How to integrate PLC/SCADA systems with on-premise digital signage systems in factories

I came across this LinkedIn post a few weeks ago, and it stuck with me, not because it was new, but because it was real.

“This lack of visibility isn’t a small problem; it’s a growth killer.”

This visibility gap, where live data remains locked inside PLC and SCADA systems, keeps factories reactive rather than proactive. When teams can’t see what’s happening in real-time, minor process deviations can turn into costly downtime, missed quotas, and even safety incidents.

Across industries, unplanned downtime can drain anywhere from $50,000 to over $2 million per hour, yet most plants still rely on manual updates or outdated HMIs that few operators can access.

What if your factory floor could see what your SCADA system already knows?

By securely connecting your existing PLC or SCADA setup to on-premise digital signage software, you can display live metrics, alarms, and performance dashboards directly on factory screens. Securely, without touching your control logic or exposing your network to the internet.

How to Integrate PLC/SCADA Systems With On-Premise Digital Signage

1. Identify the Key Tags and Metrics to Display

Start with what operators need to see, not everything your system collects. Pick 3–4 metrics that drive quick action, OEE, line speed, downtime reason, temperature, or fault alerts. Work with your automation team to list the exact SCADA tags for those metrics. For each tag, define:

• Tag name (standardized)

• Source address (PLC or SCADA)

• Normal range & alert limit

• Update frequency (e.g., every 5s)

2. Connect Your SCADA/PLC Data Securely to Your Signage Network

Now is where your live SCADA or PLC data is safely converted into dashboard-ready information for your factory screens.

3. Deploy a Secure Data Gateway

Install a data gateway or IIoT middleware inside your network. This will sit between your PLC/SCADA systems and your on-premise signage CMS.

It should:

• Read from PLCs or SCADA via OPC UA, Modbus TCP, or similar protocols.

• Convert data to a standard web format like JSON or REST API.

• Maintain read-only access; signage systems must never send commands back.

4. Choose Your Communication Protocol

Choose a communication protocol based on your network setup:

5. Isolate Networks Using a DMZ

For security, never let your signage system talk directly to the SCADA network. Instead, set up a demilitarized zone (DMZ):

• Place the Gateway in the DMZ as the only bridge between OT and IT.

• Configure industrial firewalls so traffic flows one-way—from OT → DMZ → IT.

• Allow only authorized HTTP or MQTT traffic to pass; block everything else.

• If using Ignition Edge, run it as a proxy node in the DMZ to handle outbound traffic securely. All communication between the SCADA network and the signage CMS follows strict digital signage security standards, using encrypted HTTPS and TLS connections, firewall isolation, and a read-only data flow that keeps the control environment completely protected.

6. Secure and Validate Your Data Flow

Once connected, ensure the system is both encrypted and reliable:

• Use HTTPS for REST APIs and TLS for MQTT/OPC UA.

• Configure the gateway to flag stale data after inactivity to avoid false readings.

7. Confirm Performance and Redundancy

• Test latency between PLC updates and on-screen display (should be < 2 seconds for most KPIs).

• For critical lines, deploy dual gateways or mirrored brokers for redundancy.

What You Can Display on Factory Screens

Once your PLC or SCADA data connects to your digital signage software solution, every screen on the shop floor becomes a live control point for visibility. The goal is to surface the right information at the right place, where it drives decisions and action.

1. Real-time production metrics: Display live OEE, throughput, and fault codes from SCADA so operators see performance drops the moment they occur. Track output versus target in real time to eliminate post-shift reporting delays.

2. Machine health and predictive maintenance: Display live temperature, vibration, or pressure trends to detect wear before failure. Trigger automatic alerts when readings exceed thresholds, and show maintenance queues or technician status in real time to prevent unplanned stops.

3. Safety and compliance visibility: Integrate live EHS and SCADA sensor data to deliver instant, site-wide alerts. When gas leaks, pressure drops, or overheating occurs, nearby screens flash red warnings with immediate actions. Display safety drills, PPE reminders, and compliance dashboards to keep safety visible without relying on emails or announcements.

4. Shift and workflow visibility: Show active orders, open maintenance tickets, and queue status for smooth shift handovers. Visualize Andon calls and material levels in real time so production, logistics, and maintenance teams work from the same live data.

5. Recognition and operational communication: Rotate production milestones, training reminders, and employee shout-outs alongside live dashboards. Build transparency and turn performance data into a shared, motivating scoreboard.

The Impact of SCADA-to-Signage Integration

Walk through any factory that’s integrated its SCADA or PLC data with digital signage, and you can feel the difference before you even check a dashboard.

No one’s waiting for reports. Lines self-correct in minutes. Supervisors don’t chase updates; they see them. Every screen shows the pulse of production, safety, and performance in real time.

Pickcel’s on-premise solution is built for manufacturers who demand full control without complexity. It runs entirely on your internal network, keeping your SCADA and PLC data secure, local, and under your control.

What sets Pickcel apart:

• Air-gapped, SOC 2 & ISO 27001 certified deployment for sensitive OT environments.

• Real-time dashboard integration with OPC UA, MQTT, REST API, and custom MES connectors.

• Role-based access and encryption across all devices to protect industrial data.

• Central control for multi-site networks, updating thousands of screens instantly.

• Offline-first playback engine that keeps screens running even during network failures.

• Custom screen apps & APIs to display SCADA data, KPIs, or maintenance queues live.

Our engineering team, with over a decade of industrial automation experience, will set up your on-premise deployment end-to-end, from secure server configuration to real-time dashboard integration.

Talk to our experts to bring real-time visibility to your factory floor

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