Course Syllabus

Industrial IoT & Industry 4.0 Engineer · 12 weeks · 480 hours

Programme overview · v1.1 · October 2026

A practical, full-time 3-month programme that develops machine connectivity, automation integration, edge deployment and manufacturing data skills through supervised engineering builds, with AI-assisted coding taught as a professional skill.

Course objectives

  • Read industrial drawings, wire protected 24 VDC circuits and diagnose sensor and I/O faults.
  • Develop and test PLC logic and HMI screens on Delta DVP/DOP, and port core logic to Mitsubishi FX5U and Siemens S7-1200 rotation stations.
  • Connect equipment through serial, Modbus, Ethernet and OPC UA interfaces using device manuals.
  • Build Python and ESP32 applications that acquire, validate and transmit machine data.
  • Use AI coding assistants responsibly: specify, review, test and defend AI-generated code and configuration.
  • Deploy an edge data pipeline using MQTT, Node-RED, Linux, PostgreSQL and Grafana.
  • Translate machine signals into alarms, energy trends, production reports and correctly defined OEE.
  • Apply introductory OT security practices and deliver documented FAT/SAT and commissioning evidence.

What successful learners can demonstrate

Given a machine manual, a defined tag list and a lab network, a learner can plan connectivity, collect and qualify data, deploy an edge pipeline, build a dashboard, recover from introduced faults and explain the solution to an employer.

Week by week

Syllabus

Each week: 5 days, 40 student hours (15 trainer-led + 25 supervised lab). Every day pairs a 3-hour trainer-led block with a 5-hour supervised lab and ends with documented evidence.

Outcome: Wire and test a protected sensor-to-controller circuit.
DAY 01Industry 4.0 and factory systems
Trainer-led · 3 h
Automation pyramid; PLC/HMI/SCADA/MES/ERP roles; safety induction and drawings.
Supervised lab · 5 h
Inspect a trainer panel, identify components and map the sensor-to-dashboard chain.
Evidence
System sketch, component inventory and safety checklist.
DAY 02Electrical and control-panel basics
Trainer-led · 3 h
AC/DC, 24 VDC, SMPS, NO/NC, relays, contactors, fuses, MCBs and earthing.
Supervised lab · 5 h
Build a protected lamp/relay circuit; measure voltage, continuity and current safely.
Evidence
Annotated circuit and measurement sheet.
DAY 03Industrial sensors and digital I/O
Trainer-led · 3 h
Proximity, photoelectric and limit sensors; PNP/NPN; sinking/sourcing and isolation.
Supervised lab · 5 h
Wire compatible PNP/NPN examples to a training interface; test detection and open-wire faults.
Evidence
I/O list, wiring diagram and diagnostic observations.
DAY 04Analog instrumentation and actuation
Trainer-led · 3 h
0-10 V and 4-20 mA; scaling; temperature/pressure transmitters; motor/VFD overview.
Supervised lab · 5 h
Use signal generators and a compatible analog module; scale a value; compare signal loss.
Evidence
Scaling calculation and calibration points.
DAY 05Panel build and practical checkpoint
Trainer-led · 3 h
Drawing review, labeling, ferrules, polarity checks and systematic diagnosis.
Supervised lab · 5 h
Complete an object-detection/counting panel; diagnose loose terminal, polarity and I/O faults.
Evidence
Mini-project 1 plus individual electrical practical.
Outcome: Deliver a working PLC/HMI machine simulation and port it to a second PLC brand.
DAY 06Delta DVP setup and scan cycle
Trainer-led · 3 h
ISPSoft project setup; hardware, I/O addressing (X/Y/M/D), scan cycle and online monitoring.
Supervised lab · 5 h
Connect safely, download a basic programme and verify each input/output.
Evidence
I/O checkout and saved PLC project.
DAY 07Ladder logic and sequences
Trainer-led · 3 h
Contacts/coils, interlocks, SET/RST, timers, counters and start/stop behaviour. PLC logic is written by hand; AI may explain concepts only.
Supervised lab · 5 h
Build a conveyor sequence with reset and fault handling; verify restart behaviour.
Evidence
Sequence diagram and test cases.
DAY 08Data handling and diagnostics
Trainer-led · 3 h
Registers, MOV, comparisons, arithmetic, analog scaling and pulse/encoder introduction.
Supervised lab · 5 h
Add count, runtime and scaled analog tags; use watch tables to locate logic faults.
Evidence
Tag/register map and PLC diagnostic record.
DAY 09DOP HMI screen development
Trainer-led · 3 h
DOPSoft; Ethernet/RS485 connection to the PLC, buttons, status, alarms and trends.
Supervised lab · 5 h
Build operator screens and validate PLC/HMI tag links, bounds and alarm acknowledgement.
Evidence
HMI project and screen test sheet.
DAY 10Integrated machine simulation and brand rotation
Trainer-led · 3 h
PLC/HMI integration, mode selection, permissives and documentation; mapping the same logic to GX Works3 and TIA Portal.
Supervised lab · 5 h
Complete the conveyor/counting demonstrator with Run/Idle/Stop/Fault and fault recovery; pairs rotate to a premium station to port and test a core sequence.
Evidence
Mini-project 2, programme backup, individual logic check and brand-port record.
Outcome: Acquire data over RS485 and Ethernet and isolate common faults.
DAY 11Serial data fundamentals
Trainer-led · 3 h
Binary, hex, ASCII, bytes, signed values, baud rate, parity, stop bits and UART.
Supervised lab · 5 h
Use serial tools and loopback; decode a frame and compare incompatible settings.
Evidence
Serial settings sheet and decoded examples.
DAY 12RS232 and RS485 physical layers
Trainer-led · 3 h
Point-to-point versus bus wiring; pinouts, polarity, termination, biasing and grounding.
Supervised lab · 5 h
Build an isolated RS485 bus and RS232 loopback; inspect a termination/polarity fault.
Evidence
Bus diagram and physical-layer fault log.
DAY 13Modbus RTU transactions
Trainer-led · 3 h
Device ID, function codes, coils/registers, address offsets, CRC, timeouts and endianness.
Supervised lab · 5 h
Read an energy meter using its register map; validate scaling and perform a lab-only write.
Evidence
Verified register map and request/response trace.
DAY 14Ethernet and IPv4 foundations
Trainer-led · 3 h
MAC/IP, subnet mask, gateway, DHCP/static addressing, DNS, TCP/UDP and ports.
Supervised lab · 5 h
Crimp and test CAT6; build PLC-switch-HMI networking; diagnose IP/subnet faults.
Evidence
Cable test, IP plan and connectivity checklist.
DAY 15Modbus TCP and fault isolation
Trainer-led · 3 h
TCP transactions; RTU/TCP differences; Delta DVP-SE Modbus TCP configuration and packet capture.
Supervised lab · 5 h
Read mapped lab values over TCP; compare RTU; diagnose timeout, wrong address and port faults.
Evidence
Protocol practical, packet evidence and manual references.
Outcome: Build and validate a fault-tolerant, timestamped machine-data collector using AI-assisted coding.
DAY 16Python fundamentals by hand
Trainer-led · 3 h
Environment setup, types, conditions, loops, functions and debugging; reading code line by line. No AI code generation today.
Supervised lab · 5 h
Hand-write scaling, threshold and cycle-time functions with sample machine values; trace execution on paper.
Evidence
Hand-written script and boundary-case checks.
DAY 17Structured data and the AI workflow
Trainer-led · 3 h
Lists/dictionaries, JSON/CSV, exceptions and logging; the five-step AI workflow, prompt specifications and approved tool use.
Supervised lab · 5 h
Write a specification, generate a tag-configuration parser with AI, review it line by line and test it with bad records.
Evidence
Specification, prompt log, annotated review and test results.
DAY 18AI-assisted serial collector
Trainer-led · 3 h
Serial port lifecycle, framing, buffers and timeouts; common AI mistakes in serial code.
Supervised lab · 5 h
Generate and verify a serial collector; prove reconnection after cable removal and logging of invalid frames.
Evidence
Collector, review notes and recovery evidence.
DAY 19Modbus collector: generate and verify
Trainer-led · 3 h
PyModbus, data conversion, polling, retries and quality flags; why register maps come only from device manuals.
Supervised lab · 5 h
Build the collector with AI; cross-check every value with a Modbus client tool and the meter display; handle device loss without reporting stale data as valid.
Evidence
Collector, cross-check table and disconnect/reconnect test.
DAY 20REST integration and code-review test
Trainer-led · 3 h
HTTP GET/POST, status codes and FastAPI introduction; reviewing AI-generated code for hidden defects.
Supervised lab · 5 h
Post validated readings to a lab API; then complete an individual no-AI test: find and fix seeded bugs in AI-written code.
Evidence
Mini-project 3 and individual code-review test result.
Outcome: Build an embedded sensor node and compare it with an industrial gateway.
DAY 21Embedded C and ESP32 setup by hand
Trainer-led · 3 h
C types, arrays, functions, scope; toolchain and serial diagnostics. Pin and voltage decisions are made by the student, never by AI.
Supervised lab · 5 h
Compile/upload a hand-written application and read a low-voltage digital input.
Evidence
Build notes, source and student-designed pin map.
DAY 22Firmware structure with AI assistance
Trainer-led · 3 h
Structs, state machines, debounce, non-blocking timing; reviewing AI-generated firmware for blocking calls and unsafe start-up.
Supervised lab · 5 h
Generate an input-counting state machine with AI; verify safe startup state, debounce and configuration on hardware.
Evidence
Firmware, review notes and debounce test.
DAY 23ADC, interrupts and timing
Trainer-led · 3 h
ADC limits, scaling, interrupt hygiene, timers and watchdog concepts.
Supervised lab · 5 h
Acquire a conditioned analog signal and pulse count; verify timing and missed pulses with an oscilloscope rather than trusting the code.
Evidence
Sampling results and timing observations.
DAY 24Network and RS485 node
Trainer-led · 3 h
Wi-Fi/Ethernet, UART/RS485 transceiver, Modbus and electrical interface limits.
Supervised lab · 5 h
Connect a compatible RS485 device; acquire and encode readings; test network loss.
Evidence
Embedded data node and interface schematic.
DAY 25Embedded gateway mini-project
Trainer-led · 3 h
Debugging, configuration, restart recovery; DIY versus production gateway requirements.
Supervised lab · 5 h
Complete the ESP32 node; compare isolation, enclosure and serviceability with M-Connect if available.
Evidence
Mini-project 4, firmware repository and comparison sheet.
Outcome: Move qualified machine data through a reliable publish/subscribe pipeline.
DAY 26MQTT architecture and topics
Trainer-led · 3 h
Broker/client, publish/subscribe, topic hierarchy and JSON payload contracts.
Supervised lab · 5 h
Run a lab broker; publish machine tags and inspect them with an MQTT client.
Evidence
Topic tree and payload examples.
DAY 27Messaging behaviour
Trainer-led · 3 h
QoS 0/1/2, retained messages, Last Will, sessions, timestamps and duplicate handling.
Supervised lab · 5 h
Test reconnection, stale retained state and duplicate deliveries with sequence IDs.
Evidence
Delivery test matrix and freshness rules.
DAY 28Mosquitto operations
Trainer-led · 3 h
Broker setup, configuration, authentication, client tools and logs.
Supervised lab · 5 h
Configure named users and topic access rules; diagnose a blocked publish.
Evidence
Broker configuration and access test.
DAY 29Node-RED integration
Trainer-led · 3 h
Flows, MQTT/Modbus nodes, transformation, validation and flow error handling.
Supervised lab · 5 h
Convert PLC/meter data into standard machine messages; catch invalid or absent input.
Evidence
Exported flow and validation evidence.
DAY 30End-to-end messaging project
Trainer-led · 3 h
Pipeline review; polling versus events; resilience and diagnostic checkpoints.
Supervised lab · 5 h
Integrate the Delta PLC/meter or ESP32 to gateway and MQTT; test source/broker failure.
Evidence
Mini-project 5: working pipeline, logs and recovery record.
Outcome: Select and verify a connectivity route for an unfamiliar machine.
DAY 31OPC UA foundations
Trainer-led · 3 h
Server/client, information models; when to choose OPC UA, Modbus or MQTT.
Supervised lab · 5 h
Compare the same tag through a Modbus source and an OPC UA gateway/simulator.
Evidence
Protocol selection rationale and tag mapping.
DAY 32Browsing and data access
Trainer-led · 3 h
Namespaces, NodeId, types, timestamps, status codes and subscriptions.
Supervised lab · 5 h
Browse with UaExpert; read and subscribe to typed values; identify bad-quality data.
Evidence
Node list and subscription evidence.
DAY 33Secure OPC UA practical
Trainer-led · 3 h
Endpoints, certificates, trust lists, user access and secure-channel concepts.
Supervised lab · 5 h
Establish a secure lab session; diagnose untrusted certificate and wrong endpoint.
Evidence
Trust procedure and connection test.
DAY 34PLC to OPC UA integration
Trainer-led · 3 h
Gateway/driver architecture; Delta Modbus TCP and Mitsubishi SLMP routes; data mapping and rate limits.
Supervised lab · 5 h
Connect the Delta PLC through a supported gateway or OPC server, and the FX5U on the premium station; validate updates and quality.
Evidence
Connection configuration and freshness test.
DAY 35Siemens S7-1200 practical and machine discovery
Trainer-led · 3 h
Siemens S7-1200 and TIA Portal essentials; S7 and OPC UA access; Rockwell and CNC/FANUC exposure; manuals and licences.
Supervised lab · 5 h
Rotate on the Siemens station to monitor and read tags; investigate a machine brief using a shared device or simulator; propose tags and interface options.
Evidence
Siemens tag-read record, machine-connectivity study and individual manual-reading check.
Outcome: Commission and maintain an isolated edge application.
DAY 36Linux foundations
Trainer-led · 3 h
Ubuntu install/VM, filesystem, shell, users, permissions and network configuration.
Supervised lab · 5 h
Prepare an edge host, create an application account and inspect files/logs.
Evidence
Host build checklist and permissions evidence.
DAY 37Services and remote administration
Trainer-led · 3 h
SSH/SCP, packages, systemd, journal logs, time sync and service recovery; reviewing AI-drafted service files before use.
Supervised lab · 5 h
Deploy the collector as a service; restart/reboot and verify recovery and timestamps.
Evidence
Service definition and reboot test.
DAY 38Industrial network design
Trainer-led · 3 h
Subnets/routes, DNS/NAT, VLANs, firewall rules, dual NICs and approved remote access.
Supervised lab · 5 h
Build machine/server VLANs; allow required traffic; diagnose routing and firewall faults.
Evidence
Network diagram, rule list and packet evidence.
DAY 39Git and containers
Trainer-led · 3 h
Version history, branches, secrets hygiene; Docker images, volumes and networks; checking AI-drafted Dockerfiles and commands before running them.
Supervised lab · 5 h
Version a project and containerise one service with persistent data and configuration.
Evidence
Repository history and deployment manifest.
DAY 40Edge deployment checkpoint
Trainer-led · 3 h
Configuration, health checks, storage limits, offline buffering and restore strategy.
Supervised lab · 5 h
Deploy the pipeline; test network loss, process failure and buffered replay.
Evidence
Mini-project 6, deployment guide and resilience report.
Outcome: Create a traceable machine historian and an energy dashboard.
DAY 41Relational data and SQL
Trainer-led · 3 h
Keys, tables, constraints, INSERT/SELECT/UPDATE, filters and basic joins.
Supervised lab · 5 h
Create machine/tag tables and query a seeded industrial dataset.
Evidence
SQL scripts and query results.
DAY 42PostgreSQL ingestion
Trainer-led · 3 h
Roles, connection configuration, parameterised queries, transactions and timestamps.
Supervised lab · 5 h
Store MQTT/collector data with machine ID, units, quality and source time.
Evidence
Database schema and ingestion checks.
DAY 43Time-series data quality
Trainer-led · 3 h
Indexes, retention, UTC/timezones, sample gaps, deduplication and cumulative counters.
Supervised lab · 5 h
Handle replayed records, meter resets and missing samples; calculate valid energy deltas.
Evidence
Data-quality rules and verified daily totals.
DAY 44Grafana visualisation
Trainer-led · 3 h
PostgreSQL source, panels, variables, trends, units and query permissions.
Supervised lab · 5 h
Build machine-state and energy panels; identify stale/bad-quality measurements.
Evidence
Exported dashboard and visual validation.
DAY 45Alarms and reporting
Trainer-led · 3 h
Thresholds, alert persistence, report periods, acknowledgements and evidence.
Supervised lab · 5 h
Complete an energy dashboard with daily kWh, trends and gap reporting; test alert conditions.
Evidence
Mini-project 7: historian/dashboard with report and outage test.
Outcome: Convert machine events into defensible production metrics.
DAY 46Manufacturing data semantics
Trainer-led · 3 h
Cycles, shifts, setup, downtime, rejects, WIP, planned stops and reason codes.
Supervised lab · 5 h
Define a machine state model and generate timestamped events from the PLC simulation.
Evidence
State transition chart and shift/event log.
DAY 47OEE engineering
Trainer-led · 3 h
Availability, Performance, Quality; ideal cycle time, planned production time and exclusions.
Supervised lab · 5 h
Calculate OEE from collected events/counts; reconcile a worked dataset and flag anomalies.
Evidence
OEE calculation sheet and assumption register.
DAY 48SCADA functions
Trainer-led · 3 h
Tags, alarming, trends, historian, operator roles; Ignition or equivalent demonstration.
Supervised lab · 5 h
Configure a trial/simulator SCADA view with process status, alarms and historical trends.
Evidence
SCADA configuration and alarm test.
DAY 49MES workflows
Trainer-led · 3 h
Orders, operations, downtime reasons, traceability and quality records.
Supervised lab · 5 h
Build a lightweight order/count/reject workflow linked to machine events.
Evidence
Order-to-production trace and quality report.
DAY 50ISA-95 and integration
Trainer-led · 3 h
Enterprise/control boundaries; equipment, material, personnel and production information.
Supervised lab · 5 h
Map the lab solution to ISA-95 levels and exchange a simulated ERP order/report via API.
Evidence
Mini-project 8: OEE/MES view and capstone design review.
Outcome: Harden the lab system and prove installation readiness.
DAY 51OT risk and architecture
Trainer-led · 3 h
IT/OT priorities, asset inventory, threats, zones/conduits and change control.
Supervised lab · 5 h
Inventory the capstone assets and define trust boundaries and communication needs.
Evidence
Risk register and zone/conduit diagram.
DAY 52Segmentation and access
Trainer-led · 3 h
VLAN/firewall enforcement, least privilege, remote access and packet analysis.
Supervised lab · 5 h
Apply allow-listed flows; verify blocked paths and diagnose an approved connection failure.
Evidence
Rule set, access matrix and connectivity tests.
DAY 53Secure messaging and APIs
Trainer-led · 3 h
MQTT TLS, certificates, authentication, topic ACLs, API authorisation and secret storage.
Supervised lab · 5 h
Secure the lab broker/API; verify rejected credentials and certificate validation.
Evidence
Security configuration and negative test record.
DAY 54IEC 62443 introduction and recovery
Trainer-led · 3 h
Roles, lifecycle, risk assessment, security-level concepts, backup, logging and patch planning.
Supervised lab · 5 h
Back up and restore a service; review accounts/logs and document a maintenance window.
Evidence
Recovery drill, hardening checklist and IEC 62443 concept map.
DAY 55FAT/SAT and troubleshooting
Trainer-led · 3 h
Factory/site acceptance, I/O checkout, commissioning sequence, rollback and fault isolation.
Supervised lab · 5 h
Run an introduced multi-layer fault exercise and prepare capstone acceptance procedures.
Evidence
Individual troubleshooting test and draft FAT/SAT pack.
Outcome: Deliver, commission and defend a complete manufacturing monitoring system.
DAY 56Capstone build: controls and acquisition
Trainer-led · 3 h
Trainer design clinic: scope, tag contract, safe machine states and task ownership.
Supervised lab · 5 h
Complete PLC/HMI, meter/node integration and timestamped acquisition; resolve design gaps.
Evidence
Working controls, tag map and integration checkpoint.
DAY 57Capstone build: data and insight
Trainer-led · 3 h
Trainer review: historian, dashboards, OEE boundaries and data-quality checks.
Supervised lab · 5 h
Integrate storage, alarms, energy/OEE reporting and simulated MES order linkage.
Evidence
Working dashboard and verified report calculations.
DAY 58Capstone build: resilience and portfolio
Trainer-led · 3 h
Trainer review: security, recovery, documentation; CV and project-story coaching.
Supervised lab · 5 h
Test outages, restart and restore; finish repository and portfolio; rehearse explanations.
Evidence
Recovery evidence, CV and project demonstration draft.
DAY 59FAT/SAT and handover rehearsal
Trainer-led · 3 h
Trainer witnesses critical FAT checks; reviews deviations and technical presentation.
Supervised lab · 5 h
Run remaining lab SAT-style checks, close defects, package backups and present peer demos.
Evidence
Signed test record, known issues and handover pack.
DAY 60Final practical and technical interview
Trainer-led · 3 h
Individual practical station, technical viva and capstone defence during trainer block, without AI assistance.
Supervised lab · 5 h
Complete evidence checks, mock HR/group interviews, CV refinement and learning action plan.
Evidence
Final scorecard, individual competency record and portfolio.
AI-assisted engineering

Where AI is used

WeeksAI use
1–3No AI code generation. Electrical work, PLC ladder logic, HMI and protocols are learned by hand; AI may be used only to explain concepts.
4–5First two days of each week by hand (Python, embedded C), then AI-assisted builds under the five-step workflow. The Day 20 code-review test is done without AI.
6–12AI-assisted for code, Node-RED functions, SQL, configuration files and documentation drafts; every output is reviewed, tested and logged.

Register addresses, scaling, wiring, voltages, PLC interlocks and safety logic always come from device manuals and the student, never from AI output. AI is not permitted in troubleshooting and code-review tests, theory checks or the final practical/interview.

Applied learning

Eight builds, one integrated system

BuildHands-on scope
1 · Sensor panelProtected 24 VDC circuit, sensor I/O, object detection and measurement.
2 · PLC + HMI cellDelta DVP sequence, count/runtime, fault status and DOP screens; core logic ported to a second brand.
3 · Python collectorRTU/TCP or serial acquisition, validation, timestamps and lab API.
4 · ESP32 nodeEmbedded C, conditioned I/O, counting, network and RS485.
5 · MQTT pipelineGateway/node to broker, topic contract and Node-RED transformation.
6 · Edge deploymentLinux service/container, Git, isolation and buffering.
7 · Energy historianPostgreSQL, Grafana, kWh deltas, gaps and alerts.
8 · Production insightMachine events, OEE, SCADA/MES concepts and order linkage.
Evaluation

Assessment and completion

Practical performance carries 95% of the course score; theory checks carry 5%.

AssessmentWeight
Weekly practical labs25%
Mini-projects (eight staged builds)20%
Troubleshooting & code-review tests (no AI)15%
Final capstone25%
Final practical / technical interview10%
Theory checks5%
  • At least 90% attendance and all critical labs signed off.
  • At least 60% overall, with at least 50% in troubleshooting tests, the capstone and the final individual practical.
  • Pass the mandatory safe-wiring and equipment-use check and submit the capstone handover pack.
  • Grading bands: Distinction 80%+, Merit 70–79%, Pass 60–69%.
Final project

Smart manufacturing capstone

A paired engineering build with individual defence and practical verification, integrating the components developed across the course.

Sensors + Delta PLC + HMI / Modbus energy meter → gateway → MQTT / OPC UA → Ubuntu edge → PostgreSQL → Grafana + production/OEE view → simulated MES/ERP API

  • Machine Run/Idle/Stop/Fault states; production count, cycle time, downtime reasons, rejects, alarms and energy.
  • A Modbus acquisition path plus an OPC UA demonstration; a consistent MQTT topic/payload contract.
  • At least one ESP32 sensor/count node integrated into the solution.
  • Timestamps, units, quality and stale-data indicators; OEE reconciled to raw events.
  • Least-privilege access, network boundaries, restart recovery and offline buffering/replay.
Placement preparation

Career readiness

CV and portfolio review, project storytelling, technical mock interviews and employer-style fault tasks run during Week 12. Interview practice covers scan cycles and interlocks, RS485 and IP fault diagnosis, protocol choice, OPC UA quality, MQTT topic design, SQL, downtime/OEE, certificate trust and critical review of AI-generated code.

This is a Maestro course completion programme. Vendor platforms and standards are taught as technologies; the syllabus does not imply vendor endorsement, ISA/IEC certification or a job guarantee. Placement assistance may include employer introductions and interview referrals; employment is not guaranteed.