Out of Sight, Out of Sync: The Hidden Challenge in Visibility

Aug. 25, 2025
Lessons from the energy industry show manufacturers of all types why true visibility means more than having access to data; it means turning that data into timely, trustworthy insights that empower action.
  • Many manufacturers still rely on legacy control systems and fragmented data sources, creating strategic liabilities as they face increasing complexity, regulatory requirements and the need for real-time decision-making. 
  • Industrial organizations need complete asset visibility, accurate alarm systems and data that directly supports strategic decisions, rather than dealing with information overload, reactive maintenance and siloed reporting that leads to slower responses and increased risk. 
  • Best practices include interoperable smart devices, integrated IT/OT ecosystems, AI-assisted filtering of critical alerts, role-based dashboards and unified data platforms that provide secure, real-time information for audit, analysis and action. 

 

Like many industrial sectors, the energy sector is evolving rapidly. Across global markets, distributed energy resources (DERs), electrification, tightening cyber regulations, and AI-led automation are transforming what operational excellence demands. Yet many asset owners and operators are still relying on control systems built for a different era.

As infrastructure modernizes, visibility often lags

From field teams to executive leaders, decisions are still made with only portions of the full data picture — fragmented SCADA, siloed telemetry and manual reporting. That’s no longer a technical inconvenience. In 2025, it’s a strategic liability.

Across North America to Europe to Asia Pacific, operators are contending with the same challenge — how to deliver secure, scalable and real-time operational visibility across increasingly complex asset networks. Without it, resilience, compliance and commercial outcomes are all at risk.

Global authorities in the energy industry echo this urgency. The International Energy Agency (IEA) highlights that grid modernization and digital visibility are critical to both system stability and decarbonization

The visibility gap is more than a data problem

When energy leaders talk visibility, they’re not asking for another dashboard. They want:

  • A complete view of asset conditions across sites. 
  • Confidence in alarm accuracy and relevance. 
  • Data that links asset performance to investment decisions. 

True visibility means more than having access to data; it means turning that data into timely, trustworthy insights that empower action.

But for most operators, gaps, such as the following, remain:

  • Alarm overload with no root-cause traceability. 
  • Escalating faults due to fragmented systems. 
  • Maintenance triggered by time, not condition. 
  • Strategic planning that relies on stitched-together spreadsheets.

Pperators are contending with the same challenge — how to deliver secure, scalable and real-time operational visibility across increasingly complex asset networks. Without it, resilience, compliance and commercial outcomes are all at risk.

The results of these factors are slower reactions, more risk and less resilience. In practice, the consequences of limited visibility are clear:

  • A crew gets dispatched to fix a fault only to discover it’s upstream, costing hours and risking safety. 
  • A minor alarm escalates into a shutdown because no one saw the trend line. 
  • Performance KPIs are missed due to root causes buried in noise. 
  • Capital upgrades are deferred, then fail, because reports lacked real context. 

These aren’t edge cases. They’re the predictable result of disjointed systems and incomplete insight.

To perform a visibility health check on your operations, ask yourself these questions:

  • Do your alarms escalate multiple times before action? 
  • Can your team identify root causes without switching systems? 
  • Is your maintenance strategy still date-driven? 
  • Does your SCADA allow integration with third-party and cloud platforms? 
  • Can you quantify operational risk across all asset classes? 

If you answered no to any of these questions, visibility may be the missing link. 

Why the data problem matters now

Four forces are converging to make energy visibility a non-negotiable capability:

  1. Grid modernisation and DER complexity. This is not a regional challenge. From Europe’s offshore wind mix to North America's distributed solar and Asia’s hybrid systems, visibility across grid-edge assets is now a prerequisite, not a nice-to-have. 
  2. Cybersecurity and regulatory compliance. Regulatory frameworks worldwide, from SOCI and AESCSF in Australia to NERC CIP in North America and ENTSO-E initiatives in Europe are pushing operators to demonstrate real-time visibility and rapid response across operational technology environments. 
  3. Decarbonization and ESG mandates. ESG and scope reporting requirements now demand near-real-time operational data. Visibility enables not just compliance, but proactive emissions management. McKinsey notes that accuracy in reporting increasingly depends on integrated, trusted data — not just output metrics 
  4. Workforce constraints and knowledge loss. As experienced staff exit the sector, systems must carry more of the load. Visibility reduces reliance on institutional knowledge and manual intervention, ensuring continuity and safer decision-making. 

These drivers are consistent across advanced and emerging energy markets. Partial visibility is no longer sustainable.

What visibility best practices look like in 2025

Top operators aren’t just layering on more tech; they’re redesigning how operational insight flows through their organisations. Following are a few examples: 

  • Interoperable edge sensing and smart devices. Cloud-enabled by design, modern sensors and RTUs feed consistent, reliable data upstream. 
  • SCADA as part of an OT ecosystem. Leading teams are evolving SCADA into broader IT/OT architectures that integrate third-party tools, cloud platforms and cybersecurity layers. 
  • Edge-processed, AI-assisted alarming. Alarms are triaged at the edge. AI filters noise and highlights only what’s actionable. 
  • Role-based dashboards. Field teams, engineers and executives each see data tailored to their role, all connected to the same source of truth. 
  • Unified data fabric with security by design. From edge to cloud, data flows securely and in real time, ready for audit, analysis and action. 

These are no longer future-facing aspirations. According to McKinsey, global operators are actively investing in integrated SCADA, AI-driven analytics and unified OT/IT platforms to manage complexity and meet compliance expectations.

Danny Smith is the head of energy at Sage Group, A Tetra Tech Company.  Sage is a certified member of the Control System Integrators Association (CSIA). For more information about SAGE Group, visit its profile on the Industrial Automation Exchange.

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