The factory’s heartbeat

ISO 22301 – assets (Clause 8.1: Operational planning and control)

Assets are the essential cogs that make production run. From controllers to networks to supporting IT, each element has a direct impact on uptime, safety, and operational resilience. Any undocumented, mismanaged, or unsupported asset is a potential point of failure, slowing recovery and increasing risk during a disruption.

Key asset categories

  1. Industrial controllers & PLCs

    • These devices orchestrate production processes. Failure or misconfiguration can halt operations instantly.

    • Checks: Redundancy in place? Lifecycle documentation complete? Replacement procedures defined? Maintenance schedules adhered to?

    • Typical gaps: Missing spare units, unclear ownership, incomplete update or patch records.

  2. SCADA servers & HMIs

    • Central monitoring and control; a single point of visibility for operators.

    • Checks: Backup routines tested? Failover procedures validated? Access controls documented?

    • Typical gaps: Outdated backup logs, undocumented failover steps, misaligned operator permissions.

  3. Networks & communications

    • Segmented and monitored networks prevent a single failure from cascading across production.

    • Checks: Network diagrams current? Redundant paths verified? Monitoring and alerting in place?

    • Typical gaps: Zones not clearly defined, undocumented network changes, monitoring gaps in critical paths.

  4. Field devices & sensors

    • They collect process data and trigger safety or automation functions. Faulty sensors or missing calibration can disrupt production or safety.

    • Checks: Spares available? Calibration documented and current? Monitoring of device health in place?

    • Typical gaps: Sensors missing in documentation, overdue calibration, unmonitored devices.

  5. Physical infrastructure

    • Power supplies, enclosures, and environmental controls support everything else. A failure here stops the factory even if devices are functional.

    • Checks: UPS and generators tested? Cooling and environmental controls operational? Access controlled?

    • Typical gaps: Outdated maintenance logs, untested backup power, unclear responsibility for environmental systems.

  6. Supporting IT systems

    • ERP, reporting, and logging systems tie OT processes into organisational operations. Their failure can prevent informed decision-making during incidents.

    • Checks: Backups tested? System dependencies documented? Logging and alerting operational?

    • Typical gaps: Disconnected IT-OT systems, incomplete logs, undocumented recovery steps.

Executive gap‑spotting

  • Comprehensive documentation: Are all critical assets recorded and mapped to continuity priorities? Missing items = blind spots.

  • Ownership clarity: Does each asset have a responsible owner or custodian? Ambiguity = delayed response in disruption.

  • Lifecycle completeness: Are installation, maintenance, updates, and decommissioning steps fully documented and current?

  • Criticality ratings: Are assets rated by operational impact to prioritise recovery efforts? Lack of prioritisation = wasted time and resources during recovery.

  • Redundancy & readiness: Are backups, spares, and failover mechanisms in place and tested?

Walk through the factory mentally: each asset should be visible, documented, and accounted for. Anything you can’t immediately point to or explain is a gap waiting to disrupt operations.