In 1982, director Steven Lisberger surprised the world with Tron, a film in which a programmer named Flynn is absorbed into the digital world by an evil programme from which he needs to escape to get back to the real world. Now, in the third decade of the 21st century, here we are talking about “the digital” and “the analogue” as conflicting worlds, though not in the same way that it was introduced to us in the cinema.
In this article we want to reflect on the gap between information technology (IT) and operational technology (OT) in industry and the importance of their convergence in anticipation of the not-so-future Industry 4.0.
The digital vs. analogue world in industry
Information technology (more digital) and operational technology (more hardware-based) have co-existed for a long time, albeit each in their own sphere. They have been perfect neighbours living side by side, each with their own network, objectives and requirements, which has meant that they have not developed at the same pace.
Industry 4.0 has changed the rules of the game: it has blurred the line that used to separate IT and OT.
This model has worked well up until now, but Industry 4.0 is changing the rules of the game. The integration of new communication systems, IoT, more complex machines and more advanced software coexist, blurring the clear line that used to separate IT and OT.
This new context has exposed a problem that many organisations face today: developing their OT systems is quite different from developing their IT systems.
The gap between Information Technology (IT) and Operational Technology (OT) in our industries
In recent years, everything to do with data management, software development and information processing has developed at a breathtaking pace, while many workshops are still using hardware that is decades old. In other words, there is a gap in terms of development between IT and OT systems.
Information technologies have developed more rapidly, partly due to the progressive integration of improvements that have been achieved in various sectors. Beyond the level of technological development, IT has also reached a much higher level of flexibility than OT allows.
A lot of workshops and factories continue to use “old” equipment and machinery in their day-to-day activities. This is not much of a problem on the operational side, but it is on the digital side. A lot of equipment and processors do not even have Ethernet (they have older industrial communication protocols), which can be a barrier when it comes to integrating these machines with new IT systems.
A lot of workshops and factories continue to use “old” hardware because it is not much of a problem for them on the operational side. However, it is on the digital side.
Convergence between IT and OT would make it possible for companies to solve critical problems faster, make decisions based on better information and scale processes both physically and digitally. The challenge now is to bridge the gap between information technology and operational technology. New information technologies are necessary, but, at the same time, daily production needs to continue using existing means (particularly now that we are starting to get over the pandemic).
Challenges to be resolved in relation to IT-OT integration
👉 Challenge 1: Taking the reality of the workshop into account
The operational side of the industry has a number of barriers that complicate its development: the existing stock of machinery, the cost of replacing this stock, changes to entrenched internal processes, the training and organisation of employees, etc. It is necessary to be aware of all these factors in order for IT-OT integration to be successful.
Therefore, the challenge is to integrate these two layers, the operational and the information layer, taking all the organisation’s assets into account. In other words, the machinery must be able to generate the data needed and communicate efficiently with the IT systems. This process will have to take into account not only the current but also the future technology of the workshop.
👉 Challenge 2: Adapting to the new demand that Industry 4.0 will bring
The operational side of the industry has a number of barriers that complicate its development: the existing stock of machinery, the cost of replacing this stock, changes to entrenched internal processes, the training and organisation of employees, etc. It is necessary to be aware of all these factors in order for IT-OT integration to be successful.
Therefore, the challenge is to integrate these two layers, the operational and the information layer, taking all the organisation’s assets into account. In other words, the machinery must be able to generate the data needed and communicate efficiently with the IT systems. This process will have to take into account not only the current but also the future technology of the workshop.
👉 Challenge 2: Adapting to the new demand that Industry 4.0 will bring
Integration is crucial if Industry 4.0 is to become a reality. The next smart factories will be fully connected in order so as to increase the level of automation, and improve communication, monitoring and data exchange.
Production could be much more autonomous and flexible, as processes will be interconnected both between plant cells and with other plants. The situation and location of the machinery will not limit the working process – it will be the other way round. Processes will now be king, irrespective of the physical layout of the plants.
In this context, problems can be analysed and diagnosed automatically with less need for human intervention, thereby reducing downtime and improving efficiency and profitability.
👉 Challenge 3: Giving data the importance they deserve
An important part of IT-OT integration is breaking down the walls that separate the two worlds and the professionals who are part of them. At one end of the scale are people who do not recognise the potential of good information management and integration, and at the other are data junkies who do not know what to do with their data.
Both sides need to complement each other in a harmonious way: obtaining the information required, processing it in a useful way and making decisions that improve production efficiency.
👉 Challenge 4: Increasing flexibility on the operational side
One of the other challenges is related to flexibility. As we said a few paragraphs earlier, operational technology lacks the flexibility that the digital side of industry has. Part of this IT-OT convergence involves making the operational side as flexible as the digital side in order to adapt to a demand that increasingly seeks greater personalisation and customisation of products.
👉 Challenge 5: Understanding the economic implications of change
As far as implementation costs are concerned, this is undoubtedly a source of concern for many business leaders. The cost of acquiring new hardware may be substantial, so it is important to find a system that makes it possible to bridge the gap between your current infrastructure and the new infrastructure that Industry 4.0 will bring. This will minimise costs as the changeover progresses, avoiding the need for heavy investment.
Is it really so important to integrate digital and analogue?
Yes. The market demands levels of productivity and quality that force companies to go a step further to optimise their organisation and production. This IT-OT integration also offers companies a number of advantages.
Advantages of integrating IT-OT
- Improved data collection and automation.
- Better operational control at each stage of production.
- Improved organisation of processes.
- Increased work efficiency due to better information.
- Improved customer satisfaction thanks to reduced downtime.
- In short, better company performance which increases profits.
In addition to the above points, we need to bear in mind that the convergence of IT and OT systems will be a key factor when it comes to accessing many of the advantages that Industry 4.0 will bring. In this article we talk about the need to get ready for this new industrial revolution.
Where to start
It is time to start working on reducing the gap between the IT and OT layers in companies. There are protocols, tools and ways of working that make this integration easier without the need to dismantle current production systems. It is important to follow the operational plan and continue production, but this is not an impediment to starting the change.
The process may seem daunting. But in the same way that (the lead character in the film) sought the help of “Tron” (an expert programme) to achieve his goal, your company also needs to seek professional help.
It is crucial for companies to have a partner that specialises in automation solutions and has knowledge and experience in these processes. SMARTPM can help you. Contact us and we can talk about it. You will know whether our software solutions and industrial automation services are right for your company and you will have a clearer idea of the advantages they could bring you.
