In the manufacturing industry, there has always been a clear segregation between closed-loop systems, such as Operational Technology (OT), and systems that connect to the outside world. This was mainly due to security concerns, but it held back the introduction of interconnected systems to manufacturing.
Modern technology is ushering in an era where this segregation is disappearing fast. The benefits of integrating OT and IoT devices might outweigh the risks of breaches, provided that a specialist OT security solution is in place. These solutions provide enhanced data collection while reducing an organization’s attack surface.
Operational Technology Meets the Internet of Things
In a siloed approach, different departments work independently and operate in isolation. They have processes, data, and goals, with little to no information shared between departments or devices. Sensors from OT machinery operate in a closed system, and any data collected would not be accessible to external systems for advanced analytics.
However, manufacturing is evolving with the increase in smart factories where OT is increasingly integrated into IoT devices. IoT/OT convergence is rapidly becoming a norm, allowing industries to exit the closed-off siloed approach and join the era of big data and specialized analytical insights and planning.
Why Take Advantage of IoT/OT Convergence?
Below are some benefits of integrating OT into IoT devices.
Improved Intelligence for Decision-Making
Gone are the days of isolated data. Now, information from OT systems seamlessly flows into broader IT infrastructure, creating a unified view of the entire manufacturing process. Production schedules, resource allocation, and process optimization have become more strategic, driven by valuable insights. Factory managers can now maximize efficiency by precisely allocating resources and adjusting production inputs based on real-time data.
Improved Ability to Predict Maintenance Requirements
Sensors connected to manufacturing equipment generate a wealth of data on equipment health. By analyzing this data, manufacturers can predict potential failures before they occur. This shift from reactive to predictive maintenance reduces downtime and extends equipment lifespan. They are ultimately reducing maintenance costs across the valuable life of machinery.
Putting Control Back into Quality Control
Sensor data from connected devices can monitor product quality throughout the manufacturing process. This real-time monitoring allows for the early detection of defects, enabling corrective actions to be taken before flawed products reach the final stage.
Monitoring and Control from a Distance
Convergence allows process monitoring and control of certain aspects of production from remote locations, allowing manufacturers to troubleshoot issues, change settings, and even conduct maintenance tasks remotely. This capability is beneficial for disparate plants that are geographically dispersed. Furthermore, some manufacturing plants have limited physical access to equipment, making remote access essential.
Possible Challenges to Keep in Mind
IoT/OT convergence is not without issues, with security as the main one. Connecting before-isolated OT systems to a more extensive network opens the door to cyber attacks since OT systems frequently lack robust security features and are vulnerable to threats. Manufacturers should focus on information security by establishing strong authentication regulations, splitting networks, and performing regular vulnerability assessments.
Another challenge to integration is the complexity of the process. Merging distinct OT and IoT infrastructures requires meticulous planning, expertise, and possible system overhauls. A converged system’s variety of equipment and information sources may require complex management and maintenance.
Furthermore, convergence may cause a data overload. As such, manufacturers must be able to filter, examine, and collect valuable insights from all the data and make sound decisions.
Finally, the large amounts of data IoT devices collect can raise privacy concerns. Manufacturers must establish clear guidelines for data governance to guarantee the confidentiality of data and compliance with applicable regulations.
Summary of Priority Tasks for IoT/OT Convergence
Given the challenges mentioned above, below are some of the best practices for IoT/OT convergence.
- Prioritize security and data governance.
- Thoroughly plan complex integrations.
- Expect large volumes of data and be ready to efficiently manage it.
- Upskill existing employees.
Conclusion
The manufacturing and industrial sectors are changing dramatically with the convergence of IoT and OT. This powerful trend offers many benefits, including real-time insights, predictive maintenance, and improved collaboration. Embracing IoT/OT convergence is no longer an option for businesses seeking to thrive in today’s interconnected industries dominated by data-driven decision-making.
However, the integration process can be complicated and challenging. Manufacturers can address some of the most common issues by prioritizing strong security measures, investing in a skilled workforce, and implementing data-based strategies.
