From the Commissioning of Data to Large-Scale Real-World Industrial Network Datasets for AI-Based Maintenance and Security Applications in the Automotive Industry

Over the last two decades, the automotive industry has spearheaded a shift toward data-centric manufacturing, where Real-Time Ethernet (RTE) networks defined in IEC61784-2 serve as critical components for ensuring deterministic communication at the Operation Technology level. Although AI-based systems offer significant potential for predictive maintenance and cybersecurity, their effectiveness is currently limited by a lack of structured datasets from real-world industrial environments. Most existing research relies on small-scale simulations or laboratory setups that fail to capture the scale and complexity of actual production. To address this gap, this paper introduces a novel methodology for repurposing network data collected throughout a plant’s lifecycle, specifically during the commissioning and validation phases of RTE networks according to IEC61918. An additional important contribution is the creation of the first multi-plant dataset for real RTE (PROFINET) traffic in the automotive sector, aggregating 300 GB of data from 54,000+ devices across nearly 700 production lines in 17 industrial sites. The work defines standardized methodologies and replicable processes for systematic data acquisition, validation, and labeling to ensure long-term usability for training AI models. Finally, four case studies (focused on performance, maintenance, security, and machine learning) show how this dataset can be used to enhance the reliability of modern smart manufacturing.