IT vs OT: Bridging the Gap in Digital Transformation

Manufacturers have traditionally had two separate technology domains: information technology (IT) and operational technology (OT). Both are critical to the success of manufacturing operations. But there are key differences in the functionalities of the two systems and what each team focuses on.

In a nutshell:

IT teams are primarily concerned with data acquisition and management, software, networking, and IT infrastructure in industrial settings. Systems like enterprise resource planning (ERP), data analytics, digital communication, and cybersecurity typically fall under IT. 
OT teams are focused on controlling and monitoring physical processes and devices (like workstations, machinery, and robotics) within industrial settings. OT oversees systems like programmable logic controllers (PLCs) that control the movement of an assembly line, and Internet of Things (IoT) sensors that share data between machines for activity coordination, among many others.

With more pressures to improve productivity, increase agility, and adopt advanced technologies like AI, the separation between IT and OT is becoming more of a liability. Integrating these two domains is no longer just a technical challenge; it’s a strategic necessity.

Here we explore the key differences between IT and OT in manufacturing, why the gap between them persists, and what’s driving the critical need for convergence.

IT vs OT Silos

Historically, IT vs. OT silos formed because key differences in their priorities led the two departments to operate with separate — and often incompatible — technology, protocols, and processes.

Here are a couple examples of areas with different approaches and standards used by IT vs. OT in manufacturing.

Security

Preventing cyber threats and unauthorized access is a key concern in industrial settings that both IT and OT security address, but each has different end goals. IT security measures protect digital assets, which most commonly means preventing sensitive data from getting stolen or lost. OT security, meanwhile, emphasizes the reliability and accuracy of physical devices with the goal of reducing harm on the factory floor or minimizing production downtime.

You can imagine, then, that IT and OT teams take fundamentally different approaches to security systems and protocols. For example:

In the IT realm, it’s a common practice to use newer, more modern software and security patches to address vulnerabilities and minimize the risk of cyber threats and unauthorized access.
In the OT realm, OT assets often last 15 to 20 years in factories, which makes them more vulnerable to cyber threats without the proper maintenance. Moreover, OT professionals, fearful of disrupting industrial equipment availability, are often more hesitant about patch distribution.

Data Handling

IT focuses on broader business data needs and communication. Priorities include data acquisition, storage, integrity, analytics, and protection. Meanwhile, OT prioritizes physical operational efficiency, monitoring the current state of machines in real time to detect a change that could impact production.

IT and OT handle data across different systems with opposite software standards:

IT relies on interconnected systems and newer software to surface key insights from data that support broad business decision-making. 
OT often relies on legacy industrial control systems (ICS) and historical data that resides on older software and hardware for operational continuity. It’s hard to integrate these proprietary OT systems with IT’s more modern requirements.

Driving Factors Behind IT and OT Convergence

The Fourth Industrial Revolution, or Industry 4.0, fundamentally changed the way companies viewed their historically separate IT and OT functions. As manufacturers embraced Industry 4.0 and digital transformation, it became obvious that they needed to integrate business systems and data (i.e., IT) with operational equipment systems, devices, and data (i.e., OT).

IT/OT convergence has since emerged as a crucial pillar of Industry 4.0 and a foundational capability for manufacturers aiming to digitize, connect, and optimize their operations. This convergence is being driven not only by the promise of operational efficiencies, but also by the need for more agility, traceability, and real-time decision-making.

As production environments become more complex and customer expectations shift toward greater customization and faster delivery, manufacturers need unified systems that can provide end-to-end visibility, from the shop floor to the top floor. Integrating IT and OT lets companies break down data silos, respond faster to disruptions, and create more adaptive, autonomous manufacturing ecosystems.

What is a smart factory, and how can it improve quality? Learn more

IT and OT Convergence Benefits

Bringing IT and OT closer together doesn’t just improve connectivity. It unlocks measurable business value. When information systems and operational technologies work together, manufacturers get insights that were previously inaccessible in siloed environments. Real-time data from the shop floor can now inform strategic decisions, enabling teams to be more proactive, agile, and efficient.

Here are some benefits that highlight the business value of IT/OT convergence:

Improved Operational Efficiency: Integrating IT and OT systems gives factories a more holistic view of their operations. On the plant floor, sensors on Internet of Things (IoT) devices collect real-time data on production equipment performance, including parameters like temperature, pressure, vibration, and cycle time (part of OT). IT systems can analyze this data and use it to inform and improve business-side decisions.
Reduced Downtime: By analyzing data from machines (OT), IT systems can predict when maintenance is needed. For example, if a sensor identifies the temperature moving past a range on a machine (OT), IT can then help decipher the severity of the condition and the appropriate action. This allows teams to fix problems before equipment breaks down, helping reduce unplanned downtime.
Enhanced Productivity: Combined data analytics from both IT and OT systems help manufacturers to spot bottlenecks and optimize processes, such as implementing proactive maintenance scheduling on machinery, to improve productivity and output. 
Improved Quality: When manufacturers connect detailed machine data with broader company systems (like ERP), they can better understand how products are made and how materials perform. This leads to better product designs, more efficient production, and higher-quality outcomes.

Each time an improvement is made, data about that improvement enters back into the connected system for future insights. This is critical for continuous improvement and innovation.

Challenges of IT and OT Convergence

While IT/OT convergence is more accepted as a necessary approach for smart manufacturing, there are integration challenges given the key differences between the two. They include:

Incompatible technology: Many OT systems are decades old, which presents interoperability issues when connecting with more modern IT systems.
Functional collaboration: Shared goals between IT and OT teams have not historically been normal practice. Breaking down these silos requires organizational change, which takes time and leadership commitment.
Cybersecurity Issues: More connected devices, IoT sensors, and control systems on industrial networks create more potential entry points for unauthorized access into critical infrastructure. Traditional IT threats like malware and ransomware could more easily spread into physical operations, disrupting critical production processes or creating unsafe conditions.

Best Practices for Bridging the IT and OT Gap

Given their differences, successful IT/OT convergence involves careful strategy and planning. From technology and infrastructure to change management, best practices include:

Systems and Technology: There are many solution providers that facilitate the process of integrating legacy OT systems with newer IT infrastructure. These platforms offer ways to integrate various sources of data, from IoT devices to edge and cloud systems, and to centralize insights and visibility.
Organizational and Cultural Change: Overcoming resistance requires promoting a culture that prioritizes data-driven decision-making. Manufacturers can highlight common ground between IT and OT teams and put programs in place to cultivate new skills, expertise, and opportunities for employees in this merged environment.
Data Management and Governance: Creating robust data governance frameworks is essential to ensure maintenance of data quality and consistency, as well as data privacy and regulatory compliance.
Security Infrastructure: It goes without saying that manufacturers need to implement suitable security measures for IT/OT convergence to protect critical infrastructure. These include implementing regular security assessments and a zero-trust policy (a type of security framework that operates on the principle of “never trust, always verify”).

Navigating the New IT and OT Landscape

IT/OT convergence has been a hot topic since the concept of Industry 4.0 took hold. More recently, advances in AI and automation are accelerating efforts. For example, large language models (LLMs) can be used to query complex data from across IT and OT systems. AI also can help automate certain elements of cybersecurity, an area that is currently experiencing a skills shortage on the OT side.

Most will agree that successfully breaking down IT vs. OT silos is a Herculean task. But as AI and new technologies make digital transformation more urgent, complacency is no longer an option.