Chart (SFC) or Function Block Diagram (FBD). Typical applications include: conveyor systems, filling plants, batch processes, and cleaning cycles (CIP/SIP). At 

cts Group, sequential controls are developed as part of process and manufacturing automation, verified on test systems, and accepted jointly with the customer during commissioning. 

See also: Actuator Technology, Batch Process, Commissioning, Degree of Automation

Brownfield transformation refers to the digital and technical modernization of existing (in-operation) production plants without rebuilding them from scratch. In contrast to greenfield projects (new plants built from the ground up), brownfield projects must take into account existing systems, interfaces, and production requirements. 

Typical brownfield measures include: retrofitting IIoT sensors and edge devices for data acquisition, migrating outdated control systems (retrofit), integrating legacy data into modern historian or MES systems, and gradually introducing Advanced Analytics without production interruption. 

cts Group specializes in brownfield transformations – from inventory analysis through engineering to commissioning. With the approach of modernization without production downtime, cts minimizes risks to ongoing operations and maximizes the ROI of the investment. 

See also: Plant Modernization (Retrofit), Aspentech Inmation, Aveva PI, Degree of Automation, Big Data

A burst disc is a safety component that protects pressure-bearing plants and vessels from damage or explosion in the event of overpressure by deliberately bursting when a defined pressure is reached, thereby rapidly relieving the pressure. 

Burst disc monitoring refers to the automated detection and signaling of the bursting event – typically via electrical monitoring systems (trip wires, microswitches, differential pressure measurement). The burst disc monitoring system immediately reports the bursting event to the process control system, triggers alarms, and can automatically initiate follow-up actions (valve switching, shutdown sequences). Monitoring is legally required in many industries (chemical, pharmaceutical, oil & gas). 

cts Group integrates burst disc monitoring systems into process automation projects – from instrumentation through PLC/PCS-side processing to alarm configuration – and ensures standards-compliant documentation. 

See also: Alarm Management, ATEX (Explosion Protection), EX Zones (Explosion Protection), Analog Signal Processing

C# (pronounced: C-Sharp) is an object-oriented, type-safe programming language developed by Microsoft as part of the .NET platform. It combines the strengths of C++ and Java and is today one of the most widely used languages in enterprise and industrial software development. 

In industrial automation and informatics, C# is used for the development of: HMI/SCADA applications (e.g., WPF, WinForms), backend services and APIs (ASP.NET Core), database connections (Entity Framework), OPC UA clients/servers, and desktop configuration tools. C# is also the basis for Siemens TIA Add-Ins and various engineering framework extensions. 

At cts Group, the industrial informatics team uses C# for the development of customer-specific software solutions – from database applications through OPC UA interface development to customized SCADA extensions. 

See also: Backend Architecture, Active Directory, Aveva PI, Aspentech Inmation

C++ is a powerful, low-level programming language used in industrial automation primarily for time-critical real-time applications, embedded systems, control software, and drivers. It combines the efficiency of C with object-oriented concepts and enables direct hardware control. 

In automation technology, C++ is typically used for the development of PLC runtime environments, motion control algorithms, machine vision systems, and performance-critical OPC UA servers and data middleware components. Many control system manufacturers use C++ internally for their platforms. 

cts Group uses C++ in industrial informatics and special machinery projects – where real-time capability, low latency, and direct system integration are decisive advantages over more comfortable high-level languages such as C# or Python. 

See also: C#, Backend Architecture, Programmable Logic Controller (PLC), Framework

Calibration is the process of comparing the measured values of a measuring instrument with reference values of known accuracy, and if necessary, adjusting the instrument to eliminate deviations. 

In process automation, calibration of field instruments (pressure transmitters, temperature sensors, flow meters, analyzers) is a fundamental prerequisite for measurement accuracy, process reliability, and regulatory compliance. Calibration is carried out according to defined procedures and documented in calibration records. In regulated industries (pharma, food, chemical), calibration is part of the qualification process and must be carried out at defined intervals by accredited laboratories or qualified personnel. 

cts Group carries out calibration of all field instruments as part of EMSR engineering and commissioning – using calibrated reference standards and with complete documentation of all calibration data. 

See also: Field Devices, Plant Qualification, GMP (Good Manufacturing Practice), Commissioning, SAT Checklist (Site Acceptance Test)

Capsule integration refers to an architectural approach in automation and digitalization in which software functions are provided as independent, encapsulated units (capsules or modules) that communicate via standardized interfaces. The concept is closely related to microservices architectures and the MTP standard (Module Type Package). 

Through encapsulation, individual functional modules – e.g., a control loop, a recipe management system, or a diagnostic service – can be independently developed, tested, updated, and integrated into various superordinate systems. This increases reusability, flexibility, and maintainability of automation software. 

cts Group pursues modular integration approaches in process automation and industrial informatics – as the foundation for scalable, future-proof system architectures in complex industrial environments. 

See also: MTP (Module Type Package), Framework, Interface Management, Horizontal Integration, Vertical Integration

Change control refers to the structured process for evaluating, approving, documenting, and tracking changes to systems, processes, plants, or software. It ensures that every change is introduced in a controlled manner and has no unintended negative effects on quality, safety, or compliance. 

In regulated industries (pharma, food, medical devices), change control is mandatory per GMP (Good Manufacturing Practice) and GAMP 5. It encompasses: change request, risk assessment, quality assurance approval, implementation, testing/validation, and final documentation in the audit trail. 

cts Group integrates change control processes into all projects in regulated environments – from software changes to batch systems through hardware modifications to the updating of validation documentation. 

See also: Audit Trail, GMP (Good Manufacturing Practice), Validation, Plant Qualification, Governance & Compliance

CIP (Cleaning-in-Place) refers to an automated cleaning process for production plants in the food, beverage, pharmaceutical, and biotech industries, in which vessels, pipelines, and equipment are cleaned without disassembly by rinsing with cleaning agents and disinfectants. 

CIP ensures reproducible cleaning results with minimal personnel effort. A CIP cycle typically consists of: pre-rinsing (water), caustic cleaning (NaOH), intermediate rinsing, acid cleaning (HNO3 or phosphoric acid), final rinsing, and optionally steam sterilization (SIP). Control is performed via a sequential control per ISA-88 that monitors and logs cleaning parameters (temperature, concentration, time, flow rate). 

cts Group realizes CIP control solutions for the food and pharmaceutical industries – from recipe development and process automation to GMP-compliant validation and batch documentation. 

See also: Batch Process, GMP (Good Manufacturing Practice), Validation, Plant Qualification, Binärsteuerung (Ablaufsteuerung)

Cloud computing refers to the provision of IT resources – computing power, data storage, databases, networks, and software services – over the internet on demand and as needed, without the need to operate one's own physical infrastructure. 

Leading providers are Amazon Web Services (AWS), Microsoft Azure, and Google Cloud Platform. In industry, cloud computing is used for the scalable storage and analysis of production data (e.g., from historian systems such as Aveva PI), for AI/ML model training, remote monitoring, and for SaaS-based MES and ERP solutions. The main challenge lies in secure OT/IT integration: production data must be reliably transferred from the shopfloor into the cloud without violating security and latency requirements. 

cts Group accompanies industrial companies in cloud strategies for their production environments – from architecture planning and edge computing concepts to secure data transfer and cloud integration. 

See also: Edge Computing, IIoT (Industrial Internet of Things), Backend Architecture, Industry 4.0, On-Premise

Commissioning refers to the phase in an automation or plant project in which a system is started up for the first time after installation, tested, and released for regular operation. It encompasses electrical inspections, functional testing of the control logic, calibration of measuring instruments, and the tuning of process parameters. 

Commissioning is typically divided into: cold commissioning (without product/medium), hot commissioning (with medium), and performance testing. The basis for this includes the SAT checklist and the test reports from the preceding Factory Acceptance Test (FAT). 

cts Group handles on-site commissioning – including internationally – ensuring that all relevant standards (DIN EN 60204-1, IEC 61439) and customer-specific requirements are met. Following commissioning, cts offers comprehensive Service & After Sales. 

See also: Factory Acceptance Test (FAT), SAT Checklist (Site Acceptance Test), DIN EN 60204-1 (Electrical Equipment of Machines), Switchgear Assembly

Computer System Validation (CSV) refers to the documented proof that a computer-aided system in regulated industries (pharma, medical devices, food) fulfills its intended function consistently and in compliance with regulations. It is mandatory in the pharmaceutical industry per GMP (EU Annex 11, FDA 21 CFR Part 11) and the GAMP 5 guideline. 

CSV follows a lifecycle approach: User Requirements Specification (URS), risk analysis, Design Qualification (DQ), Installation Qualification (IQ), Operational Qualification (OQ), Performance Qualification (PQ), as well as change control and regular reviews. It applies to SCADA, DCS, MES, LIMS, and other GMP-relevant software systems. 

cts Group supports pharmaceutical companies and other regulated industries in complete computer system validation – from creating validation documentation through conducting qualification tests to preparation for regulatory inspections. 

See also: GMP (Good Manufacturing Practice), GxP, Validation, Audit Trail, Plant Qualification

A control cabinet is a closed housing that accommodates electrical and electronic components of an automation system – such as PLCs, I/O modules, power supplies, frequency converters, safety relays, and fieldbus components – and protects them against environmental influences. 

Control cabinets are classified according to their degree of protection (IP rating) and climate class, and are designed in accordance with DIN EN 61439. The internal wiring, component arrangement, and labeling follow the EPLAN engineering documentation. Quality-critical aspects of control cabinet construction include: correct cable cross-sections and protection, EMC-compliant installation, thermal management (heat dissipation), and clear labeling of all components per equipment identification code (EIC). 

cts Group builds control cabinets at its own production facility – from small single-PLC cabinets to large, multi-field systems – in compliance with all relevant standards and with complete EPLAN documentation. 

See also: Switchgear Assembly, EPLAN, DIN EN 61439 / EN 61439 / IEC 61439 (Low-Voltage Switchgear), UL (Underwriters Laboratories), CSA (Canadian Standards Association), EAC (Eurasian Conformity)

A controller in the industrial context is a programmable control device that processes input signals from sensors and field instruments and, based on a stored control logic, outputs signals to actuators. The most common type is the Programmable Logic Controller (PLC). 

Modern industrial controllers range from compact micro-PLCs for simple machines to powerful process control system controllers (DCS controllers) for large-scale plants. They are programmed according to IEC 61131-3 in languages such as Ladder Diagram (LD), Function Block Diagram (FBD), Structured Text (ST), or Sequential Function Chart (SFC).

cts Group plans, programs, and commissions controllers from all leading manufacturers – including Siemens SIMATIC, Rockwell Allen-Bradley, Emerson DeltaV, ABB, and Beckhoff – in the context of EMSR, process automation, and special machinery projects. 

See also: Programmable Logic Controller (PLC), SIMATIC, Automation Pyramid, EMSR Engineering (Electrical Measurement Control & Regulation), Field Level

The CSA (Canadian Standards Association) is a Canadian standards organization that, similar to UL in the USA, tests and certifies products for safety and standards compliance. 

The CSA certificate is mandatory in Canada for electrical equipment used in regulated areas and is frequently applied for together with UL for the entire North American market. For switchgear and industrial controls, CSA certification is required according to the corresponding C22.2 standards (e.g., C22.2 No. 286 for industrial control panels). Many UL testing laboratories offer combined UL/CSA certifications that cover both markets. 

cts Group supports customers exporting their equipment to North America with correspondingly certified control cabinets and control systems. 

See also: UL (Underwriters Laboratories), EAC (Eurasian Conformity), Control Cabinet, DIN EN 61439 / EN 61439 / IEC 61439 (Low-Voltage Switchgear)

Data aggregation refers to the consolidation and compression of large quantities of individual values (e.g., measurement values at one-second intervals) into more meaningful metrics over defined time periods – such as minute, hourly, or shift averages, maxima, minima, or sums. It reduces data volume, increases clarity, and enables trend analyses. 

In industrial historian systems (Aveva PI, Aspentech Inmation, IP.21), data aggregation is a core function: raw data is stored with configurable compression algorithms and output in aggregated form on request. Data aggregation is also an essential processing step in ETL tools and analytics platforms. 

cts Group applies data aggregation strategies when configuring historian systems and developing KPI dashboards and reporting solutions – with the goal of generating actionable information from raw process data. 

See also: Data Historization, Aveva PI, ETL Tools (Extract, Transform, Load), KPI Dashboard, Data Consolidation

Data consolidation refers to the process of merging data from multiple, often heterogeneous source systems into a central data store or a unified data view. The goal is a consistent, complete, and contradiction-free database as the foundation for reporting, analytics, and decision-making processes.

In the process industry, data from PLC/DCS, historian, LIMS, MES, and ERP systems is typically consolidated. Technically, this is done via ETL tools, middleware platforms, OPC UA aggregation servers, or modern data fabric architectures that enable a federated view of distributed data. 

cts Group implements data consolidation solutions as a core component of Industry 4.0 and digitalization projects – from source analysis and interface planning through implementation to quality assurance of the consolidated database. 

See also: Data Hub, ETL Tools (Extract, Transform, Load), Industrial Data Fabric (IDF), Data Normalization, Unified Namespace (UNS)

Historization refers to the continuous, time-stamped acquisition and long-term storage of process data from industrial plants. It enables retrospective analysis of operating conditions, process progressions, and events – over hours, months, or years. Historian systems such as Aveva PI, Aspentech Inmation, or IP.21 are specifically optimized for this task. 

Historized data forms the indispensable data foundation for: Manufacturing Data Acquisition (MDA), Advanced Analytics, Predictive Maintenance, energy management, quality assurance, and regulatory reporting. Modern historian systems compress time series data with minimal loss, enabling the storage of millions of data points over long periods. 

cts Group implements historian systems as the foundation of its customers' digitalization strategy – from tag configuration and data modeling to connection to analytics platforms and management dashboards. 

See also: Aveva PI, Aspentech Inmation, IP.21 (AspenTech InfoPlus.21), Manufacturing Data Acquisition (MDA), Data Aggregation

A data hub is a central data integration platform that consolidates data from various source systems (PLC, DCS, SCADA, MES, ERP, laboratory systems), harmonizes it, and makes it available for downstream applications (analytics, dashboards, AI models). It acts as a neutral data hub and decouples data producers from data consumers. 

Unlike a classical data warehouse, an industrial data hub is primarily designed for real-time and time-series data and supports both push and pull mechanisms via protocols such as OPC UA, MQTT, REST API, or Kafka. It is a central element of modern Industrial Data Fabric and Unified Namespace architectures. 

cts Group designs and implements data hubs as part of digitalization and Industry 4.0 projects – as a scalable data foundation for Advanced Analytics, KPI dashboards, and enterprise-wide data transparency. 

See also: Unified Namespace (UNS), Industrial Data Fabric (IDF), MQTT (Message Queuing Telemetry Transport), OPC UA (Open Platform Communications Unified Architecture), Data Consolidation

Data normalization in the industrial context refers to the conversion of data from various source systems with different formats, units, naming conventions, and resolutions into a uniform, consistent data model. It is a prerequisite for meaningful cross-plant comparisons, analytics, and machine learning applications. 

Typical normalization steps include: unit conversion (e.g., °F to °C, PSI to bar), timestamp synchronization, tag name harmonization, handling of missing values, and mapping to a common asset framework model. 

cts Group incorporates data normalization in the implementation of historian systems, data hubs, and industrial data fabric architectures – as an indispensable step for data quality in digitalization projects. 

See also: Data Consolidation, ETL Tools (Extract, Transform, Load), Industrial Data Fabric (IDF), NoSQL Databases, SQL Databases

The degree of automation describes the proportion of automatically executed process steps in relation to the total number of steps in a production or business process. It is a key metric for assessing the digitalization and modernization status of a plant or company. 

A low degree of automation means high manual effort, greater error-proneness, and limited scalability. As the degree of automation increases, reproducibility, efficiency, and data availability improve. The optimal level of automation is always dependent on the process and cost – not every step justifies automation. 

cts Group analyzes the current degree of automation together with customers, identifies potential, and implements targeted measures – from individual component automation to complete process automation with data connectivity to MES or ERP. 

See also: Automation Pyramid, APC (Advanced Process Control), Plant Modernization (Retrofit), Brownfield Transformation

Digital production refers to the comprehensive digital networking, control, and optimization of production processes – from planning and work preparation through manufacturing to quality assurance and logistics. It connects automation technology, data infrastructure, AI applications, and MES into an integrated, data-driven production system. 

Core elements of digital production include: real-time data transparency on the shopfloor, paperless manufacturing, digital twins for simulation and optimization, automated quality inspection, and AI-assisted predictive maintenance. It is the operational implementation of Industry 4.0 at the factory level. 

cts Group accompanies industrial companies on the path to digital production – as a full-service provider from automation technology and data infrastructure to MES and analytics solutions. 

See also: Industry 4.0, Shopfloor, MES (Manufacturing Execution System), Paperless Manufacturing, Digitalization

The digital shadow is a data-driven, passive representation of a physical object, process, or system in the digital world. In contrast to the digital twin, the digital shadow is primarily a reflection of the current state – it reads data without actively providing feedback or executing simulations. 

In the process industry, a digital shadow is created by historizing process data (temperatures, pressures, flow rates, quality values) in historian systems such as Aveva PI. By enriching this data with contextual information (asset framework, equipment data), a comprehensive picture of the plant condition over time is created – the starting point for Advanced Analytics and machine learning. 

cts Group builds digital shadows as the first step toward a complete digital twin – through the implementation of historian systems, asset frameworks, and real-time dashboards. 

See also: Twin Technology (Digital Twin), Aveva PI, Advanced Analytics, Data Historization, Industry 4.0

Digital shift logs are digital systems for recording, documenting, and transferring operationally relevant events, observations, maintenance activities, and instructions between shifts in industrial plants. Digital shift logs replace traditional paper logbooks and offer significant advantages: structured data entry via forms and templates, searchability and filterability of all entries, automatic linking with process data and alarms, role-based access control, and complete audit trail of all entries and changes. 

In regulated industries (pharmaceutical, chemical), digital shift logs must meet GMP requirements for electronic records. Leading solutions include Siemens SIMATIC ShiftLog, Aveva Unified Operations Center, and specialized MES modules. 

cts Group implements digital shift log solutions as part of digitalization and paperless manufacturing projects – for improved information transfer between shifts and a comprehensive digital operations log. 

See also: Paperless Manufacturing, MES (Manufacturing Execution System), Audit Trail, GMP (Good Manufacturing Practice), OEE (Overall Equipment Effectiveness)

Digitalisation of Manufacturing refers to the systematic introduction of digital technologies – IIoT, cloud, AI, MES, digital twins – into industrial production environments with the goal of increasing efficiency, flexibility, quality, and transparency.

The term is used internationally as a synonym for Smart Manufacturing and the German concept of Industry 4.0. Concrete measures include: machine connectivity (brownfield retrofitting), introduction of MES and paperless manufacturing, real-time OEE monitoring, predictive maintenance, automated quality assurance, and integration of shopfloor data with ERP systems.

cts Group positions itself as a partner for the Digitalisation of Manufacturing – with reference projects in various industries and a service portfolio encompassing hardware engineering, software development, and system integration. 

See also: Industry 4.0, Digital Production, MES (Manufacturing Execution System), IIoT (Industrial Internet of Things), Shopfloor

Digitalization in the industrial context refers to the transformation of analog and manual processes, information flows, and decision-making structures toward digitally supported, networked, and data-driven systems. 

It encompasses both technological aspects (sensors, IIoT, cloud, AI) and organizational changes in processes and working methods. In production, digitalization means: machines and plants generate data that is acquired, visualized, and analyzed in real time; manual documentation is replaced by digital systems (paperless manufacturing, digital shift logs); decisions are supported by KPI dashboards and AI applications. Digitalization is the foundation for Industry 4.0. 

cts Group understands digitalization as a holistic process and accompanies industrial companies throughout – from strategy and roadmap through technical implementation (IIoT, MES, analytics) to change management and employee training. 

See also: Industry 4.0, IIoT (Industrial Internet of Things), Digital Production, MES (Manufacturing Execution System), Advanced Analytics

The standard DIN EN 60204-1 (international: IEC 60204-1) defines the safety requirements for the electrical equipment of machines. It applies to the electrical, electronic, and programmable control equipment of machines and regulates protective measures against electric shock, short circuits, and overloads, the design of the power supply connection, and the requirements for emergency stop devices and safety control circuits. 

The standard is mandatory for machine manufacturers and automation engineers in Europe, as it applies as a harmonized standard under the Machinery Directive (2006/42/EC) and is thus directly linked to CE marking. 

At cts Group, DIN EN 60204-1 is consistently applied in engineering – from the selection of protective devices through the design of control circuits to documentation in EPLAN. Standards compliance is verified during the FAT and commissioning. 

See also: DIN EN 61439 / EN 61439 / IEC 61439 (Low-Voltage Switchgear), VDE (Association for Electrical, Electronic and Information Technologies), Control Cabinet, Commissioning, Factory Acceptance Test (FAT)

The standard series IEC 61439 (international), EN 61439 (European), or DIN EN 61439 (German equivalent) defines the requirements for low-voltage switchgear assemblies – i.e., control cabinets and switchgear up to 1,000 V AC or 1,500 V DC. It regulates areas such as short-circuit protection, thermal behavior, creepage and clearance distances, degree of protection, and verification evidence. 

The manufacturer must demonstrate that their design meets the requirements either through type testing or through calculation-based verification. Compliance with this standard is mandatory for the European market and forms the basis for the CE Declaration of Conformity. 

At cts Group, standards compliance is ensured in the engineering process and documented in the context of audits and Factory Acceptance Tests (FAT). 

See also: Switchgear Assembly, Control Cabinet, VDE (Association for Electrical, Electronic and Information Technologies), Audit, Factory Acceptance Test (FAT)

The EAC mark (Eurasian Conformity) is the conformity mark for the Eurasian Economic Union (EAEU), to which Belarus, Kazakhstan, Kyrgyzstan, Russia, and Armenia belong. It is the counterpart to the European CE mark and confirms that a product meets the technical regulations of the EAEU. 

For electrical devices, switchgear, and machines that are to be used or sold in EAEU member countries, EAC certification is legally required. Accredited certification bodies review conformity with the EAEU Technical Regulations (TR EAEU). 

cts Group has experience with EAC certification and supports customers in international projects with correspondingly tested and marked plants and control cabinets. 

See also: UL (Underwriters Laboratories), CSA (Canadian Standards Association), Control Cabinet, CE-Kennzeichnung

Edge computing refers to data processing directly at the point of origin – i.e., at the 'edge' of the network, close to machines and sensors – rather than transmitting all data to a central cloud or data center. Edge systems (edge devices, industrial PCs, edge gateways) enable real-time processing with minimal latency and reduce bandwidth requirements. In industrial automation, edge computing systems are used for: local data preprocessing and filtering, execution of AI inference models (e.g., for anomaly detection directly at the machine), protocol conversion (e.g., from proprietary machine protocols to OPC UA or MQTT), and as a secure data bridge between the OT network and the cloud. cts Group integrates edge computing solutions into IIoT architectures for the secure and scalable connection of shopfloor and cloud. 

See also: Cloud Computing, IIoT (Industrial Internet of Things), OPC UA (Open Platform Communications Unified Architecture), MQTT (Message Queuing Telemetry Transport), Backend Architecture

EMSR stands for Elektro-, Mess-, Steuer- und Regeltechnik (Electrical, Measurement, Control, and Regulation Technology) and refers to the engineering discipline that encompasses the entirety of electrical equipment, measurement technology, control logic, and control loops in process plants. 

EMSR planning encompasses: instrumentation lists (IL), piping and instrumentation diagrams (P&ID per DIN EN ISO 10628), datasheet systems for measuring instruments, load lists, panel engineering (EPLAN), as well as cable and terminal diagrams. It forms the basis for procurement, installation, and commissioning. 

cts Group provides complete EMSR engineering from a single source – from the concept phase through detail engineering, control cabinet construction, and installation to commissioning and as-built documentation. 

See also: Field Devices, EPLAN, Control Cabinet, Commissioning, Field Level

The standard series EN 61439 (European), DIN EN 61439 (German equivalent), or IEC 61439 (international) defines the requirements for low-voltage switchgear assemblies – i.e., control cabinets and switchgear up to 1,000 V AC or 1,500 V DC.

It regulates areas such as short-circuit protection, thermal behavior, creepage and clearance distances, degree of protection, and verification evidence. The manufacturer must demonstrate that their design meets the requirements either through type testing or through calculation-based verification. Compliance with this standard is mandatory for the European market and forms the basis for the CE Declaration of Conformity. 

At cts Group, standards compliance is ensured in the engineering process and documented in the context of audits and Factory Acceptance Tests (FAT). 

See also: Switchgear Assembly, Control Cabinet, VDE (Association for Electrical, Electronic and Information Technologies), Audit, Factory Acceptance Test (FAT)

EPLAN is a leading CAE software (Computer Aided Engineering) for the electrical planning and documentation of switchgear, control cabinets, and automation projects. With EPLAN Electric P8 – the most widely used variant – circuit diagrams, terminal diagrams, cable diagrams, and bills of materials can be created in a standards-compliant and consistent manner. 

A key advantage of EPLAN lies in its bidirectional data integrity: changes in one part of the schema are automatically updated in all dependent documents. This significantly reduces errors and accelerates the engineering process. 

At cts Group, EPLAN is a central tool in hardware engineering. The created drawings form the basis for control cabinet construction, material ordering, quality inspection, and subsequent commissioning and maintenance of the plant. 

See also: Control Cabinet, Switchgear Assembly, Commissioning

The Equipment Identification Code (EIC) is a unique alphanumeric identifier assigned to every electrical piece of equipment (switches, terminals, transmitters, motors, valves, etc.) in a plant. It enables the unambiguous identification and assignment of devices in drawings, bills of materials, control cabinets, and in the field. 

The EIC system is standardized in DIN EN 81346 (Reference Designation System for plants). A typical hierarchical structure consists of functional and location designations (e.g., =A1+P01-M001 for Motor 001 in Plant A1, Location P01). A consistent EIC assignment is a prerequisite for efficient maintenance, fault finding, and documentation. 

At cts Group, the EIC is assigned in the EPLAN engineering project across the entire project according to customer specifications or DIN EN 81346 – as the foundation for the entire project lifecycle from engineering through commissioning to service. 

See also: EPLAN, Control Cabinet, Switchgear Assembly, Commissioning

ERP (Enterprise Resource Planning) refers to integrated software systems that map all essential business processes of a company – production, procurement, warehousing, financial accounting, human resources, sales – in a shared system and link them with each other. Leading ERP providers in industry are SAP, Oracle, Microsoft Dynamics, and Infor. 

In the manufacturing and process industry, the integration of ERP and production systems (MES, SCADA, historian) is a central topic of digitalization: production orders from the ERP are transferred to MES, and production results, material consumption, and quality data flow back. The interface follows the ISA-95 standard. 

cts Group implements ERP/MES integration solutions and connects shopfloor systems with SAP and other ERP platforms – as part of comprehensive digitalization projects in the process and manufacturing industry. 

See also: MES (Manufacturing Execution System), SAP, ISA-95 (Manufacturing Operations Management Standard), Vertical Integration, Data Consolidation

ETL (Extract, Transform, Load) refers to a data process in which data is extracted from various source systems, transformed into a uniform format (cleaned, normalized, aggregated), and loaded into a target system (data warehouse, data hub, historian). ETL tools automate and monitor this process. 

In industry, ETL processes are used to consolidate heterogeneous production data from PLC, DCS, MES, LIMS, and ERP. Modern ELT approaches (Extract, Load, Transform) first load raw data and transform it in the target system – which is more efficient for large data volumes. Common tools include Apache Spark, Talend, Azure Data Factory, and industry-specific middleware. 

cts Group uses ETL and ELT processes in data migration and digitalization projects – for the clean integration of production data into analytics platforms, historian systems, and enterprise-wide data architectures. 

See also: Data Consolidation, Data Normalization, Data Hub, Kafka (Apache Kafka), SQL Databases

EX zones (also: Ex areas or potentially explosive atmospheres) are defined areas in industrial plants where there is a risk of explosion due to flammable gases, vapors, mists, or dusts. Classification is carried out according to the European ATEX Directive (2014/34/EU) and the international standard IEC 60079. 

Ex zones are divided into: Zone 0/1/2 for gases and vapors, and Zone 20/21/22 for dusts – depending on the frequency and duration of the presence of an explosive atmosphere. Electrical and electronic equipment used in these areas must be specially certified (e.g., Ex-d, Ex-e, Ex-i). 

cts Group plans and realizes automation projects for potentially explosive atmospheres – from Ex-compliant control cabinet design through ATEX-certified remote I/O systems to safety instrumented control technology (SIS) – in industries such as chemical, pharmaceutical, and oil & gas. 

See also: RIO (Remote I/O), Control Cabinet, MCC (Motor Control Center), Commissioning, UL (Underwriters Laboratories)

The Factory Acceptance Test (FAT) is a structured inspection carried out at the manufacturer's premises prior to delivery of a plant or control cabinet. Its purpose is to demonstrate conformity with the agreed specifications, standards, and customer requirements before the system leaves the manufacturer's site. 

Typical components of a FAT include: visual inspection of the mechanical design, electrical tests (insulation resistance, continuity testing), functional testing of the control logic, simulation of process signals, and documentation review (circuit diagrams, bills of materials, certificates). 

At cts Group, the FAT is part of the standardized quality process. Customers may participate in the FAT, and the result is documented in a detailed test report – the basis for the subsequent Site Acceptance Test (SAT) on site. 

See also: SAT Checklist (Site Acceptance Test), Commissioning, Audit, DIN EN 61439 / EN 61439 / IEC 61439 (Low-Voltage Switchgear)

Fault tolerance – technically realized through redundancy – refers to a system's ability to maintain operation or transition in an orderly manner to a safe state even in the event of individual component failures. Redundancy can be implemented at the hardware level (dual power supplies, redundant PLC CPUs), software level (hot standby, clustering), or network level (ring topology, dual-homing). 

In process automation, redundancy concepts are essential for critical systems – such as process control systems (PCS/DCS), safety instrumented systems (SIS), and communication networks. Metrics such as MTBF (Mean Time Between Failures) and MTTR (Mean Time to Repair) quantify the achieved availability. High-availability systems reach availabilities of 99.99% (4 nines) and above. 

cts Group designs redundant control and network architectures for critical production processes, taking into account both the technical and economic requirements of customers. 

See also: Asset Management, Alarm Management, Batch Systems, APC (Advanced Process Control)

Federated learning is a machine learning approach in which AI models are trained in a decentralized manner on local datasets – without centralizing them. Only the model updates (gradients), not the raw data, are transmitted to a central server and aggregated there. This protects data privacy and data sovereignty. 

In industry, federated learning is relevant for scenarios in which multiple plants or companies wish to jointly improve AI models for predictive maintenance or quality forecasting without sharing sensitive production data with each other. It enables cross-site learning while maintaining data privacy. 

cts Group monitors and evaluates federated learning approaches in the context of industrial AI projects – as a forward-looking concept for privacy-compliant use of AI in networked production environments. 

See also: AI-Assisted Process Optimization, Advanced Analytics, Industry 4.0, Cloud Computing

Field devices are all measurement, control, and regulation devices installed directly at the process in the field – i.e., in the plant, not in the control cabinet. These include: temperature sensors and transmitters, pressure transmitters, flow meters (electromagnetic, Coriolis, vortex), level measurement devices, analyzers (pH, conductivity, oxygen), control valves, and process valves. 

Modern field devices communicate digitally via HART, Profibus PA, Foundation Fieldbus, or IO-Link and enable remote diagnostics, device parameterization, and condition monitoring from the control room. 

cts Group works manufacturer-independently with field devices from all leading suppliers – including Endress+Hauser, Krohne, Vega, Siemens, and Emerson Rosemount – and handles selection, ordering, installation supervision, and commissioning of the field level. 

See also: Field Level, EMSR Engineering (Electrical Measurement Control & Regulation), Calibration, Asset Management, Analog Signal Processing

The field level is the lowest level of the automation pyramid and encompasses all physical devices deployed directly at the process or machine: sensors (temperature, pressure, flow, level), actuators (valves, pumps, motors), field devices (transmitters, limit switches, analyzers), and their connection components (fieldbus couplers, remote I/O). 

The field level communicates with the superordinate control level (PLC, DCS) via fieldbus systems (Profibus PA, Foundation Fieldbus, HART) or digital protocols (IO-Link, WirelessHART, OPC UA Companion Specifications). The quality of the field level – correct selection, calibration, and installation of instruments – largely determines the accuracy and reliability of the entire automation solution. 

cts Group handles engineering, procurement, and commissioning of the entire field level – from instrumentation planning and EMSR documentation to measurement loop acceptance. 

See also: Field Devices, EMSR Engineering (Electrical Measurement Control & Regulation), Automation Pyramid, Analog Signal Processing, Actuator Technology

A framework is a structured software foundation that provides standard functions, programming interfaces (APIs), and design patterns upon which specific applications are built. It defines the architecture and allows developers to focus on the specialized logic rather than reimplementing basic functions. 

In industrial automation and digitalization, frameworks play an important role: automation frameworks standardize the programming of PLCs and DCS (e.g., Siemens APL), software frameworks such as .NET (for C#), Qt (for C++), or React structure HMI and dashboard development, and data frameworks define the modeling rules for asset frameworks (e.g., in Aveva PI AF).

cts Group uses and develops frameworks for recurring tasks in process automation and industrial informatics – for faster project execution, higher quality, and easier maintainability of delivered solutions. 

See also: C#, C++, Backend Architecture, Capsule Integration, SIMATIC

GMP (Good Manufacturing Practice) refers to a regulatory framework for the manufacture of pharmaceuticals, medical devices, food, and cosmetics that ensures products are consistently manufactured and controlled to the required quality. GMP requirements are regulated in the EU by the EU GMP Guide (Eudralex Volume 4), in the USA by FDA regulations (21 CFR), and internationally by WHO GMP guidelines. 

For automation systems in GMP environments: all computer-aided systems (DCS, SCADA, MES, LIMS) must be validated (CSV), changes are subject to change control, all safety-relevant events are documented in the audit trail, and access is controlled via user access management. 

cts Group has extensive GMP project experience in the pharmaceutical industry and realizes automation solutions that are designed to be GMP-compliant from the outset – from requirements specification to completed validation. 

See also: GxP, Validation, Computer System Validation (CSV), Audit Trail, Change Control (Change Management)

Governance & Compliance in the industrial and digital context refers to the framework of policies, processes, roles, and controls that ensures a company meets regulatory requirements (compliance) and acts according to defined rules and responsibilities (governance). 

In industry, relevant regulatory frameworks include: GMP/GxP (pharma), ATEX (explosion protection), IEC 62443 (cybersecurity), GDPR (data protection), and ISO 9001 (quality management). In the automation and digitalization environment, governance & compliance particularly concerns: access rights management, audit trail, change control, software validation (CSV), and network security (IEC 62443). 

cts Group incorporates governance and compliance requirements into system architecture and project execution – as a fixed component of the quality management system and as added value for customers in regulated industries. 

See also: GMP (Good Manufacturing Practice), GxP, Audit Trail, IEC 62443 (Industrial Cybersecurity), Change Control (Change Management)

GxP is a collective term for a series of 'Good Practice' regulations that define minimum requirements for quality, safety, and traceability in regulated industries – particularly pharmaceutical, biotech, and medical device sectors. The 'x' serves as a placeholder for the respective area: GMP (Manufacturing), GLP (Laboratory), GCP (Clinical), GDP (Distribution), and GDocP (Documentation). 

For automation and IT systems in GxP environments, special requirements apply: Computer System Validation (CSV) per GAMP 5, complete audit trail, electronic signatures per 21 CFR Part 11 (FDA) / EU Annex 11, change control, and regular periodic reviews of validated systems. 

cts Group is an experienced partner for GxP-compliant automation projects – from requirements analysis (URS) through implementation to completed qualification and validation. 

See also: GMP (Good Manufacturing Practice), Validation, Computer System Validation (CSV), Audit Trail, Plant Qualification

HAZOP (Hazard and Operability Study) is a structured, team-based method for the systematic identification of hazards and operating disturbances in process plants. Process parameters (flow, temperature, pressure, level) are examined using guide words (none, more, less, part of, as well as, other than) for possible deviations and their consequences. 

The HAZOP analysis is part of the safety lifecycle per IEC 61511 and forms the basis for defining safety functions (Safety Instrumented Functions, SIF) and their SIL classification. It is typically conducted by an interdisciplinary team of process engineers, EMSR engineers, operators, and safety officers.

cts Group supports operators in conducting HAZOP analyses – as the basis for the design of safety instrumented systems (SIS) and the standards-compliant implementation of protective functions per IEC 61511. 

See also: SIL (Safety Integrity Level), ATEX (Explosion Protection), Berstscheiben-Überwachung, Plant Qualification

Horizontal integration refers to the networking and synchronization of systems, machines, and processes at the same level of the automation pyramid – for example, communication between different production lines, machines, or plant sections at the shopfloor level. It enables a smooth flow of material and information along the entire production chain. 

Technically, horizontal integration is realized through standardized communication protocols (OPC UA, MQTT, Profinet) and middleware platforms. In the context of Industry 4.0, horizontal integration is a prerequisite for interlocked production systems, just-in-time production, and cyber-physical systems (CPS). 

cts Group realizes horizontal integration concepts in manufacturing and process automation – as part of holistic digitalization and automation projects encompassing all levels from field level to ERP level. 

See also: Vertical Integration, OPC UA (Open Platform Communications Unified Architecture), MQTT (Message Queuing Telemetry Transport), MES (Manufacturing Execution System), Automation Pyramid

IEC 62443 is the international standard series for cybersecurity in industrial automation and control systems (IACS). It defines requirements for security management systems, secure system architectures, security requirements for components, and processes for operators, integrators, and component manufacturers. 

The standard is divided into four parts: IEC 62443-1 (concepts & models), IEC 62443-2 (operator requirements & patch management), IEC 62443-3 (system requirements & security levels), and IEC 62443-4 (component requirements). Security Levels (SL 1-4) describe the required degree of protection against various threat scenarios. 

cts Group applies IEC 62443 when planning industrial network architectures and OT security concepts – as the foundation for defense-in-depth strategies, network segmentation (VLANs), and secure user access management in industrial environments. 

See also: Network Architecture, VLAN (Virtual Local Area Network), VPN (Virtual Private Network), User Access Management (UAM), OT (Operational Technology)

IIoT (Industrial Internet of Things) refers to the industrial manifestation of the Internet of Things – i.e., the networking of machines, sensors, controls, and plants via standardized communication protocols and cloud platforms to acquire data, analyze it, and optimize processes. IIoT is the technical foundation of Industry 4.0. 

Core technologies of IIoT are: edge gateways and edge computing devices, communication protocols (OPC UA, MQTT), cloud platforms (Azure IoT Hub, AWS IoT, Siemens MindSphere), data analysis services, and dashboarding tools. IIoT enables applications such as remote monitoring, predictive maintenance, energy management, and production optimization. 

cts Group implements IIoT solutions for the process and manufacturing industries – from machine connectivity and protocol conversion through edge computing to cloud integration and analytics applications. 

See also: Industry 4.0, Edge Computing, OPC UA (Open Platform Communications Unified Architecture), MQTT (Message Queuing Telemetry Transport), Cloud Computing

Industrial Data Fabric (IDF) refers to a modern data architecture that spans a uniform, context-rich, and seamlessly accessible data layer across all systems, locations, and technology levels of an industrial organization – without requiring all data to be physically centralized in one location. It integrates data in a federated manner from historian, MES, ERP, SCADA, and cloud sources. 

Core principles include: semantic data normalization (uniform contextualization through asset models), federated data access (data remains at the source but becomes uniformly addressable), active metadata management, and automated data pipelines. OPC UA, MQTT, and Unified Namespace (UNS) are important building blocks. 

cts Group develops and implements Industrial Data Fabric architectures as a forward-looking alternative to monolithic data silos – for scalable, enterprise-wide data transparency in the process and manufacturing industries. 

See also: Unified Namespace (UNS), Data Hub, OPC UA (Open Platform Communications Unified Architecture), MQTT (Message Queuing Telemetry Transport), Data Consolidation

Industry 4.0 refers to the fourth industrial revolution – the combination of automation technology, digitalization, and the Internet of Things (IIoT) into cyber-physical production systems. The term was coined by the German Federal Ministry of Education and Research and describes the intelligent networking of machines, plants, people, and data along the entire value chain. 

Concrete building blocks of Industry 4.0 include: digital twins, autonomous systems, predictive maintenance, horizontal and vertical integration, additive manufacturing, augmented reality for maintenance and training, and AI-assisted process optimization. Internationally, the concept is discussed under terms such as Smart Manufacturing, Manufacturing 4.0, or Digitalisation of Manufacturing. 

cts Group accompanies industrial companies in the strategic and operational implementation of Industry 4.0 concepts – as a full-service provider offering automation technology, digitalization, and system integration from a single source. 

See also: IIoT (Industrial Internet of Things), Digital Production, Twin Technology (Digital Twin), Predictive Maintenance, MES (Manufacturing Execution System)

Interface management refers to the systematic planning, documentation, implementation, and monitoring of all data and communication interfaces between different systems in an automation or digitalization project. 

It encompasses: identification and specification of all required interfaces (OPC UA, REST API, MQTT, database connections), definition of data formats and protocols, assignment of responsibilities between system suppliers, testing and validation of interfaces, and ongoing monitoring of interface performance and availability. 

In complex projects with multiple system suppliers (DCS, MES, ERP, historian), interface management is a critical success factor: undefined or poorly documented interfaces are one of the most common causes of project delays and integration problems. 

cts Group treats interface management as a dedicated discipline in its projects – with structured interface registers, clear responsibilities, and systematic interface testing as part of FAT and SAT. 

See also: REST-API (Representational State Transfer), OPC UA (Open Platform Communications Unified Architecture), MQTT (Message Queuing Telemetry Transport), JSON (JavaScript Object Notation), XML (Extensible Markup Language)

IP.21 (AspenTech InfoPlus.21) is a leading historian and process data management system from AspenTech, widely used in the process industry – particularly in refining, petrochemicals, and chemicals. It acquires, stores, and manages time-series data from process plants at high resolution and makes it available for optimization, analysis, and reporting purposes. 

IP.21 offers a powerful database structure for process histories, extensive connectivity to DCS, PLC, and SCADA systems, and an open API layer for integration with APC applications, energy management systems, and analytics tools. 

cts Group has experience in the integration and administration of IP.21 systems – as part of digitalization and APC projects in the process industry. 

See also: Aspentech Inmation, Aveva PI, Data Historization, APC (Advanced Process Control), Advanced Analytics

ISA-95 (internationally also IEC 62264) is an international standard that defines the integration of enterprise IT systems (ERP) and production systems (MES, SCADA). It describes information models, interfaces, and data structures for the standardized exchange of production orders, material data, personnel information, and production results between system levels. 

ISA-95 defines, among other things, the functional hierarchy (Level 0-4) of the automation pyramid, the object model for production operations, and B2MML (Business to Manufacturing Markup Language) as an XML-based exchange format. It is the de-facto standard for MES/ERP integrations in the process and manufacturing industries. 

cts Group uses ISA-95 as a reference model when planning and implementing MES deployments and ERP integrations – for clearly defined interfaces, clean data structures, and future-proof system architectures. 

See also: MES (Manufacturing Execution System), ERP (Enterprise Resource Planning), SAP, Vertical Integration, Automation Pyramid

An island solution refers to an IT or automation system operated in isolation from other systems – without standardized interfaces or integration into the company's overarching data architecture. Island solutions frequently arise from organically grown IT landscapes, proprietary systems, or a lack of integration strategies. 

The consequences of island solutions include: redundant data management, manual data transfer (e.g., via Excel), lack of real-time availability of production data, high maintenance costs, and dependency on individual vendors. Overcoming island solutions is a central goal of Industry 4.0 and digitalization initiatives. 

cts Group analyzes existing IT/OT landscapes of its customers, identifies island solutions, and develops integration strategies – via standardized interfaces (OPC UA, REST API, MQTT) and modern data architectures (Data Hub, UNS). 

See also: Unified Namespace (UNS), Interface Management, Horizontal Integration, Data Consolidation, Legacy Systems

IT (Information Technology) refers to the totality of technologies, systems, and processes used for the acquisition, processing, storage, transmission, and presentation of information in digital form. 

In the industrial context, IT systems encompass: enterprise resource planning (ERP), databases, networks, servers, cloud platforms, cybersecurity systems, and business intelligence tools. The distinction between IT and OT (Operational Technology) is of central importance in industrial environments: while IT focuses on data processing and business processes, OT controls and monitors physical production processes in real time. The convergence of IT and OT – driven by Industry 4.0 – brings significant benefits in terms of data transparency and optimization potential, but also requires new security architectures (IEC 62443) and organizational alignment. 

cts Group bridges IT and OT in its projects – as an engineering partner that masters both worlds and designs integrated solutions from the field level to the enterprise level. 

See also: OT (Operational Technology), IEC 62443 (Industrial Cybersecurity), Network Architecture, Backend Architecture, Industry 4.0

JSON (JavaScript Object Notation) is a lightweight, text-based data format used for the structured exchange of data between systems and applications. It is human-readable, easy to parse by machines, and language-independent. JSON has become the dominant format for REST APIs, configuration files, and data exchange between web services and industrial applications. 

In industrial informatics and IIoT architectures, JSON is used for transmitting measurement values, alarm messages, device configurations, and process data – for example, via MQTT brokers or REST APIs between edge devices, cloud platforms, and analytics systems.

cts Group uses JSON as the standard data format in its IIoT and industrial informatics projects – for interfaces between PLC/DCS systems, data hubs, and cloud-based analytics applications. 

See also: REST-API (Representational State Transfer), MQTT (Message Queuing Telemetry Transport), XML (Extensible Markup Language), ETL Tools (Extract, Transform, Load), Interface Management

Just-in-Time (JIT) production is a manufacturing strategy in which materials, components, and products are produced or delivered exactly when they are needed in the production process – neither too early nor too late. The goal is to minimize inventory, reduce storage costs, and increase production efficiency. 

JIT requires precise synchronization between production planning, logistics, and suppliers, as well as real-time data availability at all process steps. In modern production environments, JIT is enabled by MES systems, automated material flow systems (AMR, conveyor systems), and real-time data transparency from IIoT platforms. 

cts Group supports JIT-capable production environments through automation solutions for material handling, intralogistics, and MES integration. 

See also: MES (Manufacturing Execution System), Predictive Maintenance, Zero Downtime Strategy, ERP (Enterprise Resource Planning), Shopfloor

Apache Kafka is a distributed, highly scalable streaming platform that enables the real-time transmission and processing of large data streams. Kafka operates on the publisher-subscriber principle: data producers publish messages to topics, and consumers read these messages in real time or with a time delay. 

In industrial informatics and IIoT architectures, Kafka is used as a central message broker for high-frequency machine and process data – for example, to collect sensor data from thousands of machines in real time, route it to analytics systems, and make it available for AI applications. 

cts Group integrates Apache Kafka into Industrial Data Fabric and Big Data architectures – as a reliable, high-performance transport layer for industrial real-time data streams. 

See also: Data Hub, MQTT (Message Queuing Telemetry Transport), ETL Tools (Extract, Transform, Load), Backend Architecture, Unified Namespace (UNS)

A KPI dashboard (Key Performance Indicator Dashboard) is a visual interface that displays the most important performance indicators of a production plant, a production line, or an entire company in real time or near real time. Typical KPIs in production include: OEE (Overall Equipment Effectiveness), throughput, scrap rate, energy consumption per unit, availability, and MTBF (Mean Time Between Failures). 

KPI dashboards are implemented as web-based applications, SCADA overlays, or standalone analytics platforms and enable rapid identification of deviations and bottlenecks. The data foundation is provided by MES systems, historian platforms (Aveva PI), and MDA systems. 

cts Group designs and develops KPI dashboards as part of its industrial informatics portfolio – tailored to the specific KPIs and visualization requirements of production and plant management. 

See also: OEE (Overall Equipment Effectiveness), Real-Time Visualization, Manufacturing Data Acquisition (MDA), Aveva PI, MES (Manufacturing Execution System)

LabX is a laboratory software platform by METTLER TOLEDO for the centralized management, automation, and documentation of measurement workflows in analytical laboratories. It connects balances, titrators, pH meters, and other METTLER TOLEDO instruments to a central software system and enables automated data acquisition, result calculation, and electronic documentation in compliance with GMP/GLP requirements.

In pharmaceutical, chemical, and food industry laboratories, LabX ensures a complete audit trail for all measurement results, automated method management, and seamless integration into LIMS and ERP systems. 

cts Group integrates LabX into laboratory automation and digitalization projects in regulated industries – as part of a GMP-compliant laboratory IT infrastructure. 

See also: GxP, GMP (Good Manufacturing Practice), Audit Trail, Validation, Paperless Manufacturing

Legacy systems are older IT or automation systems that are still in productive operation but are based on outdated technology, are no longer actively maintained by the manufacturer, and are difficult or impossible to integrate with modern systems. In the industrial environment, legacy systems are found in the form of outdated PLC generations, proprietary SCADA systems, aging historian platforms, or standalone MES solutions without open interfaces. 

Legacy systems represent a challenge for digitalization projects: they contain valuable process knowledge and production data, but prevent the implementation of modern architectures (IIoT, cloud, AI) due to their lack of connectivity. 

cts Group specializes in the analysis and integration of legacy systems – either through targeted retrofitting, interface development, or systematic migration to modern platforms. 

See also: Plant Modernization (Retrofit), Brownfield Transformation, Isolated System (Island Solution), Interface Management

Lightning protection and equipotential bonding are electrical protective measures that protect people, buildings, and plants against the effects of lightning strikes and electrical potential differences. External lightning protection (air terminals, down conductors, earth electrodes) safely conducts lightning currents into the ground. 

Internal lightning protection (overvoltage protection, SPD – Surge Protective Devices) protects electrical installations from overvoltages. Equipotential bonding connects all conductive parts of a plant to the same electrical potential to prevent dangerous voltage differences. It is required per DIN VDE 0100-540 and is particularly critical in industrial and Ex-zone installations. Surge protective devices are classified according to EN 61643-11 (Type 1/2/3). 

At cts Group, lightning protection and equipotential bonding are considered during control cabinet construction and plant planning – from zone planning per IEC 62305 through selection of appropriate SPDs to testing in the FAT. 

See also: Switchgear Assembly, Control Cabinet, VDE (Association for Electrical, Electronic and Information Technologies), DIN EN 61439 / EN 61439 / IEC 61439 (Low-Voltage Switchgear), EX Zones (Explosion Protection)

Machine digitalization refers to the process of connecting existing machines and production equipment to digital systems and networks in order to make machine data available for monitoring, analysis, and optimization. 

The core of machine digitalization is the retrofit integration of IoT sensors, edge gateways, and communication interfaces (OPC UA, MQTT) into existing machines – without replacing the machines themselves. Machine digitalization enables: real-time machine monitoring (availability, performance, quality), predictive maintenance based on sensor data, remote access for service and diagnostics, and integration of machine data into MES and analytics platforms. 

cts Group realizes machine digitalization projects as part of brownfield transformation – from the selection of suitable sensors and gateways through OPC UA interface development to integration into historian and analytics platforms. 

See also: Brownfield Transformation, IIoT (Industrial Internet of Things), Edge Computing, OPC UA (Open Platform Communications Unified Architecture), Predictive Maintenance

Maintenance management encompasses all organizational and technical activities related to the planning, execution, documentation, and optimization of maintenance work on production plants and equipment. 

It distinguishes between: reactive maintenance (repair after failure), preventive maintenance (time-based, scheduled maintenance), condition-based maintenance (based on actual equipment condition), and predictive maintenance (AI-based, based on condition prognosis). 

Modern maintenance management is supported by CMMS systems (Computerized Maintenance Management Systems) such as SAP PM, IBM Maximo, or Infor EAM, which manage maintenance orders, spare parts, maintenance history, and KPIs (MTBF, MTTR). 

cts Group supports customers in setting up efficient maintenance management systems – from the selection and implementation of CMMS solutions through the definition of maintenance strategies to the integration of predictive maintenance components. 

See also: Asset Management, Predictive Maintenance, Zero Downtime Strategy, Manufacturing Data Acquisition (MDA)

Manufacturing Data Acquisition (MDA) refers to the systematic acquisition, storage, and analysis of production and machine data in real time. 

Typical MDA data includes: machine uptime, downtime and their causes, unit counts, reject quantities, energy consumption, and personnel deployment. MDA is the basis for OEE calculations (Overall Equipment Effectiveness) and production optimization. 

Modern MDA systems acquire data directly from machines (via OPC UA, Profinet, digital I/O), from handheld scanners, or via manual entries at HMI terminals. The data is stored in MES systems or historian platforms and processed for reports, dashboards, and Advanced Analytics applications. 

cts Group implements MDA solutions as part of its industrial informatics platform – from machine data connectivity and data modeling through to visualization at plant and enterprise level. 

See also: Asset Management, Automation Pyramid, Advanced Analytics, Aveva PI, Batch Systems

A Motor Control Center (MCC) is a switchgear assembly that centrally houses and controls the motor starters, frequency converters, and protective devices for multiple electric motors in an industrial plant. MCCs are used in process plants, pumping stations, and production facilities to efficiently organize and protect the power supply and control of motor-driven drives. 

Modern MCCs are equipped with intelligent motor protection relays (e.g., Siemens SIRIUS, Rockwell E300) that monitor current, voltage, temperature, and operating hours and communicate via fieldbus (Profibus, Profinet, EtherNet/IP) with the process control system. 

cts Group engineers, builds, and commissions MCCs compliant with DIN EN 61439 – from the engineering concept and EPLAN documentation through cabinet construction, FAT, and on-site commissioning. 

See also: Switchgear Assembly, Control Cabinet, DIN EN 61439 / EN 61439 / IEC 61439 (Low-Voltage Switchgear), EX Zones (Explosion Protection), UL (Underwriters Laboratories), CSA (Canadian Standards Association)

A Manufacturing Execution System (MES) is a software system that manages, controls, and documents production processes in real time at the shopfloor level. MES systems form the linking layer between the automation level (PLC, SCADA, historian) and the enterprise level (ERP). 

Core functions of an MES include: production order management, machine and personnel scheduling, real-time production monitoring, quality management, batch tracking, MDA (manufacturing data acquisition), and OEE calculation. 

Leading MES solutions include Siemens Opcenter, Rockwell FactoryTalk, Aveva MES, and SAP ME/MII. MES systems communicate with ERP systems via ISA-95 interfaces and with control systems via OPC UA. 

cts Group implements MES solutions as part of digitalization projects – from requirements analysis and system selection through implementation and integration to validation and training. 

See also: ISA-95 (Manufacturing Operations Management Standard), ERP (Enterprise Resource Planning), SAP, Shopfloor, Manufacturing Data Acquisition (MDA)

Multi-Factor Authentication (MFA) is a security mechanism that requires users to verify their identity through at least two independent authentication factors before gaining access to a system. The three possible factor types are: knowledge (password, PIN), possession (hardware token, smartphone app), and biometrics (fingerprint, face recognition). 

In industrial environments, MFA is increasingly required for access to critical systems – particularly for remote access to OT networks, SCADA systems, and cloud platforms. Standards such as IEC 62443 and NIST SP 800-82 recommend MFA as a key measure for OT cybersecurity. 

cts Group implements MFA as part of industrial network security concepts – in combination with VPN, VLAN segmentation, and user access management – for secure remote access to production systems. 

See also: User Access Management (UAM), IEC 62443 (Industrial Cybersecurity), Active Directory, VPN (Virtual Private Network), SAML (Security Assertion Markup Language)

MongoDB is a leading document-oriented NoSQL database that stores data in flexible, JSON-based documents instead of the rigid table structure of relational databases. It is particularly well-suited for storing heterogeneous, semi-structured data – such as sensor data, event logs, configuration data, and process reports – that does not fit into a uniform schema. 

In industrial informatics, MongoDB is used for: storage of IIoT data streams from edge devices, logging of machine events and alarms, storage of production reports, and as a backend database for web-based HMI and analytics applications. The horizontal scalability of MongoDB makes it suitable for Big Data scenarios with large volumes of production data. 

cts Group uses MongoDB in industrial software projects where high flexibility in data modeling and horizontal scalability are required. 

See also: NoSQL Databases, SQL Databases, Backend Architecture, JSON (JavaScript Object Notation), Data Hub

MQTT (Message Queuing Telemetry Transport) is a lightweight, publish-subscribe-based messaging protocol developed for the reliable transmission of data in networks with limited bandwidth and unstable connections. Due to its minimal resource consumption and efficient data transmission, MQTT has become the dominant protocol in IIoT and industrial communication. 

MQTT operates via a central broker (e.g., Mosquitto, HiveMQ, AWS IoT Core) that receives messages from publishers and distributes them to all subscribed consumers. In industrial automation, MQTT is used for: real-time transmission of sensor data from edge devices to the cloud, machine-to-machine communication, and as a transport layer in Unified Namespace (UNS) architectures. 

cts Group integrates MQTT into IIoT architectures and Industrial Data Fabric solutions – as a reliable, scalable communication protocol between shopfloor, edge, and cloud. 

See also: OPC UA (Open Platform Communications Unified Architecture), IIoT (Industrial Internet of Things), Unified Namespace (UNS), Edge Computing, Data Hub

MTP (Module Type Package) is a standardized description format for modular process equipment (Process Equipment Assembly, PEA) in process plants. It describes all relevant information of a process module – control interfaces, HMI representations, services, and alarm definitions – in a machine-readable XML format. 

MTP enables the plug-and-play integration of process modules from different manufacturers into a superordinate process orchestration layer (Process Orchestration Layer, POL) without the need for individual programming efforts for each combination. This significantly reduces integration effort and increases flexibility in modular plant design. 

cts Group uses the MTP standard in modular plant projects to realize standardized module integration and to implement flexible, scalable process automation architectures for the pharmaceutical, chemical, and food industries. 

See also: Capsule Integration, NAMUR Recommendations, Interface Management, Batch Systems

NAMUR (Normenarbeitsgemeinschaft für Mess- und Regeltechnik in der chemischen Industrie) is a user association of process industries that develops recommendations and standards for measurement and control technology, field instruments, and automation systems. 

NAMUR recommendations (NE) define best practices and technical requirements that go beyond existing standards – for example, for the behavior of field instruments during power failure (NE 43), for intrinsic safety (NE 96), or for the open communication standard NOA (NAMUR Open Architecture). 

In practice, NAMUR recommendations are frequently referenced in specifications and procurement documents for field instruments and process control systems in the chemical, pharmaceutical, and energy industries. 

cts Group takes NAMUR recommendations into account in the engineering and procurement of instrumentation and process control technology – as a recognized quality and safety standard in the process industry. 

See also: Field Devices, EMSR Engineering (Electrical Measurement Control & Regulation), IIoT (Industrial Internet of Things), MTP (Module Type Package), Process Control Technology

Network architecture in the industrial context refers to the structured design of communication networks within a plant or company – encompassing the physical topology (star, ring, bus), the logical segmentation (VLANs, subnets), the selection of protocols (Profinet, OPC UA, MQTT, Ethernet/IP), and the security concepts (firewalls, DMZ, IEC 62443). 

A well-designed industrial network architecture separates OT networks from IT networks and the internet via dedicated demilitarized zones (DMZ), while still enabling controlled data exchange between levels. Redundant network designs (ring topology, dual-homing) ensure high availability for critical production systems. 

cts Group plans and implements industrial network architectures in accordance with IEC 62443 and customer-specific security requirements – from the field level to cloud connectivity. 

See also: IEC 62443 (Industrial Cybersecurity), VLAN (Virtual Local Area Network), VPN (Virtual Private Network), OT (Operational Technology), IT (Information Technology)

NoSQL databases are non-relational database systems that, in contrast to classical SQL databases, do not use a fixed table schema and are optimized for specific data models and access patterns. The main NoSQL categories are: document databases (MongoDB), key-value stores (Redis), column-family databases (Cassandra), and graph databases (Neo4j). 

In industrial informatics and IIoT applications, NoSQL databases are used for the storage of large volumes of time-series data, event streams, and heterogeneous sensor data – where the flexibility of schema-less data modeling and horizontal scalability are decisive advantages. 

cts Group uses NoSQL databases in IIoT and analytics projects – as flexible, scalable components of industrial data platforms for specific use cases where relational databases reach their limits. 

See also: MongoDB, SQL Databases, Backend Architecture, Data Hub, Data Historization

OEE (Overall Equipment Effectiveness) is a key performance indicator for measuring the productivity of a production plant or machine. It is calculated as the product of three factors: Availability (actual operating time vs. planned operating time), Performance (actual output vs. theoretical maximum output), and Quality (good parts vs. total parts produced).

An OEE of 100% means the machine runs without interruption, at maximum speed, and without rejects. In practice, world-class OEE for discrete manufacturing is considered to be around 85%. 

OEE is the central KPI of TPM (Total Productive Maintenance) and forms the basis for targeted optimization measures to reduce planned and unplanned downtime, speed losses, and quality defects. 

cts Group implements OEE monitoring systems as part of MES and MDA solutions – from machine data acquisition and OEE calculation to real-time visualization on KPI dashboards. 

See also: KPI Dashboard, MES (Manufacturing Execution System), Manufacturing Data Acquisition (MDA), Real-Time Visualization, Predictive Maintenance

On-premise (also: on-prem) describes an IT deployment model in which software systems and data are operated on the company's own servers and hardware – as opposed to cloud-based solutions (SaaS, PaaS, IaaS). 

In industrial environments, on-premise deployment is often preferred for process-critical systems such as process control systems (DCS/PCS), SCADA, and historian systems due to lower latency, data sovereignty, independence from internet connectivity, and compliance with industrial security requirements. 

The decision between on-premise and cloud is often made on a use-case basis: real-time control systems typically remain on-premise, while analytics and reporting applications increasingly migrate to hybrid or cloud architectures. 

cts Group implements both on-premise and hybrid architectures depending on customer requirements – with a focus on secure, reliable, and performant industrial IT solutions. 

See also: Cloud Computing, Backend Architecture, IEC 62443 (Industrial Cybersecurity), Network Architecture, OT (Operational Technology)

An OPC server is a software component that makes data from a PLC, DCS, SCADA system, or field device available via the OPC standard (OLE for Process Control) for other applications. The OPC DA (Data Access) standard, which preceded OPC UA, enables the reading and writing of current process values via a defined interface. 

OPC servers act as translators between proprietary automation protocols (Siemens S7, Modbus, Allen-Bradley, BACnet) and standardized OPC interfaces. In legacy systems and brownfield environments, OPC-DA servers are still widely used as data sources for historian systems (Aveva PI), SCADA, and MES applications. 

cts Group develops and integrates OPC servers for the connection of legacy systems and proprietary automation components – as a bridging technology for the integration of existing systems into modern data architectures. 

See also: OPC UA (Open Platform Communications Unified Architecture), SCADA (Supervisory Control and Data Acquisition), Data Historization, Interface Management, Process Control Technology

OPC UA (Open Platform Communications Unified Architecture) is the leading industrial communication standard for platform-independent, secure, and standardized data exchange between automation systems, machines, and IT systems. 

OPC UA combines a powerful data model (objects, methods, events, historical data) with built-in security mechanisms (authentication, encryption, authorization) and supports both client-server and publish-subscribe communication patterns (via OPC UA PubSub over MQTT). OPC UA is the basis for Companion Specifications that define standardized data models for specific machine types and is the recommended communication standard for Industry 4.0 and IIoT. 

cts Group implements OPC UA interfaces for machine connectivity, system integration, and IIoT architectures – as the universal language between shopfloor and cloud. 

See also: MQTT (Message Queuing Telemetry Transport), IIoT (Industrial Internet of Things), Unified Namespace (UNS), Interface Management, Industrial Data Fabric (IDF)

OT (Operational Technology) refers to hardware and software that monitors and controls physical devices, processes, and events in industrial environments. OT encompasses: PLCs (Programmable Logic Controllers), DCS (Distributed Control Systems), SCADA systems, HMIs, field instruments, and industrial networks. In contrast to IT (Information Technology), which focuses on data processing and communication, OT is primarily concerned with the real-time control and monitoring of physical processes. 

The convergence of OT and IT (OT/IT integration) is a central topic of Industry 4.0: production data from OT systems flows into IT systems for analysis and optimization, while IT systems provide planning and resource management. This convergence also creates new cybersecurity challenges addressed by the IEC 62443 standard. 

cts Group bridges OT and IT in its projects – as an engineering partner who understands both worlds. 

See also: IT (Information Technology), IEC 62443 (Industrial Cybersecurity), Network Architecture, SCADA (Supervisory Control and Data Acquisition), Process Control Technology

Paperless Manufacturing refers to the complete digitalization of production documents, work instructions, quality records, and reports – replacing paper-based processes with digital systems. 

In regulated industries (pharmaceutical, medical devices, food), paperless manufacturing also means the implementation of Electronic Batch Records (EBR), electronic work instructions, and digital quality records in compliance with GMP and 21 CFR Part 11 requirements. 

The benefits of paperless manufacturing include: elimination of transcription errors, real-time availability of production data, faster batch release, better traceability, and reduced documentation effort. Technically, paperless manufacturing is implemented through MES systems, tablet-based operator terminals, and digital shift logbooks. 

cts Group implements paperless manufacturing solutions as part of MES and digitalization projects. 

See also: MES (Manufacturing Execution System), GMP (Good Manufacturing Practice), Audit Trail, Digital Shift Logs, Batch Process

Paperless processes refer to the comprehensive digitalization of administrative and operational workflows that previously relied on paper-based documents. In the industrial context, this encompasses engineering documentation (digital P&IDs, electronic approval workflows), maintenance processes (digital maintenance orders and reports), procurement (electronic purchase orders and delivery notes), and quality management (digital test records and certificates). 

Paperless processes increase efficiency through faster information access, reduce errors through automated data validation, and improve traceability through digital audit trails. They are a prerequisite for integrated, data-driven business processes and form the foundation for further automation and AI-assisted process optimization. 

cts Group supports industrial companies in the transition to paperless processes – as part of holistic digitalization and Industry 4.0 initiatives. 

See also: Paperless Manufacturing, MES (Manufacturing Execution System), Audit Trail, Workflow Automation, Digital Shift Logs

Physical-to-Virtual (P2V) refers to the migration or replication of physical hardware systems – servers, workstations, control systems – into virtual environments. In the industrial context, P2V is particularly relevant for the virtualization of engineering workstations, historian servers, SCADA server systems, and legacy systems that can no longer be operated on modern hardware. 

Virtualization reduces hardware costs, increases system availability through snapshots and live migration, simplifies backup and disaster recovery, and enables the parallel operation of multiple operating system environments.

Industrial virtualization must take into account special requirements such as real-time capability, deterministic response times, and industrial reliability. 

cts Group realizes P2V projects for industrial systems – from the assessment of virtualizability through platform selection (VMware, Hyper-V, Nutanix) to migration and validation. 

See also: Virtualization, Legacy Systems, Plant Modernization (Retrofit), Fault Tolerance (Redundancy)

Plant modernization – frequently referred to as retrofit – is the targeted renewal or upgrading of existing production plants without replacing them entirely. The goal is to bring outdated control technology, field devices, or infrastructure up to the current state of the art while minimizing downtime and investment costs. 

Typical retrofit measures include: replacement of outdated PLC systems with modern systems (e.g., Siemens S5 to S7 to TIA Portal), renewal of control cabinets and switchgear, migration from proprietary fieldbus systems to Profinet/Industrial Ethernet, and integration of remote monitoring functions. 

cts Group specializes in brownfield modernizations and accompanies customers from the initial assessment through the engineering phase to commissioning – with a particular focus on minimal production interruption and standards-compliant execution (DIN EN 61439, DIN EN 60204-1). 

See also: Brownfield Transformation, Switchgear Assembly, Control Cabinet, Commissioning, DIN EN 61439 / EN 61439 / IEC 61439 (Low-Voltage Switchgear)

Plant qualification is a documented proof that a production plant or automation system meets the intended requirements and functions reproducibly and correctly. It is particularly required in regulated industries such as pharmaceutical, biotech, and food industries (GMP – Good Manufacturing Practice). 

Qualification is typically divided into four phases: Design Qualification (DQ) – verification of the design against requirements; Installation Qualification (IQ) – verification of correct installation; Operational Qualification (OQ) – verification of functional capability; and Performance Qualification (PQ) – proof of process performance under real conditions. 

cts Group creates qualification documentation according to GAMP 5 and supports pharmaceutical and food processing customers in the complete qualification of their automation solutions – from DQ through to the final PQ. 

See also: Audit, Audit Trail, Factory Acceptance Test (FAT), SAT Checklist (Site Acceptance Test), Commissioning

Personal Protective Equipment (PPE) refers to all devices and equipment worn by workers to protect themselves from hazards to their health and safety. In industrial plants and during commissioning and maintenance work, PPE is mandatory and must be adapted to the specific hazards present. 

Typical PPE includes: hard hat, safety glasses, ear protection, safety shoes, protective gloves, flame-retardant work clothing, and respiratory protection. 

In Ex zones and chemical plants, additional PPE requirements apply: antistatic clothing, chemical-resistant gloves and face shields, and gas warning devices. The selection and use of PPE is regulated by national occupational health and safety regulations (DGUV, BGV) and plant-specific safety requirements. 

At cts Group, compliance with PPE requirements is a non-negotiable safety standard for all service, commissioning, and maintenance assignments at customer sites. 

See also: Work Permit (Permit-to-Work), ATEX (Explosion Protection), EX Zones (Explosion Protection), Commissioning

Predictive Maintenance (PdM) is a maintenance strategy that uses real-time sensor data, machine learning algorithms, and statistical models to predict upcoming equipment failures before they occur – enabling targeted, condition-based maintenance instead of costly emergency repairs or unnecessarily frequent preventive maintenance. 

Typical data sources for predictive maintenance models are: vibration sensors, temperature measurements, current monitoring, oil analysis, and historical fault data from historian systems. Machine learning algorithms (anomaly detection, regression models, neural networks) identify abnormal patterns in machine behavior and trigger maintenance alerts with a defined lead time. 

cts Group develops Predictive Maintenance solutions as part of IIoT and analytics projects – from sensor integration and historian connection through model development and validation to dashboard integration and alerting. 

See also: AI-Assisted Process Optimization, Advanced Analytics, Aveva PI, Asset Management, Zero Downtime Strategy

A Process Control System (PCS) – also Distributed Control System (DCS) – is an integrated automation system for the centralized control, monitoring, and optimization of complex industrial processes. In contrast to PLC-based systems, a DCS is designed for continuous process control with thousands of measuring points and features a distributed architecture with redundant controllers, dedicated operator workstations, and integrated engineering tools. 

Leading DCS systems include Siemens SIMATIC PCS 7 / PCS neo, ABB 800xA, Emerson DeltaV, Honeywell PKS, and Yokogawa CENTUM. DCS systems control processes such as: temperature and pressure regulation, flow control, reactor management, batch processes, and complex multi-variable control loops. 

cts Group plans, programs, and commissions DCS systems for the chemical, pharmaceutical, food, and energy industries – including integration with safety systems (SIS) and historian platforms. 

See also: Process Control Technology, SCADA (Supervisory Control and Data Acquisition), Programmable Logic Controller (PLC), Field Level, EMSR Engineering (Electrical Measurement Control & Regulation)

Process control technology encompasses all technical systems used for the monitoring, control, and optimization of industrial processes from a central location. The core of process control technology is the Distributed Control System (DCS) or Process Control System (PCS), which collects sensor data from the field level, executes control logic, and displays the plant status on operator workstations via HMI/SCADA interfaces. 

Process control technology includes: process control systems (Siemens PCS 7, ABB 800xA, Emerson DeltaV, Honeywell PKS), operator workstations, engineering stations, historian systems, and safety systems (SIS). In modern plants, process control technology is networked with MES and ERP systems via ISA-95 interfaces. 

cts Group plans, implements, and commissions process control technology for the chemical, pharmaceutical, food, and energy industries – from the engineering concept to FAT and commissioning. 

See also: Process Control System (PCS/DCS), SCADA (Supervisory Control and Data Acquisition), Field Level, Automation Pyramid, EMSR Engineering (Electrical Measurement Control & Regulation)

A Programmable Logic Controller (PLC) is an industrial computer specially designed for the real-time control of machines and processes. In contrast to conventional computers, PLCs are optimized for high availability, EMC resistance, wide temperature ranges, and deterministic execution of control programs. 

PLCs process digital and analog input signals (from sensors, limit switches, transmitters), execute the programmed control logic (cyclic or event-driven), and output signals to actuators (valves, motors, drives). Programming is carried out according to IEC 61131-3 in standardized languages: Ladder Diagram (LD), Function Block Diagram (FBD), Structured Text (ST), Instruction List (IL), and Sequential Function Chart (SFC). 

cts Group programs PLCs from all leading manufacturers (Siemens SIMATIC, Rockwell Allen-Bradley, Beckhoff, ABB, Schneider Electric) for process automation, machine control, and special machinery projects. 

See also: Controller (Programmable Logic Controller), SIMATIC, Process Control System (PCS/DCS), Field Level, EMSR Engineering (Electrical Measurement Control & Regulation)

Pseudocode is an informal, human-readable description of an algorithm or program logic that uses the structure of programming languages but is not tied to a specific programming language and therefore does not need to comply with exact syntax rules. 

Pseudocode serves as a planning and communication tool between engineers, developers, and customers to describe the logic of a control program or software function before the actual implementation – regardless of whether the final code will be written in ST (Structured Text), Python, C#, or another language. In automation engineering, pseudocode is used for the description of control sequences, state machines, and recipe logic before programming in a PLC language according to IEC 61131-3. 

cts Group uses pseudocode as a documentation and specification tool in software development projects to make complex logic understandable and reviewable for all project participants. 

See also: C#, C++, Programmable Logic Controller (PLC), Validation, Framework

Quality of Service (QoS) refers to the ability of a communication network or protocol to guarantee defined service quality parameters – such as bandwidth, latency, packet loss, and reliability – for specific data streams. 

In industrial networks, QoS is critical for time-sensitive control communication: process-critical data (emergency stop signals, safety messages, real-time control) must be transmitted with higher priority than non-critical data (reports, backups). In MQTT, QoS levels (0 = At most once, 1 = At least once, 2 = Exactly once) define the reliability of message delivery. Industrial Ethernet protocols such as PROFINET IRT use hardware-based QoS mechanisms to achieve real-time capability. 

cts Group takes QoS requirements into account when designing industrial network architectures and IIoT communication systems. 

See also: MQTT (Message Queuing Telemetry Transport), Network Architecture, OPC UA (Open Platform Communications Unified Architecture), IIoT (Industrial Internet of Things), Fault Tolerance (Redundancy)

Quality assurance (QA) encompasses all planned and systematic activities aimed at ensuring that a product or service meets defined quality requirements. 

In the context of automation and plant engineering, QA covers: review of engineering documents (P&IDs, circuit diagrams, software specifications), inspection of manufactured equipment (control cabinets, switchgear), functional testing (FAT, SAT), software verification, and documentation of all quality-relevant activities. 

In regulated industries (pharmaceutical, food, medical devices), quality assurance is subject to GMP requirements and includes validation, audit trails, and change control. 

cts Group has an integrated quality management system and applies systematic quality assurance measures at all project stages – from engineering review through FAT to final documentation and handover to the customer. 

See also: Factory Acceptance Test (FAT), SAT Checklist (Site Acceptance Test), Audit, GMP (Good Manufacturing Practice), Validation

Real-time data processing refers to the immediate processing, analysis, and response to data at the moment of its generation – with minimal latency between data acquisition and action. 

In industrial automation, real-time data processing is essential for: closed-loop control (PID controllers, model predictive control), safety functions (SIS, emergency shutdowns), machine monitoring (vibration monitoring, anomaly detection), and quality inspection (inline measurement). 

The required degree of real-time capability varies: hard real-time (deterministic response times in the microsecond range, e.g., motion control), soft real-time (response times in the millisecond range, e.g., process control), and near-real-time (response times in seconds, e.g., KPI monitoring). 

cts Group implements real-time data processing solutions at all levels – from deterministic PLC control through edge computing-based AI inference to near-real-time analytics in historian and cloud platforms. 

See also: Edge Computing, Kafka (Apache Kafka), MQTT (Message Queuing Telemetry Transport), OPC UA (Open Platform Communications Unified Architecture), Real-Time Visualization

Real-time visualization refers to the graphical representation of process data, machine states, and key performance indicators in real time – i.e., with minimal latency between data generation and screen display. It is a central tool for plant operators, shift supervisors, and production managers for monitoring and controlling industrial plants. 

Real-time visualizations are realized through: HMI/SCADA systems at the control level (Siemens WinCC, Wonderware, Ignition), PI Vision for historian data, and web-based dashboard platforms for the enterprise level. Quality criteria include: data currency (update frequency), clarity (UX design), configurability, and access rights management. 

cts Group develops and implements real-time visualization solutions at all levels of the automation pyramid – from machine operator panels to cross-site management dashboards. 

See also: SCADA (Supervisory Control and Data Acquisition), KPI Dashboard, Aveva PI, Alarm Management, Shopfloor

In the context of automation and software projects, a requirements matrix (also: traceability matrix) is a structured document that maps all defined requirements to the corresponding design decisions, implementation measures, and test cases. It ensures that every requirement is verifiable and that no requirement is lost during the project. 

A test matrix systematically documents all planned test cases, their test conditions, expected results, and actual test outcomes. Both tools are essential in regulated industries (pharma, medical devices) for GMP-compliant project execution and are required for qualification and validation documentation (IQ, OQ, PQ). 

cts Group uses requirements and test matrices as standard tools in all automation and software projects – as a foundation for systematic quality assurance and clear traceability from requirement to test result. 

See also: Plant Qualification, Computer System Validation (CSV), GMP (Good Manufacturing Practice), HAZOP Analysis

A REST API (Representational State Transfer Application Programming Interface) is a standardized interface for communication between software systems over the HTTP protocol. REST APIs use standard HTTP methods (GET, POST, PUT, DELETE) to access and manipulate resources, typically exchanging data in JSON format. 

In industrial informatics, REST APIs are used for: integration of MES and ERP systems, data access to historian platforms (Aveva PI REST API), connection of cloud services and IIoT platforms, and development of web-based HMI and dashboard applications. REST APIs are the predominant integration technology for horizontal integration at the IT level. cts Group develops and integrates REST APIs in industrial software projects – for seamless connectivity between automation systems, data platforms, and enterprise IT. 

See also: JSON (JavaScript Object Notation), Interface Management, Backend Architecture, ETL Tools (Extract, Transform, Load), MES (Manufacturing Execution System)

Reverse engineering in the automation context refers to the systematic analysis and reconstruction of existing technical systems – hardware, software, or process logic – in order to understand their functionality, create documentation, or use the knowledge gained for modernization or replacement. 

Typical applications in plant engineering include: reconstruction of PLC programs for which no source code exists, analysis of undocumented communication protocols of legacy systems, reconstruction of as-built documentation from existing plants, and analysis of competitor products. In the context of brownfield modernization, reverse engineering is often the first step before a retrofit or migration project. 

cts Group applies reverse engineering methods in modernization and migration projects – to preserve existing process knowledge and use it as the basis for new, modern automation solutions. 

See also: Legacy Systems, Brownfield Transformation, Plant Modernization (Retrofit), EMSR Engineering (Electrical Measurement Control & Regulation)

Remote I/O (RIO) refers to distributed input/output modules installed in the field close to sensors and actuators – rather than in the central control cabinet – and connected to the PLC or DCS via fieldbus (Profibus, Profinet, Foundation Fieldbus, Modbus TCP).

RIO systems significantly reduce cable runs from field instruments to the control cabinet, lower installation costs, and enable decentralized automation architectures. Modern remote I/O systems (e.g., Pepperl+Fuchs Remote I/O, Siemens ET 200, R. STAHL IS1) also support ATEX-certified variants for use in explosion-hazardous zones. 

cts Group uses remote I/O systems in large-scale process automation projects to design cost-efficient and flexible field instrumentation architectures. 

See also: EX Zones (Explosion Protection), Control Cabinet, Commissioning, MCC (Motor Control Center)

ROI (Return on Investment) is a financial key figure that measures the relationship between the return achieved and the capital invested in a project or measure. In the context of automation and digitalization projects, ROI quantifies the economic benefits of an investment – such as reduced maintenance costs, lower energy consumption, increased throughput, reduced scrap, or improved plant availability – in relation to investment and operating costs. 

A positive ROI means the project pays for itself; the payback period (Break-Even) indicates after how many years this occurs. In Industry 4.0 projects, ROI is often difficult to calculate due to indirect benefits (improved data quality, greater flexibility, risk reduction). 

cts Group supports customers in ROI analysis for automation and digitalization projects – through structured benefit analysis, benchmarking with comparable projects, and transparent presentation of cost-benefit relationships. 

See also: Yield Optimization, OEE (Overall Equipment Effectiveness), Predictive Maintenance, APC (Advanced Process Control), Zero Downtime Strategy

Root Cause Analysis (RCA) is a structured problem-solving method used to identify the fundamental cause of a malfunction, production problem, or quality deviation – rather than merely treating the symptoms. Common RCA methods include: the 5-Why method (repeated questioning of causes), Ishikawa diagram (cause-and-effect diagram), FMEA (Failure Mode and Effects Analysis), and fault tree analysis. 

In production environments, RCA is triggered by unplanned downtime, quality deviations, safety incidents, or recurring process problems. Historian systems and MDA data play a central role in digital RCA: time-correlated process data enables the exact reconstruction of the sequence of events leading to a fault. 

cts Group supports customers in systematic root cause analysis – through structured RCA workshops, data-driven analysis using historian and MDA data, and derivation of sustainable corrective and preventive measures (CAPA). 

See also: Alarm Management, Audit Trail, Data Historization, Aveva PI, Asset Management

SAML (Security Assertion Markup Language) is an XML-based standard for the exchange of authentication and authorization data between an identity provider (IdP) and a service provider (SP). It enables Single Sign-On (SSO) across system boundaries: a user authenticates once at the central identity provider (e.g., Microsoft Active Directory with ADFS) and receives a SAML assertion that grants them access to multiple connected applications without re-authentication. 

In industrial environments, SAML is used for SSO integration of web-based MES applications, cloud platforms, and remote access portals with the corporate Active Directory. 

cts Group integrates SAML-based SSO solutions into industrial IT infrastructures – as part of user access management and IEC 62443-compliant security architectures. 

See also: User Access Management (UAM), Active Directory, MFA (Multi-Factor Authentication), IEC 62443 (Industrial Cybersecurity), Governance & Compliance

SAP is the world's leading enterprise resource planning (ERP) software platform from the German company SAP SE. SAP systems manage all business processes of large enterprises – from financial accounting, purchasing, and inventory management to production planning, quality management, and human resources. 

In the manufacturing industry, the SAP-MES integration is a central element of digitalization: production orders flow from SAP into MES systems, and production confirmations, material consumption, and quality data flow back to SAP in real time. The SAP Plant Maintenance module (PM), the Production Planning module (PP), and SAP ME/MII are particularly relevant for production environments. 

cts Group implements SAP integration solutions and connects shopfloor automation systems with SAP – as part of ISA-95-compliant vertical integration projects. 

See also: ERP (Enterprise Resource Planning), MES (Manufacturing Execution System), ISA-95 (Manufacturing Operations Management Standard), REST-API (Representational State Transfer), Interface Management

The Site Acceptance Test (SAT) is a structured functional test carried out at the customer's site after installation and commissioning of an automation system or plant. It verifies that the system functions correctly under real process conditions and meets the agreed specifications and customer requirements. 

The SAT checklist systematically documents all test steps, test conditions, expected results, and actual outcomes – as an official acceptance protocol between supplier and customer. The SAT builds on the results of the Factory Acceptance Test (FAT) and supplements it with tests that are only possible under real plant conditions (e.g., process media, real field signals). 

cts Group carries out SATs with the customer as a standard part of every commissioning project – the signed SAT protocol forms the basis for project handover and the start of the warranty period. 

See also: Factory Acceptance Test (FAT), Commissioning, Audit

SCADA (Supervisory Control and Data Acquisition) is a computer-based system for monitoring, control, and data acquisition of industrial processes and infrastructures. SCADA systems provide operators with a graphical overview of the plant status, enable manual interventions in the process, trigger alarms when limit values are exceeded, and log all process data historically. 

SCADA systems are used in energy supply (power grids, water treatment, pipelines), manufacturing industry, and building management. Leading SCADA platforms include Siemens WinCC, Wonderware (AVEVA System Platform), Ignition (Inductive Automation), and GE iFIX. 

cts Group implements SCADA systems for process monitoring and control in various industries – from concept and screen design through programming and FAT to commissioning and training. 

See also: Process Control System (PCS/DCS), Process Control Technology, Real-Time Visualization, OPC UA (Open Platform Communications Unified Architecture), Alarm Management

The shopfloor refers to the actual production area of a manufacturing plant – the location where machines, production lines, and workers directly produce products. In the context of digitalization and Industry 4.0, the shopfloor is the data generation point: machines and sensors generate process data that is transmitted via IIoT platforms to MES and analytics systems. 

The terms shopfloor management and shopfloor digitalization describe the systematic improvement of transparency, efficiency, and decision-making on the production floor through digital systems – such as real-time OEE monitoring, digital work instructions, and mobile quality inspection. 

cts Group specializes in the digitalization of shopfloor processes – from machine connectivity and MDA through MES integration to real-time visualization and analytics on the shopfloor. 

See also: MES (Manufacturing Execution System), ERP (Enterprise Resource Planning), Digital Production, Real-Time Visualization, Manufacturing Data Acquisition (MDA)

SIL (Safety Integrity Level) is a discrete level (SIL 1 to SIL 4) that describes the required reliability of a safety function in a Safety Instrumented System (SIS). The SIL level is determined by a risk analysis (HAZOP, LOPA – Layers of Protection Analysis) and quantified by the PFD (Probability of Failure on Demand) or PFH (Probability of dangerous Failure per Hour). 

The international standard IEC 61508 defines the SIL concept; IEC 61511 applies specifically to the process industry. A higher SIL level means a lower probability of failure on demand and requires more stringent design measures (redundancy, diversity, systematic capability of components). 

cts Group designs and implements Safety Instrumented Systems (SIS) for SIL 1-3 in accordance with IEC 61511 – from SIL verification and FMEA analysis through safety PLC programming to SIL verification and validation. 

See also: HAZOP Analysis, Fault Tolerance (Redundancy), Programmable Logic Controller (PLC), ATEX (Explosion Protection)

SIMATIC is Siemens' industrial automation product family, encompassing programmable logic controllers (PLCs), process control systems, HMI systems, drives, and the associated engineering software. 

The SIMATIC S7 family – particularly the S7-300, S7-400, S7-1200, and S7-1500 – is one of the most widely used PLC platforms worldwide. 

The TIA Portal (Totally Integrated Automation Portal) is the unified engineering environment for programming, configuring, and commissioning all SIMATIC components. In process automation, Siemens SIMATIC PCS 7 and PCS neo are established process control systems. The SIMATIC ET 200 family provides distributed I/O solutions for the field level. 

cts Group is an experienced Siemens automation partner and works with the full range of SIMATIC products – from PLC programming in TIA Portal through SIMATIC PCS 7/neo DCS engineering to HMI development with WinCC. 

See also: Programmable Logic Controller (PLC), Process Control System (PCS/DCS), SCADA (Supervisory Control and Data Acquisition), EMSR Engineering (Electrical Measurement Control & Regulation)

SIMOPS (Simultaneous Operations) refers to scenarios in which multiple operational activities take place simultaneously at the same plant or location – for example, production operations and maintenance work, commissioning of new plant sections while existing systems continue to run, or drilling and production operations on an offshore platform. 

SIMOPS creates complex safety challenges because the activities can influence each other and create additional risks. SIMOPS management includes: detailed hazard analysis, coordination protocols, exclusion zones, communication procedures, and emergency plans for all parties involved. In the oil, gas, and petrochemical industries, SIMOPS management is a regulatory requirement and an essential part of the safety management system. 

cts Group takes SIMOPS requirements into account in planning commissioning and maintenance work at customer sites – to ensure the safety of all parties involved. 

See also: Work Permit (Permit-to-Work), Commissioning, Plant Modernization (Retrofit), HAZOP Analysis

A Single Point of Failure (SPOF) is a component or element in a system whose failure leads to the failure of the entire system or a critical function. In automation and IT systems, SPOFs represent a significant reliability risk: a single failed network switch, a non-redundant power supply, or a single PLC CPU can bring down an entire production line. 

The identification and elimination of SPOFs is a central task in the design of high-availability systems. Measures to eliminate SPOFs include: redundant hardware (dual power supplies, redundant PLCs, ring topology networks), hot standby systems, and UPS (uninterruptible power supplies). 

cts Group systematically analyzes SPOFs as part of availability and redundancy concepts for critical production systems – and implements appropriate measures to achieve the required availability targets (e.g., 99.99%). 

See also: Fault Tolerance (Redundancy), SIL (Safety Integrity Level), Network Architecture, HAZOP Analysis

Single Source of Truth (SSOT) describes the principle of managing a particular piece of information exclusively in one authoritative source system, from which all other systems obtain it – instead of maintaining the same data redundantly in multiple systems. 

In industrial environments, SSOT means: the master data for equipment (tag list, equipment hierarchy) is maintained in one system (e.g., EPLAN or Aveva AF) and used by all other systems; production data is historized in one historian system and not duplicated in parallel databases. 

The implementation of SSOT eliminates data inconsistencies, reduces maintenance effort for master data, and improves data quality for analytics applications. 

cts Group pursues the SSOT principle in the design of industrial data architectures – as a key principle for data quality and system integration in Industry 4.0 projects. 

See also: Unified Namespace (UNS), Industrial Data Fabric (IDF), Data Consolidation, Data Hub, ERP (Enterprise Resource Planning)

Source code refers to the human-readable set of instructions written in a programming language that defines the behavior of a software program or control system. In industrial automation, source code exists in multiple forms: PLC programs (in IEC 61131-3 languages such as ST, LD, FBD, SFC), SCADA scripts and configuration files, application code for MES and historian systems (C#, Python, Java), and configuration files for network devices and servers. 

Source code management is a critical aspect of industrial software development: version control systems (Git, SVN) track changes, enable rollbacks, and support collaborative development. In regulated environments, source code is subject to change control and must be versioned and documented in a traceable manner. 

cts Group manages all project-related source code in version control systems and transfers it to customers as part of the as-built documentation. 

See also: C#, C++, Programmable Logic Controller (PLC), Change Control (Change Management), Validation

SQL databases (Structured Query Language databases) are relational database management systems that organize data in tables with defined relationships and enable access via the standardized SQL query language. Leading SQL databases in industrial informatics include Microsoft SQL Server, Oracle Database, PostgreSQL, and MySQL. 

In industrial applications, SQL databases are used for: storage of production orders and material data in MES systems, storage of configuration data and recipes, quality databases, maintenance management systems (CMMS), and reporting systems. SQL databases offer strong consistency guarantees (ACID transactions), mature tooling for complex queries and reporting, and are well-suited for structured, schema-fixed data. 

cts Group uses SQL databases as the data storage layer for MES applications, quality management systems, and reporting solutions – in combination with NoSQL databases and historian systems for comprehensive industrial data architectures. 

See also: NoSQL Databases, MongoDB, ETL Tools (Extract, Transform, Load), Backend Architecture, MES (Manufacturing Execution System)

A switchgear assembly is an electrical installation that combines switching, protective, measuring, and control devices in a structured housing for the safe distribution and control of electrical energy. 

Switchgear assemblies are classified according to their voltage level (low-voltage switchgear per DIN EN 61439, medium-voltage switchgear per IEC 62271) and their application purpose (main distribution boards, motor control centers, process control cabinets). 

They contain: circuit breakers and load disconnectors, fuses and residual current devices, bus bars, measuring and protection relays, and control components (PLC, I/O modules). 

cts Group engineers and builds switchgear assemblies compliant with DIN EN 61439 – from the engineering concept and EPLAN documentation through manufacturing, FAT with the customer, to delivery and on-site commissioning. 

See also: Control Cabinet, MCC (Motor Control Center), DIN EN 61439 / EN 61439 / IEC 61439 (Low-Voltage Switchgear), Factory Acceptance Test (FAT)

Tracking & Tracing refers to the continuous tracking (tracking) and complete retrospective reconstruction (tracing) of products, materials, and batches along the entire production and supply chain.

In regulated industries (pharmaceutical, food, medical devices), tracking & tracing is legally required: every product must be uniquely identified and all production steps, raw materials, equipment used, and personnel must be documentarily linked. 

Technically, tracking & tracing is implemented through: barcode and RFID systems for product identification, MES modules for batch tracking and genealogy, ERP integration for supply chain traceability, and historian systems for process data linking. 

cts Group implements tracking & tracing solutions as part of MES and digitalization projects – from the concept and data model through RFID/barcode integration to MES implementation with complete batch genealogy and regulatory compliance. 

See also: Batch, GMP (Good Manufacturing Practice), MES (Manufacturing Execution System), Audit Trail, Batch Systems

A digital twin is a virtual replica of a physical object, process, system, or plant that is continuously synchronized with its real-world counterpart via real-time data. In contrast to the digital shadow (which only reflects the current state), a digital twin can actively simulate scenarios, predict behavior, and provide optimization recommendations – thus enabling bi-directional interaction between the physical and digital worlds. 

In industrial applications, digital twins are used for: simulation-based commissioning of new plants, virtual testing of control programs, predictive maintenance based on physics-based models, process optimization through digital experimentation, and training operators. 

cts Group develops digital twin concepts and implementations for industrial plants – building on data from historian systems (Aveva PI), simulation tools, and real-time sensor data to create comprehensive digital plant models. 

See also: Digital Shadow, Predictive Maintenance, AI-Assisted Process Optimization, Aveva PI, Industry 4.0

UL (Underwriters Laboratories) is a leading American safety certification organization that tests and certifies products for safety and regulatory compliance for the North American market. The UL marking is a prerequisite for electrical equipment used in the USA and Canada in many applications, and is also widely recognized in other markets.

For control cabinets and industrial switchgear, the relevant standards are UL 508A (industrial control panels) and UL 698A (industrial control panels for hazardous locations). UL certification requires the use of UL-listed components and compliance with UL standard requirements, which can differ significantly from European standards (DIN EN 61439). 

cts Group manufactures UL-listed control cabinets for customers who need to export their systems to North America – taking into account the specific UL requirements in engineering and component selection. 

See also: CSA (Canadian Standards Association), EAC (Eurasian Conformity), Control Cabinet, DIN EN 61439 / EN 61439 / IEC 61439 (Low-Voltage Switchgear), DIN EN 61439 / EN 61439 / IEC 61439 (Low-Voltage Switchgear)

Unified Namespace (UNS) is a modern architectural approach for industrial data integration in which all data sources – PLCs, DCS, SCADA, MES, ERP, sensors – publish their data in a single, hierarchically structured namespace accessible to all authorized consumers. 

UNS acts as a central semantic data hub and eliminates point-to-point connections between individual systems. MQTT brokers (especially HiveMQ and EMQX) are typically used as the technical foundation, with a defined hierarchy (Enterprise/Site/Area/Line/Cell/Device/Data) as the addressing schema. UNS is the technical basis for the Industry 4.0 vision of seamless data transparency from sensor to management level. 

cts Group designs and implements Unified Namespace architectures as part of IIoT and digitalization projects – as a future-proof foundation for Industrial Data Fabric and real-time analytics across all production levels. 

See also: MQTT (Message Queuing Telemetry Transport), OPC UA (Open Platform Communications Unified Architecture), Industrial Data Fabric (IDF), Data Hub, Isolated System (Island Solution)

User Access Management (UAM) refers to the systematic management of user identities, access rights, and authentication mechanisms in IT and OT systems. It ensures that each user has access only to the systems and data that they need for their job (principle of least privilege), and that all accesses are logged and traceable. 

In industrial environments, UAM encompasses: management of user accounts in Active Directory, role-based access control (RBAC) for SCADA, MES, and historian systems, management of remote access (VPN, SAML, MFA), and regular reviews of access rights. In regulated industries (pharma, food), UAM is part of GMP compliance and must be validated as part of computer system validation.

cts Group implements UAM concepts for industrial systems as part of IEC 62443-compliant security architectures – integrating OT access management with the corporate IT infrastructure. 

See also: Active Directory, MFA (Multi-Factor Authentication), SAML (Security Assertion Markup Language), IEC 62443 (Industrial Cybersecurity), Audit Trail

Validation in the industrial and pharmaceutical context refers to the documented proof that a process, system, or piece of equipment consistently delivers a result that meets predetermined specifications and quality attributes. 

Validation goes beyond qualification: while qualification proves that a system is correctly installed and operates as intended, validation proves that it reliably delivers the desired process result (e.g., product quality). 

Validation is required in regulated industries (pharmaceutical, food, medical devices) for processes, cleaning procedures, analytical methods, and computer systems (CSV). It follows the lifecycle approach of GAMP 5 and encompasses: risk assessment, validation planning (Validation Master Plan), execution of qualification tests (IQ, OQ, PQ), and final Validation Summary Report. 

cts Group supports customers in planning and executing validation projects – from the Validation Master Plan through test execution to regulatory submission readiness. 

See also: Computer System Validation (CSV), GMP (Good Manufacturing Practice), GxP, Plant Qualification, Change Control (Change Management)

VDE (Verband der Elektrotechnik Elektronik Informationstechnik) is Germany's largest technical-scientific association for electrical engineering, electronics, and information technology, and simultaneously a recognized certification and testing organization. 

VDE develops standards and test specifications for electrical products, systems, and installations – many of which are adopted as European (EN) or international (IEC) standards. The VDE mark on a product certifies that it has been tested for safety and compliance with applicable standards by the VDE Institute. 

In the context of switchgear and control cabinets, VDE standards (DIN VDE 0100, DIN VDE 0113, EN 61439) define the requirements for design, construction, and testing. 

cts Group applies VDE standards in all electrical engineering projects and manufactures products that meet the relevant VDE and EN requirements – as the basis for CE marking and regulatory acceptance in Germany and Europe. 

See also: DIN EN 61439 / EN 61439 / IEC 61439 (Low-Voltage Switchgear), DIN EN 61439 / EN 61439 / IEC 61439 (Low-Voltage Switchgear), DIN EN 60204-1 (Electrical Equipment of Machines), UL (Underwriters Laboratories), CSA (Canadian Standards Association)

Vertical integration refers to the seamless connectivity of data and information flows across all levels of the automation pyramid – from the field level (sensors, actuators) through the control level (PLC, DCS), the process control level (SCADA, HMI), the operations level (MES), to the enterprise level (ERP, SAP). 

Vertical integration enables production data from the shopfloor to flow in real time to management dashboards, and business decisions (production orders, recipe changes) from the ERP level to be automatically transferred to the production systems. 

The ISA-95 standard defines interfaces and data models for vertical integration. In Industry 4.0, vertical integration is a prerequisite for data-driven production management, KPI transparency across all levels, and closed-loop optimization of production processes. 

cts Group realizes vertical integration as a core element of MES and digitalization projects – connecting all levels from field device to ERP. 

See also: Horizontal Integration, ISA-95 (Manufacturing Operations Management Standard), MES (Manufacturing Execution System), ERP (Enterprise Resource Planning), Automation Pyramid

Virtualization is a technology that enables multiple virtual machines (VMs) with independent operating systems and applications to run on a single physical hardware platform using a hypervisor. 

In industrial automation, virtualization is increasingly used for: consolidation of engineering workstations and server systems, operation of SCADA and historian servers in virtual environments, enabling fast backup/restore via snapshots, and simplification of disaster recovery. 

Industrial virtualization must comply with special requirements: some real-time-capable automation systems (e.g., Siemens PCS 7) define certified virtualization platforms (VMware vSphere) and configuration specifications. 

cts Group plans and implements virtualization solutions for industrial automation environments – from feasibility assessment and platform selection through migration and performance validation to ongoing support. 

See also: Physical-to-Virtual, Legacy Systems, Fault Tolerance (Redundancy), Network Architecture, On-Premise

A VLAN (Virtual Local Area Network) is a logical network segment that groups devices into separate, isolated communication zones within a physical network infrastructure – regardless of their physical connection. 

VLANs are configured on managed network switches and enable network traffic to be separated by function, security zone, or priority. In industrial network architectures (per IEC 62443), VLANs are a key tool for OT/IT network segmentation: separate VLANs for process control systems, engineering workstations, office IT, and remote access prevent unauthorized lateral movement of attackers and reduce the propagation of network faults. 

cts Group designs and implements VLAN-based network segmentation as part of industrial network architectures – to achieve the required security levels per IEC 62443 and to enable controlled, monitored data exchange between OT and IT zones. 

See also: Network Architecture, IEC 62443 (Industrial Cybersecurity), VPN (Virtual Private Network), OT (Operational Technology), IT (Information Technology)

A VPN (Virtual Private Network) creates an encrypted, tunnel-based connection between two network endpoints over an insecure public network (internet). 

In industrial environments, VPNs are primarily used for secure remote access to OT systems: service technicians, engineers, and system suppliers connect via VPN to the plant network for remote diagnostics, programming, and maintenance – without physically being on site. 

Industrial VPN solutions (e.g., Siemens SINEMA Remote Connect, Tosibox, Secomea) are specially designed for the requirements of OT networks: simple operation, hardware-based authentication, and integration into existing firewall and VLAN architectures. In combination with MFA and user access management, VPN is a central component of IEC 62443-compliant remote access concepts. 

cts Group implements secure VPN remote access solutions for customer plants – enabling efficient remote support while maintaining the highest security standards. 

See also: Network Architecture, IEC 62443 (Industrial Cybersecurity), VLAN (Virtual Local Area Network), MFA (Multi-Factor Authentication), OT (Operational Technology)

The work permit (also: Permit-to-Work, PTW) is a formal safety system that ensures hazardous work on plants and machines is only carried out after a structured risk assessment and under defined protective measures. It regulates who is authorized to release work, what safety measures must be taken, and when the plant may be returned to operation. 

Typical permit-to-work procedures exist for: work under voltage (electrical work), hot work (welding, cutting), entry into vessels (confined space entry), and work in EX zones. The permit includes LOTO measures (Lockout-Tagout), gas measurements, and a clear chain of responsibility. 

At cts Group, compliance with work permit processes during service and commissioning assignments at customer sites is an integral part of the safety management system – particularly in the chemical and pharmaceutical industries. 

See also: EX Zones (Explosion Protection), ATEX (Explosion Protection), Commissioning, Audit

Workflow automation refers to the automatic execution of defined sequences of tasks and approvals in business and operational processes – replacing manual, paper-based workflows with digital, rule-based automated processes. 

In industrial environments, typical workflow automation applications include: automated approval processes for change control and work permits, automated generation and dispatch of maintenance orders based on alarm messages or condition monitoring data, automated quality reports triggered by batch completion in MES systems, and automated escalation procedures for overdue tasks. Workflow automation is implemented through BPM (Business Process Management) platforms, MES workflow modules, or low-code/no-code automation tools. 

cts Group integrates workflow automation into MES and digitalization projects – to reduce manual effort, minimize errors, and increase the speed and traceability of operational processes. 

See also: Paperless Processes, MES (Manufacturing Execution System), Change Control (Change Management), Work Permit (Permit-to-Work), Audit Trail

XML (Extensible Markup Language) is a text-based markup language for the structured representation and exchange of data in a human-readable and machine-processable format. XML documents consist of hierarchically nested elements with attributes and are validated against schema definitions (XSD). 

In industrial informatics, XML is used as a data exchange format in numerous standards and applications: B2MML (Business to Manufacturing Markup Language) based on ISA-95 for MES/ERP integration, AutomationML for engineering data exchange, MTP (Module Type Package) for modular plant description, OPC UA NodeSet files for node definition, and EPLAN project exports. 

cts Group uses XML-based data formats in integration and digitalization projects – wherever standardized, structured data exchange between different systems and tools is required. 

See also: JSON (JavaScript Object Notation), REST-API (Representational State Transfer), MTP (Module Type Package), ISA-95 (Manufacturing Operations Management Standard), Interface Management

Yield optimization refers to the systematic improvement of the ratio of good output to input materials (yield) in a production process – with the goal of minimizing raw material consumption, reducing waste and rejects, and maximizing the proportion of saleable end products. 

In the process industry (chemical, pharmaceutical, food), yield optimization is of central economic importance: even small improvements in yield have a significant impact on production costs and profitability. 

Technically, yield optimization is implemented through: advanced process control (APC, model predictive control), statistical process control (SPC), AI-based process optimization based on historical process data, and targeted reduction of process variability. 

cts Group develops yield optimization solutions based on data from historian systems (Aveva PI, Aspentech Inmation) and APC technologies – for customers who want to systematically increase the efficiency of their production processes. 

See also: APC (Advanced Process Control), Advanced Analytics, AI-Assisted Process Optimization, OEE (Overall Equipment Effectiveness), ROI (Return on Investment)

A Zero Downtime Strategy describes a comprehensive approach aimed at eliminating unplanned production downtime or reducing it to zero through a combination of technical and organizational measures. The technical elements include: redundant system design (no single points of failure), predictive maintenance to prevent unexpected failures, hot-swappable components for maintenance without shutdown, and automated failover mechanisms for IT and OT systems. 

Organizationally, a Zero Downtime Strategy requires: systematic root cause analysis of all incidents, continuous improvement processes, well-trained maintenance teams, and optimized spare parts management. In practice, zero downtime is an aspirational target: the focus is on approaching this goal through measurable improvement in MTBF (Mean Time Between Failures) and reduction of MTTR (Mean Time to Repair). 

cts Group supports industrial customers in developing and implementing Zero Downtime Strategies – as part of comprehensive plant reliability and maintenance management projects. 

See also: Predictive Maintenance, Fault Tolerance (Redundancy), Asset Management, Maintenance Management, ROI (Return on Investment)