From April issue of NZ Manufacturer www.nzmanufacturer.co.nz

Adam Sharman, Senior Partner, Dsifer

As manufacturers look to technology to support the productivity, efficiency and innovation of their operations, the convergence of Information Technology (IT) and Operational Technology (OT) stands out as a crucial strategy.

As at 2024, the OT market is expected to expand at a CAGR of 8.69% and the solution options available to manufacturers to digitise their operations continues to grow.

Whilst OT solutions provide significant benefit to manufacturers,  it is the integration of OT and IT across the organisation that drives the highest value for these soluions.

Historically, IT and OT have operated in silos, serving distinct functions within organisations. However, as Industry 4.0 reshapes manufacturing processes, the synergy between these two domains has become imperative for staying competitive and maximising efficiency.

The integration of IT and OT involves breaking down the barriers between these two domains to create a unified ecosystem that leverages data from both operational and informational sources.

This integration enables manufacturers to optimise production processes, enhance product quality, reduce downtime, and ultimately drive profitability.

One of the primary benefits of integrating IT and OT is improved visibility and transparency across the manufacturing operations. By connecting OT devices to IT systems, manufacturers can gather real-time data on equipment performance, production rates, and resource utilisation.

This comprehensive visibility enables better decision-making, as managers have access to timely and accurate information to identify bottlenecks, anticipate maintenance needs, and optimise workflows. Furthermore, the integration of IT and OT facilitates predictive decision making.

For example, predictive maintenance, a proactive approach to equipment upkeep that relies on data analytics and machine learning algorithms to anticipate potential failures before they occur.

In order to successfully integrate their IT and OT systems, organisations should consider the following key dimensions:

1. Understand the Business Goals: Before integrating IT and OT, it’s crucial to understand the business objectives. Identify key performance indicators (KPIs) and objectives that both IT and OT need to support.
2. Identify Integration Points: Determine where IT and OT can intersect to improve operations. This could include data exchange between enterprise resource planning (ERP) systems, manufacturing execution systems (MES), supervisory control and data acquisition (SCADA) systems, and other operational systems.
3. Standardise Communication Protocols: Establish common communication protocols and standards to facilitate data exchange between IT and OT systems. This could involve protocols like OPC UA (Open Platform Communications Unified Architecture), MQTT (Message Queuing Telemetry Transport), or other industry standards.
4. Implement Edge Computing: Deploy edge computing solutions to process data closer to the source (machines and sensors). This reduces latency and bandwidth requirements while enabling real-time decision-making.
5. Ensure Data Security: Implement robust cybersecurity measures to protect sensitive data and systems. This includes network segmentation, encryption, access controls, and regular security audits.
6. Invest in Analytics and AI: Leverage advanced analytics, machine learning, and artificial intelligence (AI) to derive insights from the integrated data. Predictive maintenance, quality optimisation, and process optimisation are areas where AI can provide significant value.
7. Train Employees: Provide training to employees from both IT and OT departments to familiarise them with the integrated systems and processes. Encourage collaboration and cross-functional teamwork.
8. Pilot Projects: Start with small-scale pilot projects to test the integration strategy and validate its effectiveness. Use the lessons learned to refine the integration approach before scaling up.
9. Continuous Improvement: Integration is an ongoing process. Continuously monitor and evaluate the integrated systems, gather feedback from stakeholders, and make necessary adjustments to optimise performance and achieve the desired business outcomes.
10. Compliance and Regulations: Ensure that the integrated systems comply with relevant industry regulations and standards such as ISO 27001 for information security and ISA-95 for manufacturing system integration.
11. Vendor Collaboration: Collaborate with vendors and solution providers to ensure compatibility and interoperability between IT and OT systems. Choose partners who understand both domains and can provide integrated solutions.By addressing these key factors, manufacturers can successfully integrate IT and OT systems to drive digital transformation, improve operational efficiency, and gain a competitive edge in the market.