Opening a New Shop Floor Line – IT & Network Checklist for Idaho Manufacturers

That coordination typically falls to your general contractor or project manager. 

At TotalCare IT, we often act as the technology coordinator on these projects. We:

• Work directly with your electricians to confirm conduit runs, outlet placement, and power for network gear.

• Collaborate with contractors and controls integrators to ensure the floor layout supports both equipment and cabling needs.

• Provide clear documentation and labeling plans so everyone on-site knows what goes where.

• Oversee final network testing and validation before production starts.

By having IT at the coordination table, you eliminate confusion between trades and ensure that everything — from fiber to firewalls — is ready when the first machine powers up.

In many cases, yes — but it takes the right planning and integration. Most Idaho manufacturers still rely on legacy machines or controllers that were built long before modern networking and cloud systems. Those assets can often stay in service if they’re connected and secured properly.

At TotalCare IT, we specialize in helping production environments bridge the gap between old and new

And now an important note about compliance:
The CMMC program recognizes that certain systems — especially older operational technology (OT), IoT or legacy industrial devices — may be “Specialized Assets” that cannot feasibly meet all modern cybersecurity controls.

• These systems must still be documented, inventoried, and their risk managed. (For example: legacy machinery that cannot support encryption or multifactor authentication is still in scope, but you must show how you isolate, monitor, or compensate for it.)

• The CMMC Scoping Guide identifies that “Specialized Assets” — which could include OT devices, IoT/IIoT equipment, or legacy control systems — may be treated differently than standard IT assets, especially if they cannot be fully secured to the same degree.

• It is absolutely essential to document the asset, its limitations, the compensating controls in place (such as segmentation, monitoring, limited access), and ensure that CUI or business-critical data is not exposed through that system.

So, in short — you don’t need to rip and replace every legacy system to modernize your shop floor. With the right network design, integration strategy, and documented compliance steps, your existing equipment can communicate securely and efficiently with today’s connected platforms and stay aligned with key compliance frameworks.

In many cases, your existing network equipment can be reused — but it depends on the age, capacity, and security features of what you have. As production lines add more connected machines, cameras, and Wi-Fi devices, older switches and firewalls often can’t handle the bandwidth, segmentation, or cybersecurity requirements modern manufacturing demands.

At TotalCare IT, we always start by assessing your current gear before recommending any upgrades. We look at:

• Performance capacity — can it handle the new traffic load?

• Security readiness — does your firewall support modern standards?

• Age and warranty — is the hardware still supported by the manufacturer?

• Redundancy — can it fail over safely if a component goes down?

If your current setup meets the performance and security needs, we’ll absolutely keep it in place. If not, we’ll propose cost-effective upgrades that future-proof your network for new lines and equipment — without overspending.

If your production, scheduling, or shipping processes rely on cloud systems — then yes, a redundant internet connection is one of the best investments you can make for uptime and reliability.

A single internet circuit means a single point of failure. If your primary provider goes down (which can happen due to construction damage, weather, or carrier issues), production data stops syncing, email and ERP access go offline, and connected equipment may lose visibility.

At TotalCare IT, we help Idaho manufacturers design dual-provider or failover internet setups using technologies like:

• Automatic failover firewalls that instantly switch to backup internet when the primary link fails.

• Cellular or Starlink-based backups for remote facilities or rural plants.

• Load-balancing configurations that use both circuits simultaneously for higher bandwidth and reliability.

Even if redundancy isn’t required for every location, it’s often essential for production-critical sites where downtime can cost thousands per hour. We can assess your network and recommend the right level of redundancy for your operations and budget.

For most small to mid-sized manufacturing operations, a dedicated server room doesn’t have to be large — but it does need to be planned correctly. Even a well-organized 6x8 foot room or enclosed closet can handle essential servers, network switches, firewalls, and backup equipment if it’s properly cooled and secured.

The key is less about square footage and more about environmental control and accessibility. A good server room should have:

• Stable cooling and ventilation (ideally 68–75°F year-round).

• Dedicated electrical circuits and UPS battery backups.

• Proper cable management and labeling for future expansion.

• Restricted access for security and safety.

• Space for growth — plan at least 25–30% extra rack capacity.

We can convert an unused office or storage space into a reliable, clean, and secure server environment that supports both shop floor and business systems.

If your team is designing a new facility or production line, we can review your floor plans and recommend the right server room footprint before construction begins — saving time and retrofit costs later.

That’s typically handled by your IT or network management team — and it’s one of the most important steps in keeping your production environment organized and secure. Every new machine controller, HMI, PC, or network device needs a unique IP address and a consistent naming convention so systems can communicate properly and technicians can quickly identify devices on the network.

At TotalCare IT, we take responsibility for:

• Planning and assigning IP address ranges to avoid conflicts and ensure scalability.

• Establishing clear naming conventions (for example, LINE1-HMI01 or QA-PC02) that make it easy to identify where each device belongs.

• Documenting all networked devices in your site diagram and management tools.

• Coordinating with your automation or controls integrator to make sure PLCs and production equipment align with the same scheme.

A standardized IP and naming plan makes troubleshooting faster, prevents duplicate addresses, and simplifies compliance documentation. It’s a small detail that saves countless hours once the line is live.

Absolutely. In fact, most of our manufacturing clients already have an automation and controls integrator they trust — the team responsible for programming and maintaining your PLC systems, robotics, machine controls, and production automation.

Our role at TotalCare IT is to complement that expertise by managing the network, security, and connectivity layer that supports those systems. We make sure your machines, HMIs, and data systems can communicate reliably and securely with your ERP, MES, and reporting tools.

We collaborate directly with your integrator to:

• Design network segments and VLANs that keep production systems isolated but accessible.

• Set up secure remote access for integrators when they need to troubleshoot or update PLCs.

• Ensure network switches, firewalls, and Wi-Fi are tuned for the specific needs of industrial equipment.

• Coordinate go-live testing so every device and control system connects properly.

In short — you focus on production, your integrator focuses on automation, and TotalCare IT makes sure the technology connecting it all works flawlessly.

We proudly serve manufacturers across Idaho — not just in Boise. With offices in Boise and Idaho Falls, our team supports clients throughout both Western and Eastern Idaho.

We also work with organizations in Northern Idaho and out-of-state locations when it makes sense for both us and them (for example, we support a large beef processing plant in Nebraska). While Boise is the nearest hub for northern sites, we’re fully equipped to travel or provide hybrid on-site and remote support as needed.

Whether your facility is in Nampa, Twin Falls, Pocatello, Idaho Falls, Coeur d’Alene, or beyond, TotalCare IT can deliver reliable, secure IT services designed for manufacturing environments.

Not usually. TotalCare IT is a managed IT company, not a structured cabling contractor. On smaller jobs — like adding a few network drops or relocating equipment — our team may handle the cabling directly.

For larger installations, we partner with trusted structured cabling companies such as System Tech Inc. We manage the process end-to-end by gathering bids, reviewing designs, and coordinating schedules, so you don’t have to juggle multiple vendors.

That way, you get professional-grade cabling done by specialists — while TotalCare IT ensures everything ties cleanly into your switches, firewalls, and production network.

The best way to budget for IT in a manufacturing environment is to treat it as a planned, ongoing investment — not a reaction to downtime or equipment failures. A predictable, proactive approach helps you avoid surprise costs, align with your production goals, and keep your systems secure as technology evolves.

At TotalCare IT, this is where our vCIO (Virtual Chief Information Officer) service comes in. Your vCIO acts as a strategic IT advisor, helping you:

• Forecast upcoming costs for hardware replacements, software renewals, and security improvements.

• Build IT budgets tied to your operational and growth plans.

• Prioritize upgrades based on risk, age, and business impact.

• Align technology strategy with your production, compliance, and cybersecurity needs.

Instead of reacting to IT issues, your leadership team gets clear visibility into what’s coming — and what it will cost — months or years in advance.

With the right planning and vCIO partnership, your IT, security, and maintenance budgets become predictable line items, not unexpected emergencies.

Well… we might be a little biased, but we’d say it’s us — TotalCare IT! 😄

We’ve been helping Idaho businesses and manufacturers build fast, reliable, and secure networks for years. From simple office setups to complex, segmented shop floor environments, our team knows how to design networks that just work — safely, efficiently, and without drama.

But don’t just take our word for it — ask around the Boise business community. Chances are, someone you know already works with us.