Reply uses this demo environment to show how its Spike Reply team secures operational technology, from PLC-based lines to connected sensors, and how manufacturers can turn security and data into ongoing service business. The stand walks through concrete OT security use cases, testbeds and training rigs that mirror real factories and critical environments, using Siemens PLCs, Fischertechnik models and industrial security appliances to make risks tangible and manageable. https://www.reply.com/
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In the OT security corner, the infrastructure is condensed into a compact line where controllers, field devices and networks are exposed to simulated faults and attacks. Firewalls, intrusion-detection sensors, data diodes and other network security components from partners such as Nozomi, Secunet and Fortinet are inserted into the topology to show defence-in-depth patterns. Customers can rehearse how to harden PLC networks, segment production cells and enforce secure remote access before rolling those architectures into live plants.
A second focus is what Reply calls the business accelerator: once sensor and time-series data are collected, how can OEMs and operators actually use it. The team explains how analytics on machine usage, vibration, throughput and alarms can support shopfloor personnel and supervisors with dashboards, alerts and recommendations. The same data can underpin new service contracts, pay-per-use models or performance guarantees, giving machine builders recurring revenue instead of one-off sales while giving end users better transparency on asset health.
The cloud and AI demo ties this together end-to-end. Sensors on the mechanical rig feed an edge device from Belden, which forwards normalised data into the cloud, where KPIs, OEE-style metrics and anomaly indicators are visualised in near real time. When a breakdown or anomaly occurs, a GenAI assistant draws on historic tickets, manuals and best-practice playbooks to propose likely root causes and step-by-step remediation, helping maintenance teams reduce mean time to repair and avoid unnecessary downtime.
Recorded at SPS 2025 in Nuremberg, the video captures how different Reply units collaborate around industrial cybersecurity and industrial data, from Spike Reply’s OT security expertise to teams working on IoT connectivity and data platforms with cloud providers like AWS. The conversation highlights that modern OT security is not only about blocking attacks, but also about using the same instrumentation to strengthen resilience, deepen customer relationships and build new as-a-service business models around connected equipment.
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