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Case study
[H1] What's hiding in your network?

See how KTH improved visibility and reduced plant-wide risk.
Belden | 08.15.2025 | 10 minutes

Read full case study

Related Tags

Transportation & Mobility
Transportation & Mobility
Monitoring & Performance

JUMP TO: Customer  |  Challenge  |  Discovery  |  Solution  |  Results

How does a leading automotive supplier move from limited visibility and repeated downtime… to a segmented, scalable foundation built for Industry 4.0?
KTH Parts Industries faced growing production demands, rising cybersecurity pressure and a network that couldn’t keep up.
14 downtime incidents. Limited visibility. Increasing risk.
So what changed?

[H2] The Customer
KTH Parts Industries is a Tier 1 automotive supplier producing stamped, welded and assembled metal components for leading global automotive manufacturers, supporting high-volume, precision-driven production environments.
With multiple facilities across North America, KTH is known for operational excellence—and a constant drive to improve how its plants perform.
But as production scaled, so did complexity.

[H2] The Challenge
[H4] What happens when your network can’t keep up with your production growth?
As KTH expanded its Ohio facility, new production lines, automation and connected devices were added rapidly.
But the network wasn’t built for it.
A flat Layer 2 architecture limited scalability
Device counts surged past 2,000
Visibility into network issues was minimal
Downtime events became more frequent
[H4] The result?
14 unexpected instances of extended downtime—and no clear way to pinpoint the root cause.
At the same time, OEM customers were asking tougher questions about cybersecurity and resilience.

[H2] Discovery
[H4] How do you fix a network when you can’t fully see it?
KTH didn’t start with a solution.
They started with discovery.
A detailed network assessment  — beginning with a gemba walk—uncovered hidden vulnerabilities, bottlenecks and blind spots across the plant.
For the first time, the team could clearly see:
What was connected
Where issues originated
How performance varied across the plant

[H4] That visibility changed everything.

“We wanted to have a bird’s-eye view so we could see what was happening on our network and quickly identify and troubleshoot problems as they arise.”
— Jim Schienda, KTH Technical Support Group Director

[H2] The Solution
[H4] What does it take to rebuild a network without disrupting production?
Instead of patching the problem, KTH reimagined its entire network architecture.
The transformation focused on:
Moving from a flat network to a segmented VLAN architecture
Creating 22 independently managed network zones
Implementing managed industrial Ethernet switches
Introducing redundancy to limit fault impact
Standardizing a repeatable design for future expansion
Each zone could now operate independently — containing issues before they spread.
AAnd importantly, this wasn’t a rip-and-replace approach. Similar to the Richmond case study — where Belden modernized a 95-year-old facility by connecting legacy equipment and enabling predictive maintenance without full replacement — deployment here was phased alongside scheduled shutdowns to avoid disruption.

[H2] Results & Impact
[H4] What changes when your network stops being the bottleneck?
With segmentation, visibility and control in place, KTH transformed how its plant operates.
Key outcomes include:
Reduced instances of unplanned downtime
Faster troubleshooting and issue isolation
Improved production reliability
Scalable infrastructure for future growth
“If an issue comes up in one area, it only affects that zone, not the whole plant.”
— Jim Schienda, KTH Technical Support Group Director
What was once a plant-wide risk is now a contained, manageable event.

[H2] Why this matters
[H4] Why are more manufacturers rethinking their network now?
Because the pressure isn’t slowing down:
More connected devices
More automation
More cybersecurity risk
Higher expectations from OEMs
KTH’s transformation didn’t just solve today’s problems—it created a foundation for:
Predictive maintenance
Real-time operational visibility
Seamless expansion of new lines
Industry 4.0 readiness

Download full case study

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Latest
[H1] Belden's 2025 Sustainability Report marks major progress and raises the bar

Belden delivers strong results across emissions reduction, renewable energy adoption, workplace culture, and ethics—while outlining bolder targets for the years ahead.
Belden | 05.20.2026

Read more

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