Charles Esther
As industries continue to evolve in an increasingly digital world.
The convergence of Information Technologies (IT) and Operational Technologies (OT) is becoming a key driver of innovation and efficiency.
The concept of IT/OT convergence has long been recognised.
But for many companies, it has remained more of a vision than a reality.
Many face obstacles in realising its potential.
Several challenges have contributed to this state of untapped potential over the years.
These include a lack of clarity in who holds responsibility for the separate systems.
A shortage of the necessary skills to ensure project success.
And difficulties in securing the investment needed to power IT/OT transformation.
However, a shift is now underway.
New research commissioned by us and conducted by Omdia shows that IT/OT convergence is accelerating across manufacturers.
According to the study, 70% of OT systems will be connected to IT networks next year.
This is a significant increase from 50% today.
Moreover, 86% of manufacturers expect business benefits from IT/OT convergence.
What Are the Drivers of IT/OT Convergence?
This shift marks a substantial leap forward.
At the forefront of this development is Industry 4.0.
Nearly half (47%) of respondents identified it as one of the top three factors accelerating IT/OT convergence over the past two years.
The business benefits targeted from Industry 4.0 include innovation (39%), reliability (38%), and profitability (34%).
Although Industry 4.0 has been discussed for years, many projects fail to move past the pilot stage.
According to the World Economic Forum, over 70% of companies investing in Industry 4.0 technologies fail to go beyond the initial phase.
This trend may be changing.
Industry 4.0 depends on key enabling technologies such as cloud services, the Industrial Internet of Things (IIoT), security platforms, and edge computing.
These technologies are now well integrated into enterprise IT stacks.
As a result, the increased maturity and knowledge base of companies improve the likelihood of successfully delivering complex projects.
After Industry 4.0, cybersecurity maturity (38%) and the need for increased resilience and availability (34%) were the next most cited drivers.
Last year, four out of five manufacturing firms experienced a significant rise in security incidents or breaches.
Attacks that began in IT and impacted OT or operations were more frequent than the reverse.
The findings underscore that as digitalisation increases, so do cyber risks.
Manufacturers understand they must digitally transform through IT/OT convergence.
At the same time, they must also manage and reduce the risk of successful cyberattacks.
The Key Use Cases of IT/OT Convergence
Interestingly, many manufacturers view IT/OT convergence not just as a source of security concerns but as a way to enhance security.
Nearly half (49%) of the respondents ranked improved cyber and physical security among their top three IT/OT use cases in manufacturing.
Other top use cases include data sharing for deeper analytics (44%) and better integration of the supply chain with manufacturing (36%).
But how does IT/OT help improve security if it can also introduce new risks?
The answer lies in adopting a strategic security approach.
Instead of merely connecting IT and OT systems, companies can embed security into the entire IT/OT transformation process.
Unsurprisingly, data sharing for deeper analytics emerged as a crucial use case.
One of the early drivers of IT/OT convergence was the realisation that OT systems produce valuable data with broader business implications.
Linking IT and OT helps eliminate data silos, allowing for analytics that convert raw data into actionable insights.
For instance, energy consumption data from specific machines can offer insights that enable procurement teams to negotiate more cost-effective energy contracts.
This level of detail is far more useful than generalised figures from operations departments.
Moreover, there’s the ultimate goal of efficiency: synchronising manufacturing with supply chains.
In today’s world, constant disruptions—political, economic, climatic, or health-related—make it hard to run both resilient and lean supply chains.
Problems at critical transportation points like the Suez and Panama Canals can cripple “Just In Time” strategies.
Meanwhile, “Just In Case” approaches demand costly stockpiling.
Improved integration between manufacturing and supply chains allows companies to make quicker and better decisions.
When supply chains face disruption, businesses can adjust manufacturing activities to minimise impact.
Building a Sustainable and Secure IT/OT Strategy
To accelerate IT/OT convergence successfully, manufacturers should take the following key steps:
1. Plan for Integration
IT/OT convergence isn’t simply about connecting a factory to corporate systems.
It requires a strategic plan aligning business goals with specific actions.
2. Embed Security from the Start
IT/OT projects will increase the attack surface.
Therefore, security must be embedded throughout the transition process—not treated as an afterthought.
3. Invest in Capabilities
Like any major transformation, IT/OT convergence demands the right talent, tools, and investment.
Without sufficient resources, even the best-laid plans will fail.
4. Define Accountability
Historically, unclear responsibility has been a barrier.
It’s essential to clearly define where IT’s responsibilities end and OT’s begin.
Any overlaps should be collaboratively managed.
5. Establish Governance Standards
IT and OT are subject to different compliance requirements.
Unified standards must be implemented, with ongoing assessments to ensure they’re maintained.
The Future of IT/OT Convergence in Manufacturing
The future of manufacturing will belong to those who master secure and strategic IT/OT convergence.
This is more than a technological upgrade.
It is a competitive necessity that will separate industry leaders from laggards.
