Categories: Case Study

Case Study on Transforming Historian Data into Actionable Industrial Analytics

Industrial environments generate massive time-series data, but industrial data historian systems often stop at storage. As a result, data remains siloed, reporting is manual and critical operational trends are identified too late.

We transform stored data into intelligence through custom industrial software development. By building a secure, scalable analytics layer on top of existing process historian software, powered by .NET industrial applications and cloud-native architecture, we deliver actionable insights, without disrupting current systems.

Executive Summary

The client had already invested in enterprise-grade industrial historian software across multiple plants. While data capture was robust, the organization struggled to convert historical process data into insights usable by operations leaders and executive teams.

Infomaze implemented a modern industrial analytics platform that integrated seamlessly with existing historians. The solution unified data across systems, automated reporting, and delivered role-based dashboards—creating a scalable foundation for operational intelligence and future AI initiatives.

Key outcomes included faster decision-making, reduced manual reporting, and improved enterprise-wide visibility.

Client Overview

The client operates within a highly complex industrial environment where multiple assets, production lines and processes generate continuous operational data. Their ecosystem included enterprise-grade industrial historian software already deployed across plants and capturing years of historical process data.

Despite having robust historians in place, the organization lacked a unified way to analyze, visualize and extract intelligence from this data at scale. Engineering teams relied on manual queries, leadership lacked consolidated views, and operational insights were fragmented across systems.

Business Challenges with Existing Industrial Historian Environments

Limited Visibility Across Historical Trends

Although data was stored in the industrial data historian, teams had no intuitive way to analyze long-term trends across assets, processes, or time periods.

Fragmented Data Across Multiple Historians

Operational data lived in multiple historian platforms, which make correlation across systems and processes time-consuming and error-prone.

Manual and Time-Intensive Reporting

Engineers manually extracted data for reports, leading to delays, inconsistencies, and high dependency on specialized resources.

No Centralized Operational Dashboards

There was no single platform for KPIs, performance tracking, energy efficiency or anomaly monitoring across roles.

Lack of Actionable Insights

While data existed, it did not translate into decisions. Root cause analysis, benchmarking, and continuous improvement initiatives lacked reliable analytical support.

The client needed a solution that enhanced their process historian software through secure integration, analytics and visualization.

Solution Overview: Building an Analytics Layer on Top of Industrial Process Historians

We designed a modular, cloud-ready platform focused on industrial process historian integration, analytics, and scalability. The architecture was purpose-built for industrial environments using .NET process historian integration and Azure-native services.

This approach allowed the organization to modernize historian data usage while preserving existing OT investments.

Historian Connectivity Through Secure OPC UA Integration

We implemented a robust integration layer that securely connects to existing historians, including:

  • OSIsoft PI System
  • Honeywell PHD
  • Yokogawa Historian
  • Enterprise industrial data lakes

Technical Highlights

  • OPC UA and OPC HDA-based data access
  • Read-only, non-intrusive historian queries
  • Millisecond-level timestamp support
  • High-performance time-series retrieval

This ensured enterprise-grade industrial process historian integration without impacting historian performance or plant operations.

Centralized Data Processing for Reliable Industrial Analytics

Normalizing Historian Data at Scale

Historian data varies widely across vendors and systems. Our processing layer handled:

  • Tag normalization across historians
  • Time alignment and resampling
  • Handling missing data and compression gaps
  • Preparing analytics-ready datasets

This created a single source of operation for analytics, reporting, and visualization, critical for scalable industrial application development.

Role-Based Dashboards for Operational Visibility

Interactive Industrial Dashboards

We developed role-specific dashboards tailored for:

  • Operations teams
  • Process and reliability engineers
  • Plant managers
  • Executive leadership

Dashboard Capabilities

  • Historical trend analysis
  • Asset and process KPIs
  • Shift-wise and batch-wise comparisons
  • Energy and efficiency metrics
  • Event and anomaly overlays

Users could explore years of historian data visually, reducing analysis time from hours to seconds.

Automated Reporting from Process Historian Software

Eliminating Manual Data Extraction

The platform introduced automated reporting that:

  • Generates daily, weekly, and monthly reports
  • Compares historical performance across time ranges
  • Highlights deviations from expected operating conditions
  • Supports audits and compliance needs

This significantly reduced reliance on manual historian queries and spreadsheets.

Advanced Industrial Analytics & Root Cause Analysis

Correlating Data Across Assets and Processes

By combining normalized historian data, the system enabled:

  • Root cause analysis of recurring failures
  • Detection of long-term process drift
  • Identification of conditions leading to downtime or quality loss

Performance Benchmarking

Teams could benchmark performance across:

  • Equipment and assets
  • Shifts and production runs
  • Time periods and operational units

This transformed historical data into a continuous improvement engine.

AI-Ready Architecture Built with .NET and Azure

Cloud-Native Industrial Platform

The solution was developed using .NET industrial applications and deployed via Azure Web Apps, aligning with modern Azure Industrial IoT principles.

Platform Benefits

  • Scalable cloud deployment
  • High availability and security
  • Easy extensibility for new historians
  • Foundation for predictive maintenance and AI

The architecture supports future machine learning models trained on historical data, powered by Azure integration services.

Overall Results and Business Impact

The engagement delivered measurable value across teams and operations:

Unified Visibility

Central access to real-time and historical operational data

Faster Decisions

Insights delivered instantly for confident, data-driven actions

Reporting Efficiency

Manual engineering reports significantly reduced through automation

Operational Awareness

Clear performance insights shared across teams and roles

Scalable Analytics

Future-ready analytics built on existing infrastructure systems

Why This Matters to CIO, CXOs and Business Leaders

For CIO, CXO and senior executives, industrial analytics initiatives are not about dashboards or technology stacks, they are about business outcomes, risk reduction, and long-term competitiveness.

This transformation enabled leadership to:

  • Gain enterprise-wide operational visibility instead of isolated plant-level views
  • Make faster strategic decisions using trusted, consistent data
  • Reduce hidden costs caused by inefficiencies, downtime, and delayed insights
  • Maximize ROI from existing historian investments without additional capital-heavy replacements
  • Build a future-ready digital foundation aligned with AI, predictive analytics, and Industry 4.0 goals

By converting historian data into executive-level intelligence, the organization moved from reactive decision-making to proactive operational leadership.

Why Choose Infomaze for Industrial Historian Analytics

Infomaze brings a unique blend of industrial domain understanding and enterprise-grade software engineering.

What sets Infomaze apart:

  • Deep Industrial Context:

     We understand how industrial environments operate—OT systems, historians, data integrity constraints, and plant-critical performance requirements.

  • Historian-First, Non-Disruptive Approach:

     We enhance existing industrial and process historian software rather than replacing it, protecting prior investments and minimizing operational risk.

  • Strong .NET and Azure Expertise:

     Our solutions are built using proven .NET industrial applications and Azure-native architectures, ensuring scalability, security, and long-term maintainability.

  • Custom Industrial Software Development:

     Every solution is tailored to real operational workflows—no one-size-fits-all dashboards or generic analytics layers.

  • Built for Today and Tomorrow:

     Our architectures are designed not just for reporting, but for advanced analytics, AI enablement, and continuous improvement at enterprise scale.

Infomaze acts as a technology partner, helping industrial organizations turn complex historian data into measurable business value.

Conclusion

Industrial historians are exceptional at capturing data but intelligence emerges only when that data is contextualized, visualized, and analyzed. Through deep expertise in .NET development, industrial historian software, and cloud-native design, Infomaze helped the client unlock the true value of their historical process data.

By delivering a scalable analytics layer on top of existing historians, we bridged the gap between raw time-series data and operational excellence, creating a future-ready platform for advanced analytics and AI-driven insights.

Partner with Infomaze to build secure, scalable and insight-driven industrial solutions that turn historian data into real business outcomes. Let’s transform your data into decisions.

Do you have a use case like this one?

Let us know! Our product experts can configure the best solution for your business.

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