How Network Latency, Outdated Hardware, and Poor Segmentation Quietly Kill Production Efficiency
In modern manufacturing, automation systems are only as fast and reliable as the IT infrastructure supporting them. CNC machines, PLCs, HMIs, robotics, and industrial control systems depend on consistent, low-latency communication to operate efficiently.
Yet many manufacturers invest heavily in automation while unknowingly running it on IT infrastructure that was never designed to support real-time production environments. The result isn’t always a dramatic system failure. More often, it shows up as unexplained slowdowns, intermittent faults, delayed machine responses, and declining throughput.
These issues are frequently misdiagnosed as equipment problems, when in reality, the root cause lies in avoidable IT infrastructure mistakes.
Why Automation Performance Is Often an IT Problem
When production performance drops, the first instinct is to inspect machines, tooling, or operators. While mechanical issues do occur, many automation slowdowns originate in the network layer.
Modern manufacturing systems rely on constant data exchange between machines, servers, sensors, and supervisory systems. Even small delays in communication can cause CNC programs to lag, PLC logic to execute late, or automation sequences to fall out of sync.
Because these delays don’t always trigger alarms or hard failures, they can persist for months—silently reducing efficiency and increasing wear on equipment.
Network Latency: The Silent Productivity Killer
Network latency is one of the most overlooked causes of automation slowdowns. In industrial environments, milliseconds matter.
Latency increases when networks are overloaded, poorly designed, or shared indiscriminately between production and office traffic. Email attachments, cloud backups, video conferencing, and general internet usage can interfere with machine communication if systems are not properly isolated.
For CNC and PLC systems, delayed packets can result in slower cycle times, delayed command execution, and inconsistent machine behavior. Over time, this not only reduces output but also increases operator intervention and troubleshooting time.
Outdated Switches and Infrastructure Not Built for Industrial Loads
Many manufacturing facilities are still running on network hardware that was installed years—or even decades—ago. While these switches may technically still function, they were never designed to handle modern automation demands.
Older switches often lack the processing power, throughput, and reliability required for high-volume machine communication. They struggle with modern protocols, fail under heavy load, and offer limited visibility into network performance issues.
As automation systems become more advanced and data-driven, outdated infrastructure becomes a bottleneck that limits the return on investment from expensive machinery.
Poor Network Segmentation Between IT and OT Systems
One of the most common and costly mistakes in manufacturing environments is failing to properly separate office IT systems from operational technology (OT).
When CNC machines, PLCs, and automation controllers share the same network as office computers, printers, guest Wi-Fi, and internet traffic, competition for bandwidth becomes unavoidable. This lack of segmentation leads to unpredictable performance and increased security risk.
Proper segmentation ensures that production systems receive priority access to network resources, protecting them from interference and minimizing latency. Without it, manufacturers are effectively gambling with uptime.
Bandwidth Contention and Hidden Traffic Conflicts
Many automation issues stem from bandwidth contention that isn’t immediately visible. Background processes such as system updates, cloud sync services, or security scans can consume large amounts of network capacity without warning.
In an unmonitored environment, these background activities can coincide with peak production periods, creating slowdowns that appear random and difficult to reproduce. Operators may notice machines responding slower or automation sequences timing out without a clear explanation.
Without proactive monitoring, these conflicts often go undetected and unresolved.
Lack of Network Visibility and Monitoring
Another critical infrastructure mistake is operating without real-time visibility into network health. When manufacturers lack monitoring tools, IT teams are forced to rely on user complaints rather than data.
This reactive approach makes it nearly impossible to identify intermittent issues or emerging trends. Problems are only addressed after production is impacted, leading to emergency responses instead of planned improvements.
Proactive monitoring provides early warning signs, allowing issues to be corrected before they disrupt operations.
How IT Infrastructure Mistakes Impact the Plant Floor
The effects of poor IT infrastructure extend beyond slower machines. They increase operator frustration, reduce confidence in automation systems, and lead to unnecessary downtime.
Over time, these issues also accelerate equipment wear. Machines forced to compensate for delayed commands or inconsistent communication experience increased stress, leading to more frequent maintenance and shorter lifespans.
What appears to be an IT problem quickly becomes a production, maintenance, and financial issue.
Why These Problems Are Often Misdiagnosed
One reason infrastructure issues persist is that they rarely present as clear IT failures. Machines don’t always crash. Systems don’t always go offline.
Instead, performance gradually declines. Small delays are tolerated. Workarounds become routine. Eventually, inefficiency becomes normalized.
Without a holistic view of the IT and OT environment, manufacturers may invest in new equipment or automation upgrades without addressing the underlying infrastructure limitations—compounding the problem rather than solving it.
How Proactive IT Infrastructure Design Solves the Problem
Manufacturers that prioritize proactive IT infrastructure take a different approach. Networks are designed specifically for industrial traffic. Production systems are isolated and prioritized. Hardware is selected based on performance, not just cost.
Continuous monitoring ensures visibility into latency, bandwidth usage, and potential failure points. Issues are addressed before they impact production, and infrastructure evolves alongside automation investments.
This alignment between IT and production systems enables automation to perform as intended—efficiently, reliably, and at scale.
The Bottom Line
CNC machines, PLCs, and automation systems can only operate at peak performance when supported by the right IT infrastructure. Network latency, outdated switches, and poor segmentation may not cause immediate failures, but they quietly erode productivity every day.
For manufacturers, these hidden inefficiencies often cost far more over time than proactive infrastructure improvements ever would.
Is Your Infrastructure Slowing Down Your Production?
At ManagePoint, we specialize in IT infrastructure designed for manufacturing environments—supporting automation, minimizing latency, and protecting uptime. Call 414-485-6169 or visit manage-point.com to evaluate whether your IT infrastructure is helping your production—or holding it back.