IT/OT Convergence: What It Is & Why It Matters
As you may expect, IT/OT convergence is pretty much what it says on the tin: the integration of your informational technology and operational technology systems. But what exactly does this involve, and what are the benefits?
Industrial companies want to migrate to more complex ecosystems to boost and enhance their digital capabilities. Often featuring tighter vertical integration, these new ecosystems can drive efficiencies and real value, but they also require different approaches on how to support and manage IT (information technology) and OT (operational technology).
Today’s industrial companies need to change how they interact with, react to and provide services if they hope to obtain desired levels of value from the next wave of digitalization.
Bridging the Gap Between IT and OT on the Factory Floor
In the production plant, it can often feel like a tug of war between two sides of the process: the machines and equipment performing the physical labor, and the data, servers, and digital devices that gather information and inform decisions. In the past, these two key production players have occupied their own corners, equally important but distinctly separate.
But this is no longer the case, or it shouldn’t be, at least. New technology (such as Industrial Internet of Things (IIoT) devices) helps these two worlds collide.
IT/OT convergence opens up a host of previously-limited possibilities. It offers a game-changing impact on efficiency, productivity, and growth. To start, scaling digitalization initiatives requires greater integration of the data between IT and OT.
Exciting, right? Let’s explore the potential that combining these two past silos provides. We’ll also outline a strategy to help you overcome any hurdles you might face, to ensure successful IT/OT convergence in your process facility.
What is IT/OT Convergence?
What is OT?
As mentioned before, Operational Technology (OT) is all of the hardware (and software) used to monitor and control physical processes in a plant. It affects real-life, tangible components that are associated with manufacturing and industrial environments, such as machinery, valves, switches, etc.
Examples of OT include systems like:
- SCADA (Supervisory Control and Data Acquisition)
- PLC (Programmable Logic Controllers)
- DCS (Distributed Control Systems)
- MES (Manufacturing Execution Systems)
- Process Historians
These are used to monitor and automate industrial activities, enabling them to react to changing conditions in real time.
The key point to remember is that OT deals with tangible operations, directly engaging with physical machinery.
What Is IT, and How Does it Differ?
Information Technology (IT) is a bit more commonly known term. It deals with computer-based processes — managing, processing, storing, and securing data through the use of servers and networks.
While OT focuses more on controlling physical equipment and processes, IT supports data-driven decision-making, improves plant efficiency, and strengthens cybersecurity, alongside business and administrative functions like coordination, logistics, and communication.
Both are important areas of technology. Their differences lie in their purpose and their approach to security, maintenance, and operational priorities.
IT systems are usually frequently updated and patched regularly to protect against cyber threats. Understandably, they place significant emphasis on data confidentiality and access control. In contrast, OT systems prioritize uptime, reliability, and safety. They often run for years with minimal changes, and it’s considered risky and costly to ‘rock the boat.’
Converging OT and IT
The problem was that, until recently, IT and OT were almost completely siloed, creating missed potential for optimal efficiency, security, and agility. But now, thanks to technological advancements, it’s possible (and increasingly necessary) to merge the two.
What exactly does this mean? Well, what it doesn’t mean is merging OT and IT into one single system. Instead, it’s about enabling them to communicate, share data, and support common operational goals while keeping their distinct functions.
Breaking it down, there are three main types of convergence:
- Physical Convergence: This is how OT and IT devices are connected. The two systems start to share the same physical infrastructure while applying proper security measures like DMZs or firewalls. It involves updating or retrofitting traditional OT equipment to allow it to securely transmit data to IT systems, providing the physical link that allows data to travel from machines to digital devices.
- Software Convergence: What happens after IT and OT devices are connected? You implement software, programs, and applications to collect, process, and analyze data coming from the connected machines and convert it into useful insights. Different types of architectures and concepts that utilize the Unified Name Space concept or traditional approaches, such as interfaces, datahubs, or data brokers, can be implemented.
- Organizational Convergence: This is more about team collaboration and breaking down silos between IT and OT departments so they share goals, responsibilities, and strategies. For example, you may have a joint task force to oversee cyber security for both, rather than protecting them separately.
Benefits of IT/OT Convergence
Increased Efficiency
By connecting your production equipment to your business systems, real-time data is shared between the shop floor and decision makers. Your teams can spot issues sooner and adjust things to reduce downtime and improve productivity. It also saves you time and reduces waste by cutting back on manual input and duplicate systems, all of which contribute to a more efficient process.
Reduced Costs
Converging IT and OT means fewer unexpected operational and maintenance expenses. It allows you to preemptively discover potential issues and take action before they escalate. This reduces the need for expensive repairs and downtime.
Better Decision Making
Integration increases visibility and transparency within your production processes and across your plant. This helps operators and managers spot patterns, predict problems, and act based on concrete facts. Accurate real-time data leads to faster and smarter decisions, from adjusting industrial operations to avoid delays to strengthening cybersecurity to address gaps.
Enhanced Sustainability
Tracking water usage, energy consumption, emissions, and other environmental factors allows you to measure your carbon footprint more accurately. It also shows you where there’s room to improve. Overall, this leads to a more thorough and effective approach to sustainable business operations.
Improved Cyber Security
Besides making operations faster and less costly, converging IT and OT systems also makes them safer. It’s a more unified approach to implementing robust security protocols that protect both your physical and digital assets. As such, it’s the best way to fortify your entire plant against cybersecurity threats.
Industry 4.0 Adaptability
Industry 4.0 emphasizes the use of digital technologies to create smart, connected systems. Converging IT and OT is a foundational step towards realizing the vision of Industry 4.0 and future concepts, enabling organizations to embrace automation, data exchange, advanced analytics and autonomous operations.
What are the Challenges and Risks of IT/OT Convergence?
Clearly, there are several advantages to merging your operational and information technologies. But it’s not without downsides. Navigating the complexities of bringing physical and digital infrastructures together successfully requires a great deal of strategy.
Here are the three greatest hurdles to prepare for in advance of converging your IT and OT networks:
Complexity in Integration
Combining such disparate systems as your operational and informational technology is easier said than done. The reality is that you’ll likely face interoperability challenges during this process. Integrating legacy systems with modern digital technology is no mean feat, but it can be done.
In addition to these technical hurdles, there’s also the human factor to consider. You’re not just integrating technology, you’re also merging two teams who are used to working separately. IT and OT professionals often come from different backgrounds, with different priorities, tools, and ways of working. As a result, bridging this gap takes work.
Without a clear strategy and open communication, these differences can create friction. But with the right mindset and support, convergence can upgrade both your technology and your culture.
What’s more, converging these two systems often involves the introduction of IIoT devices, which help to connect the two. Each of these devices creates a new potential target for cyber threats, as once-isolated OT systems now become part of a connected network. How can you ensure this disparity doesn’t result in inadequate protection methods overall?
Security Risks
While IT/OT convergence can improve cyber security when properly implemented, it can also introduce new vulnerabilities in the process.
This becomes particularly risky as competing priorities collide. While IT emphasizes data integrity and confidentiality, OT favors availability and functionality.
The good news is, with the right planning, it’s possible to unite IT’s robust security practices with OT’s operational focus. Identify and address any vulnerabilities beforehand so you end up with a more resilient and secure system than before.
Bridging Communication and Skills Gaps
As mentioned, bringing your IT and OT processes together isn’t just a technical challenge. It’s a people one too. Your success depends on having a workforce that understands both sides of the equation. But finding staff who are skilled in IT and OT is difficult. It often requires new training and cross-disciplinary learning.
Without this, you may find that you face a clash in terminologies, culture, and priorities. These lead to misunderstandings and reduced productivity. For instance, IT personnel are used to facing cyber threats. They may struggle initially to understand the urgency of the real-world challenges typically faced by OT operators.
To face this, you need to bridge the gap between mindsets as well as between systems. Building a collaborative environment helps with developing a shared appreciation and understanding of each other’s roles.
Strategies and Best Practices for Converging IT and OT
1. Define a Shared Vision
Establish clear and unified goals for the convergence process from the very start. Ensure that both teams understand the desired outcome and know their roles in achieving this. Having a shared vision helps to align efforts and reduce any confusion. It generates enthusiasm for the project across departments. This makes the task more focused and manageable.
2. Break Down Silos
Foster collaboration between IT and OT teams by encouraging open communication and teamwork. Silos can really slow down progress, so bringing teams together via regular conversations and shared projects creates more understanding between departments. The result? A more seamless partnership that improves problem-solving, ultimately supporting smoother convergence.
3. Clarify Roles and Responsibilities
As teams and systems merge, you need to clearly define who is responsible for what within the new environment. Outline specific duties and expectations, as well as who will have decision-making authority. Having this clarity prevents overlaps or gaps. It ensures you get the efficiency you’re seeking from the transition, especially when it comes to areas like security and system management.
4. Invest in Training and Upskilling
Develop and implement training programs and certifications to equip each team with the knowledge needed to navigate IT/OT convergence. Understanding each other’s priorities, tools, and challenges creates empathy and improves cooperation. What’s more, continuous learning keeps staff updated on evolving technologies to ensure long-term success and resilience.
5. Use the Right Tools
Being strategic about which tools you select is essential for effective IT/OT convergence. Choose the ones, like those found in Orise’s digital solutions suite, that give you the right amount of visibility and control over your infrastructure, and that support functionality like asset discovery, configuration management, and security. The right options will enable seamless data sharing and operational efficiency, while safeguarding against vulnerabilities.
6. Adopt Emerging Tech Thoughtfully
Exciting new technology to aid the integration of IT and OT is being developed continuously. Don’t get tempted to always opt for the newest, shiniest tool on the block. It’s more important to select tech based on how well it aligns with your business goals and unique systems. Thoughtful adoption maximizes benefits without introducing unnecessary complexity or risk, driving smarter operations.
7. Measure, Learn, and Evolve
Set clear metrics to track convergence progress and outcomes. Regularly review performance data to identify successes and areas for improvement. Being agile and ready to adapt your strategy in response to lessons learned ensures continuous enhancement of IT/OT integration efforts.
Why Orise Is Your Best Partner for IT/OT Convergence
Integrating IT and OT systems is well worth the effort. Not to mention, it’s becoming increasingly necessary as production demands change. With that all in mind, it requires not only deep technical expertise but also an understanding of how to safeguard operations across your entire automation pyramid.
This is where Orise stands out.
As a leading independent provider of complete automation and digitalization solutions for the process manufacturing industries, Orise brings a wealth of hands-on experience in aligning IT and OT systems with robust industrial cyber security practices. From life sciences and food & beverage to oil & gas and beyond, we help organizations modernize and secure their operations without disrupting uptime or productivity.
But we’re not just here to offer advice. Instead, we offer end-to-end support across your entire lifecycle, tailoring our approach to your unique goals to ensure that your digital transformation is not only seamless but also secure and sustainable.
