Technology1 min read

Air gapped, not data dark: how Bright Machines gives customers live factory dashboards without opening the plant

By · Published by Everything Blog

In short

The manufacturer resolved previous reporting delays by capturing local PostgreSQL modifications at the plant edge via Debezium and formatting them into Apache Iceberg. This information travels across a single outbound connection to Databricks, where it is read directly using Unity Catalog federation. By eliminating inbound compute access, the design enforces precise role-based controls while replacing an older, fragile cloud replication system that spanned nine separate services.

Key points

  • Outbound-only data transmission protects air-gapped production facilities while deliverin…: Outbound-only data transmission protects air-gapped production facilities while delivering minute-level dashboard updates to customers.
  • Governing records through Databricks Unity Catalog federation prevents outside compute re…: Governing records through Databricks Unity Catalog federation prevents outside compute resources from accessing raw plant databases directly.
  • The streamlined edge-to-cloud design successfully replaced an earlier, failed setup that…: The streamlined edge-to-cloud design successfully replaced an earlier, failed setup that relied on nine loosely coupled services.

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How Bright Machines streams factory changes out of air-gapped plants with Debezium, Apache Iceberg and Unity Catalog, so customers see live, governed dashboards with no inbound access to the plant

by Jitesh Soni, Anup Chatterjee, Bryan Whittington, Mark Loesel, Mauricio Caro, Caitlin Gordon and Rachel Musiker

Bright Machines gives customers live, governed dashboards of their factory data without opening any inbound access to its air-gapped plants. It captures PostgreSQL changes at the factory edge with Debezium, writes them as Apache Iceberg, sends them out over a single auditable outbound path, and reads them in place in Databricks through Unity Catalog federation. The first customer-visible dashboard went live about two months after kickoff.

Every time a customer visited one of our factory floors, the same thing happened. They would stand in front of the assembly dashboard, watch the line run, and ask for a copy of the data: yield by station, cycle time trends, downtime by cause, the genealogy of a batch.

We had all of it. We had built those dashboards for our own operations team, and they ran on…

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