Information technology (IT) and operational technology (OT) are both essential in modern manufacturing. IT manages data and business systems, while OT oversees production machinery and control systems.
Historically, IT and OT have operated side-by-side but remained separate. For example, SCADA systems might leverage ERP software data to streamline operations, and cloud platforms might aggregate information from programmable logic controllers (PLCs) and connected sensors to facilitate analytics.
The rise of Industry 4.0, however, has created the need for IT/OT convergence. By connecting these two tech domains, manufacturers can improve efficiency, strengthen security and access new insights. According to the Boston Consulting Group (BCG), the rapid evolution of artificial intelligence (AI) is accelerating the need for convergence. BCG’s research suggests that the adoption of converged technologies will increase among 10% to 50% of greenfield projects in the next five years.
But IT/OT convergence doesn’t happen automatically. Manufacturers must evaluate infrastructure limitations, identify practical use cases and balance on-site, cloud and edge technologies.
In this piece, we’ll explore the difference between IT and OT, why convergence is key to manufacturing success and how your company can bridge the gap between information and operations.
What is IT (information technology)?
Information technology refers to the use of computers, networks and software to manage data and business systems. Common examples of IT solutions include enterprise resource planning (ERP), customer relationship management (CRM) and human resource (HR) systems. Cloud computing and edge platforms, databases, cybersecurity solutions and corporate email programs also fall under the purview of IT.
Typical IT functions include:
- Processing information
- Managing enterprise data
- Providing actionable insights
- Securing digital assets
Supporting IT deployments within organizations requires the involvement of key stakeholders, such as chief information officers (CIOs), IT managers, cybersecurity teams and data engineers.
What is OT (operational technology)?
Operational technology leverages hardware and software to directly monitor and control physical devices, processes and infrastructure.
PLCs, supervisory control and data acquisition (SCADA) systems, IoT sensors, robotics, human machine interfaces (HMIs) and manufacturing execution systems (MES) are all examples of operational technologies.
Common OT functions are:
- Keeping machines operational
- Monitoring production processes
- Ensuring safety and uptime
Primary stakeholders in OT include plant engineers, maintenance teams and operations managers.
Key differences between IT and OT
While IT and OT share the same goal—improving business performance—they take different approaches. There are four key differences between IT and OT.
1. Primary purpose: The primary purposes of IT include data security and information management, making sure data gets where it’s supposed to go without putting companies at risk. For OT, primary purposes include physical process control and machine uptime.
2. Architecture: IT architecture is typically enterprise-wide and fully networked, enabling secure access from virtually anywhere with the right credentials. In contrast, OT architecture is often localized to the plant-floor and may be air-gapped for safety and reliability. As a result, physical access is frequently required to access OT systems.
3. Priorities: IT teams prioritize confidentiality and data integrity. OT teams, meanwhile, are primarily concerned with safety and availability.
4. Risks: Common risks associated with IT environments include network compromises and data breaches. In OT, the biggest concerns are production downtime or physical damage due to machine failures.
Primary purpose | Stakeholders | Technologies | Risks | |
IT | Data security and information management | CIOs, IT managers, cybersecurity teams | ERP, CRM, HR systems Cloud computing and edge platforms, databases, email | Network compromises and data breaches |
OT | Physical process control and machine uptime | Plant engineers, maintenance teams, operations managers | PLCs, SCADA and ICS systems, HMIs, MES | Production downtime and physical damage |
IT/OT convergence: Why it matters
IT and OT convergence shortens the distance between operational outputs and data inputs. For example, solutions such as computerized maintenance management systems (CMMS) bridge the gap between operations and information. In practice, these tools can ingest IoT sensor data and take action based on preset or customized conditions, in turn enabling preventative and predictive maintenance to minimize the risk of unexpected downtime.
Convergence is gaining ground as manufacturers adopt Industry 4.0 to create “smart” factories that are connected, automated and self-correcting. Benefits of convergence include:
- Unified data visibility: By combining IT and OT, organizations increase their operational visibility. This allows them to track processes from production lines all the way to databases or analytics tools.
- Faster decision-making: Increased data availability means faster decision-making. With access to both expected production line outcomes (via IT) and actual performance (via OT), manufacturers can make decisions more quickly and confidently.
- Improved predictive maintenance: Visibility from information to operations helps identify root causes and enable predictive maintenance. By combining historic IT data with information from connected sensors and automation tools, companies can create predictive maintenance schedules that lower the risk of unexpected failure.
- Enhanced cybersecurity: Knowledge of OT and IT risks helps find common ground and identify security measures that are applicable to both environments. For example, the ability of attackers to move laterally from networks to devices makes enhanced identity and access management (IAM) essential for IT and OT.
While convergence is the goal, many manufacturers encounter roadblocks tied to traditional operations. Siloes are among the most common. IT and OT teams typically have their own approach to data collection, issue detection and targeted action. These approaches include specific processes, polices, software and reporting structures that don’t account for other silos. As a result, simply mandating cooperation between IT and OT won’t work. Instead, businesses need to dismantle silos and replace them with more collaborative tools.
Another common challenge is incompatible systems. This is especially prevalent among manufacturers using older SCADA and ICS tools or those built in-house. Why? These systems were not designed to connect with external networks or process data in real-time. Overcoming this challenge often requires a platform to bridge OT and IT frameworks or the use of application programming interfaces (APIs) to create new connections.
Finally, there may be a disconnect between IT and OT security goals. For IT, the priority is keeping data safe. For OT, it’s all about protecting equipment from accidental or malicious interruption. While both are critical for overall production line performance, OT and IT teams take different approaches to security. In the case of IT, solutions such as access control and identification management are key components in reducing risk. When it comes to securing OT, teams often enable broad access to help detect issues early.
Cybersecurity considerations for IT and OT
The connection of IT and OT assets creates a hybrid manufacturing technology landscape that includes new security risks, such as:
- Growing attack surfaces: Convergence creates larger environments, which means more opportunities for attackers to compromise software or devices. It also increases the chance that these attacks will go unnoticed.
- Outdated firmware: Firmware on devices and equipment is often left in its factory default state, which may not include password protections or user identity requirements.
- Unpatched software: Unpatched software tools may contain vulnerabilities that allow attackers to bypass network protections without alerting security staff.
- Unsecured IoT devices: IoT devices are designed for ease of connection. As part of a larger IT environment that contains Internet-facing functions, however, these devices become common points of compromise.
IoT devices operate at the intersection of IT and OT—connecting networks while directly influencing machine operations. Without proper safeguards, these devices can become vulnerable entry points. Strategies to improve protection include:
- Network segmentation: Segmenting networks creates digital barriers between critical IT and OT environments. In effect, these environments cannot “see” each other, in turn blunting the impact of attacks. One common framework used by manufacturers is the Purdue model, which is a hierarchical model that helps segment ICS systems from corporate networks.
- Access controls: Implementing access controls with multifactor authentication, such as one-time codes or biometric verification, in addition to logins and passwords, adds a critical layer of protection against attacks and unauthorized access.
- Real-time monitoring: Monitoring both IT and OT systems in real-time lets teams detect and investigate odd network or user behavior before it results in data compromise or system failure.
- Incident response planning: Planning reduces risk. By mapping out potential attack vectors and running simulations to identify effective responses, manufacturers are better prepared to navigate security issues.
- OT/IT collaboration: Stronger collaboration between OT and IT teams helps reduce operational risk. For instance, a plant engineer may recognize early signs of a cyber threat, while an IT specialist might detect anomalies in sensor data that signal urgent maintenance needs. When both sides share insights, organizations can respond faster and more effectively to potential disruptions.
Best practices for bridging the gap
Successful IT/OT integration requires companies to align on best practices that balance information systems with operational needs.
This starts with creating cross-functional task forces that enable IT and OT collaboration. While it’s possible to deploy IoT solutions and robotic equipment and simply hope for the best, this can lead to gaps in responsibility and the potential for compromise that takes production systems offline. By starting with collaboration, manufacturers can build a shared vision for security, operations management and uptime.
Next is investment. Existing IT systems may not work with OT tools, and legacy OT solutions may not support external connections. By spending on interoperable technologies that support data sharing and operate at the edge, companies can keep processing close to home and improve operational visibility.
It’s also important to develop shared KPIs that align with IT and OT goals. For example, IT often tracks network uptime while OT records production throughput. These metrics could be combined into a single statistic that measures overall equipment effectiveness (OEE) as a function of both network availability and production line performance.
Additionally, organizations should take the time to train IT and OT teams on each other’s priorities and challenges. This starts with a basic overview and should also include regular refresher courses to keep teams in the loop. For example, OT teams benefit from training in common data security and access issues, while IT teams are well-served with education about the causes of downtime and the risks presented by unexpected failures.
Finally, it’s worth working with outsourced partners that understand both OT and IT environments. These partners can help your teams build unified frameworks that combine IT and OT strengths and address the emerging challenges of converged infrastructure.
Optimizing your IT & OT systems
IT and OT systems are distinct but complementary. In the era of Industry 4.0, convergence is essential for creating connected, efficient and secure manufacturing operations.
The first step in optimizing your IT and OT systems? Assessment—understanding what you have, how it works and where IT/OT intersections create potential gaps. Equipped with this knowledge, manufacturers can create convergence strategies that deliver the best of both worlds.
References
Brown, J., Ludwig, M., Kumar, A., Rees, S., & Schmieg, F. (2024, June 7). Converging IT and OT will boost value in industrial tech. Boston Consulting Group. https://www.bcg.com/publications/2024/converging-it-and-ot-will-boost-industrial-tech-value
Robles, F. and Perlroth, N. (2021, February 8). ‘Dangerous Stuff’: Hackers Tried to Poison Water Supply of Florida Town. The New York Times. https://www.nytimes.com/2021/02/08/us/oldsmar-florida-water-supply-hack.html
