When it comes to technology, manufacturers grapple with two different segments: physical equipment and the digital world of data. Traditionally, these two buckets were separate; different machinery and processes were siloed.
Today, especially with the help of analytics and the emergence of IoT devices, IT and OT are merging, resulting in benefits such as real-time visibility, data-driven decision-making, and greater operational agility.
This blog explores IT/OT convergence as a strategic approach to optimizing manufacturing operations. We’ll unpack the core concepts of IT/OT convergence, highlight common integration challenges, and explain how a modern Manufacturing Execution System (MES), such as TrakSYS, can simplify the process and deliver quantifiable business value.
Table of Contents
IT + OT = IT/OT Convergence
Let’s start by defining each technology type:
- IT (Information Technology): systems that focus on data availability, confidentiality, and integrity, including order management, inventory tracking, financial reporting, employee communication, and more.
- OT (Operational Technology): systems embedded in physical processes; the combination of hardware and software designed to manage, control, and oversee physical equipment and enforce safety standards.
Therefore, IT/OT convergence is the integration of IT and OT. Merging these two systems allows for real-time data exchange, which enhances the efficiency and effectiveness of both systems.
The Convergence Challenge
With the definitions out of the way, it is important to remember that IT and OT assets don’t intrinsically speak the same language. Furthermore, the technologies were developed for different goals, which can make integration complicated (but not insurmountable).
Common challenges in IT/OT convergence include:
- Incompatibility between legacy equipment and modern networks.
- Heightened security risks from increased connectivity.
- Costly, custom-coded integration requirements.
- Organizational silos that limit collaboration.
- Ongoing reliance on manual data collection and reporting.
These barriers can obstruct efforts to merge IT and OT systems and limit the modernization of manufacturing environments. That said, modern MES platforms can serve as an effective bridge between IT and OT environments.
How MES Simplifies Integration
TrakSYS has built-in protocols to communicate directly with PLCs, HMIs, and other shop floor equipment, eliminating the need for complex middleware and reducing reliance on costly custom programming. Each asset is seamlessly tied to the MES and becomes a part of the greater picture of the shop floor. From there, TrakSYS collects and contextualizes data from equipment and operators.
With this real-time visibility, knowledge, and control, manufacturers can respond quickly to changing production conditions and continuously monitor performance metrics.
Beyond all of the above, MES solutions also streamline digital architecture by consolidating data systems and reducing the number of integration points. With this unified data management, all levels of the organization—from the executive suite to the factory floor—gain access to their pertinent information in a timely manner.
Addressing Legacy Equipment Challenges
In many facilities, legacy equipment is the backbone of production. While reliable, these assets were never designed with connectivity in mind and, therefore, can hamper digital transformation efforts.
However, thanks to the proliferation of IoT, manufacturers are—in many cases—able to forego costly equipment replacements in favor of solutions that bring older systems into the digital age. Such solutions include smart devices, edge devices, and gateway technologies that act as translators between outdated control systems and MES platforms.
Security and Risk Management Made As Simple As Possible
Alongside the numerous benefits, bridging IT and OT systems may introduce security concerns. IT systems focus on data security and appropriate data exchange. OT, on the other hand, prioritizes equipment safety and stability while minimizing downtime. In light of these discrepancies, merging the two must be done with care.
In alignment with industry standards and best practices, TrakSYS boasts built-in security features specifically designed for manufacturing environments, including:
- Network segmentation to isolate factory systems from external threats.
- Granular user access controls to restrict data visibility.
- Built-in audit trails for traceability and compliance.
- Encrypted data transmission and authentication protocols.
With these features, manufacturers can integrate IT and OT without compromising safety or security.
Measuring Success and ROI
To evaluate the success of IT/OT convergence, look at both financial and operational results. Financially, companies often see cost reductions from reduced downtime, streamlined maintenance, and fewer manual tasks.
Operationally, improvements include higher equipment uptime, better product quality, and faster issue resolution. Many organizations also report better regulatory compliance and energy efficiency.
On a strategic level, successful convergence projects lay the foundation for advanced technologies like AI, predictive maintenance, and autonomous systems.
Implementation Best Practices
Now that we have laid out the benefits, challenges, and considerations of IT/OT convergence, here is a look at the recommended rollout process, from initial assessment to full-scale deployment:
Phase 1: Assessment
A successful initiative starts with thorough planning. First, assess your existing systems and processes. Inventory current technologies, identify bottlenecks, and align on business goals.
Phase 2: Collaborate with Stakeholders
Next, form a cross-functional team of IT and OT stakeholders. Encourage collaboration early and often. Define shared success metrics, budget requirements, and realistic implementation timelines.
Phase 3: Phased Implementation
When it’s time to roll out changes, take a phased approach. Start with pilot projects to validate your strategy and build momentum. Gradually expand the implementation based on lessons learned and confirmed benefits.
As with any digital transformation effort, ongoing support, change management, and continuous training will be key to long-term success.
Conclusion
IT/OT convergence is not just a technical upgrade—it’s a strategic shift that empowers manufacturers to make better decisions, operate more efficiently, and stay competitive in an evolving landscape. By leveraging an MES platform like TrakSYS, companies can streamline integration, lower operating costs, and unlock the full potential of their data.
As with any project or initiative, success will depend on thoughtful planning, cross-functional collaboration, and the right technology partner. If you have an IT/OT convergence project or are just looking to get more information, contact us today.